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RF 900 R
Suzuki RF 900 R Manuals
Manuals and User Guides for Suzuki RF 900 R. We have
1
Suzuki RF 900 R manual available for free PDF download: Service Manual
Suzuki RF 900 R Service Manual (459 pages)
Brand:
Suzuki
| Category:
Motorcycle
| Size: 24.88 MB
Table of Contents
Foreword
3
Important
3
Group Index
3
How to Use this Manual
4
To Locate What You Are Looking for
4
Component Parts and Work to be Done
4
Symbol
5
General Information/Contents
7
Warning/Caution/Note
8
General Precautions
8
Suzuki RF900RR (94-Model) Product View
10
Serial Number Location
10
Fuel, Oil and Engine Coolant Recommendation Fuel
10
Break-In Procedures
12
Cylinder Identification
12
Information Labels
13
Periodic Maintenance/Contents
18
Periodic Maintenance Schedule/Chart
19
Lubrication Points
20
Maintenance and Tune-Up Procedures
21
Exhaust Pipe Bolts
21
Air Cleaner
21
Tappet Clearance
22
Tappet Clearance Adjustment
23
Tappet Shim Selection Table (Intake)
24
Tappet Shim Selection Table (Exhaust)
25
Spark Plug
26
Carbon Deposit
26
Spark Plug Gap
26
Electrode's Condition
26
Engine Oil and Oil Filter
27
Necessary Amount of Engine Oil
27
Fuel Filter
28
Carburetor
28
Idling Adjustment
28
Throttle Cable Play
28
Clutch Fluid Level
29
Bleeding Air from the Clutch Fluid Circuit
29
Drive Chain Checking/Adjusting
30
Drive Chain Cleaning and Lubricating
31
Engine Coolant Level/Change
31
Brake Fluid Level
32
Brake Pads
33
Brake Pedal Height
33
Brake Light Switch
33
Air Bleeding the Brake Fluid Circuit
34
Tire Tread Condition
35
Tire Pressure
35
Steering
36
Front Fork
36
Rear Suspension
36
Chassis Bolts and Nuts
37
Compression Pressure Check/Specification
39
Compression Test Procedure
39
Oil Pressure Check/Specification
40
Oil Pressure Test Procedure
40
Low/High Oil Pressure
40
Engine/Contents
41
Engine Components Removable with Engine in Place
42
Engine Removal
43
Engine Reinstallation
48
Engine Disassembly
51
Cylinder Head Service
63
Cylinder Head Distortion
64
Valve Stem Runout/Deflection
64
Valve Head Radial Runout
64
Valve Face Wear
64
Camshaft
65
Cam Wear
66
Camshaft Journal Wear
66
Camshaft Runout
67
Cam Sprocket
67
Camshaft Reassembly
68
Cam Chain Tensioner/Guide
68
Cylinder Block Distortion
68
Cylinder Bore
69
Piston Diameter
69
Piston-Cylinder Clearance
69
Piston Ring-Groove Clearance
69
Piston Ring Free End Gap and Piston Ring End Gap
70
Piston Pin and Pin Bore
71
Conrod Small End ID
71
Conrod Big End Side Clearance
71
Conrod-Crank Pin Bearing Selection
72
Bearing Assembly
73
Crankcase-Crankshaft Bearing Selection
74
Bearing Selection Table
75
Crankcase ID Specification
75
Crankshaft Journal OD Specification
75
Crankshaft Thrust Clearance
76
Bearing Thickness Specification
76
Crankshaft Runout
77
Thrust Bearing Selection Table
77
Clutch Diaphragm Spring
78
Clutch Drive and Driven Plates
78
Clutch Bearing
78
Clutch Release Cylinder Disassembly/Inspection/Reassembly
79
Oil Pump
79
Transmission Disassembly
80
Transmission Reassembly
81
Gearshift Fork-Groove Clearance
83
Starter Clutch Disassembly and Assembly
84
Starter Clutch Reassembly
85
Engine Reassembly
86
Fuel and Lybrication System/Contents
105
Fuel System
106
Fuel Pump Description
107
Fuel Pump Removal/Inspection
108
Fuel Cock Mechanism
109
Fuel Cock Removal
109
Fuel Tank Removal
110
Fuel Filter Removal/Inspection/Cleaning
110
Carburetor Construction
111
Specifications
113
Diaphragm and Piston Operation
114
Lower/Upper Position of Piston Valve
114
Slow System
115
Main System
116
Starter/Float System
117
Float System Removal/Disassembly
118
Float System Inspection and Adjustment
121
Needle Valve Inspection
121
Float Height Adjustment/Reassembly/Remounting
121
Balance of Carburetors
122
Calibrating each Gauge
122
Balancing Carburetors
123
Oil Pressure/Filter
124
Oil Sump Filter
124
Engine Lubrication System Chart
125
Engine Lubrication System
126
Engine Oil Cooling System
127
Cooling System/Contents
129
Cooling System Description
130
Cooling System Construction
131
Engine Coolant
133
Cooling System Removal and Disassembly
134
Water Hoses and Thermostat Case
134
Radiator
134
Cooling Fan
135
Engine Coolant Temperature Gauge and Cooling Fan Thermo-Switch
135
Thermostat
135
Water Pump
135
Radiator Inspection/Removal/Installation
137
Engine Coolant Temperature Gauge Removal/Inspection
138
Engine Coolant Temperature Gauge Reassembly
139
Cooling Fan Removal/Inspection
139
Cooling Fan Thermo-Switch
139
Cooling Fan Thermo-Switch Removal/Inspection/Reassembly
140
Thermostat Removal/Inspection/Reassembly
141
Thermostat Valve Opening Temperature
141
Thermostat Valve Lift
141
Water Pump Removal/Disassembly/Inspection/Reassembly
142
Water Pump Bearing
142
Mechanical Seal
142
Chassis/Contents
144
Chassis Exterior Parts
145
Chassis Removal
146
Cowling and Cowling Brace
146
Seat
148
Chassis Remounting
149
Frame Cover
149
Front Wheel Removal
150
Front Wheel Inspection and Disassembly
151
Speedometer Gearbox Dust Seal
151
Tire and Front Wheel
151
Wheel Bearing
151
Front Wheel Reassembly and Remounting
152
Front Axle
152
Brake Disc
152
Speedometer Gearbox
153
Brake Caliper
153
Tire Removal
155
Inspection Wheel
157
Valve Inspection
157
Tire/Valve Installation
158
Brake Pad/Fluid Replacement
160
Caliper Removal and Disassembly
161
Front Brake
162
Caliper Inspection
163
Caliper Reassembly and Remounting
163
Brake Disc Inspection
164
Master Cylinder Removal and Disassembly
165
Master Cylinder Inspection/Reassembly/Remounting
166
Front Fork Removal and Disassembly
168
Front Fork Inspection/Reassembly/Remounting
171
Fork Spring
171
Inner and Outer Tube
171
Damper Rod
171
Damper Rod Bolt
172
Fork Oil
172
Inner Rod and Lock Nut
173
Suspension Setting
174
Spring Pre-Load Adjustment
174
Front Suspension Setting
174
Steering Removal and Disassembly
175
Steering Inspection and Disassembly
177
Steering Reassembly and Remounting
178
Outer Races
178
Stem Nut
178
Steering Tension Adjustment
179
Ignition Switch Removal and Remounting
180
Rear Wheel Removal
181
Rear Wheel Inspection/Disassembly/Reassembly/Remounting
183
Rear Axle
183
Cushion/Sprocket
183
Mounting Drum Bearing
184
Rear Sprocket/Axle
185
Rear Brake Exploded View
186
Caliper Inspection/Reassembly/Remounting
189
Master Cylinder Bolts
191
Rear Suspension Exploded View
192
Rear Suspension Removal
193
Rear Suspension Inspection and Disassembly
195
Swingarm
195
Cushion Lever
196
Shock Absorber
196
Swingarm Pivot Shaft
196
Chain Buffer
196
Rear Suspension Reassembly and Remounting
197
Swingarm Bearing
197
Final Inspection and Adjustment
199
Rebound/Compression Damping Force Adjustment
199
Clutch Master Cylinder Removal/Disassembly/Reassembly
200
Electrical System/Contents
201
Cautions in Servicing
202
Connector
202
Coupler
202
Clamp
202
Battery
203
Connecting Battery
203
Wiring Procedure
203
Using Pocket Tester
203
Location of Electrical Components
204
Charging System Description (Generator with IC Regulator)
205
Battery Leak Current Inspection
207
Charging Output Inspection
207
Charging System Removal and Disassembly
208
Charging System Inspection
210
Rotor Bearing
210
Stator Coil Continuity Check
210
Rotor Coil Continuity Check
210
Carbon Brush
211
Rectifier
211
IC Regulator
212
Charging System Reassembly and Remounting
213
Reassembly Information
215
Starter System Description
216
Side-Stand/Ignition Interlock System Description
216
Starter Motor Removal/Disassembly/Inspection
219
Starter Motor Reassembly
220
Commutator
220
Armature Coil Inspection
220
Oil Seal Inspection
220
Starter Relay Inspection
221
Side-Stand/Ignition Interlock System Part Inspection
222
Diode
222
Starter Relay Wiring Diagram
222
Neutral/Side-Stand Switch
223
Side-Stand/Ignition Interlock Relay
223
Ignition System Description
224
Ignition System Inspection
226
Ignition Coil (Checking with Electro/Pocket Tester)
226
Signal Generator
226
Ignition Coil Resistance
226
Heat Range
227
Ignition Unit (Checking with Digital Ignitor Checker)
228
Combination Meter Removal/Disassembly/Inspection
230
Engine Coolant Temperature Meter Inspection
232
Fuel Level Indicator Inspection
233
Headlight Bulb Replacement
235
Tail/Brake Light
236
Turn Signal Light
236
Switches
237
Battery Specifications
238
Initial Charging
238
Filling Electrolyte
238
Battery Servicing
239
Recharging Operation
240
Servicing Information/Contents
241
Troubleshooting/Engine
242
Troubleshooting/Radiator and Carburetor
245
Troubleshooting/Chassis
246
Troubleshooting/Brakes
247
Troubleshooting/Electrical
248
Troubleshooting/Battery
249
Wiring Diagram (for Canada and USA)
250
Wiring Diagram (for Australia)
257
Wiring Diagram (for the Others)
258
Wire Harness Routing
259
High-Tension Cord Routing
261
Cable Routing
262
Fuel System Hose Routing
263
Oil Hose Routing
264
Cooling System Hose Routing
265
Front Brake Hose Routing
267
Rear Brake Hose Routing
268
Clutch Hose Routing
269
Pair (Air Supply) System Hose Routing (for Austria, Switzerland and USA (California Only))
270
Cowling Set up
271
Frame Cover Set up
273
Special Tools
274
Tightening Torque/Engine
277
Tightening Torque/Chassis
278
Tightening Torque Chart
279
Service Data Valve and Guide
280
Service Data Camshaft and Cylinder Head
281
Service Data Cylinder, Piston and Piston Ring
281
Service Data Conrod and Crankshaft
282
Service Data Oil Pump
282
Service Data Clutch
283
Service Data Thermostat, Radiator and Fan
283
Service Data Transmission and Drive Chain
283
Service Data Carburetor
284
Service Data Electrical
285
Service Data Wattage
286
Service Data Brake and Wheel
287
Service Data Suspension
288
Service Data Fuel, Oil and Engine Coolant
288
Service Data Tire Pressure
289
Emission Control Information/Contents
290
Emission Control Carburetor Components
291
Evaporative Emission Control System (California Model Only)
292
Canister Hose Routing (California Model Only)
293
Pair (Air Supply) System Diagram (California Model Only)
294
Pair (Air Supply) System Hose Routing (California Model Only)
295
RF900RS (95-Model)/Contents
296
RF900RS (95-Model)/Specifications
297
RF900RS (95-Model)/Service Data
299
RF900RS (95-Model)/Service Information
309
RF900RS (95-Model)/Disassembly
310
RF900RS (95-Model)/Inspection
312
RF900RS (95-Model)/Reassembly
313
RF900RS (95-Model)/Cable Routing
315
RF900RS (95-Model)/Carburetor
318
RF900RT (96-Model)/Contents
344
RF900RT (96-Model)/Specifications
345
RF900RT (96-Model)/Service Data
347
RF900RT (96-Model)/Service Information
357
RF900RT (96-Model) Disassembly and Inspection
358
RF900RT (96-Model) Reassembly
359
RF900RT (96-Model) Ignitor Unit Inspection
360
RF900RT (96-Model) Rear Brake and Torque Link Rod
361
RF900RT (96-Model) Front Suspension
362
Suspension Setting Setting
362
RF900RT (96-Model) Wire Harness Routing
363
RF900RV (97-Model)/Contents
364
RF900RV (97-Model)/Specifications
365
RF900RV (97-Model)/Service Data
367
How to Use Microfich Parts Catalogue
378
Composition of the Micro Catalogues
378
Indexing System
379
Dimensions/Abbreviations
380
Inner Parts of Assembly
380
Modification Notice
380
Serial Frame Number
380
Color Chart
382
Millimeter-Inch Conversion Chart
383
Crankshaft
385
Starter Clutch
386
Cam Shaft - Valve
387
Cam Chain
389
Cylinder Head Cover
390
Cylinder Head
391
Cylinder
392
Crankcase
393
Crankcase Cover
395
Oil Pan/Pump
396
Carburetor Fittings
403
Muffler
405
Fuel Pump
406
Oil Cooler/Filter
407
Gear Shifting
409
Radiator Hose
412
Clutch (Model R)
414
Clutch (Model S/T/V)
416
Transmission
417
Headlamp
420
Turnsignal Lamp
421
Tail Lamp
422
Wiring Harness
423
Handle Switch
424
Starting Motor
425
Alternator
426
Electrical
430
Speedometer
431
Under Cowling Body
432
Front Damper (Model R/S)
434
Front Damper (Model T/V)
435
Steering Stem
436
Front Wheel
437
Front Calipers
438
Front Brake Hose
439
Front Master Cylinder
440
Clutch Cylinder
441
Optional
443
Rear Swinging Arm (Model R/S)
444
Rear Swinging Arm (Model T/V)
445
Rear Cushion Lever
446
Rear Wheel (Model R/S)
447
Rear Wheel (Model T/V)
448
Rear Caliper (Model R/S)
449
Rear Caliper (Model T/V)
450
Rear Master Cylinder
451
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