GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE ENGINE SHAFT DRIVE FUEL AND LUBRICATION SYSTEM COOLING SYSTEM CHASSIS ELECTRICAL SYSTEM SERVICING INFORMATION EMISSION CONTROL INFORMATION Revised 09/07...
HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily.
Use fork oil. otherwise specified. 99000-99001 SS8 Apply molybdenum oil solution. Apply or use brake fluid. (Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE “A”. Measure in voltage range. 99000-25030 Apply SUZUKI MOLY PASTE.
Use fork oil. otherwise specified. 99000-99001-SS8 Apply molybdenum oil solution. Apply or use brake fluid. (Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE “A”. Measure in voltage range. 99000-25010 Apply SUZUKI MOLY PASTE.
1-2 GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. Indicates a potential hazard that could result in death or injury.
GENERAL INFORMATION 1-3 " * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order.
) method or 91 octane or higher rated by the Research Method. 2. Suzuki recommends that customers use alcohol-free unleaded gasoline whenever possible. 3. Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted. 4. Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10% etha- nol.
1-6 GENERAL INFORMATION BREAK-IN PROCEDURES During manufacturing only the best possible materials are used and all machined parts are finished to a very high standard. It is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses.
1-8 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..............2 510 mm (98.818 in) Overall width ..............985 mm (38.779 in) Overall height ..............1 110 mm (43.700 in) Wheelbase ..............1 650 mm (64.960 in) Ground clearnce ............140 mm ( 5.511 in) Seat height ..............
GENERAL INFORMATION 1-9 CHASSIS Front suspension ............Telescopic, coil spring, oil damped Rear suspension ............Link type, coil spring, oil damped, spring pre-load 7-way adjustable Steering angle .............. 38° (right & left) Caster ................33° 20’ Trail ................141 mm (3.55 in) Turning radius ...............
1-10 GENERAL INFORMATION COUNTRY AND AREA CODES The following codes stand for the applicable country(-ies) and area(-s). CODE COUNTRY or AREA E-02 England (UK) E-03 E-19 E-24 Australia E-28 Canada E-33 California...
2-2 PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometer, miles and months, whichever comes first. IMPORTANT (USA only): The periodic maintenance intervals and service requirements have been established in accordance with EPA regulations.
PERIODIC MAINTENANCE 2-3 LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. Throttle cable Brake lever holder Brake pedal pivot and brake rod link Clutch lever holder Side-stand pivot and spring hook...
2-4 PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item mentioned in the Periodic Maintenance chart. AIR CLEANER • Remove the screws and air cleaner case cover. • Remove the air cleaner element. • Carefully use air hose to blow the dust from the cleaner ele- ment.
PERIODIC MAINTENANCE 2-5 • Remove the spark plug caps. • Remove the spark plugs with a spark plug wrench. HEAT RANGE • Check spark plug heat range by observing electrode color. If the electrode of the spark plug is wet appearing or dark color, replace the spark plug with hotter type one.
2-6 PERIODIC MAINTENANCE SPARK PLUG AND IGNITION COIL/PLUG CAP INSTALLATION • Install the spark plugs to the cylinder head with fingers, and then tighten them to the specified torque with a wrench. % Spark plug: 11 N . m (1.1 kgf . m, 8.0 Ib-ft) Do not crossthread or over tighten the spark plug, or the spark plug will damage the aluminum threads of the cyl- inder head.
PERIODIC MAINTENANCE 2-7 • Remove all the inspection caps. • Remove all the spark plugs. • Remove the generator cover plug 3 and the timing inspection plug 4. • Rotate the generator rotor to set the No.1 engine’s piston at TDC of the compression stroke.
2-8 PERIODIC MAINTENANCE Inspect the No.2 engine’s valve clearance as the same manner above. NOTE: FRONT Use the thickness gauge from the arrow marks as shown in the illustration. No. 2 Engine No. 1 Engine ENGINE OIL AND OIL FILTER ENGINE OIL REPLACEMENT •...
TER. Other manufacturer’s oil ilters may differ in thread specifications (thread diameter and pitch), filtering per- formance and durability which may lead to engine dam- age or oil leaks. Also, do not use a genuine Suzuki auto- mobile oil filter on this motorcycle.
2-10 PERIODIC MAINTENANCE FUEL HOSE Inspect the fuel hose 1 for damage and fuel leakage. If any de- fects are found, replace the fuel hose. ENGINE IDLE SPEED NOTE: Warm up the engine before adjusting the engine idle speed. • Start the engine, turn the throttle stop screw and set the engine idle speed as follows.
PERIODIC MAINTENANCE 2-11 THROTTLE CABLE PLAY Adjust the throttle cable play A as follows. MINOR ADJUSTMENT 1st step: • Loosen the lock nut 1 of the throttle returning cable 2 and fully turn in the adjuster 3. 2nd step: • Loosen the lock nut 4 of the throttle pulling cable 5. •...
2-12 PERIODIC MAINTENANCE MAJOR ADJUSTMENT • Remove the fuel tank. (!5-3) • Loosen the lock nuts 1 of the throttle returning cable 2. • Turn the returning cable adjuster 3 to obtain proper cable play. • Loosen the lock nuts 4 of the throttle pulling cable 5. •...
PERIODIC MAINTENANCE 2-13 COOLING SYSTEM ENGINE COOLANT LEVEL CHECK • Keep the motorcycle upright. • Check the engine coolant level by observing the full and lower lines on the engine coolant reservoir. A Full line B Lower line • If the level is below the lower line, add engine coolant to the full line from the engine coolant reservoir filler.
2-14 PERIODIC MAINTENANCE AIR BLEEDING THE COOLING CIRCUIT • Add engine coolant up to the radiator inlet. • Support the motorcycle upright. • Slowly swing the motorcycle, right and left, to bleed the air trapped in the cooling circuit. • Add engine coolant up to the radiator inlet. •...
PERIODIC MAINTENANCE 2-15 FINAL GEAR OIL • Keep the motorcycle upright. • Place an oil pan under the final gear case. Remove the filler cap 1 and drain plug 2 to drain oil. • Refit the drain plug 2. Pour the specified oil (SAE 90 hypoid gear oil with GL-5 under API classification) through the filler hole until the oil level reaches the filler hole.
2-16 PERIODIC MAINTENANCE REAR BRAKE PEDAL HEIGHT • Loosen the lock nut 1. • Adjust the brake pedal height A by turning the adjuster 2. " Rear brake pedal height : 75 – 85 mm REAR BRAKE ADJUSTING • Adjust the free travel B to 20 – 30 mm by turning the adjusting nut 3.
PERIODIC MAINTENANCE 2-17 AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylin- der and thus interferes with the full braking performance of the brake caliper.
2-18 PERIODIC MAINTENANCE TIRES TIRE TREAD CONDITION Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of tire tread reaches the following specification. ( 09900-20805: Tire depth gauge "...
PERIODIC MAINTENANCE 2-19 STEERING The steering should be adjusted properly for smooth turning of the handlebars and safe operation. Overtight steering prevents smooth turning of the handlebars and too loose steering will cause poor stability. Check that there is no play in the front fork. Support the motorcycle so that the front wheel is off the ground.
2-20 PERIODIC MAINTENANCE CHASSIS BOLTS AND NUTS Check that all chassis bolts and nuts are tightened to their specified torque. The locations of the following nuts and bolts on the motorcycle. N . m kgf . m Item Ib-ft 1 Steering stem head nut 65.0 2 Steering stem lock nut 58.0...
2-22 PERIODIC MAINTENANCE COMPRESSION PRESSURE CHECK The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance service. COMPRESSION PRESSURE SPECIFICATION Standard Limit...
PERIODIC MAINTENANCE 2-23 OIL PRESSURE CHECK Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. OIL PRESSURE SPECIFICATION 350 – 650 kPa (3.5 – 6.5 kgf/cm , 50 – 92 psi) at 3 000 r/min., Oil temp. at 60°C (140°F) If the oil pressure is lower or higher than the specification, the following causes may be considered.
3-2 ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to the page listed in this section for removal and reinstallation instructions. ENGINE CENTER PARTS REMOVAL INSTALLATION...
ENGINE 3-3 ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal pro- cedure.
3-4 ENGINE • Disconnect the neutral switch lead wire coupler 1. • Disconnect the generator lead wire coupler 2 and the signal generator lead wire coupler 3. • Disconnect the side-stand switch lead wire coupler 4. • Remove the clutch release mechanism. •...
ENGINE 3-5 • Remove the air cleaner box bracket. • Disconnect the negative pressure hose 1. • Remove the carburetor. Caburetor removal !5-15 • Remove the spark plug caps. • Remove the right frame cover. • Remove the No. 1 muffler.
3-6 ENGINE • Remove the No. 1 exhaust pipe and the No. 2 muffler. • Remove the No.2 exhaust pipe. • Remove the rear clutch cover. • Remove the cooling fan mounting bolts. • Remove the engine mounting bolt 1.
ENGINE 3-7 • Remove the frame down tube. • Support the engine with an engine jack. • Remove the engine mounting bolts and nuts. • Gradually lower the engine.
3-8 ENGINE ENGINE INSTALLATION Install the engine in the reverse order of engine removal. Pay attention to the following points: • Install the universal joint. NOTE: Be sure to face the short portion A backward when installing it. • Install the boot. NOTE: Make sure that the “UP”...
ENGINE 3-9 NOTE: * The engine mounting nuts are self-locking. Once the nut has been removed, they are no longer of any use. * Be sure to use new nuts and tighten them to the specified torque. 50 N . m (5.0 kgf .
" Gearshift lever height A Standard: 90 mm (3.5 in) • Apply grease to the push rod and install it. # 99000-25030: SUZUKI SUPER GREASE “A” (For USA) 99000-25010: SUZUKI SUPER GREASE “A” (For the others) • Apply grease to the clutch release mechanism and install it.
ENGINE 3-11 ENGINE DISASSEMBLY • Remove the PAIR pipes. • Remove the spark plugs. % 09930-10121: Spark plug wrench set • Remove the valve timing inspection plug 1 and the generator cover cap 2. • Position “RIT” mark on the generator with the center of the valve timing inspection hole.
3-12 ENGINE CYLINDER HEAD/CYLINDER • Loosen the water hose clamp screws. • Remove the cylinder head bolts. (Front cylinder) • Remove the cylinder head and cylinder. (Front cylinder) • After unlocking the ratchet, push the cam chain tension ad- juster rod fully. •...
ENGINE 3-13 • Remove the cylinder head bolt and nut. (Rear cylinder) • Push the cam chain tension adjuster rod and insert the special tool. % 09918-53810: Chain tensioner lock tool • Remove the cylinder head by removing the cylinder head bolts. •...
3-14 ENGINE STARTER MOTOR • Remove the starter motor cover. • Remove the starter motor. CLUTCH • Remove the clutch cover. • Remove the clutch spring mounting bolts and springs diago- nally. • Remove the pressure plate 1.
ENGINE 3-15 • Remove the thrust washer 1, bearing 2, push piece 3 and push rod. • Remove the clutch drive and driven plates. • Remove the spring washer 4 and spring washer seat 5. • Remove the clutch sleeve hub nut with the special tool. % 09920-53740: Clutch sleeve hub holder •...
3-16 ENGINE • Remove the primary driven gear assembly and the oil pump drive chain. • Remove the thrust washer 1 and spacer 2. OIL PUMP • Remove the oil pump by removing the circlip. % 09900-06107: Snap ring pliers •...
ENGINE 3-17 • Remove the gearshift cam plate 1. • Remove the gearshift cam stopper 2. PRIMARY DRIVE GEAR Remove the primary drive gear by removing the primary drive gear bolt with the special tool. % 09930-40113: Rotor holder & This bolt has left-hand thread.
3-18 ENGINE NEUTRAL SWITCH • Remove the neutral switch assembly. • Remove the oil pressure switch lead wire. GENERATOR • Remove the generator cover. • Remove the starter motor driven gear and the idle gear. • Loosen the generator rotor bolt. NOTE: When loosen the rotor bolt, do not remove it.
ENGINE 3-19 • Remove the cam chain tensioner and the chain. WATER PUMP • Remove the water pump cover. • Remove the water pump assembly. SECONDARY DRIVEN GEAR • Remove the secondary driven gear housing bolts. • Remove the secondary driven gear case.
3-20 ENGINE • Remove the secondary driven gear assembly. • Remove the bearing 1. • Remove the oil jet 2. OIL JET • Remove the oil jets. CRANKCASE • Remove the crankcase bolts. • Separate the crankcase into two parts with the special tool. % 09920-13120: Crankcase separator...
ENGINE 3-21 • Remove the crankshaft. • Remove the gearshift fork shafts and gearshift forks. • Remove the transmission. SECONDARY DRIVE BEVEL GEAR • Remove the over driving gear 1 and bush 2. • Remove the secondary drive bevel gear assembly.
(0.4724 – 0.4731 in) % 09900-20605: Dial calipers REASSEMBLY • Apply SUZUKI MOLY PASTE to the rocker arms and their shafts. ' 99000-25140: SUZUKI MOLY PASTE ( Rocker arm shaft: 27 N . m (2.7 kgf . m, 19.5 lb-ft)
To properly measure the oi clearance with plastigauge, all gas- ket material must be removed from fitting surfaces of cylinder head and cover. Do not apply SUZUKI BOND “1216B” until after the oil clearance has been determined. • Tighten the cylinder head cover bolts evenly and diagonally to the specified torque.
3-24 ENGINE If the camshaft journal oil clearance measured exceeds the limit, measure the outside diameter of camshaft. Replace either the cylinder head set or the camshaft if the clear- ance is incorrect. " Camshaft journal O.D. (Sprocket side) : 24.959 – 24.980 mm (0.9826 –...
ENGINE 3-25 CYLINDER HEAD VALVE AND VALVE SPRING DISASSEMBLY • Using special tools, compress the valve springs and remove the two cotter halves 1 from valve stem. % 09916-14510: Valve spring compressor 09916-14910: Valve spring compressor attachment 09916-84511: Tweezers • Remove the valve spring retainer, inner spring and outer spring. •...
3-26 ENGINE VALVE STEM RUNOUT Support the valve with “V” blocks, as shown, and check its runout with a dial gauge. The valve must be replaced if the runout exceeds the limit. " Valve stem runout Service Limit: 0.05 mm (0.002 in) % 09900-20701: Magnetic stand 09900-20606: Dial gauge (1/100 mm) 09900-21304: V-block...
ENGINE 3-27 VALVE GUIDE SERVICING • Using the valve guide remover, drive the valve guide out to- ward the intake or exhaust rocker arm side. % 09916-44910: Valve guide remover/installer NOTE: * Discard the removed valve guide subassemblies. * Only oversized valve guides are available as replacement parts. (Part No.
3-28 ENGINE VALVE SEAT WIDTH • Coat the valve seat with prussian blue uniformly. Fit the valve and tap the coated seat with the valve face in a rotating man- ner, in order to obtain a clear impression of the seating contact. In this operation, use the valve lapper to hold the valve head.
ENGINE 3-29 • Insert the solid pilot 1 (09916-24450: N-100-5.52) with a slight rotation. Seat the pilot snugly. Install the 45° cutter, attachment and T-handle. INITIAL SEAT CUT • Using the 45° cutter, descale and clean up the seat. Rotate the cutter one or two turns.
3-30 ENGINE BOTTOM NARROWING CUT • If the contact area W is too wide or too low, use the 60° (intake side only) to narrow and raise the contact area. 60˚ (Intake only) FINAL SEAT CUT Contact area too low and too •...
ENGINE 3-31 VALVE STEM END CONDITION Inspect the valve stem end face for pitting and wear. If pitting or wear of the stem end face are present, the valve stem end may be resurfaced, providing that the length 1 will not be reduced to less than the service limit.
3-32 ENGINE • Insert the valves, with their stems coated with high quality mo- lybdenum disulfide lubricant (SUZUKI MOLY PASTE) all around and along the full stem length without any break. ' 99000-25140: SUZUKI MOLY PASTE & When inserting each valve, take care not to damage the lip of the stem seal.
Service Limit: 83.085 mm (3.2711 in) % 09900-20508: Cylinder gauge set NOTE: When installing the water union to the cylinder, apply grease to the new O-rings. # 99000-25030: SUZUKI SUPER GREASE “A” (For USA) 99000-25010: SUZUKI SUPER GREASE “A” (For the others) PISTON PISTON DIAMETER Using a micrometer, measure the piston outside diameter at the place shown in Fig.
3-34 ENGINE PISTON-TO-CYLINDER CLEARANCE As a result of the aforesaid measurement, if the piston to cylinder clearance exceeds the following limit, overhaul the cylinder and use an oversize piston, or replace both cylinder and piston. " Piston to cylinder clearance Service Limit: 0.12 mm (0.0047 in) Piston oversize: 0.5, 1.0 mm PISTON RING TO GROOVE CLEARANCE...
ENGINE 3-35 Oversize piston ring The following two types of oversize piston rings are used. They bear the following identification numbers. SIZE 0.5 mm O.S. 0.5 mm O.S. 1.0 mm O.S. Oversize oil ring The following two types of oversize oil rings are available as op- 1.0 mm O.S.
3-36 ENGINE PISTON RING REASSEMBLY • Install the piston rings in the order of oil ring, 2nd ring and 1st ring. • The first member to go into the oil ring groove is a spacer 1. After placing the spacer, fit the two side rails 2. NOTE: Side designations, top and bottom, are not applied to the spacer and side rails: you can position each either way.
ENGINE 3-37 CONROD/CRANKSHAFT CONROD SMALL END I.D. Using a small bore gauge, measure the conrod small end inside diameter. ! Conrod small end I.D. Service Limit: 20.040 mm (0.7890 in) " 09900-20602: Dial gauge (1/1000 mm, 1 mm) 09900-22403: Small bore gauge (18 – 35 mm) If the conrod small end inside diameter exceeds the above men- tioned limit, replace the conrod.
3-38 ENGINE • Place plastigauge axially on the crank pin avoiding the oil hole, at TDC or BDC side as shown. • Tighten the bearing cap with two-step torque values. NOTE: When fitting the bearing cap to crank pin, be sure to discriminate between its two ends, I.D.
1 first and press in the other end. • Apply molybdenum oil solution to the crank pin and bearing surface. % 99000-25140: SUZUKI MOLY PASTE • When mounting the conrod on the crankshaft, make sure that I.D. code 2 of the conrod faces rearward.
ENGINE 3-41 • Measure the crankshaft journal bearing I.D. 1 by using the special tool. ! Crankshaft journal bearing I.D. 1 Standard: 48.000 – 48.015 mm (1.8898 – 1.8904 in) " 09900-20508: Cylinder gauge set If each crankshaft journal bearing I.D. is not within the standard range, replace them with new ones.
3-42 ENGINE CRANKSHAFT THRUST CLEARANCE Install the crankshaft in the right crankcase half after installing the thrust shim on the crankshaft. NOTE: The oil grooved face A of thrust shim 1 is faced to crankshaft web side. • Place the thrust washer, camshaft drive sprocket and primary drive gear on the right end of the crankshaft and tighten pri- mary drive gear bolt to the specified torque.
ENGINE 3-43 CLUTCH CLUTCH DRIVE AND DRIVEN PLATES NOTE: Wipe off the engine oil from the drive and driven plates with a clean rag. Measure the thickness of drive plates with a vernier calipers. If each drive plate is not within the standard range, replace it with a new one.
3-44 ENGINE GENERATOR/SIGNAL GENERATOR/ STARTER CLUTCH GENERATOR STATOR AND SIGNAL GENERATOR STATOR INSPECTION&8-8, 19, 20 GENERATOR STATOR AND SIGNAL GENERATOR STATOR SERVICING When replacing the generator stator or signal generator stator, route the wire properly. STARTER CLUTCH INSPECTION Install the starter driven gear onto the starter clutch and turn the starter driven gear by hand to inspect the starter clutch for a smooth movement.
ENGINE 3-45 STARTER CLUTCH SERVICING • Hold the rotor with off-set wrench and remove the starter clutch securing bolts. • When fitting the one way clutch to the guide 1, position flange side A of one way clutch to the rotor side. •...
3-46 ENGINE TRANSMISSION DISASSEMBLY • Disassemble the transmission gears as shown in the illustration. 1 Driveshaft bolt 2 Over driving gear 3 1st driven gear 4 4th driven gear 5 3rd driven gear 6 Driveshaft 7 5th driven gear 8 2nd driven gear 9 Counter haft/1st drive gear 0 4th drive gear A 3rd drive gear...
Before installing the gears, coat lightly moly paste or engine oil to the driveshaft and countershaft. % 99000-25140: SUZUKI MOLY PASTE * Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded and a new circlip must be installed.
3-48 ENGINE When installing the 1st and 3rd driven gear bushings, align the bushing oil hole with the driveshaft oil hole. TRANSMISSION GEARS AND RELATED PARTS...
ENGINE 3-49 GEARSHIFT FORK GEARSHIFT FORK TO GROOVE CLEARANCE Using a thickness gauge, check the shifting fork clearance in the groove of its gear. The clearance for each of the three shifting forks plays an impor- tant role in the smoothness and positiveness of shifting action. If the clearance checked is noted to exceed the limit specified, replace the fork or its gear, or both.
• Remove the oil sump filter. • Clean the oil sump filter using compressed air. • When installing the O-ring, apply grease to it. ( 99000-25030: SUZUKI SUPER GREASE “A” (For USA) 99000-25010: SUZUKI SUPER GREASE “A” (For the others) OIL PIPE •...
ENGINE 3-51 • When installing the oil pipe, use the new O-rings. • Apply a small quantity of the THREAD LOCK “1342” to the oil pipe retainer bolts and tighten them securely. ) 99000-32050: THREAD LOCK “1342” OIL PRESSURE REGULATOR •...
" 09913-70210: Bearing installer set OIL PRESSURE SWITCH • Remove the oil pressure switch. • When installing the switch, apply SUZUKI BOND “1207B”. # Oil pressure switch: 14 N . m (1.4 kgf . m, 10.0 lb-ft) * 99104-31140: SUZUKI BOND ‘‘1207B” (For USA) 99000-31140: SUZUKI BOND ‘1207B”...
ENGINE 3-53 ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassembly. The following steps require special attention or precautionary mea- sures should be taken. NOTE: Apply engine oil to each running and sliding part before reas- sembling. SECONDARY DRIVE BEVEL GEAR •...
Use the new O-ring to prevent oil leakage • Clean the mating surfaces of the lef and right crankcase halves. • Apply SUZUKI BOND “1207B” to the mating surface of the right crankcase. * 99104-31140: SUZUKI BOND ‘1207B” (For USA) 99000-31140: SUZUKI BOND ‘‘1207B”...
(For the others) • Clean the mating surfaces of the crankcase and the secondary gear case. • Apply SUZUKI BOND “1207B” to the mating surface of the sec- ondary gear case. * 99104-31140: SUZUKI BOND ‘‘1207B” (For USA) 99000-31140: SUZUKI BOND ‘‘1207B” (For the others)
3-56 ENGINE • Tighten the secondary gear case bolts to the specified torque. # Secondary gear case bolt (Initial): 15 N . m (1.5 kgf . m, 11.0 lb-ft) (Final) : 22 N . m (2.2 kgf . m, 16.0 lb-ft) NOTE: Fit the washer to the bolt A .
ENGINE 3-57 • Install the new O-ring. • Install the water pump cover. NOTE: Fit the clamp to the bolt A . CAM CHAIN/CAM CHAIN TENSIONER • Install the cam chain tensioner and cam chain. # Cam chain tensioner bolt: 10 N . m (1.0 kgf . m, 7.0 lb-ft) 1 For front cylinder 2 For rear cylinder NOTE:...
3-58 ENGINE • Install the starter driven gear and the idle gear. • Install the new gasket and dowel pins. • Install the generator cover. NOTE: Fit the new gaskets to the bolts A . NEUTRAL SWITCH • Install the springs and switch contacts. •...
ENGINE 3-59 OIL FILTER • Apply engine oil lightly to the gasket of the oil filter before in- stallation. • Install the oil filter turning it by hand until feeling that the filter gasket contacts the mounting surface. Then tighten it 2 turns using the oil filter wrench.
3-60 ENGINE • Install the cam driven gear 1 after installing the springs, pins and gearshift pawls. • Install the cam guide and the pawl lifter. • Apply a small quantity of THREAD LOCK “1342” to the nuts. ) 99000-32050: THREAD LOCK “1342” •...
ENGINE 3-61 • Install the oil pump driven gear and the circlip. " 09900-06107: Snap ring pliers CLUTCH • Install the spacer 1 and the thrust washer 2. • Engage the chain with the oil pump drive gear. • Install the primary driven gear assembly and engage the chain with the oil pump driven gear.
3-62 ENGINE • Install the washer 1 and the clutch sleeve hub nut 2. NOTE: The convex side of the washer faces outside. • Tighten the clutch sleeve hub nut to the specified torque with the special tool. # Clutch sleeve hub nut: 60 N . m (6.0 kgf . m, 43.5 lb-ft) "...
ENGINE 3-63 • Install the wave washer seat 1 and the wave washer 2. • Install the clutch drive plate No.2 A first. • Install the drive and driven plate one by one into the clutch sleeve hub. • Install the push rod. •...
• Apply engine oil to the new O-ring and install the oil jets. PISTON • Apply a light coat of SUZUKI MOLY PASTE to the piston pins. % 99000-25140: SUZUKI MOLY PASTE • When installing the piston, the arrow mark on the piston head...
" 09918-53810: Chain tensioner lock tool # Cam chain tension adjuster mounting bolt: 10 N . m (1.0 kgf . m, 7.0 lb-ft) • Coat SUZUKI BOND “1207B” lightly to the mating surfaces among the crankcase mating surfaces. * 99104-31140: SUZUKI BOND ‘‘1207B” (For USA) 99000-31140: SUZUKI BOND ‘‘1207B”...
3-66 ENGINE CYLINDER HEAD • Install the cam chain guide. 1 For front cylinder 2 For rear cylinder • Fit the dowel pins and the new cylinder head gasket. Use a new gasket to prevent gas leakage. • Install the cylinder head and tighten the cylinder head bolts diagonally to the specified torque.
Pull the cam chains upward, or the chain will be caught between crankcase and cam drive sprocket. • Before installing the camshafts onto each cylinder head, apply SUZUKI MOLY PASTE onto the camshaft journals. Also, apply engine oil onto the camshaft journal holders. % 99000-25140: SUZUKI MOLY PASTE NOTE: The camshaft is identified by the embossed letters “F”...
3-68 ENGINE • Align the arrow marks on the front and rear camshafts so it is parallel with the surface of the cylinder heads. NOTE: Arrow marks are located to forward. Front Rear (No. 1) cylinder he d • Engage the chains on the cam sprockets with the locating pin holes A as shown in the photograph.
ENGINE 3-69 • Apply SUZUKI BOND “1216B” to the mating surface of the cyl- inder head cover. • Fit the camshaft end caps 1. • Apply grease to the O-ring 2 and install it. (Front cylinder only) 99000-31230: SUZUKI BOND “1216B”...
FRONT REAR NOTE: * Before installing the bolt 1 , apply SUZUKI BOND “1207B” to the thread of the bolt. * Allen bolt: 2 * Stainlessbolt: 1 , 3 , 4 . * Fit the gasket to the bolt 5 .
• Install the intake pipe. • Apply grease to the new O-ring and install the water outlet union. ( 99000-25030: SUZUKI SUPER GREASE “A” (For USA) 99000-25010: SUZUKI SUPER GREASE “A” (For the others) • Install the gasket and the breather cover.
3-72 ENGINE • Install the PAIR pipes. • Install the head cover caps 1. • Install the spark plugs. " 09930-10121: Spark plug wrench set...
4-2 SHAFT DRIVE SECONDARY BEVEL GEARS CONSTRUCTION A Secondary drive gear shaft nut 1 Bush B Secondary drive bevel gear 2 Overdriving driven gear 3 Circlip bearing retainer bolt C Secondary driven bevel gear 4 Output cam dog 5 Damper spring bolt 6 Secondary bevel gear set 7 Shims (5 kinds)
SHAFT DRIVE 4-3 0.05 – 0.32 mm Backlash (0.002 – 0.013 in) Standard clearance A: 1.00 mm (0.039 in) B: 1.00 mm (0.039 in) Adjust backlash by selecting shims. (Use two pieces of shims.) Shim 1 size table Part number Thickness 24945-05A-0A0 0.30 mm (0.012 in)
4-4 SHAFT DRIVE REMOVAL SECONDARY DRIVE BEVEL GEAR The crankcase must be separated to service the secondary drive bevel gear. The secondary drive bevel gear service requires en- gine removal and disassembly. Refer to the engine removal and the engine disassembly sections for secondary drive bevel gear assembly removal.
SHAFT DRIVE 4-5 SECONDARY DRIVEN BEVEL GEAR • Remove the bearing stopper with the special tool. # 09921-21820: Bearing retainer wrench • Remove the oil seal. INSPECTION Inspect the removed parts for the following abnormalities. * Drive and driven bevel gears damage or wear * Improper tooth contact * Abnormal noise of bearings * Bearing damage or wear...
NOTE: * Hollow portion A of the secondary driven bevel gear assembly faces inside. * It is not necessary to apply SUZUKI BOND “1207B” to the matching surface at this stage. • Measure the backlash as follows. • Set-up a dial gauge as shown in photo.
SHAFT DRIVE 4-7 • Adjust the dial gauge so that it touches the secondary drive bevel gear cam dog; hold the driven bevel gear securely, and turn the drive bevel gear in each direction, reading the total backlash on the dial gauge. % Secondary bevel gear backlash Standard: 0.05 –...
4-8 SHAFT DRIVE TOOTH CONTACT 1 INCORRECT (Contact at tooth top) After bringing the backlash within specification by changing the secondary driven bevel gear shims, it will be necessary to check tooth contact. • Remove the drive bevel gear assembly from the crankcase. •...
REASSEMBLY SECONDARY DRIVEN BEVEL GEAR • Apply grease to the lip of oil seal. & 99000-25030: SUZUKI SUPER GREASE “A” (For USA) 99000-25010: SUZUKI SUPER GREASE “A” (For the others) • Tighten the bearing stopper to the specified torque with the special tool.
4-10 SHAFT DRIVE FINAL BEVEL GEARS CONSTRUCTION ITEM kgf.m lb-ft 16.5 29.0 10.0 72.5 A Final gear case bolt 1 Oil seal D Stopper plate (2 kinds) B Final driven beve gear bearing 2 Final gear bearing case E Final drive gear bearing 3 O-ring F Final drive bevel gear retainer screw...
SHAFT DRIVE 4-11 Standard clearance C: 1.00 mm (0.039 in) Shim 3 size table Part number Thickness Standard clearance A: 1.00 mm (0.039 in) 27327-34200 0.35 mm (0.014 in) Shim 1 size table 27327-34210 0.40 mm (0.016 in) 27327-34220 0.50 mm (0.020 in) Part number Thickness 27327-34230...
4-12 SHAFT DRIVE FINAL GEAR CASE REMOVAL After draining final gear oil, the following components must be removed in the described order before removing the final gear case. NOTE: Refer to the following pages for the details of each step. •...
SHAFT DRIVE 4-13 1 Spring 2 Propeller shaft 3 Circlip • Using a chisel, unlock the nut. • Remove the final drive bevel gear coupling nut with the special tool. # 09924-62430: 22 mm Long socket 09924-64510: Final drive gear coupling holder •...
4-14 SHAFT DRIVE • Remove the bearing from the final drive bevel gear with the bearing puller. The removed bearing must be replaced with a new one. NOTE: If no abnormal noise, the bearing removal is not necessary. • Remove the final gear bearing case bolts. •...
SHAFT DRIVE 4-15 • Remove the bearing retainer screws, using an impact driver set. # 09900-09004: Impact driver set • Remove the final driven gear bearing and oil seal with the spe- cial tools. # 09941-64511: Bearing remover 09930-30102: Sliding shaft The removed bearing and oil seal must be replaced with new ones.
! Final gear case bolt: 23 N . m (2.3 kgf . m, 16.5 lb-ft) NOTE: It is not necessary to apply SUZUKI BOND “1207B” to the match- ing surface at this stage. • Measure the clearance between the shims and bearing. If it is not within the specification, the shims must be changed.
SHAFT DRIVE 4-17 If the backlash is not within the specification, adjust the shim thick- ness as follows: • Remove shims from final gear bearing case and final gear case, and measure total thickness. • In order not to change the clearance between final driven bevel gear and bearing, the total thickness of the shims installed af- ter a change is made must equal the original total thickness of shims.
4-18 SHAFT DRIVE TOOTH CONTACT 1 INCORRECT (Contact at tooth top) After backlash adjustment is carried out, the tooth contact must be checked. • Remove the bolts from the final gear bearing case, and remove the case with the two 5 mm screws. ("4-14) Do not mis- place the shims.
SHAFT DRIVE 4-19 FINAL GEAR CASE REASSEMBLY Reassemble the final gear case in the reverse order of disassem- bly. Pay attention to the following points. • Install a new oil seal 1 and O-ring 2 to the bearing stopper. Use new O-ring and oil seat to prevent oil leakage. •...
4-20 SHAFT DRIVE • Install the needle roller bearing for the final driven bevel gear into the final gear case with the special tool. # 09913-76010: Bearing installer NOTE: The stamped ward on the bearing end should face to the driven bevel gear side.
SHAFT DRIVE 4-21 • Apply SUZUKI BOND “1207B” to the mating surface of the final gear case and final gear bearing case. Do not block the breather passage when applying SUZUKI BOND “1207B”. ( 99000-31140: SUZUKI BOND “1207B” • Apply THREAD LOCK “1342” to the final gear case bolts and tighten them to the specified torque.
• Apply grease to the lip of the oil seal and install it to the final drive bevel gear coupling. Use a new oil seal to prevent oil leakage. & 99000-25030: SUZUKI SUPER GREASE ‘‘A’’ (For USA) 99000-25010: SUZUKI SUPER GREASE ‘‘A’’ (For the others)
SHAFT DRIVE 4-23 • Install the stopper plate. When installing the plate, fit the protrusion A of plate to the one of the bearing stopper grooves. NOTE: Two kinds of plates are available to lock the stopper at the proper position.
5-2 FUEL AND LUBRICATION SYSTEM FUEL SYSTEM The fuel pump is operated by a vacuum force which is supplied from the carburetor intake pipe. The fuel sent under pressure by the fuel pump flows into the float chamber when the float of the carburetor has dropped and the needle valve is open.
FUEL AND LUBRICATION SYSTEM 5-3 FUEL TANK/FUEL VALVE REMOVAL Gasoline is highly flammable and explosive. Keep heat, sparks, and flames away from gasoline. • Remove the front seat. ("7-2) • Remove the speedometer. • Disconnect the speedometer coupler. Be careful not to scratch the fuel tank. •...
5-4 FUEL AND LUBRICATION SYSTEM • Disconnect the fuel hose 1 and vacuum hose 2. • Remove the throttle stop screw. • Remove the fuel tank. • Remove the fuel valve. • Remove the fuel level gauge mounting bolts. • Remove the fuel level gauge 3. •...
FUEL AND LUBRICATION SYSTEM 5-5 INSPECTION FUEL VALVE If the fuel filter is dirty with sediment or rust, fuel will not flow smoothly and loss in engine power may result. Clean the fuel filter with compressed air. Also check the fuel valve for cracks. REMOUNTING •...
5-6 FUEL AND LUBRICATION SYSTEM * Gasket 3 must be replaced with new ones to prevent fuel leakage. * Tighten the fuel level gauge bolts evenly. NOTE: mark A on the fuel level gauge forward. Face 10 N . m (1 0 kgf m, 7.0 lb-ft) Fuel tank FUEL PUMP REMOVAL...
FUEL AND LUBRICATION SYSTEM 5-7 • Disconnect the fuel hoses 1, 2 and vacuum hose 3. INSPECTION Gasoline is highly flammable and explosive. Keep heat, sparks, and flames away from gasoline. • Disconnect the fuel hose 1, connect the suitable hose and insert the free end of the hose into a receptacle.
5-8 FUEL AND LUBRICATION SYSTEM CARBURETOR CONSTRUCTION 1 Top cap A Throttle stop screw 2 Spring B Pilot screw 3 Jet needle stopper C Float 4 O-ring D Pilot jet 5 E-ring E Main jet holder 6 Jet needle F Main jet 7 Diaphragm/Piston valve G Needle valve 8 Funnel...
5-10 FUEL AND LUBRICATION SYSTEM DIAPHRAGM AND PISTON OPERATION The carburetor is a variable-venturi type, whose venturi cross sectional area is increased or decreased automatically by the piston valve 1. The piston valve moves according to the negative pressure present on the downstream side of the venturi A.
FUEL AND LUBRICATION SYSTEM 5-11 SLOW SYSTEM This system supplies fuel to the engine during engine operation with throttle valve 1 closed or slight opened. The fuel from the float chamber 2 is first passage and metered by the pilot jet 3 where it mixes with air coming in through #1 pilot air jet 4 and #2 pilot air jet 5.
5-12 FUEL AND LUBRICATION SYSTEM MAIN SYSTEM As the throttle valve 1 is opened, engine speed rises and negative pressure in the venturi A increases. This causes the piston valve 2 moves upward. The fuel in the float chamber 3 is metered by the main jet 4. The metered fuel passes around main air bleed pipe 5, mixes with the air admitted through main air jet 6 to from an emulsion and emulsion fuel enters needle jet 7.
FUEL AND LUBRICATION SYSTEM 5-13 STARTER (ENRICHER) SYSTEM Pulling the starter (enricher) plunger 1 causes fuel to be drawn into the starter circuit from the float chamber The starter jet 3 meters this fuel. The fuel then flows into the fuel pipe 4 and mixes with the air coming from the float chamber 2.
5-14 FUEL AND LUBRICATION SYSTEM ACCELERATOR PUMP SYSTEM This system works only when the rider opens throttle grip quickly as pump send the necessary amount of fuel to the carburetor bore for correcting fuel/air mixture ratio. When the rider open the throttle grip quickly, the intaken air volume becomes large and air velocity at the bottom of the throttle valve (piston valve) is slow and sucking volume of fuel is less.
FUEL AND LUBRICATION SYSTEM 5-15 REMOVAL • Remove the fuel tank. ("5-3) • Loosen the air intake pipe clamp screws. • Disconnect the breather hose. • Move the air inlet pipe to forward. • Remove the throttle cables 1. • Disconnect the throttle position sensor coupler 2. •...
5-16 FUEL AND LUBRICATION SYSTEM • Loosen the clamp screw and remove the carburetor. • Remove the starter plunger. DISASSEMBLY • Remove the carburetor top cap 1. • Remove the spring 2 and piston valve 3 along with diaphragm • Pull out the jet needle holder 5.
FUEL AND LUBRICATION SYSTEM 5-17 • Remove the spring 1, washers 2, 3, retainer 4 and jet needle • Remove the float chamber 6. $ 09900-09004: Impact driver set • Remove the accelerator pump plunger 7. • Remove the O-ring 8. Use a new O-ring to prevent fuel leakage.
5-18 FUEL AND LUBRICATION SYSTEM • Use a %” size drill bit with a drill-stop to remove the pilot screw plug. Set the drill-stop 6 mm from the end of the bit to prevent drilling into the pilot screw. Carefully drill through the plug. Drill-stop Thread a self-tapping sheet metal screw into the plug.
FUEL AND LUBRICATION SYSTEM 5-19 • Remove the casting valve cover. • Remove the casting valve 1 and the spring 2.
5-20 FUEL AND LUBRICATION SYSTEM CARBURETOR CLEANING Some carburetor cleaning chemicals, especially diptype soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and storage. • Clean all jets with a spray-type carburetor cleaner and dry them using compressed air.
FUEL AND LUBRICATION SYSTEM 5-21 CARBURETOR HEATER INSPECTION (for E02, E19) • Disconnect the carburetor heater terminal lead wires. • Connect the positive + terminal of a 12V battery to the termi- nal of the carburetor heater and the battery negative - termi- nal to the terminal.
5-22 FUEL AND LUBRICATION SYSTEM FLOAT HEIGHT ADJUSTMENT • Measure the float height A by using a calipers with the carbu- retor slanting at an angle of 45° (as shown in the right illustra- tion) and the float arm just contacting the needle valve. •...
Replace the O-ring A with a new one. • Apply grease to the O-ring and install the accelerating plunger. For USA ' 99000-25030: SUZUKI SUPER GREASE “A” For the other countries ' 99000-25010: SUZUKI SUPER GREASE “A” • Fit the seal rings securely to the float chamber and install the...
• Align the protrusion C of the carbureto top cap with the O-ring STARTER PLUNGER Apply a small quantity of grease to the starter plunger O-ring. For USA ' 99000-25030: SUZUKI SUPER GREASE “A” For the other countries ' 99000-25010: SUZUKI SUPER GREASE “A” Replace the O-rings with new ones.