Suzuki LT-Z50 Service Manual
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Suzuki LT-Z50 Service Manual

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FOREWORD
This manual contains an introductory description on
the SUZUKI LT-Z50 and procedures for its inspec-
tion/service and overhaul of its main components.
Other information considered as generally known is
not included.
Read the GENERAL INFORMATION section to
familiarize yourself with the vehicle and its mainte-
nance. Use this section as well as other sections to
use as a guide for proper inspection and service.
This manual will help you know the vehicle better so
that you can assure your customers of fast and reli-
able service.
* This manual has been prepared on the basis
of the latest specifications at the time of publi-
cation. If modifications have been made since
then, differences may exist between the con-
tent of this manual and the actual vehicle.
* Illustrations in this manual are used to show
the basic principles of operation and work
procedures. They may not represent the
actual vehicle exactly in detail.
* This manual is written for persons who have
enough knowledge, skills and tools, including
special tools, for servicing SUZUKI vehicles.
If you do not have the proper knowledge and
tools, ask your authorized SUZUKI motorcy-
cle dealer to help you.
Inexperienced mechanics or mechanics
without the proper tools and equipment
may not be able to properly perform the
services described in this manual.
Improper repair may result in injury to the
mechanic and may render the vehicle
unsafe for the rider.
© COPYRIGHT SUZUKI MOTOR CORPORATION 2005
GROUP INDEX

GENERAL INFORMATION

PERIODIC MAINTENANCE

ENGINE

FUEL SYSTEM

CHASSIS

ELECTRICAL SYSTEM

SERVICING INFORMATION

1
2
3
4
5
6
7
99500-40011-03E

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Summary of Contents for Suzuki LT-Z50

  • Page 1: General Information

    FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI LT-Z50 and procedures for its inspec- tion/service and overhaul of its main components. GENERAL INFORMATION Other information considered as generally known is not included. Read the GENERAL INFORMATION section to...
  • Page 3 SUPPLEMENTS LT-Z50K9 ( 09-MODEL)
  • Page 4 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.
  • Page 5 Apply molybdenum oil solution. (mixture of engine oil and SUZUKl Measure in resistance range. MOLY PASTE in a ratio of 1 : 1) Apply SUZUKI SUPER GREASE “A” or equivalent. Measure in diode test range. 99000-25010 Apply SUZUKI MOLY PASTE or equiva- lent.

  • Page 6: Table Of Contents

    GENERAL INFORMATION 1-1 GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE .................1- 2 GENERAL PRECAUTIONS................1- 2 SUZUKI LT-Z50K6 (’06-MODEL) ..............1- 4 SERIAL NUMBER LOCATION..............1- 4 FUEL AND OIL RECOMMENDATION ............1- 5 FUEL (FOR USA AND CANADA)............1- 5 FUEL (FOR OTHER COUNTRIES)............1- 5 ENGINE OIL AND FINAL REDUCTION GEAR BOX OIL (FOR USA) ....................1- 5...

  • Page 7: Warning/Caution/Note

    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. ...
  • Page 8 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 and orientation.

  • Page 9: Suzuki Lt-Z50K6 ('06-Model)

    1-4 GENERAL INFORMATION SUZUKI LT-Z50K6 (’06-MODEL) RIGHT SIDE LEFT SIDE • Difference between photograph and actual vehicle may exist depending on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the left side of the rear frame pipe.

  • Page 10: Fuel And Oil Recommendation

    Suzuki recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or equivalent engine oil. Use of API SF/SG or SH/SJ with JASO MA. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an alternative according to the following chart.

  • Page 11: Break-In Procedures

    1-6 GENERAL INFORMATION BREAK-IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses.

  • Page 12: Information Labels

    GENERAL INFORMATION 1-7 INFORMATION LABELS 1 Certification plate A (For P-03, 19) 2 Compliance label A (For P-28) 3 Manual notice label A (For P-03) 4 Parking brake label (English) A (For P-03, 19, 28) 5 Parking brake label (French) A (For P-28) 6 Tire air pressure and warning no-passenger label (English) A (For P-03, 19, 28)

  • Page 13: Specifications

    1-8 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length................1 270 mm (50.0 in) Overall width ................760 mm (29.9 in) Overall height................765 mm (30.1 in) Wheelbase ................830 mm (32.7 in) Ground clearance ..............120 mm (4.7 in) Seat height................

  • Page 14: Chassis

    GENERAL INFORMATION 1-9 CHASSIS Front suspension..............Independent, swing axle, coil spring, oil damped Rear suspension ..............Swingarm, coil spring, oil damped Front wheel travel..............52 mm (2.0 in) Rear wheel travel ..............51 mm (2.0 in) Caster..................3 ° Trail ..................10 mm (0.39 in) Toe-in ..................

  • Page 16: Periodic Maintenance

    PERIODIC MAINTENANCE 2-1 PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE .............2- 2 PERIODIC MAINTENANCE CHART .............2- 2 MAINTENANCE AND TUNE-UP PROCEDURES ........2- 3 AIR CLEANER ..................2- 3 EXHAUST PIPE NUTS AND MUFFLER MOUNTING BOLT ....2- 5 VALVE CLEARANCE ................2- 5 SPARK PLUG ..................2- 7 SPARK ARRESTER ................2- 8 FUEL LINE .....................2- 8 ENGINE OIL ...................2- 9...

  • Page 17: Periodic Maintenance Schedule

    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 vehicle operating at peak performance and economy. NOTE: More frequent servicing may be required on vehicles that are used under severe conditions. PERIODIC MAINTENANCE CHART Interval Initial...

  • Page 18: Maintenance And Tune-Up Procedures

    PERIODIC MAINTENANCE 2-3 MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item of the periodic maintenance requirements. Before performing the servicing procedures mentioned in the periodic maintenance chart, remove following parts to ease ser- vicing work; •...
  • Page 19 2-4 PERIODIC MAINTENANCE • Fill a container with a non-flammable cleaning solvent. • Immerse the air cleaner element in the cleaning solvent and wash it. • Squeeze the cleaning solvent out of the washed element by pressing it between the palms of both hands: do not twist or wring the element or it will develop tears.

  • Page 20: Exhaust Pipe Nuts And Muffler Mounting Bolt

    PERIODIC MAINTENANCE 2-5 EXHAUST PIPE NUTS AND MUFFLER MOUNTING BOLT Tighten initially at 1 month and every 3 months there- after. • Tighten the exhaust pipe nuts 1 and muffler mounting bolt 2 to the specified torque.  Exhaust pipe nut: 10 N·m (1.0 kgf-m, 7.0 lb-ft) Muffler mounting bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) VALVE CLEARANCE...
  • Page 21 2-6 PERIODIC MAINTENANCE • Turn the crankshaft counterclockwise, to bring the line A on the generator rotor to the index mark B of the generator case. • Press intake and exhaust rocker arm to the inside and mea- sure the valve clearance. ...

  • Page 22: Spark Plug

    PERIODIC MAINTENANCE 2-7 SPARK PLUG Inspect every 6 months. Replace every 18 months. • Disconnect the spark plug cap 1 and remove the spark plug Standard Cold type CR6HSA CR7HSA DENSO U20FSR-U U22FSR-U CARBON DEPOSITS Check carbon deposits on the spark plug. •...

  • Page 23: Spark Arrester

    2-8 PERIODIC MAINTENANCE SPARK PLUG INSTALLATION  To avoid damaging the cylinder head threads; first, tighten the spark plug by hand and then tighten it to the specified torque using the spark plug wrench. • Tighten the spark plug to the specified torque. ...

  • Page 24: Engine Oil

    PERIODIC MAINTENANCE 2-9 ENGINE OIL Inspect each time the vehicle is ridden. Replace initially 1 month and every 6 months thereaf- ter. ENGINE OIL LEVEL CHECK Follow the procedure below to inspect the engine oil level. • Place the vehicle on level ground. •...

  • Page 25: Final Reduction Gear Box Oil

    2-10 PERIODIC MAINTENANCE FINAL REDUCTION GEAR BOX OIL Inspect every 6 months. Replace every 2 years. FINAL REDUCTION GEAR BOX OIL LEVER CHECK • Place the vehicle on level ground. • Remove the right frame cover. (5-4) • Remove the generator cover 1. •...

  • Page 26: Engine Idle Speed

    PERIODIC MAINTENANCE 2-11 • Loosen the lock-nut 1 of the throttle cable. • Turn the adjuster 2 in or out to obtain the correct play. • After adjusting the throttle cable play, tighten the locknut 1.  Throttle cable play: 3 – 5 mm (0.12 – 0.20 in) ...
  • Page 27 2-12 PERIODIC MAINTENANCE • Remove the fixed drive face nut 3 and starter cup 4 with the special tool.  09930-40113: Rotor holder • Remove the fixed drive face 5. • Remove the clutch housing 6 with the special tool. ...
  • Page 28 PERIODIC MAINTENANCE 2-13 REMOUNTING Remount the drive belt in the reverse order of removal. Pay attention to the following points: • Insert the drive belt, as low as possible, between the movable driven face to provide the maximum drive belt clearance before installing.

  • Page 29: Drive Chain

    * Rusted links * Kinked or binding links If any defects are found, the drive chain must be replaced.  The standard drive chain is D.I.D. 415. SUZUKI recom- mends to use this standard drive chain as a replace- ment. NOTE: When replacing the drive chain, replace the drive chain and sprockets as a set.

  • Page 30: Drive Chain Slack

    PERIODIC MAINTENANCE 2-15 • Count out 21 pins (20-pitch) on the chain and measure the distance between the two points. If the distance exceeds the service limit, the chain must be replaced.  Drive chain 20-pitch length: Service limit: 259.0 mm (10.20 in) ADJUSTING •...
  • Page 31 2-16 PERIODIC MAINTENANCE • After cleaning and drying the chain, oil it with a heavy-weight engine oil.  Direction of travel The drive chain joint clip should be attached in the way that the slit end will face opposite to the direction of travel.

  • Page 32: Brakes

    PERIODIC MAINTENANCE 2-17 BRAKES Inspect initially at 1 month and every 3 months there- after. FRONT BRAKE LEVER PLAY • Adjust the right and left cable end length A to become equal by adjusting nuts 1. 2 – 3 mm •...

  • Page 33: Tires

    2-18 PERIODIC MAINTENANCE TIRES 4.0 mm Inspect every month. TIRE TREAD CONDITION Operating the vehicle 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 the tire tread reaches the following specification.

  • Page 34: Steering

    PERIODIC MAINTENANCE 2-19 STEERING Inspect initially at 1 month and every 3 months there- after. Steering system should be adjusted properly for smooth manip- ulation of the handlebar and safe running. TOE-IN • Place the vehicle on level ground. • Make sure the tire pressure for both tire is the same and set to the proper specification.

  • Page 35: Chassis Nuts And Bolts

    2-20 PERIODIC MAINTENANCE CHASSIS NUTS AND BOLTS Tighten initially at 1 month and every 3 months there- after. Check that all chassis nuts and bolts are tightened to their specified torque. (Refer to page 2-21 for the loca- tions of the following nuts and bolts.) Item N·m kgf-m...
  • Page 36 PERIODIC MAINTENANCE 2-21...

  • Page 37: General Lubrications

    2-22 PERIODIC MAINTENANCE GENERAL LUBRICATIONS Lubricate every 3 months. Proper lubrication is important for smooth operation and long life of each working part of the vehicle. Major lubrication points are indicated below. 1 Steering shaft holder 2 Brake lever holder 3 Brake cable 4 Throttle cable 5 Drive chain...

  • Page 38: Compression Pressure Check

    PERIODIC MAINTENANCE 2-23 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: Standard: 1 100 –...

  • Page 39: Initial Engagement And Clutch Lock-Up Inspection

    2-24 PERIODIC MAINTENANCE INITIAL ENGAGEMENT AND CLUTCH LOCK-UP INSPECTION The LT-Z50 is equipped with a centrifugal type automatic clutch. To insure proper performance and longevity of the clutch assemblies it is essential that the clutches engage smoothly and gradually. Before checking the initial engagement and clutch lock-up two inspection checks must be performed to thoroughly check the operation of the drive train.

  • Page 40: Clutch Lock-Up Inspection

    PERIODIC MAINTENANCE 2-25 CLUTCH LOCK-UP INSPECTION Perform this inspection to determine if the clutch is engaging fully and not slipping. • Connect a multi-circuit tester onto the spark plug high-tension code. • Start the engine. • Apply the front and rear brakes as firmly as possible. •...
  • Page 42 ENGINE 3-1 ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ...3- 2 ENGINE CENTER ..................3- 2 ENGINE LEFT SIDE ................3- 2 ENGINE RIGHT SIDE ................3- 2 ENGINE REMOVAL AND INSTALLATION ..........3- 3 ENGINE REMOVAL ................3- 3 ENGINE INSTALLATION ...............3- 6 POWER REDUCTION SPACER ............3- 8 ENGINE DISASSEMBLY ................3- 9 ENGINE COMPONENTS INSPECTION AND SERVICING ......3-15...

  • Page 43: Engine Components Removable With Engine In Place

    3-2 ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and installed without removing the engine from the frame. Refer to the page listed in each section for removal and installation instructions. ENGINE CENTER PARTS REMOVAL INSTALLATION...

  • Page 44: Engine Removal And 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. • Drain engine oil. (2-9) • Remove the frame center cover. (5-5) MUFFLER •...
  • Page 45 3-4 ENGINE • Remove the vacuum hose 5. • Remove the carburetor assembly 6. DRIVE CHAIN • Remove the clip 1. • Remove the drive chain 2. ELECTRICAL PARTS AND HOSES • Disconnect the starter motor lead wire coupler 1. •...
  • Page 46 ENGINE 3-5 ENGINE MOUNTING BRACKET AND BOLTS • Remove the engine mounting bracket 1. • Remove the engine mounting bolts and nuts. • Remove the engine from the left side.

  • Page 47: Engine Installation

    3-6 ENGINE ENGINE INSTALLATION Install the engine in the reverse order of engine removal. Pay attention to the following points:  1 Engine mounting bolt (25 mm) 4 Engine mounting bolt (40 mm) 2 Engine mounting bolt (30 mm) A Engine mounting nut ITEM N·m kgf-m lb-ft 3 Engine mounting bolt (35 mm)
  • Page 48 Direction of travel • Apply SUZUKI SUPER GREASE “A” to the O-ring.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent  The removed O-ring must be replaced with a new one.

  • Page 49: Power Reduction Spacer

    The power reduction spacer has been installed inside of the movable drive.  Do not remove the power reduction spacer until the rider develops sufficient skills to operate LT-Z50 safety at the maximum speed with the power reduc- tion system in place. REMOVAL •...

  • Page 50: Engine Disassembly

    ENGINE 3-9 ENGINE DISASSEMBLY SPARK PLUG • Remove the spark plug with a spark plug wrench. CYLINDER HEAD COVER • Remove the cylinder head cover 1 and its gasket. GENERATOR COVER • Remove the generator cover 1. A: Hooked part CYLINDER HEAD •...
  • Page 51 3-10 ENGINE • Remove the push rods 2. • Remove the gasket 3 and dowel pins 4. STARTER MOTOR • Remove the starter motor 1. GENERATOR • Remove the generator rotor nut with the special tool.  09930-40113: Rotor holder ...
  • Page 52 ENGINE 3-11 RECOIL STARTER • Remove the recoil starter 1. MOVABLE DRIVE • Remove the CVT case cover 1. • Remove the dowel pins 2 and gasket 3. • Remove the starter pinion 4. • Remove the fixed drive face nut 5 with the special tool. ...
  • Page 53 3-12 ENGINE • Remove the movable drive spacer 7 together with the power reduction spacer 8 and movable drive face assembly 9. NOTE: Movable drive face disassembly. (3-36) • Remove the washer 0. MOVABLE DRIVEN • Remove the clutch housing 1 with the special tool. ...
  • Page 54 ENGINE 3-13 • Remove the dowel pins 2 and gasket 3. GENERATOR CASE • Remove the generator case 1. • Remove the dowel pins 2 and gasket 3. CAM ROCKER ARM • Remove the washer 1 and camshaft assembly 2. •...
  • Page 55 3-14 ENGINE UPPER CRANKCASE/CYLINDER AND LOWER CRANK- CASE • Remove the crankcase bolts. • Remove the dowel pins 1. CRANKSHAFT • Remove the crankshaft 1 together with piston. • Remove the crankshaft bearing retainer 2. PISTON • Remove the piston pin circlip 1. •...

  • Page 56: Engine Components Inspection And Servicing

    ENGINE 3-15 ENGINE COMPONENTS INSPECTION AND SERVICING CYLINDER HEAD DISASSEMBLY • Remove the intake pipe 1 and insulator 2. • Pull out the rocker arm shaft 3. • Remove the intake rocker arm 4 and exhaust rocker arm 5. • Push the spring retainer 6 by the finger and move it side- ways.
  • Page 57 3-16 ENGINE • Remove the intake valve stem seal 0 with an acute angle bar.  The removed valve stem seal must be replaced with a new one. ROCKER ARM SHAFT INSPECTION Inspect the rocker arm shaft for abnormal wear or damage. If it is worn or damaged, replace it with a new one.
  • Page 58 ENGINE 3-17 VALVE FACE WEAR Visually inspect each valve for wear or damage of its seating face. If anything unusual is found, replace the valve with a new one. Measure the valve head thickness T. If the thickness is less than the service limit, replace the valve with a new one.
  • Page 59 3-18 ENGINE VALVE STEM WEAR If the valve stem is worn down to the limit, as measured with a micrometer, replace the valve. If the stem is within the limit, replace the cylinder head. After replacing the valve, be sure to recheck the deflection. ...
  • Page 60 ENGINE 3-19 VALVE SPRING The force of the coil spring keeps the valve seat tight. Weak- ened spring results in reduced engine power output, and often account for the chattering noise coming from the valve mecha- nism. • Check the valve springs for proper strength by measuring their free length and also by the force required to compress them.

  • Page 61: Rocker Arm Push Rod

    3-20 ENGINE • Assemble the valve spring 1 and spring retainer 2. • Push the spring retainer by the finger with the valve prevented from falling. • Incline the spring retainer 2 and set it into the valve stem groove. ...

  • Page 62: Camshaft Assembly

    ENGINE 3-21 CAMSHAFT ASSEMBLY INSPECTION Check the camshaft for abnormal wear or damage. Measure the cam height H with a micrometer. If the cam height H is less than the service limit, replace the camshaft assembly with a new one. ...

  • Page 63: Piston And Piston Ring

    3-22 ENGINE CYLINDER BORE Inspect the cylinder wall for any scratches, nicks or other dam- age. If anything unusual is found, replace the upper crankcase/cylin- der. Measure the cylinder bore diameter at six places.  Cylinder bore: Standard: 36.005 – 36.015 mm (1.4175 – 1.4179 in) PISTON AND PISTON RING PISTON DIAMETER Measure the piston outside diameter at 5 mm (0.2 in) height...

  • Page 64: Piston Ring End Gap

    ENGINE 3-23 PISTON RING FREE END GAP AND PISTON RING END GAP Measure the piston ring free end gap with a vernier calipers. Next, fit the piston ring squarely into the cylinder and measure the piston ring end gap with a thickness gauge. If any of the measurements exceeds the service limit, replace the piston ring with a new one.

  • Page 65: Conrod And Crankshaft

    3-24 ENGINE CONROD AND CRANKSHAFT CONROD SMALL END I.D. Measure the conrod small end inside diameter with a caliper gauge. If the conrod small end inside diameter exceeds the service limit, replace the conrod.  Conrod small end I.D.: Service Limit: 10.040 mm (0.3952 in) ...
  • Page 66 ENGINE 3-25 CRANKSHAFT BEARING INSPECTION Play Inspect the outer race play and smooth rotation of the bearing by hand while it is on the crankshaft. If any abnormality is found, replace the bearing with a new one. Play NOTE: If there is no abnormal noise, the bearing removal is not neces- sary.
  • Page 67 3-26 ENGINE CRANKSHAFT BEARING INSTALLATION • Press-fit the bearing with the bearing installer and suitable plate as shown in the illustration. Suitable plate • Press-fit the cam drive gear 1 with the suitable tool.  Phase angle between the crank pin center A and the cam drive gear engraved line B: 0°...

  • Page 68: Cam Rocker Arm

    ENGINE 3-27 CONROD BIG END SIDE CLEARANCE INSPECTION Push the big end of the conrod to one side and measure the side clearance with a thickness gauge. If the clearance exceeds the limit, replace the crankshaft assem- bly with a new one or bring the deflection and the side clearance within the service limit by replacing the worn parts (conrod, crank pin bearing, crank pin, etc.) with the new ones.
  • Page 69  ...
  • Page 70 ENGINE 3-1 ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ...3- 2 ENGINE CENTER ..................3- 2 ENGINE LEFT SIDE ................3- 2 ENGINE RIGHT SIDE ................3- 2 ENGINE REMOVAL AND INSTALLATION ..........3- 3 ENGINE REMOVAL ................3- 3 ENGINE INSTALLATION ...............3- 6 POWER REDUCTION SPACER ............3- 8 ENGINE DISASSEMBLY ................3- 9 ENGINE COMPONENTS INSPECTION AND SERVICING ......3-15...

  • Page 71: Final Reduction Gear Box And Cvt Case

    3-28 ENGINE FINAL REDUCTION GEAR BOX AND CVT CASE DISASSEMBLY • Remove the snap ring 1 and engine sprocket 2. • Remove the drain plug 3 and gasket. • Drain final reduction gear box oil. • Remove the final reduction gear box cover 4. NOTE: Loosen the final reduction gear box cover bolts little by little and diagonally.
  • Page 72 ENGINE 3-29 DRIVE SHAFT INSPECTION Inspect the drive shaft for wear or damage. If it is worn or damaged, replace it with a new one. BEARING INSPECTION Play Play Rotate the bearing inner race by finger to inspect for abnormal play, noise and smooth rotation while the bearings are in the those cases.
  • Page 73  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the oil seal 2 with the special tool.  09913-70210: Bearing installer set • Apply SUZUKI SUPER GREASE “A” to the oil seal lip.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
  • Page 74 • Install the snap ring 4 securely. • Install the oil seal 5 with the special tool.  09913-70210: Bearing installer set • Apply SUZUKI SUPER GREASE “A” to the oil seal lip.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent BUSHING INSPECTION Inspect the CVT case bushing for wear or damage.
  • Page 75 • Install the washer 4 and 5. • Install the dowel pins 6.  Apply final reduction gear box oil to the gears. • Apply SUZUKI BOND “1215” to the final reduction gear box cover matching surface.  99000-31110: SUZUKI BOND “1215” or equivalent NOTE: * Make surfaces free from moisture, oil, dust and other foreign materials.

  • Page 76: Cvt Case Cover

    ENGINE 3-33 • Install the engine sprocket 8. • Install the snap ring 9.  The removed snap ring must be replaced with a new one.  Snap ring Thrust When installing a new snap ring, pay attention to the direction of the snap ring.

  • Page 77: Starter Pinion

    The removed oil seal must be replaced with a new one. • Install the oil seal 2 with the special tool.  09913-70210: Bearing installer set • Apply SUZUKI SUPER GREASE “A” to the oil seal lip.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent STARTER PINION INSPECTION •...

  • Page 78: Movable And Fixed Drive And Driven Face

    ENGINE 3-35 MOVABLE AND FIXED DRIVE AND DRIVEN FACE 1 Concaved washer C Movable driven face spring 2 Fixed drive face D Movable driven face spring seat 3 Drive belt E Roller 4 Movable drive spacer F Pin 5 Power reduction spacer G Movable driven face 6 Movable drive face H Fixed driven face...
  • Page 79 3-36 ENGINE MOVABLE DRIVE DISASSEMBLY • Remove the movable drive face plate 1 and dampers 2. • Remove the rollers 3. SPACER INSPECTION Inspect the movable drive spacer 1 and power reduction spacer 2 for any wear or damage. If they are worn or damaged, replace them with new ones. MOVABLE AND FIXED DRIVE FACE INSPECTION Inspect the drive face for any abnormal condition such as stepped wear or discoloration caused by burning.
  • Page 80 ENGINE 3-37 DAMPER INSPECTION Inspect the dampers for wear or damage. If any defects are found, replace the dampers with new ones. REASSEMBLY • Position the rollers 1 on the movable drive face 2. • Mount the dampers 3 on the movable drive face plate 4. •...
  • Page 81 3-38 ENGINE • Loosen the special tool handle slowly and remove the clutch shoe assembly 4 and spring 5.  Do not attempt to disassemble the clutch shoe assem- bly. • Remove the movable driven face spring seat 6. • Remove the pins 7 together with rollers 8. •...
  • Page 82 ENGINE 3-39 BEARING INSPECTION Play Play Rotate the bearing inner race by finger to inspect for abnormal play, noise and smooth rotation while the bearing is in the fixed driven face. Replace the bearing in the following procedure if there is any- thing unusual.
  • Page 83 3-40 ENGINE Measure the thickness of clutch shoe at the center position. If the thickness is less than the service limit, replace the clutch shoe assembly with a new one.  Clutch shoe thickness: Service Limit: 3.0 mm (0.12 in) ...
  • Page 84 Position the needle bearing with its punch mark out- side. • Apply SUZUKI SUPER GREASE “A” to the needle bearing.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the movable driven face 5 onto the fixed driven face...
  • Page 85 3-42 ENGINE • Install the pins 6 to the pin hole with the rollers 7 fitted. • Install the movable driven face spring seat 8 to the movable driven face 5 securely. • Install the spring 9 and clutch shoe assembly 0 onto the movable driven face 5.

  • Page 86: Recoil Starter

    ENGINE 3-43 RECOIL STARTER 1 Starter cup spacer 8 Reel 2 Starter cup 9 Spiral spring 3 Starter cup bolt 0 Starter case 4 Friction plate A Rope  5 Friction spring B Knob 6 Ratchet C Cap ITEM N·m kgf-m lb-ft 7 Return spring A Recoil starter friction plate bolt 0.54...
  • Page 87 3-44 ENGINE DISASSEMBLY • Remove the bolt 1 and friction plate 2. • Remove the ratchet 3 and return spring 4. • Remove the cap 5 from the knob 6. • Untie a knot at the rope. • Hook the rope to the groove A of the reel 7. •...
  • Page 88 • Tie a knot at the end of the rope. • Install the cap 3 to the knob 4. • Apply SUZUKI SUPER GREASE “A” to the sliding part of the ratchet and reel.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
  • Page 89 • Apply SUZUKI SUPER GREASE “A” to the return spring 5.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the return spring 5. • Apply SUZUKI SUPER GREASE “A” to the sliding part of the friction spring 6 and ratchet.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent •...

  • Page 90: Engine Reassembly

    ENGINE 3-47 ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassembly. Pay special attention to the following points: NOTE: Apply engine oil to each running and sliding surface before reas- sembling. PISTON RING AND PISTON • Install the piston rings in the order of oil ring, 2nd ring and 1st ring.
  • Page 91 CRANKSHAFT • Apply engine oil to the crankshaft bearing 1. • Apply SUZUKI SUPER GREASE “A” to the oil seal lip.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the oil seal 2 to the crankshaft.
  • Page 92 NOTE: Apply engine oil to the bearing 6 balls and conrod big end 7. CRANKCASE • Apply SUZUKI BOND “1215” to the lower crankcase matching surface.  99000-31110: SUZUKI BOND “1215” or equivalent NOTE: Use of SUZUKI BOND is as follows: * Make surfaces free from moisture, oil, dust and other foreign materials.
  • Page 93 • Align the hole A of the camshaft 1 with the matching mark B on the cam drive gear 3. NOTE: Piston must be at TDC before installing the cam assembly. • Apply SUZUKI BOND “1215” to the part shown in the photo- graph.  99000-31110: SUZUKI BOND “1215” or equivalent NOTE: Make surfaces free from moisture, oil, dust and other foreign materials.
  • Page 94 ENGINE 3-51 • Tighten the generator case bolts to the specified torque.  Generator case bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft) CVT CASE • Install the dowel pins 1 and gasket 2.  The removed gasket must be replaced with a new one. •...
  • Page 95 3-52 ENGINE • Tighten the clutch housing nut 3 to the specified torque with the special tool.  09930-40113: Rotor holder  Clutch housing nut: 50 N·m (5.0 kgf-m, 36.0 lb-ft) NOTE: Degrease the inside of the clutch housing and clutch shoe. MOVABLE DRIVE FACE •...
  • Page 96 ENGINE 3-53 NOTE: Turn the fixed drive face 3 until the drive belt is seated in and both the drive and driven faces will move together smoothly without slip. CVT CASE COVER • Install the dowel pins 1 and gasket 2. ...
  • Page 97 3-54 ENGINE • Tighten the generator rotor nut 4 to the specified torque with the special tool.  09930-40113: Rotor holder  Generator rotor nut: 35 N·m (3.5 kgf-m, 25.5 lb-ft)  Be careful not to damage the generator coil by the special tool.
  • Page 98 ENGINE 3-55 • Install the gasket 2 and dowel pins 3.  The removed gasket must be replaced with a new one. • Install the cylinder head. • Position the push rods 1 to the rocker arm adjust bolt hollows ...
  • Page 99 3-56 ENGINE B: Hooked part CYLINDER HEAD COVER • Assemble the cylinder head cover gasket 1.  The removed gasket must be replaced with a new one. • Tighten the cylinder head cover bolts to the specified torque.  Cylinder head cover bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft) •...
  • Page 100 FUEL SYSTEM 4-1 FUEL SYSTEM CONTENTS FUEL TANK AND FUEL VALVE ..............4- 2 REMOVAL ....................4- 3 FUEL FILTER INSPECTION AND CLEANING ........4- 3 REMOUNTING ..................4- 4 CARBURETOR ....................4- 5 SPECIFICATIONS...................4- 6 I.D. NO. LOCATION ................4- 6 REMOVAL ....................4- 7 DISASSEMBLY ..................4- 8 CLEANING ....................4-11 INSPECTION AND ADJUSTMENT............4-11 REASSEMBLY AND REMOUNTING............4-12...

  • Page 101: Fuel Tank And Fuel Valve

    4-2 FUEL SYSTEM FUEL TANK AND FUEL VALVE 1 Fuel tank breather hose 6 Fuel hose 2 Fuel tank cap 7 O-ring  3 Fuel tank inlet rubber 8 Vacuum hose 4 Fuel tank 9 Gasket ITEM N·m kgf-m lb-ft 5 Fuel valve A Fuel valve bolt 0.45...

  • Page 102: Removal

    FUEL SYSTEM 4-3 REMOVAL  * Gasoline is highly flammable and explosive. * Keep heat, spark and flame away. • Remove the frame center cover. (5-5) • Turn the fuel valve to “ON” position. • Disconnect the fuel hose 1. •...

  • Page 103: Remounting

    4-4 FUEL SYSTEM REMOUNTING Remount the fuel tank and fuel valve in the reverse order of removal. Pay attention to the following points: • Tighten the fuel valve bolts to the specified torque.  Fuel valve bolt: 4.5 N·m (0.45 kgf-m, 3.3 lb-ft) ...

  • Page 104: Carburetor

    FUEL SYSTEM 4-5 CARBURETOR 1 Choke lever 0 Spring I Needle jet 2 Carburetor top cap A Throttle stop screw J Main jet 3 Spring B Air vent hose K Float pin 4 Spring seat C O-ring L Float 5 Jet needle D Needle valve seat M Gasket 6 Piston valve...

  • Page 105: Specifications

    4-6 FUEL SYSTEM SPECIFICATIONS ITEM SPECIFICATION Carburetor type MIKUNI VM13 Bore size 13 mm I.D. No 43G0 Idle r/min. 2 000 ± 150 r/min. Float height 23.4 ± 1.0 mm (0.92 ± 0.04 in) Main jet (M.J.) #58.8 Jet needle (J.N.) 3N39-1st Needle jet (N.J.) Pilot jet (P.J.)

  • Page 106: Removal

    FUEL SYSTEM 4-7 REMOVAL • Remove the left frame cover. (5-4) • Remove the right frame cover. (5-4) • Remove the fuel hose 1. • Remove the air vent hose 2. • Remove the vacuum hose 3. • Loosen the drain plug 4. •...

  • Page 107: Disassembly

    4-8 FUEL SYSTEM DISASSEMBLY  The removed O-rings and gasket must be replaced with new ones. • Remove the spring 1 and piston valve 2 from the throttle cable. • Remove the spring seat 3. • Remove the jet needle 4 from the piston valve 2. •...
  • Page 108 FUEL SYSTEM 4-9 • Remove the gasket 7. • Remove the float pin 8. • Remove the float 9. • Remove the needle valve 0. • Remove the main jet A and needle jet B. • Remove the pilot jet C. •...
  • Page 109 4-10 FUEL SYSTEM • Remove the spring H, washer I and O-ring J. • Remove the choke lever K. • Remove the starter plunger L.

  • Page 110: Cleaning

    FUEL SYSTEM 4-11 CLEANING  Some carburetor cleaning chemicals, especially dip-type 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 with compressed air.

  • Page 111: Reassembly And Remounting

    4-12 FUEL SYSTEM If the needle valve is worn, as shown in the illustration, replace the needle valve assembly with a new one. Clean the fuel pas- sage of the mixing chamber with compressed air. FLOAT HEIGHT ADJUSTMENT To check the float height, turn the carburetor upside down. Mea- sure the float height A while the float arm is just contacting the needle valve with vernier calipers.
  • Page 112 PISTON VALVE AND SPRING • Install the piston valve 1 and spring 2 to the throttle cable. CARBURETOR • Apply SUZUKI SUPER GREASE “A” to the O-ring 1.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent  The O-ring must be replaced with a new one.
  • Page 113 4-14 FUEL SYSTEM • After remounting the carburetor, perform the following: * Inspect fuel leakage. * Engine idle r/min adjustment..... 2-11 * Throttle cable play adjustment ....2-10...
  • Page 114 CHASSIS 5-1 CHASSIS CONTENTS EXTERIOR PARTS ..................5- 2 CONSTRUCTION .................. 5- 2 FASTENER REMOVAL AND INSTALLATION ........5- 3 REMOVAL ..................... 5- 4 REMOUNTING ..................5- 6 FRONT AND REAR WHEELS ..............5- 7 CONSTRUCTION .................. 5- 7 REMOVAL ..................... 5- 7 REMOUNTING ..................

  • Page 115: Exterior Parts

    5-2 CHASSIS EXTERIOR PARTS CONSTRUCTION 1 Seat 5 Maintenance lid 9 Fuel tank cap 2 Battery holder 6 Front frame cover 0 Fuel tank inlet rubber 3 Frame center cover 7 Left frame cover A Fuel tank 4 Right frame cover 8 Front grip...

  • Page 116: Fastener Removal And Installation

    CHASSIS 5-3 FASTENER REMOVAL AND INSTALLATION FASTENER Removal • Depress the head of fastener center piece 1. • Pull out the fastener a. Installation • Let the center piece stick out toward the head so that the pawls 2 close. •...

  • Page 117: Removal

    5-4 CHASSIS REMOVAL SEAT • Remove the seat. FRONT FRAME COVER • Remove the fasteners. • Remove the ignition switch ring nut 1. • Remove the front frame cover 2. NOTE: “✩” indicates hook location. LEFT FRAME COVER • Remove the screws 1 and fasteners. •...
  • Page 118 CHASSIS 5-5 FRAME CENTER COVER • Remove the seat. (5-4) • Remove the front frame cover. (5-4) • Remove the left frame cover. (5-4) • Remove the right frame cover. (5-4) • Disconnect the - battery cable first, and then + battery cable.

  • Page 119: Remounting

    5-6 CHASSIS MAINTENANCE LID • Remove the fastener. • Remove the maintenance lid 1. FRONT GRIP • Remove the front grip. REMOUNTING Remount the exterior parts in the reverse order of removal. Pay attention to the following points: FUEL TANK INLET RUBBER •...

  • Page 120: Front And Rear Wheels

    CHASSIS 5-7 FRONT AND REAR WHEELS CONSTRUCTION  1 Front tire 4 Rear wheel 2 Front wheel A Wheel set nut (front & rear) ITEM N·m kgf-m lb-ft 3 Rear tire 20.0 REMOVAL • Place the vehicle on level ground. •...

  • Page 121: Tires

    5-8 CHASSIS TIRES TIRE REPLACEMENT • Remove the front and rear wheels. (5-8) • After removing the air valve caps, release the tire pressure by depressing the valves. • Dismount the bead from the rim completely as shown. • Separate the tire from the rim using a set of tire levers and rim protectors.
  • Page 122 CHASSIS 5-9 • When installing each tire, make sure the arrow A on the tire points in the direction of rotation. Also, make sure the outer side of the wheel rim is facing outward. NOTE: For inspecting the tires, refer to page 2-18. Inspect the valve cores, before installing.

  • Page 123: Front Brake

    5-10 CHASSIS FRONT BRAKE CONSTRUCTION 1 Wheel center cap 0 Front brake camshaft 2 Axle spacer A O-ring 3 Outer dust seal B Front brake dust seal 4 Wheel hub outer bearing C Brake plate 5 Front wheel hub D Brake cam lever ...

  • Page 124: Removal

    CHASSIS 5-11 REMOVAL • Remove the front wheel. (5-8) • Remove the wheel center cap. • Remove the cotter pin and front hub nut 1.  The removed cotter pin must be replaced with a new one. • Remove the front wheel hub 2. •...

  • Page 125: Inspection And Disassembly

    5-12 CHASSIS • Remove the brake plate 0. • Remove the axle spacer A. INSPECTION AND DISASSEMBLY BRAKE DRUM/WHEEL HUB Inspect the brake drum and measure the brake drum I.D. to determine the extent of wear. Replace the brake drum if the measurement exceeds the service limit.
  • Page 126 CHASSIS 5-13 DUST SEAL • Remove the each dust seal with the special tool.  09913-50121: Oil seal remover  The removed dust seal must be replaced with a new one. BEARING Inspect the play A of the wheel hub bearings by finger while they are in the wheel hub.

  • Page 127: Reassembly And Remounting

    5-14 CHASSIS REASSEMBLY AND REMOUNTING BEARING • Apply SUZUKI SUPER GREASE “A” to the bearing before installing.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the wheel hub inner bearing with the special tool.  09913-70210: Bearing installer set ...
  • Page 128 • Align the punched mark A of the brake cam lever with the slit B of the front brake camshaft. • Apply SUZUKI SUPER GREASE “A” to the front brake cam- shaft and pin, and install the brake shoes.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent ...

  • Page 129: Steering And Front Suspension

    5-16 CHASSIS STEERING AND FRONT SUSPENSION CONSTRUCTION 1 Front shock absorber 0 Knuckle arm bushing  2 Front suspension arm A Knuckle arm 3 Bushing B Spacer ITEM N·m kgf-m lb-ft 4 Front suspension arm nut A Front shock absorber upper bolt 21.0 5 Tie-rod B Front shock absorber lower bolt...
  • Page 130 CHASSIS 5-17 1 Handlebar upper holder 7 Steering shaft lower dust seal  2 Handlebars 8 Steering shaft bushing 3 Handlebar lower holder 9 O-ring ITEM N·m kgf-m lb-ft 4 Steering shaft A Handlebar clamp bolt 19.0 5 Steering shaft holder B Steering shaft holder bolt 16.5 6 Dust seal...

  • Page 131: Removal And Disassembly

    5-18 CHASSIS REMOVAL AND DISASSEMBLY FRONT SUSPENSION • Remove the front wheel. (5-8) • Remove the front grip. (5-6) • Remove the front brake. (5-12 to -13) • Remove the front brake cable 1. • Remove the cotter pin and knuckle arm nut 2. ...
  • Page 132 CHASSIS 5-19 • Remove the dust seals and spacer. • Remove the knuckle arm bushings with the special tools.  09923-73210: Bearing remover 09930-30104: Sliding shaft STEERING • Remove the front frame cover. (5-4) • Remove the front suspension. (5-19) •...
  • Page 133 5-20 CHASSIS • Remove the cotter pin and steering shaft lower nut 1 and O- ring. • Remove the cotter pins and tie-rod end nuts 2.  * The removed cotter pins must be replaced with new ones. * The removed O-ring must be replaced with a new one.

  • Page 134: Inspection

    CHASSIS 5-21 • Remove the steering shaft bushing.  The removed steering shaft bushing must be replaced with a new one. • Remove the dust seals 3 and steering shaft lower dust seal • Separate the tie-rod ends 5, locknuts (6, 7) and tie-rods 8. ...
  • Page 135 5-22 CHASSIS SUSPENSION ARM Inspect the suspension arm and suspension arm bushing for wear or damage. If any defects are found, replace it with a new one. FRONT SHOCK ABSORBER Inspect the shock absorber body and bushing for damage and oil leakage.

  • Page 136: Reassembly And Remounting

    CHASSIS 5-23 REASSEMBLY AND REMOUNTING Reassemble and remount the steering in the reverse order of removal and disassembly. Pay attention to the following points: • Install the steering shaft bushing with the special tool.  09924-84521: Bearing installer set STEERING SHAFT •...
  • Page 137 5-24 CHASSIS • Tighten the steering shaft holder bolts to the specified torque and install the new cotter pins.  Steering shaft holder bolt: 23 N·m (2.3 kgf·m, 16.5 Ib-ft) TIE-ROD • Tighten the tie-rod end nuts to the specified torque. ...
  • Page 138 CHASSIS 5-25 • Install the handlebar upper holders as shown. • First, tighten the bolts 1 to the specified torque and then tighten the bolts 2 to the specified torque. Forward  Handlebar clamp bolt: 26 N·m (2.6 kgf-m, 19.0 lb-ft) •...
  • Page 139 5-26 CHASSIS • Tighten the front suspension arm bolts to the specified torque.  Front suspension arm bolt: 50 N·m (5.0 kgf·m, 36.0 lb-ft) • Tighten the front shock absorber bolts to the specified torque.  Front shock absorber lower bolt: 29 N·m (2.9 kgf·m, 21.0 Ib-ft) Front shock absorber upper bolt: 29 N·m (2.9 kgf·m, 21.0 Ib-ft)

  • Page 140: Toe-In Adjustment

    CHASSIS 5-27 TOE-IN ADJUSTMENT Adjust the toe-in as follows: • Place the vehicle on level ground and set the handlebar straight. • Make sure all the tires are inflated to the standard pressure. (2-18) • Place 30 kg (66 lbs) weight on the seat. •...

  • Page 141: Rear Brake And Rear Axle Housing

    5-28 CHASSIS REAR BRAKE AND REAR AXLE HOUSING CONSTRUCTION 1 Center cap H Rear axle housing bearing (L) 2 Rear axle washer I Spacer 3 Rear wheel J Chain adjuster 4 Rear wheel hub K Rear axle housing 5 Spacer (L) L Rear axle housing bearing (R) 6 Rear brake drum cover M Dust seal (R)

  • Page 142: Removal

    CHASSIS 5-29 REMOVAL • Remove the cotter pin 1.  The removed cotter pin must be replaced with a new one. • Remove the rear hub nut by applying the rear brake. • Remove the rear wheels. • Remove the center cap holder 2, rear axle washer 3 and rear wheel hub 4.
  • Page 143 5-30 CHASSIS • Remove the rear brake drum cover. • Remove the rear axle. • Remove the rear brake drum. • Remove the rear brake shoes 7. • Disconnect the rear brake cable 8. • Remove the rear brake panel 9.

  • Page 144: Inspection And Disassembly

    CHASSIS 5-31 • Remove the rear brake cam lever bolt and cam lever. • Remove the rear brake camshaft 0, brake lining indicator plate A, spring B and O-rings C. • Remove the rear axle housing. INSPECTION AND DISASSEMBLY BRAKE DRUM Inspect the brake drum and measure the brake drum I.D.
  • Page 145 5-32 CHASSIS BRAKE SHOE Inspect the brake shoes for wear or damage. If any wear or defects are found, replace the brake shoes as a set.  Replace the brake shoes as a set. Otherwise braking performance will be adversely affected. REAR AXLE Support the rear axle with the V-blocks and measure the rear axle runout with the dial gauge as shown.

  • Page 146: Reassembly And Remounting

    Pay attention to the following points: BEARING AND REAR AXLE HOUSING • Apply SUZUKI SUPER GREASE “A” to the rear axle housing bearings and the lip of the dust seals before installing them.  99000-25010: SUZUKI SUPER GRESE “A” or equivalent...
  • Page 147 • Tighten the rear axle housing bolts to the specified torque.  Rear axle housing bolt: 50 N·m (5.0 kgf-m, 36.0 lb-ft) REAR BRAKE • Apply SUZUKI SUPER GREASE “A” to the rear brake cam- shaft and new O-rings.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
  • Page 148 CHASSIS 5-35 NOTE: Face the groove on the camshaft to the inside. • Install the brake lining indicator plate 1, spring 2 and rear brake cam lever 3. • Align the punched mark A on the cam lever with the slit B on the camshaft.
  • Page 149 5-36 CHASSIS • Apply SUZUKI SUPER GREASE “A” to the brake camshaft and pin.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the brake shoes.  Be careful not to apply too much grease to the cam and pin. If grease gets on the lining, brake slippage will result.
  • Page 150 CHASSIS 5-37 • Install the spacers left 4 and right 5. • Tighten the rear hub nut to the specified torque.  Rear hub nut: 75 N·m (7.5 kgf·m, 54.0 Ib-ft) • Install the new cotter pin. NOTE: Bend the cotter pin to outside. •...

  • Page 151: Rear Suspension

    5-38 CHASSIS REAR SUSPENSION CONSTRUCTION 1 Rear shock absorber 7 Spacer  2 Chain case 8 Swingarm pivot shaft 3 Chain case cover A Rear shock absorber bolt ITEM N·m kgf-m lb-ft 4 Rear shock absorber lower bolt B Rear shock absorber nut 21.0 5 Swingarm pivot bushing C Swingarm pivot nut...

  • Page 152: Removal And Disassembly

    CHASSIS 5-39 REMOVAL AND DISASSEMBLY • Remove the rear brake and rear axle housing. (5-31 and 5-32) • Remove the chain case 1. • Remove the rear shock absorber lower bolt 2. • Remove the rear shock absorber bolt 3. •...

  • Page 153: Inspection

    5-40 CHASSIS INSPECTION REAR SHOCK ABSORBER Inspect the shock absorber body and bushing for damage and oil leakage. If any defects are found, replace it with a new one.  Do not attempt to disassemble the rear shock absorber. It is unserviceable. SWINGARM PIVOT SHAFT Check the pivot shaft for runout with a dial gauge and replace it if the runout exceeds the limit.
  • Page 154 CHASSIS 5-41 • Install the swingarm pivot bushings with the special tool.  09941-34513: Steering race installer NOTE: 1.5 mm (0.059 in) When installing the swingarm bushings 1 to the swingarm 2, and confirm the distance between the end of the swingarm 2 and bushing edge A is 1.5 mm (0.059 in).
  • Page 155 5-42 CHASSIS • Install the rear axle housing and rear brake. (5-35 to -37) • After installing the rear suspension, adjust the following items. * Rear brake lever play ........2-17 * Drive chain slack......... 2-15...
  • Page 156 ELECTRICAL SYSTEM 6-1 ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ................6- 2 CONNECTOR..................6- 2 COUPLER ....................6- 2 CLAMP ....................6- 2 FUSE .......................6- 2 SEMI-CONDUCTOR EQUIPPED PART ..........6- 3 BATTERY ....................6- 3 CONNECTING THE BATTERY...............6- 3 WIRING PROCEDURE................6- 3 USING THE MULTI-CIRCUIT TESTER ..........6- 4 LOCATION OF ELECTRICAL COMPONENTS ...........6- 5 CHARGING SYSTEM ...................6- 7 TROUBLESHOOTING ................6- 7...

  • Page 157: Cautions In Servicing

    6-2 ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTOR • When disconnecting a connector, be sure to hold the termi- nals and do not pull the lead wires. Click • When connecting a connector, be sure to push it in until a click is felt.

  • Page 158: Semi-Conductor Equipped Part

    ELECTRICAL SYSTEM 6-3 SEMI-CONDUCTOR EQUIPPED PART • Be careful not to drop the part with a semi-conductor built in INCORRECT such as a CDI unit and regulator/rectifier. • When inspecting this part, follow inspection instruction strictly. Neglecting proper procedure may cause damage to this part. BATTERY •...

  • Page 159: Using The Multi-Circuit Tester

    6-4 ELECTRICAL SYSTEM USING THE MULTI-CIRCUIT TESTER • Properly use the multi-circuit tester + and - probes. Improper use can cause damage to the vehicle and tester. • If the voltage and current values are not known, begin mea- suring in the highest range. •...

  • Page 160: Location Of Electrical Components

    ELECTRICAL SYSTEM 6-5 LOCATION OF ELECTRICAL COMPONENTS 1 Battery 5 Ignition coil 2 Starter relay 6 Starter motor 3 Fuse box 7 Generator 4 CDI unit 8 Pick-up coil...
  • Page 161 6-6 ELECTRICAL SYSTEM 1 Ignition switch 4 Starter button 2 Parking brake switch 5 Regulator/rectifier 3 Engine stop switch 6 Remote engine stop switch...

  • Page 162: Charging System

    ELECTRICAL SYSTEM 6-7 CHARGING SYSTEM Regulator/rectifier Ignition Fuse switch Battery Generator TROUBLESHOOTING Battery runs down quickly Step 1 1) Check accessories which use excessive amounts of electricity. Are accessories being installed? Remove accessories. Go to Step 2. Step 2 1) Check the battery for current leaks. (6-8) Is the battery current leaks OK? Go to Step 3.

  • Page 163: Inspection

    6-8 ELECTRICAL SYSTEM Step 5 1) Measure the generator no-load performance. (6-10) Is the generator no-load performance OK? Go to Step 6. Faulty generator. Step 6 1) Inspect the regulator/rectifier. (6-10) Is the regulator/rectifier OK? Go to Step 7. Faulty regulator/rectifier. Step 7 1) Inspect wiring harness.
  • Page 164 ELECTRICAL SYSTEM 6-9 REGULATED VOLTAGE • Remove the seat. (5-4) • Start the engine and keep it running at 2 800 r/min. Measure the DC voltage between the + and - battery termi- nals with the multi-circuit tester. If the voltage is not within the standard range, inspect the generator and regulator/rectifier.
  • Page 165 6-10 ELECTRICAL SYSTEM GENERATOR NO-LOAD PERFORMANCE • Remove the left frame cover. (5-4) • Disconnect the regulator/rectifier coupler 1. • Start the engine and keep it running at 2 800 r/min. Measure the voltage between W/R wire and ground with the multi-circuit tester.

  • Page 166: Starter System

    ELECTRICAL SYSTEM 6-11 STARTER SYSTEM Starter relay Fuse 10A W/B W/B B/W W/B Starter Parking Engine Remote engine Ignition button brake switch stop switch stop switch switch Starter motor TROUBLESHOOTING Make sure that the fuse is not blown and the battery is fully-charged before diagnosing. Starter motor will not run Step 1 1) Turn on the ignition switch with the engine stop switch, parking brake switch and remote engine stop...

  • Page 167: Starter Motor Removal

    6-12 ELECTRICAL SYSTEM Step 3 1) Measure the starter relay voltage at the starter relay connectors (between Y/G + and B/W -) when the starter button is pushed. Is a voltage OK? Go to Step 4. • Faulty engine stop switch. •...

  • Page 168: Starter Motor Disassembly

    ELECTRICAL SYSTEM 6-13 STARTER MOTOR DISASSEMBLY • Disassemble the starter motor as shown in the illustration. 1 Starter motor case 4 Housing end assembly 2 Armature 5 O-ring 3 Starter motor lead wire...

  • Page 169: Starter Motor Inspection

    6-14 ELECTRICAL SYSTEM STARTER MOTOR INSPECTION CARBON BRUSH Inspect the brushes for abnormal wear, cracks or smoothness in the brush holder. If any defects are found, replace the housing end assembly with a new one. Measure the brush length with a vernier calipers. If brush length is less than the service limit, replace the housing end assembly with a new one.

  • Page 170: Starter Motor Reassembly

    Reassemble the starter motor in the reverse order of disassem- bly. Pay attention to the following points: • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Apply a small quantity of SUZUKI MOLY PASTE to the arma- ture shaft.

  • Page 171: Starter Motor Installation

    6-16 ELECTRICAL SYSTEM STARTER MOTOR INSTALLATION • Tighten the starter motor lead wire screw 1 and starter motor mounting bolts 2. STARTER RELAY INSPECTION • Remove the seat. (5-4) • Remove the starter relay 1 from the frame center cover. •...
  • Page 172 ELECTRICAL SYSTEM 6-17 Measure the relay coil resistance between the terminals with the multi-circuit tester. If the resistance is not within the standard range, replace the starter relay with a new one.  09900-25008: Multi-circuit tester set  Tester knob indication: Resistance (Ω) ...

  • Page 173: Ignition System

    6-18 ELECTRICAL SYSTEM IGNITION SYSTEM Parking brake CDI unit switch Engine stop switch Ignition coil Remote engine Spark stop switch plug Ignition switch Fuse 10A Pick-up Generator coil Battery TROUBLESHOOTING No spark or poor spark NOTE: Check that the engine stop switch, parking brake switch and remote engine stop switch are in the “RUN”, “ON”...
  • Page 174 ELECTRICAL SYSTEM 6-19 Step 2 1) Measure the battery voltage between input lead wires (O/W and B/W) at the CDI unit with the ignition switch in the “ON” position. Is the voltage OK? Go to Step 3. • Faulty ignition switch. •...

  • Page 175: Inspection

    6-20 ELECTRICAL SYSTEM INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Disconnect the spark plug cap. • Connect a new spark plug 1 to spark plug cap and ground it to the cylinder head. NOTE: Make sure that the spark plug cap and spark plug are connected properly and the battery is fully-charged.
  • Page 176 ELECTRICAL SYSTEM 6-21 IGNITION COIL RESISTANCE • Disconnect the ignition coil lead wires and spark plug cap, and remove the ignition coil. Measure the ignition coil resistance in both the primary and sec- ondary windings with the multi-circuit tester. If the resistance is not within the standard range, replace the ignition coil.
  • Page 177 6-22 ELECTRICAL SYSTEM • Repeat the above procedure a few times and measure the highest pick-up coil peak voltage.  Tester knob indication: Voltage ()  Pick-up coil peak voltage: 1.5 V and more If the peak voltage measured on the CDI unit coupler is lower than the standard value, measure the peak voltage on the gen- erator coupler as follows.

  • Page 178: Switches

    ELECTRICAL SYSTEM 6-23 SWITCHES Measure each switch for continuity using a multi-circuit tester. If any abnormality is found, replace the respective switch assemblies with new ones.  09900-25008: Multi-circuit tester set  Tester knob indication: Continuity test () IGNITION SWITCH PARKING BRAKE SWITCH Color Color...

  • Page 179: Battery

    6-24 ELECTRICAL SYSTEM BATTERY SPECIFICATIONS Type designation YTX5L-BS Capacity 12 V, 14.4 kC (4 Ah)/10 HR 1 Upper cover breather 5 Terminal 2 Cathode plates 6 Safety valve 3 Stopper 7 Anode plates 4 Filter 8 Separator (Fiberglass plate) INITIAL CHARGING Filling electrolyte •...
  • Page 180 ELECTRICAL SYSTEM 6-25 NOTE: If no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the container from the battery. • After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the bat- tery.

  • Page 181: Servicing

    6-26 ELECTRICAL SYSTEM SERVICING Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, clean the battery terminals with sandpaper.
  • Page 182 SERVICING INFORMATION 7-1 SERVICING INFORMATION CONTENTS TROUBLESHOOTING ...................7- 2 ENGINE ....................7- 2 CARBURETOR ..................7- 6 CHASSIS ....................7- 7 BRAKES....................7- 9 ELECTRICAL ..................7-10 BATTERY ....................7-12 WIRING DIAGRAM .................7-13 WIRING HARNESS, CABLE AND HOSE ROUTING........7-14 WIRING HARNESS ROUTING ...............7-14 CABLE ROUTING ...................7-16 FUEL HOSE PIPING ................7-17 CARBURETOR AND CVT CASE HOSE ROUTING.......7-18 HANDLEBARS AND HANDLEBAR PAD INSTALLATION ....7-19...

  • Page 183: Troubleshooting

    7-2 SERVICING INFORMATION TROUBLESHOOTING ENGINE ENGINE WILL NOT START OR IS HARD TO START Symptom, possible causes and remedy 1) Compression too low • Valve clearance out of adjustment. Adjust. • Worn valve guides or poor seating of valves. Repair or replace. •...
  • Page 184 SERVICING INFORMATION 7-3 NOISY ENGINE Symptom, possible causes and remedy 1) Excessive valve chatter • Too large valve clearance. Adjust. • Weakened or broken valve springs. Replace. • Worn rocker arm or cam surface. Replace. 2) Noise seems to come from piston •...
  • Page 185 7-4 SERVICING INFORMATION ENGINE RUNS POORLY IN HIGH SPEED RANGE Symptom, possible causes and remedy • Weakened valve springs. Replace. • Worn camshaft. Replace. • Valve timing out of adjustment. Adjust. • Too narrow spark plug gap. Adjust. • Ignition not advanced sufficiently due to poorly Replace.
  • Page 186 SERVICING INFORMATION 7-5 ENGINE LACKS POWER Symptom, possible causes and remedy • Loss of valve clearance. Adjust. • Weakened valve springs. Replace. • Valve timing out of adjustment. Adjust. • Worn piston rings or cylinder. Replace. • Poor seating of valves. Repair.

  • Page 187: Carburetor

    7-6 SERVICING INFORMATION CARBURETOR STARTING DIFFICULTY Symptom, possible causes and remedy • Clogged fuel pipe. Clean. • Air leaking from joint between intake port and car- Tighten or replace gasket. buretor. • Air leaking from carburetor joint. Tighten or replace defective parts. •...

  • Page 188: Chassis

    SERVICING INFORMATION 7-7 CHASSIS HEAVY STEERING Symptom, possible causes and remedy • Distorted steering shaft. Replace. • Not enough pressure in tires. Adjust. • Improper front wheel alignment. Adjust. • Insufficiently lubricated. Lubricate. • Linkage connections tending to seize. Repair or replace. •...
  • Page 189 7-8 SERVICING INFORMATION FRONT SUSPENSION TOO SOFT Symptom, possible causes and remedy • Weakened spring of shock absorber. Replace. • Shock absorber leaks oil. Replace. FRONT SUSPENSION TOO STIFF Symptom, possible causes and remedy • Bent shock absorber shaft. Replace. •...

  • Page 190: Brakes

    SERVICING INFORMATION 7-9 BRAKES INSUFFICIENT BRAKE POWER Symptom, possible causes and remedy • Worn brake drum. Replace. • Oil adhesion on friction surface of shoes. Clean drum and shoes. • Worn shoe linings. Replace. • Too much play on brake lever. Adjust.

  • Page 191: Electrical

    7-10 SERVICING INFORMATION ELECTRICAL NO SPARKING OR POOR SPARKING Symptom, possible causes and remedy • Defective CDI unit. Replace. • Defective ignition coil. Replace. • Defective spark plug. Replace. • Defective generator coil. Replace. • Loose connection of lead wire. Connect or tighten.
  • Page 192 SERVICING INFORMATION 7-11 UNSTABLE CHARGING Symptom, possible causes and remedy • Lead wire insulation frayed due to vibration, Repair or replace. resulting in intermittent short-circuiting. • Internally short-circuited generator. Replace. • Defective regulator/rectifier. Replace. START BUTTON IS NOT EFFECTIVE Symptom, possible causes and remedy •...

  • Page 193: Battery

    7-12 SERVICING INFORMATION BATTERY “SULFATION”, ACIDIC WHITE POWDERY SUBSTANCE OR SPOTS ON SURFACE OF CELL PLATES Symptom, possible causes and remedy • Cracked battery case. Replace the battery. • Battery has been left in a run-down condition for a Replace the battery. long time.

  • Page 194: Wiring Diagram

    SERVICING INFORMATION 7-13 WIRING DIAGRAM...

  • Page 195: Wiring Harness, Cable And Hose Routing

    7-14 SERVICING INFORMATION WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Battery plus terminal CDI unit Battery minus terminal Starter relay Fuse box Clamp Clamp Wiring harness Generator Wiring harness Clamp Storter motor Remote engine stop switch To the rear fender Regulator/rectifier Remote engine stop switch Ignition switch...
  • Page 196 SERVICING INFORMATION 7-15 Clamp Clamp Generator lead wire Starter motor lead wire Pick-up coil Generator rotor Handleber switch leadwire...

  • Page 197: Cable Routing

    7-16 SERVICING INFORMATION CABLE ROUTING 3 – 5 mm Front brake cable (R) (0.12 – 0.20 in) Rear brake cable Throttle cable 4 – 6 mm (0.16 – 0.24 in) 4 – 6 mm (0.16 – 0.24 in) Front brake cable (R) Front brake cable (L) Front brake cable (L) Align the clearance less than...

  • Page 198: Fuel Hose Piping

    SERVICING INFORMATION 7-17 FUEL HOSE PIPING Front brake cable (L) Front brake cable (R) Rear brake cable Wiring harness Throttle cable Fuel tank breather hose Handlebars Fuel tank breather hose Cable guide Clip Fuel hose Air vent hose Clip Vacuum hose Air breather hose Air vent hose Fuel valve...

  • Page 199: Carburetor And Cvt Case Hose Routing

    7-18 SERVICING INFORMATION CARBURETOR AND CVT CASE HOSE ROUTING Screw Clamp Clamp Clamp Upper Air vent hose CVT case breather hose Left Right Clamp Lower Clamp Screw Clamp Drain hose Clamp...

  • Page 200: Handlebars And Handlebar Pad Installation

    SERVICING INFORMATION 7-19 HANDLEBARS AND HANDLEBAR PAD INSTALLATION Handlebar upper holder Handlebar clamp bolt Handlebars Handlebar lower holder Clamp Punched mark Handlebar pad Align the center of knurling on handlebars Handlebars Clamp with the center of handlbar holders. Handlebars Clamp Handlebar pad...

  • Page 201: Heat Shield Installation

    7-20 SERVICING INFORMATION HEAT SHIELD INSTALLATION 0 – 4 mm (0 – 0.16 in) 13 – 17 mm (0.51 – 0.67 in) Right frame cover Heat shield...

  • Page 202: Special Tools

    SERVICING INFORMATION 7-21 SPECIAL TOOLS 09900-20101 09900-20202 09900-20205 09900-20602 09900-20605 09900-20102 Micrometer Micrometer Dial gauge Dial calipers Vernier calipers (25 – 50 mm) (0 – 25 mm) (1/1000 mm, 1 mm) (1/100 mm, 10 – 34 mm) 09900-20607 09900-20803 Dial gauge 09900-20701 09900-20806 09900-20805...
  • Page 203 7-22 SERVICING INFORMATION 09923-73210 09924-84510 09924-84521 09930-30104 09930-40113 Bearing remover Bearing installer set Bearing installer set Sliding shaft Rotor holder 09941-34513 Steering race 09941-50111 installer Bearing remover NOTE: When order the special tool, please confirm whether it is available or not.

  • Page 204: Tightening Torque

    SERVICING INFORMATION 7-23 TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lb-ft Cylinder head cover bolt Cylinder head bolt 10.0 Valve clearance adjuster locknut Generator rotor nut 25.5 Clutch housing nut 36.0 Clutch shoe nut 43.5 Initial Fixed drive face nut Final 36.0 Generator coil bolt Pick-up coil bolt...

  • Page 205: Chassis

    7-24 SERVICING INFORMATION CHASSIS ITEM N·m kgf-m lb-ft Front suspension arm bolt 36.0 Knuckle arm nut 36.0 Tie-rod end nut 21.0 Tie-rod locknut 21.0 Steering shaft lower nut 21.0 Steering shaft holder bolt 16.5 Handlebar clamp bolt 19.0 (upper) 21.0 Front shock absorber bolt (lower) 21.0...

  • Page 206: Tightening Torque Chart

    SERVICING INFORMATION 7-25 TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt A (mm) N·m kgf-m lb-ft N·m kgf-m lb-ft 0.15 0.23 0.45 0.55...

  • Page 207: Service Data

    7-26 SERVICING INFORMATION SERVICE DATA VALVE + VALVE GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. 14.5 ---- (0.57) 12.5 ---- (0.49) Valve clearance (when cold) 0.05 – 0.10 ---- (0.002 – 0.004) 0.10 – 0.15 ---- (0.004 – 0.006) Valve guide to valve stem 0.010 –...
  • Page 208 SERVICING INFORMATION 7-27 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 28.43 – 28.63 28.13 IN. & EX. (1.119 – 1.127) (1.107) Rocker arm I.D. 4.015 – 4.027 IN. & EX. ---- (0.1581 – 0.1585) Rocker arm shaft O.D. 3.990 –...
  • Page 209 7-28 SERVICING INFORMATION ITEM STANDARD LIMIT Piston ring groove width 1.01 – 1.03 ---- (0.0398 – 0.0405) 1.21 – 1.23 ---- (0.0476 – 0.0484) 1.51 – 1.53 ---- (0.0594 – 0.0602) Piston ring thickness 0.97 – 0.99 ---- (0.0382 – 0.0390) 1.17 –...
  • Page 210 SERVICING INFORMATION 7-29 REDUCTION GEAR + DRIVE BELT + DRIVE CHAIN Unit: mm (in) Except raito ITEM STANDARD LIMIT Reduction ratio Variable change (2.091 – 1.879) — Reduction gear ratio 4.272 (47/11) — Final reduction ratio 3.700 (37/10) — Drive belt width 15.9 14.9 (0.63)
  • Page 211 7-30 SERVICING INFORMATION ELECTRICAL Unit: mm (in) ITEM STANDARD/SPECIFICATION LIMIT NOTE Spark plug NGK: CR6HSA Type — DENSO: U20FSR-U 0.6 – 0.7 — (0.024 – 0.028) Spark performance Over 8 (0.3) at 1 atm. — Ignition coil resistance Terminal – 0.1 –...
  • Page 212 SERVICING INFORMATION 7-31 BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Front brake lever play 4 – 6 — (0.16 – 0.23) Rear brake lever play 4 – 6 — (0.16 – 0.23) Brake drum I.D. 80.7 Front — (3.18) 110.7 Rear...
  • Page 213 7-32 SERVICING INFORMATION SUSPENSION Unit: mm (in) ITEM STANDARD LIMIT Front wheel travel ---- (2.0) Rear wheel travel ---- (2.0) Swingarm pivot shaft runout ---- (0.02) FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the Research Method.
  • Page 214 LT-Z50K9 ('09-MODEL) 8-1 LT-Z50K9 ('09-MODEL) CONTENTS PAGE SPECIFICATIONS..................8-2 NOTE: * Asterisk mark (*) indicates the New K9-MODEL specifications. * The service data is the same as the K8-MODEL.
  • Page 215 8-2 LT-Z50K9 ('09-MODEL) SPECIFICATIONS DIMENSIONS AND CURB MASS Overall length ..................1 270 mm (50.0 in) Overall width..................760 mm (29.9 in) Overall height ..................765 mm (30.1 in) Wheelbase ..................830 mm (32.7 in) Ground clearance................120 mm (4.7 in) Seat height ..................

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