Suzuki GZ250 Marauder Service Manual
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Suzuki GZ250 Marauder Service Manual

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  • Page 1 Downloaded from www.Manualslib.com manuals search engine...

  • Page 2: General Information

    FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI GZ250 and procedures for its inspec- GENERAL INFORMATION tion/service and overhaul of its main components. Other information considered as generally known is not included. PERIODIC MAINTENANCE Read the GENERAL INFORMATION section to fa- miliarize yourself with the motorcycle and its mainte- nance.

  • Page 3: How To Use This Manual

    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 4 Apply oil. Use engine oil unless otherwise specified. Measure in voltage range. Apply molybdenum oil solution (mix - ture of engine oil and SUZUKI MOLY PASTE in a ratio of 1 : 1). Measure in resistance range. Apply SUZUK I SUPE R GREASE "A".

  • Page 5: Table Of Contents

    GENERAL INFORMATION --------------------------------------------CONTENTS ------------------------------------------------- 1 WARNING/CAUTION/NOTE ............... 1- 1 GENERAL PRECAUTIONS................. 1- 1 SUZUKI GZ250X ('99-MODEL) ..............1-3 SERIAL NUMBER LOCATION ..............1-3 FUEL AND OIL RECOMMENDATIONS............ 1-3 FUEL ......................1-3 ENGINE OIL ..................1-4 BRAKE FLUID ..................1-4 FRONT FORK OIL ................... 1-4 BREAK-IN PROCEDURES ................

  • Page 6: Warning/Caution/Note

    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 messages highlighted by these signal words. WARNING Indicates a potential hazard that could result in death or injury.
  • Page 7 GENERAL INFORMATION CAUTION * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent. * 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.
  • Page 8 * To protect the environment, do not unlawfully dispose of used motor oil and all other fluids, batteries, and tires. * To protect the earth's natural resouces, properly dispose of used motorcycles and parts. Downloaded from www.Manualslib.com manuals search engine...

  • Page 9: Suzuki Gz250X ('99-Model)

    GENERAL INFORMATION SUZUKI GZ250X ('99-MODEL) SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) is stamped on the right side of the steering head pipe. The engine serial number is located on the left side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts.

  • Page 10: Engine Oil

    Never re-use brake fluid left over from a last servicing or which has been stored for a long period of time. FRONT FORK OIL Use SUZUKI fork oil SS-08 (#10). BREAK-IN PROCEDURES During manufacturing only the best possible materials are used and all machined parts are finished to a very high standard.
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  • Page 12: Specifications

    GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ......... 2 160 mm (85.0 in) 815 mm (32.1 in) Overall width ..........Overall height .......... 1 090 mm (42.9 in) Wheelbase ..........1 450 mm (57.1 in) 125 mm ( 4.9 in) Ground clearance ........
  • Page 13 1-7 GENERAL INFORMATION ELECTRICAL Ignition type ............Electronic ignition (Transistorized) Ignition timing ............ 10° B. T.D.C. at 1 300 r/min Spark plug ............NGK DR8EA or DE NSO X24ES R-U Battery ..............12V 21.6 kC (6 Ah)/ 10 HR Generat or............. Three-phase A.C. generator Fuse ..............

  • Page 14: Country And Area Codes

    GENERAL INFORMATION 1- 8 COUNTRY AND AREA CODES The following codes stand for the applicable country(-ies) and area(-s). CODE COUNTRY OR AREA E-01 General E-02 E-03 U.S.A. (Except for California) E-04 Franc e E-17 Sweden, Finland (E-15), Norway (E-16), Denmark (E -26) E-22 Germany E-24...
  • Page 15 PERIODIC MAINTENANCE --------------------------------------------CONTENTS --------------------------------------------- PERIODIC MAINTENANCE SCHEDULE ..........2- 1 PERIODIC MAINTENANCE CHART ............2- 1 LUBRICATION POINTS ................ 2-2 MAINTENANCE AND TUNE-UP PROCEDURES ........2-3 EXHAUST PIPE BOLTS AND MUFFLER MOUNTING BOLTS... 2-3 AIR CLEANER ..................2- 3 VALVE CLEARANCE ................2-4 SPARK PLUG ..................

  • Page 16: Periodic Maintenance Schedule

    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 ex- pressed in terms of kilometers and months, and are dependant on whichever comes first. NOTE: More frequent servicing may be performed on motorcycles that are used under severe conditions.

  • Page 17: Lubrication Points

    PERIODIC MAINTENANCE LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motor- cycle. Major lubrication points are indicated below. Side-stand pivot Drive chain and spring hook Brake pedal pivot Brake lever holder Clutch lever holder NOTE: * Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.

  • Page 18: Maintenance And Tune-Up Procedures

    PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item in the Periodic Maintenance chart. EXHAUST PIPE BOLTS AND MUFFLER MOUNTING BOLTS Tighten every 5 000 km (3 000 miles, 15 months). • Tighten the exhaust pipe bolts and muffler mounting bolt to the specified torque.

  • Page 19: Valve Clearance

    PERIODIC MAINTENANCE • Carefully use compressed air to clean the air cleaner element. CAUTION _________________________________ CAUTION Always apply compressed air to the outside of the air cleaner element. If compressed air is applied to the inside, dirt will be forced into the pores of the air cleaner element, restricting air flow through the air cleaner element.
  • Page 20 2-5 PERIODIC MAINTENANCE Remove the valve inspection caps The valve clearance specification is different for intake and exhaust valves. Valve clearance adjustment must be checked and adjusted, 1) at the time of periodic inspection, 2) when the valve mechanism is serviced, and 3) when the camshaft is re- moved for servicing.

  • Page 21: Spark Plug

    PERIODIC MAINTENA NCE ADJUSTMENT The clearance is adjusted using the special tool and offset wrench. • Loosen the locknuts • Insert a thickness gauge between the valve stem end and the adjusting screw on the rocker arm. • Adjust the valve clearance by turning the adjusting screw using the special tool while holding the locknuts 09917-14920: Valve adjuster wrench CAUTION...

  • Page 22: Fuel Hose

    2-7 PERIODIC MAINTENANCE Check the spark plug for burns. If any abnormalities are found, replace the spark plug as indicated below. DENSO Remarks DR7EA X22ESR-U If the standard spark plug is apt to get wet, replace wit h this plug. DR8EA X24ESR-U Standard...

  • Page 23: Throttle Cable Play

    PERIODIC MAINTENANCE 2-8 • Start the engine, turn the throttle stop screw and set the engine idle speed as follows. Engine idle speed: 1 300 ± 50 r/min ..For E-03, -28, -33 1 300 ±100 r/min ..For the others 09900-26006: Tachometer THROTTLE CABLE PLAY Inspect initially at 1 000 km (600 miles, 3 months)

  • Page 24: Starter Plunger Cable Play

    2-9 PERIODIC MA INTENA NCE STARTER PLUNGER CABLE PLAY Starter plunger cable play should be 0.5-1.0 mm (0.02-0.04 in) as shown. If the play is incorrect, adjust it as follows: • Loosen the lock nut and turn the adjuster in or out until the specified play is obtained.

  • Page 25: Drive Chain

    • Dry or rusted links * Missing O-ring seals • Twisted or seized links If any defects are found, the drive chain must be replaced. The standard drive chain is DID520VC5. SUZUKI recommends to use this standard drive chain as a replacement. CAUTION __________________________________ The standard drive chain is DID520VC5.
  • Page 26 replacement. Downloaded from www.Manualslib.com manuals search engine...
  • Page 27 2-11 PERIODIC MA INTENA NCE CHECKING AND ADJUSTING • Remove the rear axle cotter pin. (For E-28 model) • Loosen the rear axle nut • Tense the drive chain fully by turning chain adjuster nuts • Count out 21 pins (20-pitch) on the chain measure the distance between the two points.

  • Page 28: Brakes

    PERIODIC MAINTENANCE 2-12 • After cleaning and drying the chain, oil it with a heavy- weight engine oil. CAUTION Do not use any oil sold commercially as "drive chain oil", this type of oil can such oil can damage the "0"-rings (or seals). BRAKES (BRAKE) Inspect initially at 1 000 km (600 miles, 3 months)
  • Page 29 2-13 PERIODIC MAINTENANCE FRONT BRAKE PADS The extent of brake pad wear can be checked by observing the limit line on the pad. When the wear exceeds the limit line, replace the pads with new ones. (See p. 5-8.) A CAUTION Replace the brake pad as a set, otherwise braking performance will be adversely affected.
  • Page 30 PERIODIC MAINTENA NCE 2-14 REAR BRAKE PEDAL HEIGHT • Loosen the lock nut • Adjust the brake pedal height by turning the adjuster to locate the pedal 50 mm (2.0 in) above the top face of the footrest. REAR BRAKE ADJUSTING •...

  • Page 31: Tire

    2-15 PERIODIC MAINTENANCE TIRE Inspect every 5 000 km (3 000 miles, 15 months). TIRE TREAD CONDITION Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a danger- ous situation. It is highly recommended to replace a tire when the remaining depth of tire tread reaches the follow- ing specification.

  • Page 32: Front Fork

    PERIODIC MAINTENA NCE 2-16 FRONT FORK Inspect every 10 000 km (6 000 miles, 30 months). Inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defec- tive parts, if necessary. REAR SUSPENSION Inspect every 10 000 km (6 000 miles, 30 months).
  • Page 33 2-17 PERIODIC MAINTENANCE Downloaded from www.Manualslib.com manuals search engine...

  • Page 34: Compression Pressure Check

    PERIODIC MAINTENANCE 2-18 COMPRESSION PRESSURE CHECK The compression pressure reading of the 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 maintenance records kept at your dealership should include compression readings for each mainte- nance service.

  • Page 35: Oil Pressure Check

    2-19 PERIODIC MAINTENANCE OIL PRESSURE CHECK Check the oil pressure periodically. This will give a good indication of the condition of the moving parts. OIL PRESSURE SPECIFICA TION Above 30 kPa (0.3 kg/cm , 4.3 psi) at 3 000 r/min., Oil temp, at 60°C (140°F) Below 70 kPa (0.7 kg/cm , 10.0 psi) If the oil pressure is lower or higher than the specification, the following caus es may be considered.
  • Page 36 ENGINE i ----------------------------------------------- CONTENTS -------------------------------- ..3- 1 ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE ....................... ENGINE REMOVAL AND REINSTALLATION ..........3- 2 ..3- ENGINE REMOVAL................... ENGINE REINSTALLATION ..............3- 6 ..3- ENGINE DISASSEMBLY ................ ENGINE COMPONENTS INSPECTION AND SERVICE ......

  • Page 37: Engine Components Removable With The Engine In Place

    ENGINE ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to the pages listed in each section for removal and reinstallation instructions. ENGINE CENTER See page Exhaust pipe and muffler ...

  • Page 38: Engine Removal

    ENGINE 3-2 ENGINE REMOVAL AND REINSTALLATION ENGINE REMOVAL • Remove the front seat. (See p. 5-1.) • Remove the fuel tank. (See p. 4-1.) • Remove the right frame cover. (See p. 5-1.) • Disconnect the battery lead wire. • Drain the engine oil. (See p. 2-9.) •...
  • Page 39 3-3 ENGINE • Remove the engine sprocket cover. • Flatten the lock washer. • Remove the engine sprocket nut and washer. NOTE: When loosening the engine sprocket nut, temporarily install the right footrest bracket and depress the brake pedal. • Remove the engine sprocket. NOTE: If it is difficult to remove the engine sprocket, loosen the rear axle nut and chain adjuster nuts to provide additional...
  • Page 40 ENGINE 3-4 • Remove the starter plunger . • Loosen the carburetor clamp screws. • Remove the carburetor. ¿WARNING Gasoline is very explosive. Extreme care must be taken. • Disconnect the engine ground wire. • Disconnect the crankcase breather hose •...
  • Page 41 3-5 ENGINE • Support the motorcycle with a jack or wooden block. • Remove the engine mounting bolts and nuts • Remove the frame down tube mounting bolts and nuts • Remove the lower engine mounting bolt and nut • Remove the upper engine mounting bolt and nut NOTE: When removing the upper mounting bolt, support the en- gine with a jack.

  • Page 42: Engine Reinstallation

    ENGINE 3-6 ENGINE REINSTALLATION Reinstall the engine in the reverse order of engine removal. • Install the engine mounting bolts and nuts as shown in the following illustration. • Tighten the engine mounting nuts to the specified torque. NOTE: The engine mounting nuts are self-locking. Once the nuts have been removed, they are no longer of any use.
  • Page 43 3-7 ENGINE • Tighten the engine ground wire and the clamp by crank- case bolt as shown. • Clamp the neutral switch lead wire and side-stand switch lead wire • Position the carburetor clamps as shown in the illustra- tion. •...
  • Page 44 ENGINE 3-8 • Tighten the exhaust pipe bolts and muffler mounting bolt to the specified torque. Exhaust pipe bolt: 14 N-m (1.4 kg-m, 10.0 Ib-ft) Muffler mounting bolt: 29 N-m (2.9 kg-m, 21.0 Ib-ft) CAUTION Check the wire, cable and hose routing. (See pp.

  • Page 45: Engine Disassembly

    ENGINE ENGINE DISASSEMBLY The procedure for engine disassembly is sequentially ex- plained in the following steps. • Remove the valve inspection caps • Remove the spark plug. • Remove the valve timing inspection plug and generator cover cap. • Rotate the crankshaft and align the "T" line on the generator rotor with the mark on the generator cover.
  • Page 46 ENGINE 3-10 • Remove the camshaft and camshaft sprocket . CAUTION Do not drop the cam chain into the crankcase. • Remove the C-ring CAUTION Do not drop the C-ring into the crankcase. • Remove the cylinder head nuts diagonally. •...
  • Page 47 ENGINE 3-11 • Remove the cylinder gasket and dowel pins. • Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into the crankcase. Then, remove the piston pin circlip with a long-nose pliers. •...
  • Page 48 ENGINE 3-12 • Remove the generator cover. • Remove the gasket and dowel pins. • Remove the clutch cover. • Remove the gasket and dowel pins. • While holding the generator rotor using the special tool, remove the clutch spring mounting bolts in a crisscross pattern, and remove the clutch springs and clutch pres- sure plate 09930-44913: Rotor holder...
  • Page 49 3-13 ENGINE • Remove the washer , bearing , clutch push piece and clutch push rod • Remove the clutch drive and driven plates. • Remove the spring washer and washer seat • Flatten the lock washer of the clutch sleeve hub nut. •...
  • Page 50 ENGINE 3-14 • Remove the thrust washer and primary driven gear assembly • Remove the spacer and thrust washer • Remove the círclíp and oil pump driven gear • Remove the pin and washer . • Remove the oil pump A CAUTION Do not attempt to disassemble the oil pump as- sembly.
  • Page 51 3-15 ENGINE • While holding the generator rotor using the special tool, remove the balancer shaft bolt 09930-44913: Rotor holder • Remove the cam chain • Remove the primary drive gear nut using the special tool. 09930-44913: Rotor holder A CAUTION The primary drive gear nut has left-hand threads.
  • Page 52 ENGINE 3-16 • Remove the shaft and starter idle gear • Remove the generator rotor nut using the special tool. 09930-44913: Rotor holder • Remove the generator rotor using the special tool. 09930-34960: Rotor remover • Remove the generator rotor key •...
  • Page 53 3-17 ENGINE • Remove the gearshift cam stopper. • Remove the crankcase bolts. • Separate the left and right crankcases using the special tool. 09920-13120: Crankcase separator NOTE: * Fit the crankcase separator, so that the tool arms are in parallel with the side of crankcase.
  • Page 54 ENGINE 3-18 • Remove the gearshift cam stopper spring • Remove the gearshift fork shafts and gearshift forks • Remove the gearshift cam • Remove the transmission. • Remove the balancer shaft • Remove the balancer shaft drive gear • Remove the crankshaft using the special tool. 09920-13120: Crankcase separator Downloaded from www.Manualslib.com...

  • Page 55: Engine Components Inspection And Service

    ENGINE 3-19 ENGINE COMPONENTS INSPECTION AND SERVICE CRANKCASE BEARINGS BEARING INSPECTION While the bearing is in the crankcase, rotate its inner race and check to see that it turns smoothly. If it does not turn quietly and smoothly, or if there are signs of any abnormali- ties, the bearing is defective and must be replaced as fol- lows.
  • Page 56 ENGINE 3-20 • Remove the oil seal using the special tool. 09913-75510: Bearing remover/installer A CAUTION The removed oil seal should be replaced with a new one. BEARING INSTALLATION • Install the bearings using the special tools. 09913-75510: Bearing remover/installer (For ) 09913-75520: Bearing remover/installer (For , ) 09913-75830: Bearing remover/installer (For ) 09913-84510: Bearing remover/installer (For )
  • Page 57 Apply a small quantity of THREAD LOCK "1342" to the bearing retainer screws. 99000-32050: THREAD LOCK "1342" • Apply grease to the oil seal lip 99000- 25010: SUZUKI SUPER GREASE "A" • Install the driveshaft oil seals as shown. CAUTION When installing the oil seal , Do not block the oil passage.

  • Page 58: Clutch Release Camshaft

    ENGINE 3-22 CLUTCH RELEASE CAMSHAFT REMOVAL • Remove the oil seal retainer and clutch cable guide • Remove the oil seal • Remove the clutch release cam shaft REASSEMBLY • Apply engine oil to the clutch release camshaft shown in the illustration. •...

  • Page 59: Cylinder Head Cover

    ENGINE 3-23 CYLINDER HEAD COVER CAUTION Identify the position of each removed part. Organize the parts in their re spective groups (i.e., intake or exhaust) so that they can be installed in their original locations. DISASSEMBLY • Remove the rocker arm shaft bolts •...

  • Page 60: Cylinder Head

    ENGINE 3-24 REASSEMBLY Reassemble the cylinder head cover in the reverse order of disassembly. Pay attention to the following points: • Apply engine oil to the rocker arm shafts. • Install the rocker arms , wave washers shafts [ A CAUTION] Use the new O-rings to prevent oil leakage.
  • Page 61 3-25 ENGINE • Compress the valve spring using the special tools. 09916-14510: Valve lifter 09916-14910: Valve lifter attachment • Remove the valve cotters from the valve stem. 09916-84511: Tweezers • Remove the valve spring retainer and valve spring • Remove the valve from the combustion chamber side. •...
  • Page 62 ENGINE 3-26 CYLINDER HEAD DISTORTION Decarbon the combustion chamber. Check the gasket surfac e of the cylinder head for distortion using a straightedge and thickness gauge. Take clearance readings at several places. If readings exceed the service limit, replace the cylinder head. 09900-20803: Thickne ss gauge Service Limit: 0.05 mm (0.002 in) VALVE FACE W EAR...
  • Page 63 3-27 ENGINE VALVE STEM WEAR Measure the valve stem O.D. using the micrometer. If it is out of s pecification, replac e the valve with a new one. If the valve stem O.D. is within specification but the valve stem deflection is not, replace the valve guide.
  • Page 64 ENGINE 3-28 • After installing the valve guides, re-finish their guiding bores using the special tools. Be sure to clean and oil the guides after reaming. 09916-34550: Valve guide reamer (5.5 mm) 09916-34542: Handle VALVE SEAT WIDTH • Coat the valve seat uniformly with Prussian blue. Install the valve and attach a valve lapper onto it.
  • Page 65 3-29 ENGINE • When installing the solid pilot , rotate it slightly. Seat the pilot snugly. Install the 45° cutter, attachment and T-handle. • Using the 45° cutter, descale and clean up the seat. Ro- tate the cutter one or two turns. •...
  • Page 66 Contact area too low and too narrow on face of valve Downloaded from www.Manualslib.com manuals search engine...
  • Page 67 ENGINE 3-30 VALVE SPRINGS Check the valve springs for proper strength by measuring their free length and also the force required to compress them. If the spring length is less than the service limit or if 35.0 mm the force required to compress the spring does not fall with- (1.38 in) in the specified range, replace the spring.
  • Page 68 Be sure to install all of the parts in their original positions. INTAKE PIPE • When installing the intake pipe, apply grease to the CD- ring. 99000-25010: SUZUKI SUPER GREASE "A" CAUTION Use the new O-ring to prevent sucking air from the joint. Downloaded from www.Manualslib.com...

  • Page 69: Cam Chain Guide And Cam Chain Tensioner

    ENGINE 3-32 NOTE: Make sure that the "UP" mark comes upward. CAM CHAIN GUIDE AND CAM CHAIN TENSIONER Check the cam chain guide and cam chain tensioner for wear and damage. If it is found to be damaged, replace it with a new one.
  • Page 70 ENGINE 3-33 NOTE: Install the cylinder head cover to its original position. Tighten the cylinder head cover bolts evenly and diagonally to the specified torque. Cylinder head cover bolt: 10 N ■ m (1.0 kg-m, 7.0 Ib-ft) NOTE: Do not rotate the camshaft with the plastigauge in place. Remove the cylinder head cover and measure the width of the compressed plastigauge using the envelope scale.

  • Page 71: Cam Chain Tension Adjuster

    ENGINE 3-34 CAM CHAIN TENSION ADJUSTER The cam chain tension adjuster is maintained at the proper tension by an automatically adjusted tensioner. Insert a flat- head screwdriver into the slotted end of the cam chain ten- sion adjuster and turn it clockwise to release the tension. Remove the screwdriver to make sure that the push rod moves properly.
  • Page 72 3-35 ENGINE PISTON RING-GROOVE CLEARANCE Measure the side clearance of the 1st and 2nd rings using the thickness gauge If any of the clearances exceed the limit, replace both the piston and piston rings. 09900-20803: Thickness gauge 09900- 20205: Micrometer (0-25 mm) Service Limit Piston ring-groove clearance 1st: 0.180 mm...
  • Page 73 ENGINE 3-36 OVERSIZE RINGS Oversize piston ring The following oversize piston ring is used. It bears the fol- lowing identification number. 0.5mmO.S Piston ring 1st and 2nd 0.5 mm: 50 1.0 mm: 100 Oversize oil ring The following oversize oil ring is used. It bears the follow- I.OmmO.S.

  • Page 74: Crankshaft And Conrod

    3-37 ENGINE CRANKSHAFT AND CONROD Crankshaft, RH Conrod Bearing Crank pin Crankshaft, LH CONROD SMALL END I.D. Measure the conrod small end inside diameter using the dial calipers. If the conrod small end inside diameter ex- ceeds the service limit, replace the conrod. 09900-20605: Dial calipers Service Limit: 18.040 mm (0.7102 in) Downloaded from...
  • Page 75 ENGINE 3-38 CONROD DEFLECTION AND CONROD BIG END SIDE CLEARANCE Wear on the big end of the conrod can be estimated by checking the movement of the small end of the rod. This method can also check the extent of wear on the parts of the conrod's big end.

  • Page 76: Balancer Shaft And Balancer Shaft Driven Gear

    3-39 ENGINE BALANCER SHAFT AND BALANCER SHAFT DRIVEN GEAR DISASSEMBLY • Disassemble the balancer shaft as shown in the illustration. Balancer shaft Balancer shaft driven gear Spring (6 pcs.) Pin (3 pcs.) INSPECTION Inspect the balancer shaft and balancer shaft driven gear for wear or damage.

  • Page 77: Starter Clutch And Starter Driven Gear Bearing

    ENGINE 3-40 STARTER CLUTCH AND STARTER DRIVEN GEAR BEARING 1 Starter driven gear 2 Starter clutch 3 Roller 4 Push piece 5 Spring STARTER CLUTCH Install the starter driven gear onto the starter clutch and turn the starter driven gear by hand (the gear turns in only one direction).

  • Page 78: Generator Stator And Pick-Up Coil

    3-41 ENGINE • Hold the generator rotor with the rotor holder and re- move the starter clutch bolts. 09930-44913: Rotor holder REASSEMBLY • Locate the shim to the proper position. • Apply a small quantity of THREAD LOCK SUPE R "1303" to the starter clutch bolts and tighten them to the specified torque while holding the rot or holder.

  • Page 79: Transmission

    ENGINE 3-42 TRANSMISSION DISASSEMBLY • Disassemble the transmission gears as shown in the illustration. 1 1st dri v en gear 2 5th driven gear 3 3rd driven gear 4 4th driven gear 5 2nd driven gear 6 Driveshaft 7 Countershaft 8 5th drive gear 9 3rd drive gear 10 4th drive gear 11 2nd...
  • Page 80 3-43 ENGINE When installing a new circlip, pay attention to the direc- tion of the circlip. Fit the circlip to the side where the thrust is as shown in the illustration. The rounded side Thrust should be against the gear surface. Sharp edge Washers and circlips thickness 1.2 mm (0.05 in) 1.0 mm...

  • Page 81: Primary Driven Gear

    ENGINE 3-44 GEARSHIFT FORKS Measure the gearshift fork clearance in the groove of its respective gear using the thickness gauge. The clearance for each of the two gears hift forks plays an import ant role in the smoothness and positiveness of the shifting action. Each fork has its prongs fitted into the annu lar groove provided in its gear.

  • Page 82: Clutch

    3-45 ENGINE CLUTCH CLUTCH DRIVE PLATES Measure the thickness and claw width of the clutch drive plates using vernier calipers. If a clutch drive plate is not within the service limit, replace the clutch plates as a set. 09900-20101: Vernier calipers Service Limit Thickness (No.1): 2.62 mm (0.103 in) (No.2): 3.15 mm (0.124 in) Claw width:...

  • Page 83: Clutch Cover

    ENGINE 3-46 CLUTCH COVER • Remove the oil seal retainer • Remove the oil seal using the special tool. 09913-50121: Oil seal remover • Install the new oil seal using a suitable socket • Install the oil seal retainer. NOTE: Apply a small quantity of THREAD LOCK "1342"...

  • Page 84: Oil Sump Filter

    3-47 ENGINE OIL SUMP FILTER • Remove the oil sump filter cap • Remove the oil sump filter INSPECTION Check the oil sump filter for any damage or clogs. CLEANING Clean the oil sump filter with a compressed air. Downloaded from www.Manualslib.com manuals search engine...

  • Page 85: Engine Reassembly

    ENGINE 3-48 ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassembly. The following steps require special atten- tion or precautionary measures should be taken. NOTE: Apply engine oil to each running and sliding part before reassembling. CRANKSHAFT • When installing the crankshaft into the crankcase, it is necessary to pull its left end into the left crankcase with the special tools.

  • Page 86: Gearshift Cam And Gearshift Forks

    3-49 ENGINE • Install the washer balancer shaft driven gear washer and shim onto the balancer shaft. NOTE: Make sure that the key is aligned with the keyway. • Align the punch mark on the balancer shaft driven gear with the punch mark on the balancer shaft drive gear GEARSHIFT CAM AND GEARSHIFT...

  • Page 87: Crankcase

    • Install the the gearshift cam stopper spring CRANKCASE • Wipe both crankcase mating surfaces with a cleaning solvent. • Apply SUZUKI BOND "1215" uniformly to the mating surface of the right crankcase and assemble the cases within a few minutes. 99000-31110: SUZUKI BOND "1215"...
  • Page 88 3-51 ENGINE • Install the dowel pins into the left half of the crankcase. • Install the O-ring A CAUTION Use a new O-ring • Apply engine oil to the conrod big end and transmission gears. • Tighten the crankcase bolts to the specified torque. Crankcase bolt: 11 N-m (1.1 kg-m, 8,0 Ib-ft) NOTE: Install the clamp to the bolt...

  • Page 89: Generator Rotor

    GENERATOR ROTOR • Remove any grease from the tapered portion of the gen- erator rotor and crankshaft. • Install the washer so that the convex side of it faces the crankcase bearing. • Install the bearing • Install the starter driven gear •...

  • Page 90: Balancer Shaft Bolt

    3-53 ENGINE • Install the primary drive gear , wave washer primary drive gear nut NOTE: This nut has left hand threads. • Tighten the primary drive gear nut to the specified torque using the special tool. 09930-44913: Rotor holder Primary drive gear nut : 100 N-m (10.0 kg-m, 72.5 Ib-ft) BALANCER SHAFT BOLT...

  • Page 91: Oil Pump

    ENGINE 3-54 • Install the gearshift cam driven gear assembly. • Install the pawl lifter and cam guide NOTE: Apply a small quantity of THREAD LOCK "1342" to the threads of the screws. 99000-32050: THREAD LOCK "1342" • Install the return spring to the gearshift shaft as shown.

  • Page 92: Clutch

    3-55 ENGINE CLUTCH Clutch pressure plate Push piece Clutch drive plate No.1 (T: 3.00) Clutch driven plate Clutch drive plate No.2 (T: 3.50) Clutch push rod Concaved washer Washer seat Clutch sleeve hub Clutch housing Oil pump drive gear • Install the washer and spacer onto the counter- shaft.
  • Page 93 ENGINE 3-56 • Install the clutch sleeve hub and lock washer. • Install the clutch sleeve hub nut, and tighten it to the specified torque using the special tool. 09920-53740: Clutch sleeve hub holder Clutch sleeve hub nut: 50 N-m (5.0 kg-m, 36.0 Ib-ft) •...

  • Page 94: Clutch Cover

    3-57 ENGINE CLUTCH COVER • Install the two dowel pins and new gasket • Tighten the clutch cover bolts securely. A CAUTION Install the new gasket washer to the bolt STARTER IDLE GEAR • Install the starter idle gear A CAUTION Apply engine oil to the starter idle gear GENERATOR COVER •...

  • Page 95: Neutral Switch

    O-ring • Install the neutral switch. ENGINE SPROCKET SPACER • Apply SUZUKI SUPER GREASE "A" to the O-ring of the engine sprocket spacer and the oil seal lip. 99000-25010: SUZUKI SUPER GREASE "A" A CAUTION Use a new O-ring * Install the engine sprocket spacer onto the driveshaft.

  • Page 96: Piston And Piston Ring

    3-59 ENGINE PISTON AND PISTON RING • First, install a spacer into the oil ring groove and then install the two side rails . The spacer and side rails do not have a specific top or bottom when they are new.

  • Page 97: Cylinder

    ENGINE 3-60 The following are reminders for piston installation: • Before Installing the piston pin, apply molybdenum oil solution onto its surface. • Apply engine oil to the big and small ends of the conrod. • Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into crankcase.

  • Page 98: Cylinder Head

    3-61 ENGINE CYLINDER HEAD • Install the dowel pins into the cylinder and then install the cylinder head gasket onto the cylinder. A CAUTION Use a new gasket to prevent gas leakage. • Place the cylinder head onto the cylinder. •...

  • Page 99: Camshaft

    ENGINE 3-62 CAMSHAFT • Turn the crankshaft counterclockwise, and align the T line on the generator rotor with the mark on the generator cover while keeping the cam chain tight. I A CAUTION] If the crankshaft is turned without drawing the cam chain upward, the cam chain will catch be- tween crankcase and cam chain drive sprocket.

  • Page 100: Cam Chain Tension Adjuster

    3-63 ENGINE • Bend the lock washer securely. Camshaft Bolt Lock washer Camshaft sprocket • Install the camshaft end cap. CAM CHAIN TENSION ADJUSTER NOTE: * Before installing the cam chain tension adjuster, lock the tension spring with a flat-head screwdriver. * Before installing the cam chain tension adjuster, turn the crankshaft counterclockwise to remove any cam chain slack between the cam chain drive sprocket and cam-...

  • Page 101: Cylinder Head Cover

    • Clean the mating surfaces of the cylinder head and head cover. • Install the dowel pins. • Apply SUZUKI BOND N0.1215 uniformly to the mating surface of the cylinder head cover and install it within a few minutes. 99000-31110: SUZUKI BOND N0.1215 •...
  • Page 102 FUEL AND LUBRICATION SYSTEM -------------------------------------------- CONTENTS --------------------------------------------- FUEL TANK AND FUEL VALVE ..............4- 1 REMOVAL ....................4- 1 INSPECTION .................... 4- 1 REMOUNTING ..................4- 1 CARBURETOR..................... 4- 2 SPECIFICATIONS .................. 4-2 I.D. NO. LOCATION ................. 4-2 CONSTRUCTION ..................4-3 REMOVAL ....................

  • Page 103: Fuel Tank And Fuel Valve

    FUEL AND LUBRICATION SYSTEM FUEL TANK AND FUEL VALVE REMOVAL A WARNING Gasoline is very explosive. Extreme care must be taken. • Remove the front seat. (See p. 5-1.) • Remove the fuel tank mounting bolts. • Turn the fuel valve to "ON" or "RES" position. •...

  • Page 104: Carburetor

    FUEL AND LUBRICATION SYSTEM 4-2 CARBURETOR SPECIFICATIONS ITEM SPECIFI CATION E-01, 02, 04, 25, 34 E-17, 22, 24 Carburetor type MIKUNI BSR32SS Bore size 32 mm I.D. No 13F0 13F2 Idle r/min. 1 300 ± 100 r/min. Float height 13.0 ±0. 5 mm Main jet (M.J.) #115...

  • Page 105: Construction

    4-3 FUEL AND LUBRICATION SYSTEM CONSTRUCTION Top cap Spring Jet needle holder Washer Spacer Jet needle Piston valve/diaphragm Diaphragm Starter plunger Pilot jet Jet holder Main jet Pilot screw Starter jet Throttle stop screw Float Gasket Needle valve seat Needle valve Float chamber Downloaded from www.Manualslib.com...

  • Page 106: Removal

    FUEL AND LUBRICATION SYSTEM 4-4 REMOVAL • Remove the fuel tank. (See p. 4-1.) • Remove the starter plunger • Loosen the lock nuts and disconnect the throttle cables • Remove the overflow hose and air vent hose • Loosen the clamp screws. •...
  • Page 107 4-5 FUEL AND LUBRI C ATI O N SYSTEM Remove the diaphragm cover ©. Remove the diaphragm • Remove the carburetor top cap. • Remove the spring and piston valve along with diaphragm • Remove the jet needle holder Downloaded from www.Manualslib.com manuals search engine...
  • Page 108 FUEL AND LUBRICATION SYSTEM 4-6 • Remove the jet needle Holder Spring Washer Spacer The O-ring should be replaced with a new one. A CAUTION • Remove the float chamber body • Remove the screw • Remove the float pin •...
  • Page 109 4-7 FUEL AND LUBRICATION SYSTEM • Remove the pilot air jet No.1 and No.2 • Remove the needle jet PILOT SCREW REMOVAL (For E-03, -28, -33) Because harsh cleaning solvents can damage the O-rlng seals In the pilot system, the pilot system components should be removed before cleaning.

  • Page 110: Cleaning

    FUEL AND LUBRICATION SYSTEM 4- 8 CLEANING AWARNING 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 using compressed air.

  • Page 111: Reassembly

    4-9 FUEL A ND LUBRICA TION SYSTE M FLOAT HEIGHT ADJUSTMENT To check the float height, turn the carburetor upside down. Measure the float height while the float arm is just con- tacting the needle valve using vernier calipers. Bend the tongue as necessary to bring the float height to the...

  • Page 112: Lubrication System

    FUEL AND LUBRICATION SYSTEM 4-10 LUBRICATION SYSTEM OIL PRESSURE See p. 2-19. OIL FILTER See pp. 2-9 and -10. OIL SUMP FILTER When replacing the engine oil, make sure that the oil sump filter has no tears or damage. Also, be sure to clean the oil sump filter periodically.

  • Page 113: Engine Lubrication System Chart

    4-11 FUEL AND LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM CHART Downloaded from www.Manualslib.com manuals search engine...
  • Page 114 CHASSIS --------------------------------------------CONTENTS ---------------------------------------------- EXTERIOR PARTS ..................5- 1 REMOVAL ....................5- 1 REMOUNTING ..................5- 1 FRONT WHEEL ..................5-2 CONSTRUCTION ..................5-2 REMOVAL ....................5- 3 INSPECTION AND DISASSEMBLY............5-3 REASSEMBLY ..................5- 5 REMOUNTING ..................5- 6 FRONT BRAKE ..................5- 7 CONSTRUCTION ..................

  • Page 115: Exterior Parts

    5-1 CHASSIS EXTERIOR PARTS REMOVAL FRONT SEAT • Remove the seat with the ignition key. RIGHT FRAME COVER • Remove the screw. • Remove the right frame cover. hooked part LEFT FRAME COVER • Remove the screw. • Remove the left frame cover. hooked part •...

  • Page 116: Front Wheel

    CHASSIS 5-2 FRONT WHEEL CONSTRUCTION Dust cover Spacer Bearing Front w heel Spacer Bearing Brake disc Speedometer gearbox Front axle Axle pinch bolt Brake disc bolt ITEM kg-m Ib-ft 47.0 16.5 16.5 Downloaded from www.Manualslib.com manuals search engine...
  • Page 117 Left Right Downloaded from www.Manualslib.com manuals search engine...

  • Page 118: Removal

    5-3 CHASSIS REMOVAL FRONT WHEEL • Loosen the axle pinch bolt • Loosen the front axle • Raise the front wheel off the ground with a jack or wood- en block. • Remove the front wheel by removing the front axle •...
  • Page 119 CHASSIS 5-4 Remove the wheel bearings as follows: • Insert the adapter into the wheel bearing. • After inserting the wedge bar from the opposite side, lock the wedge bar into the slit of the adapt er. • Drive out both bearings by striking the wedge bar. 09941-50111: Bearing remover A CAUTION The removed bearings should be replaced with new...

  • Page 120: Reassembly

    5-5 CHASSIS REASSEMBLY • Apply SUZUKI SUPER GREASE "A" to the bearings be- fore installing. 99000-25010: SUZUKI SUPER GREASE "A" • Install the wheel bearings using the special tools as de- scribed below. 09924-84510: Bearing installer set 09924-84521: Bearing installer set...

  • Page 121: Remounting

    Remount the front wheel in the reverse order of removal. Pay attention to the following points: • Apply SUZUK I SUPE R GREASE "A" to the speedometer gearbox. 99000-25010: SUZUKI SUP ER GREAS E "A" • Align the lugs on the speedometer gearbox with the recesses on the front wheel.

  • Page 122: Front Brake

    5-7 CHASSIS FRONT BRAKE CONSTRUCTION ITEM kg-m kg-m 16.5 28.0 13.0 0.75 Reservoir cap Diaphragm Brake piston/primary cup Brake hose Brake caliper holder Brake pad Spring Dust seal Piston seal Piston Brake hose union bolt Brake master cylinder mounting bolt Brake caliper mounting bolt Brake pad mounting bolt Brake caliper air bleeder valve...

  • Page 123: Brake Pad Replacement

    CHASSIS 5-8 BRAKE PAD REPLACEMENT • Loosen the brake pad mounting bolt • Remove the brake caliper mounting bolts • Remove the brake pad mounting bolt • Remove the brake pads A CAUTION * Do not operate the brake lever during or after brake pad removal.

  • Page 124: Brake Caliper Removal And Disassembly

    5-9 CHASSIS BRAKE CALIPER REMOVAL AND DISASSEMBLY • Disconnect the brake hose from the brake caliper by re- moving the brake hose union bolt and allow the brake fluid to drain into a suitable receptacle. • Loosen the brake pad mounting bolt. •...

  • Page 125: Brake Caliper Inspection

    * Apply brake fluid to all of the seals, brake caliper Dust seal bore and piston before reassembly. • Install the piston seal as shown in the illustration. Caliper body • Apply grease to the brake caliper holder. Piston seal 99000-25100: SUZUKI SILICONE GREASE Downloaded from www.Manualslib.com manuals search engine...

  • Page 126: Brake Disc Inspection

    5-11 CHASSIS • Tighten the brake caliper mounting bolts and brake pad mounting bolt to the specified torque. • Tighten the brake hose union bolt to the specified torque. Brake caliper mounting bolt 39 N-m (3.9 kg-m, 28.0 Ib-ft) Brake pad mounting bolt : 18 N-m (1.8 kg-m, 13.0 Ib-ft) Brake hose union bolt : 23 N-m (2.3 kg-m, 16.5 Ib-ft)
  • Page 127 CHASSIS 5-12 • Place a rag underneath the brake hose union bolt on the master cylinder to catch any spilt brake fluid. • Remove the brake hose union bolt. A CAUTION Immediately wipe off any brake fluid contacting any part of the motorcycle. The brake fluid reacts chemically with paint, plastics and rubber materi- als, etc.

  • Page 128: Master Cylinder Inspection

    5-13 CHASSIS • Remove the piston/secondary cup and return spring MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other damage. Inspect the piston surface for any scratches or other dam- age. Inspect the primary cup, secondary cup and dust seal for wear or damage.
  • Page 129 CHASSIS 5-14 • When remounting the master cylinder onto the handle- bars, align the master cylinder holder's mating surface with punch mark on the handlebars and tighten the upper clamp bolt first. Master cylinder bolt: 10 N-m (1.0 kg-m, 7.0 Ib-ft) Upper clamp bolt...

  • Page 130: Front Fork

    5-15 CHASSIS FRONT FORK CONSTRUCTION O-ring Spacer Washer Front fork spring Damper rod ring Damper rod Rebound spring Inner tube Dust seal Oil seal stopper ring Oil seal Washer Slide metal Guide bushing Oil lock piece Outer tube ITEM kg-m Ib-ft Gasket 16.5...
  • Page 131 CHASSIS 5-16 • Remove the front fork after loosening the front fork upper and lower clamp bolts NOTE: Slightly loosen the front fork cap bolt to facilitate later disassembly. • Remove the front fork cap bolt , spacer , washer and spring •...

  • Page 132: Inspection

    5-17 CHASSIS • Remove the damper rod and rebound spring from the inner tube. • Separate the inner tube from the outer tube. • Remove the following parts. Oil seal Washer Outer tube slide metal Inner tube slide metal The removed oil seal and slide metals should be replaced with new ones.

  • Page 133: Reassembly And Remounting

    * When installing the oil seal onto the inner tube, protect their seal lips to prevent seal lip damage. * Before installing the oil seal, apply SUZUKI SU PER GREASE "A" to its seal lip lightly. 99000-25010: SUZUKI SUPER GREASE "A" Downloaded from www.Manualslib.com...
  • Page 134 Make sure that the oil seal stopper ring is fitted securely. NOTE: Before installing the dust seal , apply a small quantity of SUZUKI SUPER GREASE "A" to the lip of dust seal. 99000-25010: SUZUKI SUPER GREASE "A" Downloaded from www.Manualslib.com...
  • Page 135 CHASSIS 5-20 • Pour the specified fork oil into the inner tube. Fork oil type: SUZUKI FORK OIL SS-08 (#10) 99000-99001-SS8: SUZUKI FORK OIL SS-08 Specification Front fork oil capacity (each leg): 369 ml (12.5/13.0 US/Imp oz) • Hold the front fork leg in a vertical position and adjust the fork oil level using the special tool.
  • Page 136 5-21 CHASSIS • Tighten the front fork lower clamp bolts and front fork cap bolts to the specified torque. • Tighten the front fork upper clamp bolts to the speci- fied torque. Front fork upper clamp bolt: 23 N-m (2.3 kg-m, 16.5 Ib-ft) Front fork lower clamp bolt: 33 N •...

  • Page 137: Steering

    CHASSIS 5-22 STEERING CONSTRUCTION Steering stem upper bracket Handlebar clamp Handlebar holder Steering stem nut Dust seal Bearing, upper Bearing, low er Steering stem Steering stem low er cover Handlebars Handlebar balancer Steering stem head bolt Handlebar clamp bolt Handlebar holder nut Front fork upper clamp bolt Front fork low er clamp bolt ITEM...

  • Page 138: Removal And Disassembly

    REMOVAL AND DISASSEMBLY • Remove the front wheel. (See p. 5-4.) • Remove the front fork. (See p. 5-15.) • Disconnect the front brake light switch lead wires. • Remove the front brake master cylinder. • Remove the right handlebar balancer . •...
  • Page 139 5-23 CHASSIS • Remove the left handlebar balancer . • Remove the handlebar left switch • Disconnect the clutch lever position switch coupler • Remove the rear view mirror • Disconnect the clutch cable. • Remove the handlebar clamp bolt caps. •...
  • Page 140 CHASSIS 5-24 • Remove the steering stem lower cover • Remove the front brake hose/speedometer cable guide • Disconnect the speedometer cable ^5© - TJ«E • Remove the speedometer . • Remove the front turn signal light brackets. • Remove the handlebar holders •...

  • Page 141: Inspection

    5-25 CHASSIS • Remove the steering stem nut using the special tool. 09940-14911: Steering stem nut wrench • Draw out the steering stem lower bracket. NOTE: Hold the steering stem lower bracket to prevent it from fal- ling. • Remove the dust seal , upper bearing inner race and upper bearing •...

  • Page 142: Reassembly And Remounting

    • Apply grease to the upper and lower bearings. 99000-25010: SUZUKI SUPER GREASE "A" • Tighten the steering stem nut using the special tool. 09940-14911: Steering stem nut wrench Steering stem nut: 45 N ■ m (4.5 kg-m, 32.5 Ib-ft) Downloaded from www.Manualslib.com...
  • Page 143 5-27 CHASSIS • Turn the steering stem lower bracket about fi ve or six times to the left and right. • Loosen the steering stem nut of a turn NOTE: This adjustment will vary from motorcycle to mot orcycle. Mak e sure that the steering turns smoothly and easily in both directions.
  • Page 144 NOTE: Insert the projection into the hole of the handlebars. * Install the handlebar right switch. NOTE: * Apply SUZUKI SUPER GREASE "A" to the end of the throttle cable. 99000-25010: SUZUKI SUPER GREASE "A" * Insert the projection into the hole of the handlebars.

  • Page 145: Rear Wheel And Rear Brake

    5-29 CHASSIS REAR WHEEL AND REAR BRAKE CONSTRUCTION Spacer Brake panel Brake shoe Spring Bearing Spacer Brake camshaft Rear w heel Bearing Damper Drive chain guide Rear sprocket mounting drum Retainer Bearing Dust seal Spacer Rear sprocket Rear axle Rear axle nut Rear brake cam lever nut Rear sprocket mounting nut Downloaded from...
  • Page 146 ITEM kg-m kg-m 56.5 36.0 Downloaded from www.Manualslib.com manuals search engine...

  • Page 147: Removal

    CHASSIS 5-30 REMOVAL • Remove the clip and rear brake adjusting nut • Remove the cotter pin, torque link nut and bolt. • Remove the rear axle nut • Raise the rear wheel off the ground with a jack or wood- en block.

  • Page 148: Inspection And Disassembly

    5-31 CHASSIS • Remove the brake cam lever bolt and nut. • Remove the brake cam lever • Remove the washer , O-ring and brake camshaft INSPECTION AND DISASSEMBLY WHEEL BEARING ......See pp. 5-3 and -4. WHEEL AXLE ..........See p. 5-4. WHEEL ............
  • Page 149 CHASSIS 5-32 • Remove the retainer BRAKE DRUM 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. The value of this limit is indicated inside the brake drum. 09900-20101: Vernier calipers Service Limit: 130.7 mm (5.15 in)

  • Page 150: Reassembly And Remounting

    Pay atten- tion to the following points: WHEEL BEARING • Apply SUZUKI SUPER GREASE "A" to the bearing be fore installation. 99000-25010: SUZUKI SUPER GREASE "A" • Press fit the bearing to the wheel using the special tools.
  • Page 151 NOTE: The stamped mark on the rear sprocket should face to the outside. BRAKE CAMSHAFT • When installing the brake camshaft, apply SUZUKI SU- PER GREASE "A" to the camshaft. 99000-25010: SUZUKI SUPER GREASE "A" BRAKE CAM LEVER • Install the new O-ring and washer •...
  • Page 152 5-35 CHASSIS • Apply SUZUKI SUPER GREASE "A" to the brake cam and pin, and install the brake shoes. 99000-25010: SUZUKI SUPER GREASE "A" A CAUTION Be careful not to apply too much grease to the cam and pin. If grease gets on the lining, brake slippage will result.

  • Page 153: Rear Suspension

    CHASSIS 5-36 REAR SUSPENSION CONSTRUCTION Rear shock absorber Rear torque link Sw ingarm Spacer Dust seal Dust seal Spacer Drive chain buffer Sw ingarm pivot shaft Rear shock absorber nut Rear torque link nut Rear shock absorber bolt Sw ingarm pivot nut ITEM kg-m Ib-ft...
  • Page 154 Downloaded from www.Manualslib.com manuals search engine...

  • Page 155: Removal

    5-37 CHASSIS REMOVAL • Remove the rear wheel. (See p. 5-30.) • Remove the drive chain case. • Remove the rear brake cable holder • Remove the rear brake cable from the swingarm. • Remove the shock absorbers . • Remove the swingarm pivot shaft end caps. •...

  • Page 156: Inspection And Disassembly

    CHASSIS 5-38 • Remove the rear torque link from the swingarm. • Remove the chain buffer from the swingarm. • Remove the spacers INSPECTION AND DISASSEMBLY SWINGARM PIVOT SPACERS AND DUST SEALS Inspect the swingarm pivot spacers and dust seals for damage.
  • Page 157 5-39 CHASSIS • Remove the swingarm needle bearings using the special tools. 09923-74510: Bearing remover 09930-30102: Sliding shaft A CAUTION The removed needle bearings should be replaced with new ones. SWINGA RM Inspect the swingarm for damage. If any defects are found, replac e the swingarm with a new one.

  • Page 158: Reassembly And Remounting

    Install the needle bearings with the stamped mark facing out. • Apply grease to the spacers, dust seals and needle bearings. 99000-25010: SUZUKI SUPER GREASE "A" • Install the rear torque link to the swingarm. • Tighten the rear torque link nut to the specified torque.
  • Page 159 5-41 CHASSI S • Install the rear shock absorber and tighten the mounting bolts and nuts to the specified torque. Shock absorber mounting bolt/nut: 29 N-m (2.9kg-m,21.0lb-ft) NOTE: Install the rear shock absorbers with the spring tension ad- justing holes facing out.
  • Page 160 ELECTRICAL SYSTEM -------------------------------------------- CONTENTS --------------------------------------------- CAUTIONS IN SERVICING ................ 6- 1 LOCATION OF ELECTRICAL COMPONENTS ........6-3 CHARGING SYSTEM ................6-5 DESCRIPTION..................6- 5 TROUBLESHOOTING................6- 6 INSPECTION .................... 6- 7 STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM ......................6-10 STARTER SYSTEM DESCRIPTION ............6-10 SIDE-STAND/IGNITION INTERLOCK SYSTEM DESCRIPTION ...

  • Page 161: Cautions In Servicing

    ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTORS • When disconnecting a connector, be sure to hold the ter- minals; do not pull the lead wires. • When connecting a connector, push it in so it is firmly attached. • Inspect the connector for corrosion, contamination and any breakage in the cover.

  • Page 162: Connecting The Battery

    ELECTRICAL SYSTEM 6-2 BATTERY • The MF battery used in this motorcycle does not require maintenance (e.g., electrolyte level inspection, distilled water replenishing). • During normal charging, no hydrogen gas is produced. However, if the battery is overcharged, hydrogen gas may be produced.

  • Page 163: Location Of Electrical Components

    ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS Clutch lever position switch Horn Ignitor Generator Turn signal/side-stand relay Neutral switch Fuse box Side-stand switch Regulator/rectifier Ignition coil Downloaded from www.Manualslib.com manuals search engine...
  • Page 164 ELECTRI C AL SYSTEM 6-4 Front brake light switch Starter relay Rear brake light switch Main fuse Starter motor Battery Downloaded from www.Manualslib.com manuals search engine...

  • Page 165: Charging System

    6-5 ELECTRICAL SYSTEM CHARGING SYSTEM DESCRIPTION The circuit of the charging system is indicated in the figure, which is composed of an AC generator, regulator/rectifier unit and battery. The AC current generated from AC generator is converted by rectifier and is turned into DC current, then it charges the battery.

  • Page 166: Troubleshooting

    ELECTRICAL SYSTEM TROUBLESHOOTING Battery runs down quickly. Check accessories which use exces sive Accessories • Remove accessories. amounts of electricity. are installed No accessories Check the battery for current • Short circuit of the wire harness. Current leaks leaks. (See p. 6-7.) •...
  • Page 167 • Faulty regulator/rectifier Battery overcharges • Faulty battery • Poor cont act of stator coil coupler Downloaded from www.Manualslib.com manuals search engine...

  • Page 168: Inspection

    6-7 ELECTRICAL SYSTEM INSPECTION BATTERY LEAK CURRENT INSPECTION • Remove the front seat and right frame cover. (See p. 5-1.) • Turn the ignition switch to the OFF position. • Disconnect the battery lead wire. • Connect the tester between the battery terminal and the battery lead wire.
  • Page 169 ELECTRICAL SYSTEM STATOR COIL RESISTANCE • Remove the front seat. (See p. 5-1.) • Remove the fuel tank. (See p. 4-1.) • Disconnect the stator coil coupler. Measure the resistance between the three lead wires using a tester. Also check that the stator core is insulated. If the resistance is incorrect, replace the stator coil with a new one.
  • Page 170 ELECTRICAL SYSTEM REGULATOR/ RECTIFIER • Remove the front seat. (See p. 5-1.) • Remove the fuel tank. (See p. 4-1. ) • Disconnect the regulator/rectifier couplers. Measure the voltage between the lead wires in the follow- ing table. 09900-25008: Multi circuit tester set Tester knob indication: Diode test Unit: V Probe of tester to:...

  • Page 171: Starter System And Side-Stand/Ignition Interlock System

    ELECTRICAL SYSTEM 6-10 STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM STARTER SYSTEM DESCRIPTION The start er system consists of the following components: the start er motor, starter relay, clutch lever position s witch, side-stand relay, side-stand s witch, neutral switch, starter button, engine stop switch, ignition switch and battery.

  • Page 172: Troubleshooting

    6-11 ELECTRICAL SYSTEM TROUBLESHOOTING Starter motor will not run. Check if the starter motor runs The transmission is in neutral. Grasp when its terminal is connected to the clutch lever. Turn on the ignition switch with the engine stop switch in the battery terminal.
  • Page 173 • Faulty starter clutch Downloaded from www.Manualslib.com manuals search engine...

  • Page 174: Starter Motor Removal And Disassembly

    ELECTRICAL SYSTEM 6-12 STARTER MOTOR REMOVAL AND DISASSEMBLY • Disconnect the starter motor lead wire. • Remove the starter motor. • Disassemble the starter motor, as shown in the illustration. Housing end (Outside) O-ring Brush spring Brush holder Starter motor case Armature O-ring Housing end (Inside)

  • Page 175: Starter Motor Reassembly

    Pay attention to the following points: A CAUTION Replace the O-rings with new ones to prevent oil leakage and moisture. • Apply SUZUKI SUPER GREASE "A" to the lip of the oil seal. 99000-25010: SUZUKI SUPER GREASE "A" Downloaded from www.Manualslib.com...

  • Page 176: Starter Relay Inspection

    99000-25140: SUZUKI MOLY P ASTE • Apply SUZUK I SUPE R GREASE "A" to the O-rings. 99000-25010: SUZUKI SUP ER GREAS E "A" • Apply a small quantity of THREAD LOCK "1342" to the starter motor housing bolts.

  • Page 177: Side-Stand/Ignition Interlock System Part Inspection

    6-15 ELECTRICA L SY STEM Measure the starter relay resistance between the terminals ( and Starter relay resistance: 3-6 SIDE-STAND/IGNITION INTERLOCK SYSTEM PART INSPECTION If the interlock system does not operate properly, check each component. If any abnormality is found, replace the component with a new one.
  • Page 178 ELECTRICAL SYSTEM 6-16 TURN SIGNAL/SIDE-STAND RELAY The turn signal relay is corporated with the side-stand relay and diode to form the one component part which is called the turn signal/side-stand relay. It is located under the luggage box. • Remove the front seat. (See p. 5-1.) •...
  • Page 179 6-17 ELECTRICA L SYSTEM DIODE INSPECTION Using multi circuit tester, measure the voltage between the terminals in the following table. Unit: V Probe of tester to: 1.4-1.5 0.4-0.6 09900-25008: Multi circui t te ster set Tester knob indication: Diode te st NOTE: If the tester read under 1.4V, replace the battery of multi circuit tester when do not connecting the tester probes.

  • Page 180: Ignition System

    ELECTRICAL SYSTEM 6- 18 IGNITION SYSTEM (DIGITAL IGNITOR) DESCRIPTION The fully transistorized ignition system consists of the following components: a generator, ignitor, igni- tion coil and spark plug. The ignition timing is programmed and stored in the ignitor. The pick-up coil is mounted in the generator.

  • Page 181: Troubleshooting

    6-19 ELECTRICAL SYSTEM TROUBLESHOOTING * Check that the transmission is in neutral and the engine No spark or poor spark stop switch is in the "RUN" position. Grasp the clutch lever. Check that the fuse is not blown and the battery is fully-charged before diagnosing.
  • Page 182 • Open circuit in wiring harness • Poor connection of ignition couplers Downloaded from www.Manualslib.com manuals search engine...

  • Page 183: Inspection

    ELECTRI C AL SYSTEM 6-20 INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the front seat. (See p. 5-1.) • Remove the fuel tank. (See p. 4-1.) • Disconnect the spark plug cap. • Connect new spark plug to the spark plug cap and ground it to the cylinder head.
  • Page 184 6-21 ELECTRICAL SYSTEM IGNITION COIL RESISTANCE Measure the ignition coil resistance in both the primary and secondary windings. If the windings are in sound condition, their resistance should be close to the specified values. Ignition coil resistance Primary: 3-5 ( terminal- terminal) Secondary: 17-28 k ( terminal-Spark plug cap) IGNITOR •...
  • Page 185 ELECTRICAL SYSTEM 6-22 PICK-UP COIL PEAK VOLTAGE • Remove the front seat. (See p. 5-1.) • Remove the luggage box. NOTE: Be sure that all of the couplers are connected properly and the battery is fully-charged. • Disconnect the ignitor coupler at the ¡gnitor. •...
  • Page 186 6-23 ELECTRICAL SYSTEM • Remove the front seat. (See p. 5-1.) • Remove the fuel tank. (See p. 4-1.) • Disconnect the pick-up coil coupler and connect the mul- ti circuit tester with the peak volt adaptor. Probe: Green lead wire Probe: Blue lead wire •...

  • Page 187: Speedometer

    ELECTRICAL SYSTEM 6-24 SPEEDOMETER REMOVAL AND DISASSEMBLY • Remove the speedometer. • Disassemble the speedometer as follows. Speedometer Speedometer bracket Speedometer cover Socket assy. Downloaded from www.Manualslib.com manuals search engine...

  • Page 188: Inspection

    6-25 ELECTRICAL SYSTEM WIRE COLOR : Black B/W : Black with White tracer : Gray Bl/B : Blue with Black tracer : Light green O/G : Orange wit h Green tracer : Yellow Bl/B: Neutral B: Turn signal (L) Y: High beam Lg: Turn signal Gr: Illumination Neutral...

  • Page 189: Lamps

    ELECTRICAL SYSTEM 6-26 LAMPS HEADLIGHT AND POSITION LIGHT Headlight: 12V 60/55W Position light: 12V 4W ..Except for E-03, -24, -28 and -33 models HEADLIGHT BULB REPLACEMENT • Remove the headlight. • Disconnect the socket • Remove the rubber cap •...

  • Page 190: Brake Light/Taillight

    6-27 ELECTRICAL SYSTEM BRAKE LIGHT/TAILLIGHT Brake light/Taillight: 12V 21/5W BRAKE LIGHT/TAILLIGHT BULB REPLACEMENT • Remove the rubber cap behind the rear fender. • Push in on the bulb socket , turn it counterclockwise, and pull it out. • Remove the brake light/taillight bulb A CAUTION If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or...

  • Page 191: Turn Signal Lights

    ELECTRICAL SYSTEM 6-28 TURN SIGNAL LIGHTS Turn signal light/Running light: 12V 21/5W ..For E-03, -28 and -33 models Turn signal light: 12V 21W ..For the others TURN SIGNAL LIGHT BULB REPLACEMENT • Remove the lens by removing the screws. •...

  • Page 192: Relays

    6-29 ELECTRICAL SYSTEM RELAYS STARTER RELAY The starter relay is located behind the right frame cover. (See pp. 6-14 and -15.) TURN SIGNAL/SIDE-STAND RELAY The turn signal relay is corporated with the side-stand relay and diode to form the one component part which is called the turn signal/side-stand relay.

  • Page 193: Switches

    ELECTRICAL SYSTEM 6-30 SWITCHES If any abnormality is found, replace the respective Measure eac h switch for continuity using a tester. switch assemblies with new ones. STARTER BUTTON IGNITION SWITCH HORN BUTTON For E-24 FRONT BRAKE LIGHT SWITCH LIGHTING SWITCH (Except for E-03, -24, -28, -33) REAR BRAKE LIGHT SWITCH...

  • Page 194: Battery

    6-31 ELECTRICAL SYSTEM BATTERY Filter Stopper SPECIFICATIONS Upper cover breather Terminal Type designation FTX7L-BS Safety valve Cathode Capacity 12V, 21.6 kC(6Ah)/10HR plates Standard electrolyte Separator 1.320 at 20°C (68°F) (fiberglass S.G. plate) Anode plates INITIAL CHARGING FILLING ELECTROLYTE • Remove the aluminum tape which seals the battery filler holes * Remove the caps from the electrolyte container.

  • Page 195: Servicing

    ELECTRICAL SYSTEM 6-32 NOTE: If air bubbles do not rise from any one of the filler ports, tap the bottom of the electrolyte container two or three times. Never remove the electrolyte container from the battery while there is still electrolyte in the container. •...

  • Page 196: Recharging Operation

    6-33 ELECTRICAL SYSTEM RECHARGING OPERATION • Measure the battery voltage using a tester. If the voltage reading is less than 12.0V (DC), recharge the battery with a battery charger. ! ________________________ A CAUTION When recharging the battery, remove the battery from the motorcycle.
  • Page 197 SERVICING INFORMATION ------------------------------------------- CONTENTS -------------------------------------------- TROUBLESHOOTING ................. 7- 1 WIRING DIAGRAM ..................7- 8 WIRE, CABLE AND HOSE ROUTING ............7-11 FRAME REAR COVER SET-UP ............... 7-19 SPECIAL TOOLS ..................7-20 TIGHTENING TORQUE................7-23 SERVICE DATA ..................7-26 Downloaded from www.Manualslib.com manuals search engine...

  • Page 198: Troubleshooting

    7-1 SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not start, or Compression too low Rebore or replace. is hard to start. Worn cylinder. Replace. Worn piston ring. Repair or replace Worn valve guide or improper valve seating. Tighten.
  • Page 199 SERVICING INFORMATION 7-2 Complaint Symptom and possible causes Remedy Engine is noisy. Excessive valve chatter Nois y engine. 1. Excessive valve clearance. Adjust. 2. Weak or broken valve spring. Replace. 3. Worn cam surface. Replace. Replace camshaft. 4. Worn or burnt camshaft journal. Noise seems to come from the piston 1.
  • Page 200 7-3 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Transmission will Broken gearshift shaft return spring. Replace. not shift back. Rubbing or stuck gearshift shaft. Repair or replace. Worn or distorted gearshift fork. Replace. Transmission jumps Worn gear. Replace. out of gear. Worn or distorted gearshift fork.
  • Page 201 SERVICING INFORMATION 7-4 Complaint Symptom and possible causes Remedy Engine overheats. 1. Heavy carbon deposit on piston crown. Clean. 2. Not enough oil in the engine. Add oil. 3. Defective oil pump or clogged oil circuit. Replace or clean. 4. Too low in float chambers fuel level. Adjust.
  • Page 202 7-5 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Front wheel Distorted wheel rim. Replace. wobbles. Worn front wheel bearing. Replace. Defective or incorrect tire. Replace. Loose front axle. Tighten. Incorrect front fork oil level. Adjust. Loose wheel spoke. Tighten. Front suspension Weak spring.
  • Page 203 SERVICING INFORMATION 7-6 Complaint Symptom and possible causes Remedy Brake squeaks. Clean surface with sand- Carbon adhesion on brake pad surface. paper. Readjust brake pad position Tilted brake pad. or replace. Replace. Replace. Change brake fluid. Damaged wheel bearing. Disassemble and clean Worn brake pad.
  • Page 204 7-7 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Repair or tighten. Generator charges Lead wires tend to get shorted or open-circuited or Replace. but charging rate is loosely connected at terminal. Replace. Replace below the Grounded or open-circuited stator coils or genera battery.

  • Page 205: Wiring Diagram

    SERVICING INFORMATION 7-8 WIRING DIAGRAM FOR E-03, -28 and -33 Downloaded from www.Manualslib.com manuals search engine...
  • Page 206 7-9 SERVICING INFORMATION FOR E-24 Downloaded from www.Manualslib.com manuals search engine...
  • Page 207 FOR THE OTHERS SERVICING INFORMATION 7-10 Downloaded from www.Manualslib.com manuals search engine...
  • Page 208 Clamp Clamp Handlebar switch (L&R) Handlebar sw itch (L&R) Starter motor Clamp Clamp Pass through the w iring harness right side of the clutch cable, Brake light/Taillight speedometer cable and brake Rear turn signal light (L) hose. Wiring harness Wiring harness Starter motor Clamp Clamp...
  • Page 209 Clamp Clamp Wiring harness Handlebar switch (L&R) Starter motor Starter motor Wiring harness Generator Clamp Clamp Wiring harness High tension cord Wiring (Ignition coil) harness Handlebar switch Clamp (L&R) ________ Clamp Clamp Battery Rear turn signal Pass through the handlebar terminal light (R) Rear turn signal...
  • Page 210 7-13 SERVICING INFORMATION Clamp Engine Side-stand switch ground wire lead w ire Clamp Generator rolor Neutral switch lead wire Side-stand switch lead w i r e Neutral sw itch lead w ire Generator lead wire Neutral sw itch Pick-up coil Downloaded from www.Manualslib.com manuals search engine...
  • Page 211 Stator coil Downloaded from www.Manualslib.com manuals search engine...

  • Page 212: Cable Routing

    SERVICING INFORMATION 7-14 CABLE ROUTING Clamp Clamp Throttle cables Clamp Throttle cable (returning Clamp cable) Clamp Throttle cable (pulling cable) Wiring harness Throttle cable (pulling cable) Throttle cable (returning cable) Brake hose Handlebar sw itch (R) Throttle cables Clamp Brake hose Throttle cables Starter cable Clutch cable...
  • Page 213 7-15 SERVICING INFORMATION Speedometer cable Guide Pass the speedometer cable outside of the brake hose. Brake hose Clamp 100 mm (4.0 in) Ma x. 10 mm (0.4 in) 4 Do not contact the guide to the caliper rubber bushing. Caliper rubber bushing Guide...
  • Page 214 SERVICING INFORMATION 7-16 Clamp Seat lock cable Rear brake switch cable Clamp Rear brake cable Rear brake Clamp cable clip Rear brake cable Clamp Rear brake switch cable Downloaded from www.Manualslib.com manuals search engine...

  • Page 215: Front Brake Hose Routing

    7-17 SERVICING INFORMATION FRONT BRAKE HOSE ROUTING Clamp Master cylinder Master cylinder Clamp / Clamp the brake \ \ hose securely. / Brake hose Clamp Speedometer cable Clamp / Clamp the brake \ \ hose securely. / Brake caliper After touching the brake hose union to the stopper, tighten the union bolt to the specified torque.

  • Page 216: Carburetor Hose Routing

    SERVICING INFORMATION 7-18 CARBURETOR HOSE ROUTING Right Right Left Left (Engine side) (Air cleaner side) Carburetor clamp position Air cleaner Carburetor Carburetor air vent hose Battery case Clamp Air cleaner drain hose Carburetor overflow hose VIEW A Downloaded from www.Manualslib.com manuals search engine...

  • Page 217: Frame Rear Cover Set-Up

    7-19 SERVICING INFORMATION FRAME REAR COVER SET-UP Rear fender Frame rear cover Cushion Spacer Frame Rear fender brace Downloaded from www.Manualslib.com manuals search engine...

  • Page 218: Special Tools

    SERVICING INFORMATION 7-20 SPECIAL TOOLS 09900-00401 "L" type hexagon 09900-00410 Hexagon 09900-06107 09900-06108 09900-09004 wrench set wrench set Snap ring pliers Snap ring pliers Impact driver set 09900-20202 09900-20203 09900-20205 09900-20101 09900-20508 Micrometer Micrometer Micrometer Vernier calipers Cylinder gauge set (25-50 mm) (50-75 mm) (0-25 mm)
  • Page 219 7-21 SERVICING INFORMATION 09916-14910 Valve 09915-74510 lifter attachment 09915-64510 09916-14510 09913-85210 Oil pressure gauge Compression gauge Valve li f ter Bearing installer 09916-24450 09916-34550 Valve 09916-34542 Valve 09916-21111 Solid pilot (N- guide reamer handle guide reamer (5.5 Valve seat cutter set 100-5.52) See p.
  • Page 220 SERVICING INFORMATION 7-22 09941-54911 09941-74910 09943-74111 Front 09941-50111 Bearing outer race Steering bearing fork oil level gauge installer remover Bearing remover NOTE: When ordering a special tool, please confirm whether it is available or not. Downloaded from www.Manualslib.com manuals search engine...
  • Page 221 SERVICING INFORMATION 7-24 CHASSIS ITEM kg-m Ib-ft 11.5 Handlebar clamp bolt 32.5 Handlebar holder nut 47.0 Steering stem head bolt 16.5 Front fork upper clamp bolt Front fork lower clamp bolt 24.0 Front fork cap bolt 16.5 Front fork damper rod bolt 14.5 Front axle 47.0...

  • Page 222: Tightening Torque

    7-25 SERVICING INFORMATION TIGHTENING TORQUE CHART For other bolts and nuts listed previously, refer to this chart: Conventional or "4" marked bolt "7" marked bolt Bolt Diameter kg-m Ib-ft kg-m (mm) Ib-ft 0.15 16.5 21.0 36.0 32.5 61.5 47.0 97.5 13.5 10.5 21.0...

  • Page 223: Service Data

    SERVICING INFORMATION 7-26 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STA NDA RD LIMIT Valve diam. (1.0) E X. (0.9) 0.03-0.08 Valve clearance (when cold) (0.001 -0. 003) 0.08-0.13 E X. (0.003-0.005) 0.025-0.052 Valve guide to valve stem (0.0010-0.0020) clearance 0.040-0.067...
  • Page 224 7-27 SERVICING INFORMATION CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT 34.990-35.040 Cam height 34.690 (1.3776-1.3795) (1.3657) 35.030-35.080 E X. 34.730 (1.3791-1.3811) (1.3673) 0.032-0.066 0.150 Camshaft journal oil clearance (0.0013-0.0026) (0.0059) 25.012-25.025 Camshaft journal holder I.D. R. side (0.9847-0.9852) 20.012-20.025 L.
  • Page 225 SERVICING INFORMATION 7-28 STANDARD LIMIT ITEM 1.01-1.03 Piston ring groove width (0.040-0.041) 1.21-1.23 (0.047-0.048) 2.51-2.53 (0.099-0.100) 0.975-0.990 Piston ring thickness (0.0384-0.0390) 1.170-1.190 (0.0461 -0.0469) 18.002-18.008 18.030 Piston pin bore (0.7087-0.7090) (0.7098) 17.992-18.000 17.980 Piston pin O.D. (0.7083-0.7087) (0.7079) CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD...
  • Page 226 7-29 SERVICING INFORMATION TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3.238(68/21) Final reduction ratio 2.733(41/15) Gear ratios 2.636(29/11) 1.687(27/16) 1.263(24/19) 1.000(20/20) 0.818(18/22) 0.20-0.40 0.60 Shift fork to groove clearanc e (0.008-0.016) (0.024) 4.25-4.35 Shift fork groove width (0.167-0.171)
  • Page 227 SERVICING INFORMATION 7-30 CARBURETOR ITEM SPECIFI CATION E-03, 28 E-33 Carburetor type MIKUNI BSR32SS Bore size 32 mm I.D. No 13F3 13F4 Idle r/min. 1 300 ± 50 r/min. 13.0 ± 0. 5 mm Float height Main jet (M.J.) Jet needle (J.N.) 5C65 Needle jet...
  • Page 228 7-31 SERVICING INFORMATION WATTAGE Unit: W SPECIFI CATION ITEM E-01,02, 04, E-24 E-03, 28, 33 17,22, 25,34 Headlight Position light Brake light/ Taillight 21/5 Turn signal light (rear) Front turn signal light/Running light 21/5 Speedometer light Neut ral indicator light Turn signal indic ator light High beam indicator light BRAKE + WHEEL...

  • Page 229: Tire Pressure

    SERVICING INFORMATION 7-32 ITEM STANDARD LIMIT Tire tread depth Front (0.06) Rear (0.08) SUSPENSION Unit: mm (in) STANDARD LIMIT NOTE ITEM Front fork stroke (4.7) Front fork spring free length (11-9) Front fork oil level (4.1) Rear wheel travel (3.5) Swingarm pivot shaft runout (0.01) TIRE PRESSURE...
  • Page 230 Prepared by SUZUKI MOTOR CORPORATION Motorcycle Service Department June, 1998 Part No. 99500-32100-01E Printed in Japan Downloaded from www.Manualslib.com manuals search engine...

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