Suzuki LT-Z250 Service Manual
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Suzuki LT-Z250 Service Manual

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FOREWORD
This manual contains an introductory description on
the SUZUKI LT-Z250 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 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
Improper repair may result in injury to the
mechanic and may render the vehicle
unsafe for the rider.
' COPYRIGHT SUZUKI MOTOR CORPORATION 2003
in
this
manual.
GROUP INDEX

GENERAL INFORMATION

PERIODIC MAINTENANCE

ENGINE
DRIVE TRAIN

FUEL SYSTEM

LUBRICATION SYSTEM
CHASSIS

ELECTRICAL SYSTEM

SERVICING INFORMATION

1
2
3
4
5
6
7
8
9
99500-42175-03E

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  • Page 1: General Information

    FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI LT-Z250 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-Z250K5 ( 05-MODEL) LT-Z250K6 ( 06-MODEL) LT-Z250K7 ( 07-MODEL) LT-Z250K8 ( 08-MODEL) LT-Z250K9 ( 09-MODEL)

  • Page 4: 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 5 Apply molybdenum oil solution. Apply or use brake fluid. (mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 : 1) Apply SUZUKI SUPER GREASE A . Measure in voltage range. 99000-25030 (USA) 99000-25010 (Others) Apply SUZUKI SILICONE GREASE.
  • Page 6  ...

  • Page 7: Table Of Contents

    GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE .................1- 2 GENERAL PRECAUTIONS ................1- 2 SUZUKI LT-Z250K4 (2004-MODEL) .............1- 4 SERIAL NUMBER LOCATION ..............1- 4 FUEL AND OIL RECOMMENDATION ............1- 4 FUEL (FOR CANADA AND USA) ............1- 4 FUEL (FOR THE OTHER COUNTRIES) ..........1- 4 ENGINE OIL (FOR USA) ................1- 5...

  • Page 8: 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 mes- sages highlighted by these signal words. Indicates a potential hazard that could result in death or injury.
  • Page 9 GENERAL INFORMATION " * 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 10: Suzuki Lt-Z250K4 (2004-Model)

    Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) method or 91 octane or higher rated by the Research Method. SUZUKI recommends that customers use alcohol-free unleaded gasoline whenever possible. Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted.

  • Page 11: Engine Oil (For Usa)

    GENERAL INFORMATION ENGINE OIL (FOR USA) SUZUKI recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or oils that meet API service classifications SF or SG and that have a viscosity rating of SAE 10W-40. If engine oil with a rating of SAE 10W-40 is not available, select an alter- native according to the chart.

  • Page 12: Information Labels

    GENERAL INFORMATION INFORMATION LABELS APPLIED SPECIFICATION LABEL or PLATE NAME E-19 E-28 E-33 Certification plate E Information label E Gearshift pattern label E Gearshift pattern label E/ F Tire air pressure label E Tire air pressure label and warning no-passenger label F General warning label E General warning label F Warning no-passenger label E...

  • Page 13: Specifications

    GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ............1 720 mm (67.7 in) Overall width ............1 070 mm (42.1 in) Overall height ............1 090 mm (42.9 in) Wheelbase ............1 135 mm (44.7 in) Front track ............830 mm (32.7 in) Rear track............

  • Page 14: Chassis

    GENERAL INFORMATION CHASSIS Front suspension ..........Independent, double wishbone, coil spring, oil damped Rear suspension ..........Swingarm type, coil spring, oil damped Front wheel travel ..........160 mm (6.3 in) Rear wheel travel ..........170 mm (6.7 in) Caster ..............7 40 ..1G Trail ..............33 mm (1.30 in) ..1G Toe-in..............5 mm (0.20 in) ..1G Steering angle............45 Turning radius ............2.7 m (8.9 ft)

  • Page 15: Country And Area Codes

    GENERAL INFORMATION COUNTRY AND AREA CODES The following codes stand for the applicable countries and areas: CODE COUNTRY OR AREA E-19 E-28 Canada E-33 USA and California...
  • Page 16  ...

  • Page 17: Periodic Maintenance

    PERIODIC MAINTENANCE 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 BOLTS ........2- 5 VALVE CLEARANCE ................2- 5 SPARK PLUG ..................2- 7 FUEL LINE .....................2- 8 THROTTLE CABLE PLAY ..............2- 9 ENGINE IDLE SPEED ................2- 9...

  • Page 18: 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 vehicle operating at peak performance and economy. NOTE: More frequent servicing may be performed on vehicles that are use under severe conditions. PERIODIC MAINTENANCE CHART Interval Initial...

  • Page 19: Maintenance And Tune-Up Procedures

    PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item mentioned in the Periodic Maintenance chart. AIR CLEANER Clean every 3 months. If the air cleaner is clogged with dust, intake resistance will be increased, with a resultant decrease in power output and an increase in fuel consumption.
  • Page 20 PERIODIC MAINTENANCE Fill a wash pan of a proper size with a non-flammable clean- ing solvent. Immerse the air cleaner element in the cleaning solvent and wash it. Press the air cleaner element between the palms of both hands to remove the excess solvent: do not twist or wring the element, or it will tear.

  • Page 21: Exhaust Pipe Nuts And Muffler Bolts

    PERIODIC MAINTENANCE EXHAUST PIPE NUTS AND MUFFLER BOLTS Tighten initially at 1 month and every 3 months there- after. Tighten the exhaust pipe nuts 1 and muffler mounting bolts/ nuts 2. Remove the right footrest mud guard. (!7-7) Tighten the muffler connecting bolt 3. # Exhaust pipe nut: 23 N•m (2.3 kgf-m, 16.5 lb-ft) Muffler connecting bolt: 23 N•m (2.3 kgf-m, 16.5 lb-ft) Muffler mounting bolt/nut: 23 N•m (2.3 kgf-m, 16.5 lb-ft)
  • Page 22 PERIODIC MAINTENANCE Remove the valve inspection caps 3. NOTE: Valve clearance is to be checked when the engine is cold. The intake and exhaust valves must be checked and adjusted when the piston is at Top-Dead-Center (TDC) on the compres- sion stroke.

  • Page 23: Spark Plug

    PERIODIC MAINTENANCE Apply grease to new O-rings and install them to the valve inspection caps. & 09900-25030: SUZUKI SUPER GREASE A ( USA) 09900-25010: SUZUKI SUPER GREASE A ( Others) Tighten the valve inspection caps. SPARK PLUG Inspect every 6 months.

  • Page 24: Fuel Line

    PERIODIC MAINTENANCE SPARK PLUG GAP Measure the spark plug gap using the thickness gauge. If the spark plug gap is out of specification, adjust the gap. % Standard Spark plug gap: 0.6 0.7 mm (0.024 0.028 in) $ 09900-20803: Thickness gauge or 0.6 0.7 mm 09900-20804: Thickness gauge (0.024 0.028 in)

  • Page 25: Throttle Cable Play

    PERIODIC MAINTENANCE THROTTLE CABLE PLAY Inspect initially at 1 month and every 3 months there- after. Adjust the throttle cable play A as follows: Loosen the locknut 1 of the throttle cable. Turn the adjuster 2 in or out to obtain the correct play. % Throttle cable play A: 3 5 mm (0.12 0.20 in)

  • Page 26: Engine Oil And Oil Filter

    2-10 PERIODIC MAINTENANCE ENGINE OIL AND OIL FILTER Replace initially at 1 month and every 6 months there- after. The oil should be changed while the engine is warm. Oil filter replacement should be done together with the engine oil change at the intervals shown above.

  • Page 27: Final Gear Oil

    PERIODIC MAINTENANCE 2-11 Apply engine oil lightly to new O-rings A and B before install- ing the oil filter cap. Install the new O-ring A onto the oil filter fitting boss of the clutch cover. Install the new O-ring B to the groove of the oil filter cap. Install new oil filter 2.

  • Page 28: Spark Arrester

    2-12 PERIODIC MAINTENANCE Place an oil pan under the final gear case, and then drain oil by removing the drain plug 2 and filler plug 3. Tighten the drain plug 2. Remove the oil level check plug 4 and pour the specified oil through the filler hole until the oil over flows from the oil level check hole.

  • Page 29: Clutch

    PERIODIC MAINTENANCE 2-13 CLUTCH Adjust every 6 months. Remove the clutch adjuster cap 1. NOTE: Adjust the clutch release, when the engine is cold. Loosen the locknut 2. Tighten the adjusting screw 3 until it stops. Loosen the adjusting screw 3 1/16 1 /8 turn. Tighten the locknut 2 to the specified torque while holding the adjusting screw 3.

  • Page 30: Brakes

    2-14 PERIODIC MAINTENANCE BRAKES Inspect initially at 1 month and every 3 months there- after. BRAKE PADS Remove the front wheels. (!7-11) The extent of brake pad wear can be checked by observing the limit line 1 on the side of brake pads. When the wear reaches the limit line, replace the pads with new ones.

  • Page 31: Brake Fluid

    PERIODIC MAINTENANCE 2-15 Rear brake lever (Minor brake adjustment) After adjusting the brake pedal, check the rear brake lever play. The brake lever play B as measured at the lever holder should be between 3 5 mm (0.1 0.2 in) when the lever is lightly pulled in towards the grip.
  • Page 32 2-16 PERIODIC MAINTENANCE AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cyl- inder and thus interferes with the full braking performance of the brake caliper.

  • Page 33: Brake Hose

    PERIODIC MAINTENANCE 2-17 BRAKE HOSE Inspect every 6 months. Replace every 4 years. Check the brake hoses for leakage, cracks, wear and dam- age. If any damages are found, replace the brake hoses with new ones. TIRES Inspect every 3 months. TIRE TREAD CONDITION Operating the vehicle with excessively worn tires will decrease riding stability and consequently cause a dangerous situation.
  • Page 34 2-18 PERIODIC MAINTENANCE TIRE PRESSURE If the tire pressure is too high or too low, steering will be adversely affected and tire wear will increase. Therefore, main- tain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows. COLD INFLATION TIRE PRESSURE kgf/cm FRONT...

  • Page 35: 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 han- dling of the handlebars and safe running. TOE-IN Place the vehicle on level ground. Make sure the tire pressure for right and left tires is same and set to the proper specification.

  • Page 36: Chassis Bolts And Nuts

    2-20 PERIODIC MAINTENANCE CHASSIS BOLTS AND NUTS 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 and 2-22 for the locations of the following nuts and bolts.) Item N•m kgf-m...
  • Page 37 PERIODIC MAINTENANCE 2-21...
  • Page 38 2-22 PERIODIC MAINTENANCE...

  • Page 39: General Lubrication

    PERIODIC MAINTENANCE 2-23 GENERAL LUBRICATION Lubricate initially at 1 month and every 3 months thereafter. Proper lubrication is important for smooth operation and long life of each working part of the vehicle. Major lubrication points are indicated below. &)Grease 1 Brake lever holder 5 Brake cam *)Motor oil 2 Throttle lever and cable...

  • Page 40: Compression Pressure Check

    2-24 PERIODIC MAINTENANCE COMPRESSION PRESSURE CHECK The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership shoud include compression readings for each maintenance service. % Compression pressure: Standard: 1 400 kPa (14.0 kgf/cm†...

  • Page 41: Oil Pressure Check

    PERIODIC MAINTENANCE 2-25 OIL PRESSURE CHECK Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. % Oil pressure: Above 30 kPa (0.3 kgf/cm† , 4.3 psi) at 3 000 r/min, oil temp. at 60 C (140 F) Below 70kPa (0.7 kgf/cm†...

  • Page 42: Initial Engagement And Clutch Lock-Up Inspection

    2-26 PERIODIC MAINTENANCE INITIAL ENGAGEMENT AND CLUTCH LOCK-UP INSPECTION The LT-Z250 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 thor- oughly check the operation of the drive train.
  • Page 43 ENGINE ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE.... 3- 2 ENGINE REMOVAL AND INSTALLATION ..........3- 3 ENGINE REMOVAL................3- 3 ENGINE INSTALLATION ............... 3- 8 ENGINE DISASSEMBLY ................3-12 ENGINE TOP SIDE................. 3-12 ENGINE BOTTOM SIDE................. 3-15 ENGINE COMPONENTS INSPECTION AND SERVICE......

  • Page 44: Engine Components Removable With Engine In Place

    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 LEFT SIDE PARTS REMOVAL INSTALLATION...

  • Page 45: Engine Removal And Installation

    ENGINE ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal procedure. Drain engine oil. (!2-10) Remove the seat.
  • Page 46 ENGINE Turn the fuel valve to the ON position. Disconnect the fuel and vacuum hoses. Remove the carburetor. (!5-7) Disconnect the engine ground lead wire 5. Disconnect the neutral switch lead wire coupler 6, signal generator lead wire coupler 7 and generator lead wire cou- pler 8.
  • Page 47 ENGINE Remove the gearshift lever link 0. Remove the reverse lock release cable A. Disconnect the spark plug cap. Remove the right footrest B. Remove the brake pedal C.
  • Page 48 ENGINE Loosen the muffler connecting bolt. Remove the exhaust pipe and gasket. Disconnect the breather hose D. Remove the starter motor lead wire. Remove the rear upper engine mounting nut, bolts and bracket E.
  • Page 49 ENGINE Remove the front and rear lower engine mounting nuts and bolts. Disengage the secondary driven gear shaft from the universal joint. Remove the right front fender bracket F. Dismount the engine to the right side.

  • Page 50: Engine Installation

    ENGINE ENGINE INSTALLATION Remount the engine in the reverse order of engine removal. Pay attention to the following points: NOTE: * The engine mounting nuts are self-locking. * Once the nut has been removed, it is no longer of any use. Be sure to use new nuts, and then tighten them to the specified torque.
  • Page 51 ENGINE Check that the gearshift lever plays A, up and down, are same. If not, set the clutch release outer guide in suitable position. Gearshift lever Fix the clutch release outer guide by tightening the clutch release outer guide nuts 1. Loosen the locknut 2.
  • Page 52 4. EXHAUST GAS SEALER: PERMATEX 1372 Apply SUZUKI SUPER GREASE to the O-rings. # 99000-25030: SUZUKI SUPER GREASE A ( USA) 99000-25010: SUZUKI SUPER GREASE A (Others) Install the washer 5. Install the brake pedal as its slit matches with the punched mark on the shaft.
  • Page 53 ENGINE 3-11 Install the reverse gearshift arm. % Reverse gearshift arm angle B: 20 Install the gearshift lever. % Gearshift arm angle C: 35 Adjust the gearshift lever height D. % Gearshift lever height D D D D : 0 10 mm (0 0 .4 in) Position the carburetor clamps as shown in the illustration.

  • Page 54: Engine Disassembly

    3-12 ENGINE ENGINE DISASSEMBLY ENGINE TOP SIDE SPARK PLUG Remove the spark plug. & 09930-10121: Spark plug wrench set STARTER MOTOR Remove the starter motor. Remove the valve timing inspection plug 1 and generator cover cap 2. Turn the crankshaft until the TDC line A on the generator rotor aligns with the index mark B on the crankcase.
  • Page 55 ENGINE 3-13 CAM CHAIN TENSION ADJUSTER Remove the spring holder bolt 1, pin and spring. Remove the cam chain tension adjuster. CYLINDER HEAD COVER Remove the cylinder head cover. CAMSHAFT Remove the camshaft end cap 1. Flatten the lock washer and remove the camshaft sprocket bolts.
  • Page 56 3-14 ENGINE Remove the C-ring 5. Do not drop the C-ring 5 into the crankcase. CYLINDER HEAD Remove the cylinder head nuts (M6) 1. Loosen the cylinder base nuts (M6) 2. Remove the cylinder head nuts (M8) diagonally. Remove the cylinder head. NOTE: If the cylinder head does not come off, lightly tap on the finless portion of it with a plastic hammer.

  • Page 57: Engine Bottom Side

    ENGINE 3-15 ENGINE BOTTOM SIDE NEUTRAL SWITCH Remove the neutral switch 1. Remove the switch contacts 2 and springs. SECONDARY DRIVEN BEVEL GEAR Remove the secondary driven bevel gear cover. Remove the dowell pins and secondary driven bevel gear assembly 1. GENERATOR COVER Remove the generator cover and reverse lock release cable holder 1.
  • Page 58 3-16 ENGINE OIL FILTER Remove the oil filter cover. Remove the oil filter and O-ring 1. CLUTCH COVER Remove the clutch cover. Remove the dowel pins and gasket. Remove the clutch release ball assembly 1, inner ball guide 2, washer 3 and clutch release arm 4. CLUTCH NOTE: Slightly loosen the clutch spring bolts with holding the clutch...
  • Page 59 ENGINE 3-17 Remove the clutch wheel assembly 1. Remove the clutch bolts. Remove the clutch release plate 1 and springs. Using a chisel, unlock the nut. Remove the clutch sleeve hub nut with the special tool. & 09920-53730: Clutch sleeve hub holder Remove the washer 2 and primary driven gear assembly 3.
  • Page 60 3-18 ENGINE GEARSHIFT Remove the gearshift arm 1. Remove the shift cam shaft assembly 2. Remove the gearshift cam plate 3 and stopper 4. OIL PUMP DRIVE GEAR Remove the oil pump drive gear 1 and pin 2. OIL PUMP Remove the E-ring.
  • Page 61 ENGINE 3-19 Remove the pin 2 and washer 3. Remove the oil pump. GENERATOR Remove the generator rotor nut with the special tool. & 09930-44520: Rotor holder Install the special tool to the crankshaft end. & 09930-31921: Rotor remover attachment Remove the generator rotor with the special tool.
  • Page 62 3-20 ENGINE CAM CHAIN Remove the cam chain. CRANKCASE Remove the left crankcase bolts. Remove the right crankcase bolts. Separate the crankcase with the special tool. NOTE: * The crankcase separator arms should be parallel with the end face of the crankcase. * The crankshaft must remain in the left crankcase half.
  • Page 63 ENGINE 3-21 DRIVE TRAIN/GEARSHIFT CAM Remove the reverse idle gear assembly 1. Remove the gearshift cam 2 Remove the shafts 3 and forks 4. Remove the shift cam lock shaft 5. Remove the washers, reverse driven gear 6 and reverse dog CRANKSHAFT Remove the crankshaft with the special tool.
  • Page 64 3-22 ENGINE DRIVE BEVEL GEAR Using a chisel, unlock the nut. Fit the special tool onto the driveshaft. & 09930-73150: Output shaft holder Loosen the secondary drive bevel gear and nut by holding the special tool with a vise. Remove the secondary drive bevel gear and driveshaft assembly, countershaft assembly.

  • Page 65: Engine Components Inspection And Service

    ENGINE 3-23 ENGINE COMPONENTS INSPECTION AND SERVICE CYLINDER HEAD COVER DISASSEMBLY Be sure to identify each removed part as to its loca- tion, and lay the parts out in groups designated as Exhaust , Intake , so that each will be restored to the original location during assembly.
  • Page 66 " Rocker arm shaft bolt: 9 N•m (0.9 kgf-m, 6.5 lb-ft) Install the gasket washers to prevent oil leakage. Install new O-rings to the valve inspection caps. Apply SUZUKI SUPER GREASE to the O-rings. # 09900-25030: SUZUKI SUPER GREASE A ( USA) 09900-25010: SUZUKI SUPER GREASE A (Others)

  • Page 67: Cylinder Head

    ENGINE 3-25 CYLINDER HEAD DISASSEMBLY Remove the intake pipe 1. Remove the cam chain tensioner 2. Cam chain tentioner inspection (!3-34) Compress the valve spring and remove the valve cotters from the valve stem with the special tools. & 09916-14510: Valve spring compressor 09916-14910: Attachment 09916-84511: Tweezers Remove the valve spring retainer and valve spring.
  • Page 68 3-26 ENGINE VALVE STEM RUNOUT Support the valve with the V-blocks and measure the valve stem runout with the dial gauge, as shown. If the runout exceeds the service limit, replace the valve with a new one. % Valve stem runout Service Limit: 0.05 mm (0.002 in) &...
  • Page 69 ENGINE 3-27 VALVE STEM WEAR Measure the valve stem outside diameter with the micrometer. If the outside diameter is not within the specified value, replace the valve with a new one. If the valve stem outside diameter is within specification, but the valve stem deflection is not, replace the valve guide with a new one.
  • Page 70 3-28 ENGINE After fitting all valve guides, re-finish their guiding bores with the valve guide reamer. Be sure to clean and oil the guide after reaming. & 09916-34550: Valve guide reamer (5.5 mm) 09916-34542: Reamer handle NOTE: Insert the reamer from the combustion chamber and always turn the reamer handle clockwise.
  • Page 71 ENGINE 3-29 When installing the solid pilot, rotate it slightly. Seat the pilot snugly. Install the 45 cutter, attachment and T-handle. INITIAL SEAT CUT Descale and clean up the seat with the 45 cutter. Rotate the cutter one or two turns. Measure the valve seat width W after every cut.
  • Page 72 3-30 ENGINE FINAL SEAT CUT Too low or too narrow contact surface on the valve If the contact area W is too low or too narrow, use the 45 cut- ter to raise and widen the contact area. NOTE: After cutting the 15 angle, it is possible that the valve seat (45 ) is too narrow.
  • Page 73 ENGINE 3-31 VALVE SPRING The force of the coil spring keeps the valve seat tight. Weak- ened spring result 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 74 Be sure to restore each spring, valve and spring retainer to their original positions. INTAKE PIPE When installing the intake pipe, apply SUZUKI SUPER GREASE to the O-ring. # 99000-25030: SUZUKI SUPER GREASE A ( USA) 99000-25010: SUZUKI SUPER GREASE A (Others) Use the new O-ring to prevent sucking air from the joint.

  • Page 75: Camshaft

    To properly measure the oil clearance with plastigauge, all gas- ket material must be removed from fitting surfaces of cylinder head and cover. Do not apply SUZUKI BOND until after the oil clearance has been determined. Tighten the cylinder head cover bolts evenly and diagonally to the specified torque.

  • Page 76: Cam Chain Tension Adjuster

    3-34 ENGINE If the camshaft journal oil clearance measured exceeds the limit, measure the outside diameter of camshaft. Replace either the cylinder head set or the camshaft if the clear- ance is incorrect. % Camshaft journal O.D. Standard: 21.959 21.976 mm (0.8645 0 .8652 in) &...

  • Page 77: Cylinder

    ENGINE 3-35 CYLINDER CYLINDER DISTORTION Check the gasket surface of the cylinder for distortion with a straightedge and the thickness gauge, taking a clearance read- ing at several places as indicated. If any clearance reading exceeds the service limit, replace the cylinder with a new one. % Cylinder distortion Service Limit: 0.05 mm (0.002 in) &...

  • Page 78: Piston Ring Thickness

    3-36 ENGINE PISTON RING TO GROOVE CLEARANCE Measure the side clearances of the 1st and 2nd piston rings with the thickness gauge. If any clearance reading exceeds the ser- vice limit, replace both the piston and piston rings. % Piston ring to groove clearance Service Limit (1st) : 0.18 mm (0.0071 in) (2nd): 0.15 mm (0.0059 in) % Piston ring groove width...
  • Page 79 ENGINE 3-37 Oversize piston ring The following oversize piston rings are used. They bear the fol- lowing identification numbers. SIZE 0.5 mm O.S. 0.5 mm O.S. Oversize oil ring The following oversize oil ring is available as optional parts. They bear the following identification mark. SIZE COLOR 0.5 mm O.S.

  • Page 80: Conrod And Crankshaft

    3-38 ENGINE CONROD AND CRANKSHAFT CONROD SMALL END I.D. Measure the conrod small end inside diameter with the small bore gauge. If the conrod small end inside diameter exceeds the service limit, replace the conrod with a new one. % Conrod small end I.D. Service Limit: 16.040 mm (0.6315 in) &...

  • Page 81: Clutch

    ENGINE 3-39 CLUTCH CLUTCH DRIVE PLATES NOTE: Wipe off engine oil from the clutch drive plates with a clean rag. Measure the thickness of drive plates with a vernier calipers. If each drive plate is not within the standard range, replace it with a new one.
  • Page 82 3-40 ENGINE CLUTCH SHOES Inspect the clutch shoes for chips, cracks, uneven wear, and heat discoloration. Also, check the depth of the grooves on the clutch shoes. If there is no groove at any part of the shoes, replace the shoes as a set. NOTE: The clutch shoes must always be changed as a set.
  • Page 83 ENGINE 3-41 Apply THREAD LOCK SUPER to the bolts, and then tighten them to the specified torque with a offset wrench. " Starter clutch bolt: 26 N•m (2.6 kgf-m, 19.0 lb-ft) * 99000-32030: THREAD LOCK SUPER 1303 & 09930-44520: Rotor holder Install the starter driven gear to the starter clutch.

  • Page 84: Transmission

    3-42 ENGINE TRANSMISSION DISASSEMBLY Insert the special tool between the 2nd drive gear and 4th drive gear. Remove the 2nd drive gear by a hydraulic press. & 09950-81910: Remover Disassemble the transmission as shown. Reverse driven gear Reverse gear dog "...
  • Page 85 ENGINE 3-43 REASSEMBLY Assemble the transfer in the reverse order of disassembly. Pay attention to the following points: NOTE: * Always use new snap rings. * Before installing the gears, coat lightly engine oil to the shafts and gears. * Never reuse a snap ring. After a snap ring has been removed from a shaft, it should be discarded and a new snap ring must be installed.
  • Page 86 3-44 ENGINE When installing the bushings, align the shaft hole with the bushing hole.

  • Page 87: Gearshift Fork

    ENGINE 3-45 GEARSHIFT FORK SHIFT FORK TO GROOVE CLEARANCE Clearance for each gearshift fork plays an important role in the smoothness and positiveness of the shifting process. Measure the gearshift fork clearance in the groove of its respec- tive gear with the thickness gauge. If the clearance exceeds specification, replace the fork, its respective gear, or both.

  • Page 88: Clutch Cover

    3-46 ENGINE CLUTCH COVER DISASSEMBLY Remove the clutch release outer guide 1. Remove the bearing with the special tool. & 09921-20240: Bearing remover set NOTE: If there is no abnormal noise, the bearing removal is not neces- sary. INSPECTION Rotate the balls by hand to inspect for an abnormal noise and a smooth rotation.

  • Page 89: Crankcase

    ENGINE 3-47 CRANKCASE Play Play BEARING INSPECTION Rotate the bearing inner race by finger to inspect for abnormal play, noise and smooth rotation while the bearings are in the crankcase. Replace the bearing in the following procedure if there is any- thing unusual.
  • Page 90 3-48 ENGINE BEARING INSTALLATION Install the bearings with the special tool. & 09913-70210: Bearing installer set Install the bearing retainers. NOTE: When installing the bearing retainers, apply a small quantity of THREAD LOCK to the screws. $ 09900-32050: THREAD LOCK 1342 OIL SEAL REMOVAL AND INSTALLATION Remove the oil seal.
  • Page 91 ENGINE 3-49 Apply SUZUKI SUPER GREASE to the oil seal. # 99000-25030: SUZUKI SUPER GREASE A ( USA) 99000-25010: SUZUKI SUPER GREASE A ( Others) NOTE: When installing the oil seal, the stamped mark on the oil seal must face outside.

  • Page 92: Crankshaft

    3-50 ENGINE CRANKSHAFT DISASSEMBLY Crankshaft (R) Crank pin " Bearing Conrod Crankshaft (L) REASSEMBLY Determine the width between the webs referring to the figure when rebuilding the crankshaft. % Crank web to web width Standard: 53.0 – 0.1mm (2.087 – 0.004 in)

  • Page 93: Drive Train

    ENGINE 3-51 DRIVE TRAIN SECONDARY BEVEL GEARS CONSTRUCTION Bearing Shim " Secondary bevel drive gear Washer Washer Secondary bevel driven gear & Shim Bearing Secondary bevel gear shaft Bearing Oil seal O-ring Water proof cover Snap ring ITEM N•m kgf-m lb-ft 10.0 72.5...
  • Page 94 3-52 ENGINE SECONDARY DRIVEN BEVEL GEAR REMOVAL The following components must be removed in the described order before removing the secondary driven bevel gear. NOTE: Refer to the following pages for the details of each step. Remove the rear wheel. (!7-11) Remove the swingarm.
  • Page 95 ENGINE 3-53 INSPECTION Inspect the removed parts for the following abnormalities. * Drive and driven bevel gears damage or wear * Improper tooth contact * Abnormal noise of bearings * Bearing damage or wear * Oil seal damage or wear SECONDARY DRIVEN BEVEL GEAR REASSEMBLY Install the bearing.
  • Page 96 Apply 4 5 gram of WATER RESISTANCE GREASE to the outside of the seal lip groove. Apply SUZUKI SUPER GREASE to the seal lip groove and install it. + 99000-25160: WATER RESISTANCE GREASE # 99000-25030: SUZUKI SUPER GREASE A ( USA)

  • Page 97: Secondary Gear Shims Adjustment

    ENGINE 3-55 SECONDARY GEAR SHIMS ADJUSTMENT Remove the secondary bevel gear cover. Hold the bearings with the special tool. & 09921-21910: Bearing holder Set a dial gauge on the driven bevel gear as shown. Measure the backlash by turning the driven bevel gear shaft in For driven bevel gear ( 3-58) each direction, reading the total backlash on the dial gauge.
  • Page 98 3-56 ENGINE TOOTH CONTACT After backlash adjustment is carried out, the tooth contact must be checked. Pay attention to the following procedures: Remove the driven bevel gear. Clean and degrease several teeth of the drive and driven bevel gears. Apply a coating of machinist s layout dye or paste to several teeth of the driven bevel gear.
  • Page 99 ENGINE 3-57 For drive bevel gear ( 3-58) Shim thickness Part No. 0.25+0.25=0.50 mm (0.0197 in) 24935-19B00-025: 0.25 mm (0.0098 in) 0.25+0.30=0.55 mm (0.0217 in) 0.30+0.30=0.60 mm (0.0236 in) 24935-19B00-030: 0.30 mm (0.0118 in) 0.30+0.35=0.65 mm (0.0256 in) 0.35+0.35=0.70 mm (0.0276 in) 0.25+0.25+0.25=0.75 mm (0.0295 in) 24935-19B00-035: 0.35 mm (0.0138 in) 0.25+0.25+0.30=0.80 mm (0.0315 in)

  • Page 100: Reassembly Information

    3-58 ENGINE REASSEMBLY INFORMATION List of shims available for the driven bevel gear side Part No. Shim thickness 09181-25051 0.60 mm (0.0236 in) 09181-25052 0.65 mm (0.0256 in) 09181-25053 0.70 mm (0.0276 in) 09181-25054 0.75 mm (0.0295 in) 09181-25055 0.80 mm (0.0315 in) 09181-25056 0.85 mm (0.0335 in) 09181-25057...

  • Page 101: Engine Reassembly

    ENGINE 3-59 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 part before reas- sembling. ENGINE BOTTOM SIDE DRIVE TRAIN Install the driveshaft and countershaft assembly. DRIVE BEVEL GEAR Install the shim 1.
  • Page 102 3-60 ENGINE CRANKSHAFT When mounting the crankshaft in the crankcase, it is neces- sary to pull its left end into the crankcase with the special tool. NOTE: Use proper bars. & 09910-32812: Crankshaft installer Install the reverse dog and washer 1. Install the reverse driven gear and washer 2.
  • Page 103 ENGINE 3-61 Install the gearshift cam. Install the gearshift forks and shafts as shown. NOTE: Each fork differs in shape. 1 For reverse/1st gear 2 For 2nd/3rd gear 3 For 4th/5th gear Install the reverse idle gear shaft 4. Install the snap ring 5, washer 6 and spacer 7. Install the reverse idle gear 8 and washer 9.
  • Page 104 Fit the dowel pins onto the left half on the crankcase. Apply engine oil to the conrod big end and gears. Apply SUZUKI BOND to the mating surface of the right crank- case. , 99104-31140: SUZUKI BOND 1207B (USA)
  • Page 105 ENGINE 3-63 Assemble the crankcase within a few minutes. NOTE: Fit the clamp to the bolt A. " Crankcase bolt: 11 N•m (1.1 kgf-m, 8.0 lb-ft) CAM CHAIN Install the cam chain. GENERATOR Install the starter driven gear 1. Install the key 2. NOTE: Degrease the tapered portion of the generator rotor assembly and also the crankshaft.
  • Page 106 3-64 ENGINE OIL PUMP Install the oil pump. Install the washer 1 and pin 2. Install the oil pump driven gear and E-ring. OIL PUMP DRIVE GEAR Install the pin 1. Install the oil pump drive gear. NOTE: Flange side of the gear is positioned inside. GEARSHIFT Install the spring 1, washer 2 and gearshift cam stopper 3.
  • Page 107 ENGINE 3-65 Apply THREAD LOCK to the gearshift cam bolt and install the gearshift cam plate guide. $ 99000-32050: THREAD LOCK 1342 Install the gearshift cam shaft assembly so that the stopper 5 comes between the spring ends 6. Install the washer 7 and gearshift arm. CLUTCH Apply engine oil to each of the clutch drive/driven plate.
  • Page 108 3-66 ENGINE Install the clutch pressure plate 2. Align the clutch drive plates in line to facilitate later assembly. Install the washer 3 onto the countershaft. Install the primary driven gear assembly. Install the washer 4. Install the clutch sleeve hub assembly into the primary driven gear assembly.
  • Page 109 ENGINE 3-67 Tighten the clutch sleeve hub nut to the specified torque with the special tool. " Clutch sleeve hub nut: 100 N•m (10.0 kgf-m, 72.5 lb-ft) & 09920-53730: Clutch sleeve hub holder Stake the clutch sleeve hub nut with a center punch. Install the clutch springs and clutch release plate.
  • Page 110 3-68 ENGINE Install the clutch shoes. Install the washer as its convex side faces outside. Before installing the clutch shoe nut, apply engine oil to the thread and inside surface of the nut. INSIDE OUTSIDE Washer While holding the generator rotor with the special tool, tighten the clutch shoe nut to the specified torque.
  • Page 111 ENGINE 3-69 OIL FILTER Before installing the oil filter, fit new O-rings and apply engine oil lightly to them. Install the spring 1 and oil filter 2. Use new O-rings to prevent oil leakage. STARTER IDLE GEAR Install the idle driven gear 1, shaft 2 and spacer 3. GENERATOR COVER Install the dowel pins and new gasket.

  • Page 112: Engine Top Side

    3-70 ENGINE Apply SUZUKI BOND to the mating surface of the secondary bevel gear cover. , 99104-31140: SUZUKI BOND 1207B (USA) - 99000-31110: SUZUKI BOND 1215 (Others) Install the secondary bevel gear cover. NEUTRAL SWITCH Install the springs and switch contacts.
  • Page 113 ENGINE 3-71 Install the 2nd ring 3 and the 1st ring 4. NOTE: 1st ring and 2nd ring differ in shape. 1st ring has letter R marked on the side. Be sure to bring the marked side to the top when fitting it to the piston. 1st ring Position the gaps of the three rings as shown.
  • Page 114 3-72 ENGINE CYLINDER Fit the dowel pins and new gasket 1. Use a new gasket to prevent gas leakage. NOTE: * The dowel pins are identified by their length. * Shorter ones A are for cylinder base. * Apply engine oil to the piston ring grooves and cylinder wall. Hold each piston ring with proper position, insert the piston into the cylinder.
  • Page 115 ENGINE 3-73 Install the cylinder head. Install the washers and cylinder head nuts (M8) as shown. Tighten the cylinder head nuts (M8) diagonally to the speci- fied torque. " Cylinder head nut (M8): 23 N•m (2.3 kgf-m, 16.5 lb-ft) Tighten the cylinder base nuts (M6) 3 and head nuts (M6) 4 to the specified torque.
  • Page 116 3-74 ENGINE Install the camshaft and camshaft sprocket. Engage the hole of the sprocket C with the locating pin on the camshaft as shown. Align the lines D on the camshaft so that they are parallel with the surface of the cylinder head. NOTE: * Do not rotate the generator while doing this.
  • Page 117 Clean the mating surface of the cylinder head and head cover before matching. Install the dowel pins to the cylinder head. Apply SUZUKI BOND to the periphery of the camshaft end cap 1 and fit it 99000-31230: SUZUKI BOND 1216B...
  • Page 118 23 N•m (2.3 kgf-m, 16.5 lb-ft) Generator cover cap: 15 N•m (1.5 kgf-m, 11.0 lb-ft) STARTER MOTOR Apply SUZUKI SUPER GREASE to new O-ring. # 99000-25030: SUZUKI SUPER GREASE A (USA) 99000-25010: SUZUKI SUPER GREASE A (Others) Install the starter motor and tighten the starter mortor mount- ing bolts to the specified torque.
  • Page 119 DRIVE TRAIN DRIVE TRAIN CONTENTS REAR DRIVING SYSTEM ................4- 2 REAR DRIVE REMOVAL ...............4- 3 REAR DRIVE DISASSEMBLY ...............4- 4 REAR DRIVE INSPECTION ..............4- 9 REAR DRIVE REASSEMBLY ..............4-11 REAR DRIVE INSTALLATION ..............4-16 SHIM ADJUSTMENT ................4-18 REASSEMBLY INFORMATION .............4-21...

  • Page 120: Rear Driving System

    DRIVE TRAIN REAR DRIVING SYSTEM Final gear case cover Shim, LH " Bevel ring gear Shim, RH Final gear case Shim & Bevel pinion gear Pinion gear shaft coupling joint Propeller shaft Universal joint...

  • Page 121: Rear Drive Removal

    DRIVE TRAIN REAR DRIVE REMOVAL Remove the final gear case under cover 1. Drain gear oil. (!2-11) Remove the rear wheels. (!7-11) Remove the rear wheel hubs. (!7-11) Remove the rear brake 2. (!7-46) Remove the axle housing set bolts/nuts. Remove the final gear case together with the propeller shaft.

  • Page 122: Rear Drive Disassembly

    DRIVE TRAIN Remove the rear axle together with the axle housing. Remove the O-ring 4. REAR DRIVE DISASSEMBLY FINAL GEAR CASE Remove the final gear case cover bolts diagonally and evenly. Pry the cover at the arrows as shown by tapping with a plastic mallet.
  • Page 123 DRIVE TRAIN Remove the snap ring. Remove the O-ring 1. Drive out the bearing from the other side with the special tool. " 09913-70210: Bearing installer set NOTE: If there is no abnormal condition, the bearing removal is not nec- essary.
  • Page 124 DRIVE TRAIN Remove the bearing with the special tool. " 09913-70210: Bearing installer set NOTE: If there is no abnormal condition, the bearing removal is not nec- essary. The removed bearing must be replaced with a new one. Remove the pinion gear shaft coupling joint with the special tools.
  • Page 125 DRIVE TRAIN Remove the pinion gear assembly and shim. Remove the stopper ring 1 and O-ring 2. Remove the bearing with a commercially available bearing puller or a hydraulic press. NOTE: If there is no abnormal condition, the bearing removal is not nec- essary.
  • Page 126 DRIVE TRAIN UNIVERSAL JOINT Remove the C-rings from the universal joint. Replace the removed C-rings with new ones. Remove the bearings by tapping with the special tool and a hammer. " 09913-70210: Bearing installer set Remove the universal joint.

  • Page 127: Rear Drive Inspection

    DRIVE TRAIN REAR DRIVE INSPECTION PROPELLER SHAFT Inspect the splines of the propeller shaft for wear or damage. Also, inspect the boot for cuts or damage. If any defects are found, replace the propeller shaft and its boot with new ones. UNIVERSAL JOINT Inspect the universal joint and outer surface of the bearing for scuffing, wear and damage.
  • Page 128 4-10 DRIVE TRAIN Check the outer race play and smooth rotation of the bearing by hand while it is on the pinion gear shaft. Inspect the pinion gear for wear or damage. If the pinion gear is damaged, inspect the ring gear also. If any defects are found, replace the bearing and gear with the new ones.

  • Page 129: Rear Drive Reassembly

    FINAL GEAR CASE OIL SEAL Install new oil seals into the gear case and case cover with the special tool. Apply SUZUKI SUPER GREASE to the new oil seal lips. " 09913-70210: Bearing installer set $ 99000-25030: SUZUKI SUPER GREASE A ( USA)
  • Page 130 Fix the bearing race with the snap ring. Apply SUZUKI SUPER GREASE to the bearing. $ 99000-25030: SUZUKI SUPER GREASE A ( USA) 99000-25010: SUZUKI SUPER GREASE A (Others) Install new dust seal with the special tool and then apply SUZUKI SUPER GREASE to the seal lip.
  • Page 131 DRIVE TRAIN 4-13 BEVEL PINION GEAR SHAFT BEARING Drive the bearing onto the shaft with the special tool. " 09913-70210: Bearing installer set BEVEL PINION GEAR/SHIM/LOCKNUT [FINAL ASSEMBLY] Install new O-ring 1 onto the pinion gear shaft. Install the shim, pinion gear assembly and new bearing locknut.
  • Page 132 BEVEL PINION GEAR SHAFT OIL SEAL Install new stopper ring to pinion gear shaft securely. Install new oil seal to the gear case with the special tool. Apply SUZUKI SUPER GREASE to the new oil seal lip groove. " 09913-85210: Bearing/oil seal installer...
  • Page 133 FINAL GEAR CASE COVER/GEAR CASE [FINAL ASSEMBLY] Coat new O-ring with SUZUKI SUPER GREASE and apply SUZUKI BOND to the mating surface of the cover, then install the gear case cover. $ 99000-25030: SUZUKI SUPER GREASE A ( USA) 99000-25010: SUZUKI SUPER GREASE A ( Others)

  • Page 134: Rear Drive Installation

    Install the rear drive in the reverse order of removal. Pay atten- tion to the following points: Coat new O-ring with SUZUKI SUPER GREASE and install it into the groove in the gear case. $ 99000-25030: SUZUKI SUPER GREASE A ( USA) 99000-25010: SUZUKI SUPER GREASE A (Others) Apply SUZUKI SUPER GREASE to the splines of the axle.
  • Page 135 DRIVE TRAIN 4-17 Install the spring into the rear end of the propeller shaft. Apply SUZUKI SUPER GREASE to the splines of the propel- ler shaft. $ 99000-25030: SUZUKI SUPER GREASE A ( USA) 99000-25010: SUZUKI SUPER GREASE A ( Others) Tighten the axle housing set bolts/nuts 1 (RH) and 2 (LH) to the specified torque of each.

  • Page 136: Shim Adjustment

    4-18 DRIVE TRAIN SHIM ADJUSTMENT BACKLASH Install the pinion gear assembly, removed shim and new bearing locknut. (!4-13) Tighten the bearing locknut to the specified torque. (!4-13) NOTE: At this time, it is not necessary to stake the bearing locknut. (!4-13) Install the removed right side shim and ring gear.
  • Page 137 DRIVE TRAIN 4-19 Install the final gear case cover and tighten its bolts to the specified torque in a crisscross pattern. (!4-15) NOTE: * It is not necessary to install the O-ring to the final gear case cover at this time. * Do not apply THREAD LOCK SUPER to the final gase cover bolts at this time.
  • Page 138 4-20 DRIVE TRAIN TOOTH CONTACT After backlash adjustment and left shim selection are carried out, the tooth contact must be checked. Pay attention to the fol- lowing procedures: Remove the ring gear. Clean and degrease several teeth on the ring gear and pinion Incorrect gear, and then apply a coating of machinist s layout dye or paste to several teeth of the pinion gear.

  • Page 139: Reassembly Information

    DRIVE TRAIN 4-21 REASSEMBLY INFORMATION 4 5 g ram 100 N . m (10.0 kgf-m, 72.5 lb-ft) Pinion gear shim Left side of ring gear shim Right side of ring gear shim 26 N•m (2.6 kgf-m, 19.0 lb-ft) 26 N•m (2.6 kgf-m, 19.0 lb-ft) Matching surfaces...
  • Page 140 4-22 DRIVE TRAIN...

  • Page 141: Fuel System

    FUEL SYSTEM FUEL SYSTEM CONTENTS FUEL TANK ....................5- 2 CONSTRUCTION ..................5- 2 FUEL LINE INSPECTION ...............5- 3 REMOVAL ....................5- 3 REMOUNTING ..................5- 3 FUEL VALVE ....................5- 4 REMOVAL AND INSPECTION ...............5- 4 FUEL STRAINER ..................5- 4 REMOUNTING ..................5- 4 CARBURETOR ....................5- 5 CONSTRUCTION ..................5- 5 SPECIFICATIONS...................5- 6 I.D.

  • Page 142: Fuel Tank

    FUEL SYSTEM FUEL TANK CONSTRUCTION Fuel tank Fuel cap " Breather hose Gasket Seal washer Fuel valve Fuel hose...

  • Page 143: Fuel Line Inspection

    FUEL SYSTEM FUEL LINE INSPECTION Inspect the fuel lines, fuel tank, fuel tank breather hoses and fuel tank cap for damage, clogging and leakage of fuel. If any dam- ages are found, replace the defective parts with the new ones. REMOVAL Remove the front fender.

  • Page 144: Fuel Valve

    FUEL SYSTEM FUEL VALVE REMOVAL AND INSPECTION Remove the fuel tank. (!5-3) Drain fuel completely. Remove the fuel valve. " Gasoline is highly flammable and explosive. Keep heat, sparks and flames away from gasoline. FUEL STRAINER If the fuel strainer is dirty with sediment or rust, fuel will not flow smoothly and loss in engine power may result.

  • Page 145: Carburetor

    FUEL SYSTEM CARBURETOR CONSTRUCTION Top cap Spring Holder O-ring Spring Washer (t=0.5 mm, 0.02 in) E-ring Spacer Washer (t=1.0 mm, 0.04 in) Jet needle Diaphragm Ring Piston valve Vacuum hose Air vent hose Side cover O-ring Coasting enrichment valve Coasting enrichment valve cover Starter plunger Pilot air jet Pilot jet...

  • Page 146: Specifications

    FUEL SYSTEM SPECIFICATIONS SPECIFICATION ITEM E-19, 28 E-33 ← Carburetor type MIKUNI BSR29 29.0 mm ← Bore size (1.14 in) I.D. No. 21G0 21G1 ← Idle r/min 1 500 – 100 r/min 13.0 – 1.0 mm ← Float height (0.51 – 0.04 in) Main jet (M.J.) #125...

  • Page 147: Removal

    FUEL SYSTEM REMOVAL Remove the seat. (!7-5) Disconnect the air vent hose 1. Disconnect the fuel hose 2 and vacuum hose 3. Disconnect the starter cable 4. Loosen the carburetor clamp screws. Pull out the carburetor from between the engine and air cleaner.

  • Page 148: Disassembly

    FUEL SYSTEM DISASSEMBLY Remove the fuel hose 1, overflow hose 2, vacuum hose 3 and air vent hose 4. Remove the throttle stop screw 5. Remove the carburetor top cap. Do not use compressed air on the carburetor body before removing the diaphragm; this may damage the diaphragm.
  • Page 149 FUEL SYSTEM Remove the following parts. 7 Jet needle holder 8 O-ring 9 Spring 0 Washer (t=0.5 mm, 0.02 in) A Jet needle B Washer (t=1.0 mm, 0.04 in) Remove the diaphragm by removing the ring C. Remove the coasting enrichment valve cover D and spring. Remove the coasting enrichment valve E.
  • Page 150 5-10 FUEL SYSTEM Remove the float chamber. Remove the O-ring G. Replace the removed O-ring with a new one to prevent leakage of fuel. Remove the float pin H, float I and needle valve J. Remove the valve seat K.
  • Page 151 FUEL SYSTEM 5-11 Remove the following parts. L Main jet, main jet ring, needle jet holder and needle jet M Pilot screw N Starter jet O Pilot jet NOTE: Before removing the pilot screw M, its setting must be deter- mined.

  • Page 152: Cleaning

    5-12 FUEL SYSTEM CLEANING " Some carburetor cleaning chemicals, especially dip- type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical man- ufacturer s instructions on proper use, handling and storage. Clean all jets with a spray-type carburetor cleaner and dry them using compressed air.

  • Page 153: Reassembly

    FUEL SYSTEM 5-13 NEEDLE VALVE INSPECTION If foreign matter is caught between the valve seat and the nee- dle valve, the gasoline will continue flowing and overflow. If the valve seat and needle valve are worn beyond the permissible limits, similar trouble will occur. Conversely, if the needle valve sticks, the gasoline will not flow into the float chamber.
  • Page 154 THROTTLE STOP SCREW Apply SUZUKI SUPER GREASE to thread part of the throttle stop screw, then install the throttle stop screw to the carbure- tor. & 99000-25030: SUZUKI SUPER GREASE A ( USA)

  • Page 155: Remounting

    FUEL SYSTEM 5-15 REMOUNTING Remount the carburetor assembly in the reverse order of removal. Pay attention to the following points: Fit the lug on the carburetor with the intake pipe s projection. Position the carburetor clamps as shown in the illustration. Left Right Left...
  • Page 156  ...
  • Page 157 LUBRICATION SYSTEM LUBRICATION SYSTEM CONTENTS LUBRICATION SYSTEM ................6- 2 ENGINE LUBRICATION CIRCUIT ............6- 2 ENGINE LUBRICATION FLOW CHART ..........6- 4 OIL PRESSURE .....................6- 5 OIL FILTER ....................6- 5 OIL STRAINER ....................6- 5 OIL PUMP ......................6- 5...

  • Page 158: Lubrication System

    LUBRICATION SYSTEM LUBRICATION SYSTEM ENGINE LUBRICATION CIRCUIT OIL PUMP OIL FILTER LUBRICATION OIL RETURNED OIL...
  • Page 159 LUBRICATION SYSTEM EXHAUST SIDE INTAKE SIDE LUBRICATION OIL RETURNED OIL...

  • Page 160: Engine Lubrication Flow Chart

    LUBRICATION SYSTEM ENGINE LUBRICATION FLOW CHART...

  • Page 161: Oil Pressure

    LUBRICATION SYSTEM OIL PRESSURE (!2-25) OIL FILTER (!2-10) OIL STRAINER (!3-20, -61 and -62) OIL PUMP (!3-18 and -64)
  • Page 162  ...
  • Page 163 CHASSIS CHASSIS CONTENTS EXTERIOR PARTS ..................7- 3 CONSTRUCTION ..................7- 3 REMOVAL ....................7- 5 REMOUNTING ..................7- 8 FRONT AND REAR WHEELS...............7-10 CONSTRUCTION ..................7-10 REMOVAL ....................7-11 INSPECTION AND DISASSEMBLY ............7-12 REASSEMBLY AND REMOUNTING............7-13 TIRES ......................7-16 TIRE REPLACEMENT ................7-16 FRONT BRAKE .....................7-18 CONSTRUCTION ..................7-18 BRAKE PAD REPLACEMENT ...............7-19 BRAKE FLUID REPLACEMENT ............7-19 BRAKE CALIPER REMOVAL AND DISASSEMBLY......7-20...
  • Page 164 CHASSIS CHASSIS CONTENTS REAR BRAKE ....................7-45 CONSTRUCTION ................... 7-45 REMOVAL AND DISASSEMBLY............7-46 INSPECTION ..................7-48 REASSEMBLY AND REMOUNTING ............. 7-49 REAR SHOCK ABSORBER ................. 7-53 CONSTRUCTION ................... 7-53 REMOVAL ....................7-53 INSPECTION ..................7-53 REASSEMBLY ..................7-54 REMOUNTING ..................7-54 SUSPENSION SETTING ................

  • Page 165: Exterior Parts

    CHASSIS EXTERIOR PARTS CONSTRUCTION Front fender Fuel tank top cover " Fuel tank side cover Front fender bracket Headlight case...
  • Page 166 CHASSIS Rear fender Rear fender cover Footrest mud guard...

  • Page 167: Removal

    CHASSIS REMOVAL SEAT Remove the seat by pulling the lever. FRONT GRIP BAR Remove the front grip bar 1. REAR GRIP BAR Remove the rear grip bar 1. FUEL TANK SIDE COVER Remove the seat. (!Above) Remove the fuel tank side covers 1 and 2.
  • Page 168 CHASSIS FRONT FENDER Remove the fuel tank side covers. (!7-5) Remove the screws and fasteners. Open the fuel tank cap and remove the fuel tank top cover 1. Remove the reverse lock release knob 2. Remove the screws that connect the front fender with the head light.
  • Page 169 CHASSIS FOOTREST MUD GUARD Remove the fuel tank side covers. (!7-5) Remove the footrest mud guards 1 and 2. FOOTREST Remove the footrest mud guards. (!Above) Remove the footrest 1 and 2. REAR FENDER Remove the fuel tank side covers. (!7-5) Remove the battery holder 1 and battery.

  • Page 170: Remounting

    CHASSIS Remove the screws. Pull out the taillight assembly 2 with the bracket. Remove the rear fender mounting bolts. Remove the footrest mud guards. Remove the rear fender. REMOUNTING Remount the exterior parts in the reverse order of removal. Pay attention to the following points: FRONT GRIP BAR Tighten the front grip bar mounting bolts to the specified...
  • Page 171 CHASSIS FOOTREST Apply THREAD LOCK to the bolts A and tighten each bolt to the specified torque. # 99000-32050: THREAD LOCK 1342 " Footrest mounting bolt A: 55 N•m (5.5 kgf-m, 40.0 lb-ft) Footrest mounting bolt B: 26 N•m (2.6 kgf-m, 19.0 lb-ft)

  • Page 172: Front And Rear Wheels

    7-10 CHASSIS FRONT AND REAR WHEELS CONSTRUCTION Front brake disc Spacer " Dust seal Bearing Spacer Front wheel Hub & Rear wheel Hub Hub plate Disc cover ITEM N•m kgf-m lb-ft 16.5 36.0 47.0 13.8 99.9...

  • Page 173: Removal

    CHASSIS 7-11 REMOVAL FRONT AND REAR WHEELS Place the vehicle on the level ground. Support the vehicle with a jack or wooden block. Remove the wheel. FRONT WHEEL HUB Remove the front wheel. (!Above) Remove the front hub plate 1. Remove the cotter pin and loosen the wheel hub nut with applying the front brake.

  • Page 174: Inspection And Disassembly

    7-12 CHASSIS INSPECTION AND DISASSEMBLY DUST SEAL Inspect the dust seal lips for wear or damage. If any damages are found, replace the dust seal with a new one. Remove the dust seals with the special tool. % 09913-50121: Oil seal remover Replace the removed dust seals with new ones.

  • Page 175: Reassembly And Remounting

    7-13 REASSEMBLY AND REMOUNTING FRONT WHEEL HUB Apply SUZUKI SUPER GREASE to the hub bearings and the lips of the dust seals before installing them. & 99000-25030: SUZUKI SUPER GREASE A ( USA) 99000-25010: SUZUKI SUPER GREASE A ( Others) Install the hub bearings and spacer into the front wheel hub.
  • Page 176 Install the front wheel. (!7-15) Replace the removed cotter pin with a new one. REAR WHEEL HUB Apply small amount of SUZUKI SUPER GREASE to the left rear wheel hub s spline. & 99000-25030: SUZUKI SUPER GREASE A ( USA)
  • Page 177 CHASSIS 7-15 Install the rear wheel hub and washer. NOTE: The convex side of the washer faces outside. INSIDE OUTSIDE Washer Tighten the rear wheel hub nut to the specified torque. " Rear wheel hub nut: 138 N•m (13.8 kgf-m, 99.9 lb-ft) Install the cotter pin into the rear axle as shown.

  • Page 178: Tires

    7-16 CHASSIS TIRES TIRE REPLACEMENT Remove the front and rear wheels. (!7-11) After removing the air valve cap, release the tire pressure by depressing the valve. Dismount the bead from the rim completely as shown. Separate the tire from the rim by using a set of tire levers and rim protectors.
  • Page 179 CHASSIS 7-17 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 tire refer to page 2-17. Inspect the valve core, before installation.

  • Page 180: Front Brake

    7-18 CHASSIS FRONT BRAKE CONSTRUCTION Master cylinder mounting bolt Brake hose union bolt ITEM N•m kgf-m lb-ft Air bleeder valve Brake caliper mounting bolt Brake pad mounting pin 16.5 Caliper holder pin Caliper holder slide pin Brake disc bolt Brake pipe nut 19.0 13.0 13.0...

  • Page 181: Brake Pad Replacement

    CHASSIS 7-19 BRAKE PAD REPLACEMENT Remove the front wheel. (!7-11) Remove the brake caliper mounting bolts 1 and brake pad mounting pins 2. Remove the brake pads. * Do not operate the brake lever during or after brake pad removal. * Replace the brake pads as a set, otherwise braking performance will be adversely affected.

  • Page 182: Brake Caliper Removal And Disassembly

    7-20 CHASSIS Connect a clear hose to the air bleeder valve and insert the other end of the hose into a receptacle. Loosen the air bleeder valve and pump the brake lever until the old brake fluid is completely out of the brake system. Close the air bleeder valve and disconnect the clear hose.

  • Page 183: Brake Caliper Inspection

    CHASSIS 7-21 Place a rag over the brake caliper piston to prevent the piston from popping out and then force out the piston using com- pressed air. Do not use high pressure air to prevent brake caliper piston damage. Remove the dust seal and piston seal. Do not reuse the dust seal and piston seal to prevent fluid leakage.
  • Page 184 7-22 CHASSIS BRAKE CALIPER PISTON Inspect the brake caliper piston for any scratches or other dam- age. If any damages are found, replace the piston with a new one. RUBBER PARTS Inspect the rubber parts for damage. If any damages are found, replace them with new ones.

  • Page 185: Brake Caliper Reassembly And Remounting

    BRAKE CALIPER HOLDER Tighten the pin 2 to the caliper holder 1 to the specified torque. " Caliper holder pin: 18 N•m (1.8 kgf-m, 13.0 lb-ft) Apply SUZUKI SILICONE GREASE to the brake caliper holder pin 2. * 99000-25100: SUZUKI SILICONE GREASE...

  • Page 186: Brake Disc Removal And Disassembly

    7-24 CHASSIS Apply SUZUKI SILICONE GREASE to the brake caliper holder slide pin. * 99000-25100: SUZUKI SILICONE GREASE Install the pin 1, washer 2 and caliper holder 3 to the cali- per. Apply THREAD LOCK SUPER to the pin 1.

  • Page 187: Brake Disc Inspection

    CHASSIS 7-25 BRAKE DISC INSPECTION Remove the front wheel. (!7-10) Remove the caliper. (!7-19) Inspect the brake disc for cracks or damage and measure the thickness using the micrometer. If any damages are found or if the thickness is less than the service limit, replace the brake disc with a new one.

  • Page 188: Master Cylinder Removal And Disassembly

    7-26 CHASSIS MASTER CYLINDER REMOVAL AND DISASSEMBLY Place a rag underneath the brake hose union bolt on the mas- ter cylinder to catch any split brake fluid. Remove the brake hose union bolt and disconnect the brake hose. Immediately wipe off any brake fluid contacting any part of the vehicle.

  • Page 189: Master Cylinder Inspection

    CHASSIS 7-27 Remove the piston/secondary cup, primary cup and spring. 7 Secondary cup 8 Piston 9 Primary cup 0 Spring MASTER CYLINDER INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or damage. If any damages are found, replace the master cylinder with a new one.
  • Page 190 7-28 CHASSIS Align the master cylinder holder s mating surface 1 with the punched mark 2 on the handlebars and tighten the upper clamp bolt first. " Master cylinder clamp bolt: 10 N•m (1.0 kgf-m, 7.0 lb-ft) A Master cylinder B Master cylinder upper clamp bolt C Handlebar D Clearance...

  • Page 191: Front Suspension

    CHASSIS 7-29 FRONT SUSPENSION CONSTRUCTION Front shock absorber Upper wishbone arm " Bushing Lower wishbone arm Steering knuckle Snap ring Knuckle end Shock absorber mounting upper nut Shock absorber mounting lower nut Wishbone arm pivot nut Steering knuckle nut Tie rod end nut kgf .

  • Page 192: Removal And Disassembly

    7-30 CHASSIS REMOVAL AND DISASSEMBLY Remove the wheel hub. (!7-11) Remove the brake hose clamp 1. Disconnect the brake hose from the brake hose clamp 2. Remove the front disc cover 3. Remove the cotter pin, tie rod end nut and washer. Disconnect the tie rod end with a commercially available ball bearing joint remover 4.

  • Page 193: Inspection

    CHASSIS 7-31 Remove the front shock absorber 7. Remove the cotter pins, knuckle nuts and washers. Disconnect the steering knuckle 8 with a commercially avail- able ball bearing joint remover. INSPECTION FRONT SHOCK ABSORBER Inspect the shock absorber for oil leakage or damage. If any damages are found, replace the front shock absorber with a new one.
  • Page 194 7-32 CHASSIS KNUCKLE Inspect the knuckle for damage. If any damages are found, replace the knuckle with a new one. KNUCKLE END Inspect the knuckle end boots for wear or damage. If any dam- ages are found, replace the wishbone arm with a new one. WISHBONE ARM Inspect the wishbone arms for wear or damage.

  • Page 195: Reassembly And Remounting

    CHASSIS 7-33 REASSEMBLY AND REMOUNTING Reassemble and remount the front suspension in the reverse order of removal and disassembly. Pay attention to the following points: Degrease the tapered portions of the knuckle, knuckle end and tie rod end with nonflammable cleaning solvent. Install the wishbone arms to the knuckle.

  • Page 196: Suspension Setting

    7-34 CHASSIS Apply THREAD LOCK SUPER to the wishbone arm pivot bolts 3. Tghten the upper and lower front shock absorber mounting nuts 2 and the wishbone arm pivot nuts 3 to the specified torque. , 99000-32030: THREAD LOCK SUPER 1303 (USA) - 99000-32110: THREAD LOCK SUPER 1322 (Others) "...

  • Page 197: Steering

    CHASSIS 7-35 STEERING CONSTRUCTION Steering head cover Handlebars " Handlebar upper clamp Handlebar lower clamp Brake cable guide Steering shaft holder & Steering shaft Dust seal Bushing Dust seal O-ring Dust seal Tie rod Tie rod end Handlebar clamp bolt Steering shaft holder bolt Steering shaft nut Tie rod end nut...

  • Page 198: Removal

    7-36 CHASSIS REMOVAL Remove the front fender. (!7-6) Remove the master cylinder assembly 1 from the handle- bars. (!7-26) Remove the throttle lever case 2. Disconnect the rear brake cable 3 and remove the handlebar switch 4. Disconnect the fuel vent hose and remove the steering head cover 5.
  • Page 199 CHASSIS 7-37 Remove the tie rod ends with a commercially available ball bearing joint remover. Remove the cotter pin and steering shaft nut 9, washer 0 and dust seal A. Replace the removed cotter pins with new ones. Remove the O-ring B. Remove the steering shaft holder bolts.

  • Page 200: Inspection And Disassembly

    7-38 CHASSIS Remove the steering shaft. Remove the dust seal F from the steering shaft. INSPECTION AND DISASSEMBLY Inspect the removed parts for the following abnormalities. * Handlebar distortion * Handlebar clamp wear DUST SEALS AND O-RING Inspect the dust seals and O-ring for wear or damage. If any damages are found, replace the dust seals with new ones.
  • Page 201 CHASSIS 7-39 STEERING SHAFT Inspect the steering shaft for distortion or bends. If any damages are found, replace the steering shaft with a new one. STEERING SHAFT HOLDER Inspect the two steering shaft holders for wear or damage. If any damages are found, replace the steering shaft holders with new ones.

  • Page 202: Reassembly And Remounting

    Pay attention to the following points: STEERING SHAFT Apply SUZUKI SUPER GREASE to the O-ring, dust seals and steering shaft before remounting the steering shaft. & 99000-25030: SUZUKI SUPER GREASE A (USA) 99000-25010: SUZUKI SUPER GREASE A (Others) Install the dust seal 1 to the steering shaft.
  • Page 203 CHASSIS 7-41 Tighten the steering shaft holder bolts to the specified torque. " Steering shaft holder bolt: 23 N•m (2.3 kgf-m, 16.5 lb-ft) NOTE: Make sure that the wiring harness, cables and brake hose rout- ing are properly. (!9-12 to -14) Degrease the tapered portions of the tie rod ends with non- flammable cleaning solvent.
  • Page 204 7-42 CHASSIS Install the steering head cover with the projection A inserting into the cushion B on the steering head cover bracket. NOTE: The indicator light position on the steering head cover is shown on page 8-24. Install the handle switch with the lug 5 on the switch half inserted into the hole 6 on the handlebars.

  • Page 205: Toe-In Adjustment

    CHASSIS 7-43 TOE-IN ADJUSTMENT Adjust the toe-in as follows: Place the vehicle on level ground and set the handlebars straight. Make sure all the tires are inflated to the standard pressure. (!2-18) Place 75 kg (165 lbs) of weight on the seat. Forward Loosen the locknuts ( 1, 2) on each tie rod.

  • Page 206: Front Wheel, Front Brake, Front Suspension And Steering Reassembling Information

    7-44 CHASSIS FRONT WHEEL, FRONT BRAKE, FRONT SUSPENSION AND STEERING REASSEMBLING INFORMATION...

  • Page 207: Rear Brake

    CHASSIS 7-45 REAR BRAKE CONSTRUCTION & Dust seal Brake camshaft Brake panel nut Drum cover O-ring Brake cam lever nut " Brake drum Brake lining indicator plate Brake shoe O-ring O-ring Brake panel Snap ring Brake cam lever Bearing ITEM N•m kgf-m lb-ft...

  • Page 208: Removal And Disassembly

    7-46 CHASSIS REMOVAL AND DISASSEMBLY Raise the rear wheel off the ground and support the vehicle with a jack or wooden block. Remove the right rear wheel hub. (!7-11) Disconnect the brake cables. Remove the drum cover bolts. Remove the drum cover 1 with a flat head screwdriver. * Be careful not to distort the drum cover.
  • Page 209 CHASSIS 7-47 Disconnect the brake breather hose. Remove the brake panel and panel cover 6. Remove the O-ring 7. Remove the brake cam lever 8. Remove the brake lining indicator prate 9, washer 0 and spring A. Remove the brake camshaft B and O-rings C from the brake panel.

  • Page 210: Inspection

    7-48 CHASSIS INSPECTION BRAKE DRUM Measure the brake drum s I.D. to determine the extent of wear. If the measurement value exceeds the service limit, replace the brake drum with a new one. ' Brake drum I.D. Service Limit: 140.7 mm (5.54 in) BRAKE SHOE Inspect the brake shoes for wear or damage.

  • Page 211: Reassembly And Remounting

    % 09913-70210: Bearing installer set Install the snap ring. Install new dust seal 2 to the drum cover 3 by using the removed dust seal 1. Apply SUZUKI SILICONE GREASE to the dust seal lips. Dust seal * 99000-25100: SUZUKI SILICONE GREASE Drum cover...
  • Page 212 7-50 CHASSIS Apply SUZUKI SUPER GREASE to new O-rings and brake camshaft. Install the O-rings and brake camshaft to the anchor panel. & 99000-25030: SUZUKI SUPER GREASE A (USA) 99000-25010: SUZUKI SUPER GREASE A (Others) O-rings should be replaced with new ones.
  • Page 213 Install new O-ring to the brake panel. Replace the removed O-ring with a new one. Apply SUZUKI SUPER GREASE to the anchor pin and brake camshaft sliding surface lightly. & 99000-25030: SUZUKI SUPER GREASE A (USA)
  • Page 214 7-52 CHASSIS Install the brake drum. Do not apply grease to the spline portion of brake drum. NOTE: Before installing the brake drum, make sure that the brake drum is clean and free of any greasey matter. Install the drum cover and tighten the bolts. NOTE: When installing the drum cover, make sure that the O-ring must be fitted into the groove on the brake panel securely.

  • Page 215: Rear Shock Absorber

    CHASSIS 7-53 REAR SHOCK ABSORBER CONSTRUCTION 78 N•m (7.8 kgf-m, 55 lb-ft) 60 N•m (6.0 kgf-m, 43.0 lb-ft) REMOVAL Raise the rear wheel off the ground and support the vehicle with a jack or wooden block. Remove the rear shock absorber 1. INSPECTION REAR SHOCK ABSORBER Inspect the rear shock absorber body and rubber bushing for...

  • Page 216: Reassembly

    7-54 CHASSIS REAR SHOCK ABSORBER SPACER AND BEARING Remove the spacers and dust seals. The removed dust seals must be replaced with new ones. Inspect the spacers for any flaws or other damage. If any dam- ages are found, replace the spacers with new ones. Insert the spacer into the rear shock absorber bearing and then check the play by moving the spacer up and down.

  • Page 217: Suspension Setting

    CHASSIS 7-55 SUSPENSION SETTING SPRING PRE-LOAD ADJUSTMENT The rear suspension spring pre-load is adjustable. This adjust- ment is performed by changing spring set length. Loosen the locknut 1. Adjust the spring set length by turning the adjuster 2. SPRING SET LENGTH A MAXIMUM MINIMUM STANDARD...

  • Page 218: Rear Suspension

    7-56 CHASSIS REAR SUSPENSION CONSTRUCTION Rear shock absorber Swingarm Bearing Rear shock absorber mounting nut (Upper) Rear shock absorber mounting nut (Lower) Swingarm pivot nut Axle housing mounting nut (RH) Axle housing bolt Axle housing mounting nut (LH) ITEM N•m kgf-m lb-ft 55.0...

  • Page 219: Removal

    CHASSIS 7-57 REMOVAL Remove the footrest mud guards. (!7-7) Remove the rear drive gear case assembly. (!4-3) Remove the rear shock absorber. (!7-53) Disconnect the brake breather hose 2 from the swingarm. Loosen the swingarm pivot bolts/nuts 3. Remove the swingarm. INSPECTION AND DISASSEMBLY REAR SHOCK ABSORBER Inspect the rear shock absorber.

  • Page 220: Reassembly

    5.0 mm (0.197 in) 5.0 mm (0.197 in) % 09924-84510: Bearing installer set Apply SUZUKI SUPER GREASE to the bearings, spacers and ips of the dust covers. & 99000-25030: SUZUKI SUPER GREASE A (USA) 99000-25010: SUZUKI SUPER GREASE A (Others) Install the spacers and dust covers to the swingarm.

  • Page 221: Remounting

    CHASSIS 7-59 REMOUNTING Remount the rear swingarm and suspension in the reverse order of removal. Pay attention to the following points: Apply THREAD LOCK SUPER to the swingarm pivot bolts. Install the swingarm pivot bolts and upper and lower shock absorber mounting bolts temporarily.

  • Page 222: Rear Axle

    7-60 CHASSIS REAR AXLE CONSTRUCTION Do not apply grease to the spline portion of the brake drum. 65 N •m (6.5 kgf-m, 47 lb-ft) Rear axle Rear axle housing 60 N •m (6.0 kgf-m, 43.5 lb-ft)

  • Page 223: Removal

    CHASSIS 7-61 REMOVAL Remove the rear wheels. (!7-11) Remove the rear wheel hubs. (!7-11) Remove the rear brake. (!7-46) Remove the rear axle housing/final gear case bolts 1 and rear axle housing set bolts/nuts 2. Remove the rear axle housing 3 and rear axle 4. Remove the O-ring 5.

  • Page 224: Reassembly And Remounting

    Reassemble and remount the rear axle in reverse order of removal and disassembly. Pay attention to the following points: Apply SUZUKI SUPER GREASE to the rear drive case spline. & 99000-25030: SUZUKI SUPER GREASE A (USA) 99000-25010: SUZUKI SUPER GREASE A (Others) Install new O-ring to the rear drive gear case.

  • Page 225: Rear Wheel, Rear Brake, Rear Suspension, Rear Swingarm And Rear Axle Shaft Reassembling Information

    CHASSIS 7-63 REAR WHEEL, REAR BRAKE, REAR SUSPENSION, REAR SWIN- GARM AND REAR AXLE SHAFT REASSEMBLING INFORMATION...

  • Page 226: Reverse Lock Release Cable

    7-64 CHASSIS REVERSE LOCK RELEASE CABLE REMOVAL Remove the reverse lock release knob 1 from the front fender. Open the fixed clamp. Remove the clip 2 and pin 3. Loosen the locknuts 4 and remove the reverse lock release cable. Remove the bracket 5.

  • Page 227: Remounting

    Pay attention to the following points: Install the spring so that the spring end A matches the groove B on the housing. Apply SUZUKI SUPER GREASE to the O-ring 1. & 99000-25030: SUZUKI SUPER GREASE A (USA) 99000-25010: SUZUKI SUPER GREASE A (Others) Install the O-ring 1 to the reverse lock release cable 2.
  • Page 228 7-66 CHASSIS CABLE PLAY ADJUSTMENT After installing the reverse lock release cable, adjust the cable play. Loosen the locknuts 1. Slide the adjuster 2 until the cable play at the reverse lock release knob A reaches 1 2 mm (0.04 0.08 in).

  • Page 229: Electrical System

    ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ................8- 2 CONNECTORS ..................8- 2 COUPLERS .....................8- 2 CLAMPS ....................8- 2 FUSES .....................8- 2 SEMI-CONDUCTOR EQUIPPED PARTS ..........8- 2 BATTERY ....................8- 3 CONNECTING THE BATTERY...............8- 3 WIRING PROCEDURE................8- 3 USING THE MULTI CIRCUIT TESTER...........8- 3 LOCATION OF ELECTRICAL COMPONENTS ...........8- 4 CHARGING SYSTEM ...................8- 6 TROUBLE SHOOTING ................8- 6...

  • Page 230: Cautions In Servicing

    ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTORS When disconnecting a connector, be sure to hold the termi- nals; 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 231: Battery

    ELECTRICAL SYSTEM BATTERY The MF battery used in this vehicle does not require mainte- nance (e.g., electrolyte level inspection, distilled water replen- ishment). During normal charging, no hydrogen gas is produced. How- ever, if the battery is overcharged, hydrogen gas may be pro- duced.

  • Page 232: Location Of Electrical Components

    ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS 1 CDI unit 2 Battery 3 Fuse 4 Ignition switch 5 Front brake light switch 6 Rear brake light pedal switch 7 Starter motor...
  • Page 233 ELECTRICAL SYSTEM 1 Handlebar switch (L) 7 Ignition coil 2 Rear brake light switch 8 Generator 3 Parking brake switch 9 Neutral switch 4 Neutral switch diode 0 Regulator/rectifier 5 Fuse A Neutral relay 6 Starter relay...

  • Page 234: Charging System

    ELECTRICAL SYSTEM CHARGING SYSTEM Ignition switch Fuse Battery Generator Regulator/rectifier TROUBLE SHOOTING 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.
  • Page 235 ELECTRICAL SYSTEM Step 4 1) Measure the resistance of the generator coil. (!8-9) Is the resistance of generator coil OK ? Go to Step 5. Faulty generator coil or disconnected lead wires Step 5 1) Measure the generator no-load voltage. (!8-9) Is the generator no-load voltage OK ? Go to Step 6.

  • Page 236: Inspection

    ELECTRICAL SYSTEM INSPECTION BATTERY CURRENT LEAKAGE Remove the seat. (!7-5) Turn the ignition switch to the OFF position. Disconnect the - battery lead wire 1. Measure the current between the - battery terminal and the - battery lead wire using the multi circuit tester. If the reading exceeds the specified value, leakage is evident.
  • Page 237 ELECTRICAL SYSTEM GENERATOR COIL RESISTANCE Remove the left fuel tank side cover. (!7-5) Disconnect the generator lead wire coupler. Measure the resistance among the three lead wires. If the resistance is not specified value, replace the stator coil with a new one. Also, check that the generator core is insulated.
  • Page 238 8-10 ELECTRICAL SYSTEM REGULATOR/RECTIFIER Remove the regulator/rectifier. Measure the voltage between the terminals using the multi cir- cuit tester, as indicated in the table below. If the voltage is not within the specified value, replace the regu- lator/rectifier with a new one. $ 09900-25008: Multi circuit tester set * Tester knob indication: Diode test (+) Unit: V...

  • Page 239: Starter System

    ELECTRICAL SYSTEM 8-11 STARTER SYSTEM Engine Ignition Starter button stop switch switch Fuse Neutral relay Starter motor Neutral Reverse indicator indicator light light B/Bl Starter relay Bl/R Neutral Parking brake switch switch TROUBLE SHOOTING Starter motor will not run. Step 1 1) The transmission is in neutral.
  • Page 240 8-12 ELECTRICAL SYSTEM Step 3 1) Measure the starter relay voltage at the starter relay connectors (between Y/B + and B/W -) when the starter button is pushed. Is the voltage OK ? Go to Step 4. Faulty ignition switch Faulty engine stop switch Faulty neutral relay Faulty neutral switch...

  • Page 241: Starter Motor Removal And Disassembly

    ELECTRICAL SYSTEM 8-13 STARTER MOTOR REMOVAL AND DISAS- SEMBLY Remove the starter motor 1. Disassembly the starter motor, as shown. Housing end (outside) Brush holder Brush spring O-ring Brush terminal set Starter motor case Washer set Armature Housing end (inside) O-ring STARTER MOTOR INSPECTION CARBON BRUSHES...

  • Page 242: Starter Motor Reassembly And Remounting

    " Replace the removed O-rings with new ones to pre- vent oil leakage and moisture. Apply SUZUKI SUPER GREASE to the lip of the oil seal. . 99000-25030: SUZUKI SUPER GREASE A (USA) 99000-25010: SUZUKI SUPER GREASE A (Others) Apply a small quantity of SUZUKI MOLY PASTE to the arma- ture shaft.

  • Page 243: Starter Relay Inspection

    Apply a small quantity of THREAD LOCK to the starter motor housing bolts and tighten it securely. 0 99000-32050: THREAD LOCK 1342 Apply SUZUKI SUPER GREASE to the O-ring. . 99000-25030: SUZUKI SUPER GREASE A (USA) 99000-25010: SUZUKI SUPER GREASE A (Others) STARTER RELAY INSPECTION Remove the left fuel tank side cover.

  • Page 244: Neutral Relay Inspection

    8-16 ELECTRICAL SYSTEM Apply 12 V to the terminals and check for continuity between the positive and negative terminals using the multi circuit tester. If the starter relay clicks and continuity is found, the relay is OK. $ 09900-25008: Multi circuit tester set , Tester knob indication: Continuity test (-) "...

  • Page 245: Ignition System

    ELECTRICAL SYSTEM 8-17 IGNITION SYSTEM TROUBLESHOOTING NOTE: * Check that the transmission is in neutral and the engine stop switch is in the RUN position. Check that the fuse is not blown and the battery is fully-charged before diagnosing. No spark or poor spark Step 1 1) Check the ignition system couplers for poor connections.
  • Page 246 8-18 ELECTRICAL SYSTEM Step 3 1) Measure the ignition coil primary peak voltage. (!8-19) NOTE: This inspection method is applicable only with the multi circuit tester and the peak volt adaptor. Is the peak voltage OK ? Go to Step 4. Go to Step 5.

  • Page 247: Inspection

    ELECTRICAL SYSTEM 8-19 INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE Disconnect the spark plug cap. Connect a new spark plug to the 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 248 8-20 ELECTRICAL SYSTEM IGNITION COIL RESISTANCE Disconnect the ignition coil lead wires and spark plug cap. Measure the ignition coil resistance in both the primary and sec- ondary windings using the multi circuit tester. If the resistance in both the primary and secondary windings is close to the speci- fied values, the windings are in sound condition.
  • Page 249 ELECTRICAL SYSTEM 8-21 Shift the transmission to the neutral position, turn the ignition switch to the ON position. Press the starter button and allow the engine to turn for a few seconds, and then measure the pickup coil peak voltage. Repeat the above procedure a few times and measure the highest pickup coil peak voltage.

  • Page 250: Lamps

    8-22 ELECTRICAL SYSTEM LAMPS HEADLIGHT Head light: 12 V 40/40 W 7.8 N •m (0.78 kgf-m, 5.6 lb-ft) E-28 ONLY 1.8 N •m (0.18 kgf-m, 1.3 lb-ft) If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.

  • Page 251: Brake Light/Taillight

    ELECTRICAL SYSTEM 8-23 BRAKE LIGHT/TAILLIGHT Brake light/taillight: 12 V 21/5 W E-28 Only " If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure. BULB REPLACEMENT Disconnect the socket.

  • Page 252: Indicator Light

    8-24 ELECTRICAL SYSTEM INDICATOR LIGHT INSPECTION ITEM RE: Reverse indicator light O/Bl Bl/R Steering NU: Neutral indicator light O/Bl Bl/B stem head cover WIRE COLOR Bl/B : Blue with Black tracer Bl/R : Blue with Red tracer O/Bl : Orange with Blue tracer INDICATOR LIGHT POSITION Steering stem head...

  • Page 253: Diode

    ELECTRICAL SYSTEM 8-25 DIODE Remove the fuel tank left side cover. (!7-5) Remove the neutral switch diode 1. Measure the voltage between the terminals using the multi cir- cuit tester as indicated in the table below. " 09900-25008: Multi circuit tester set # Tester knob indication: Diode test ($) Unit: V + Tester probe...

  • Page 254: Switches

    8-26 ELECTRICAL SYSTEM SWITCHES Measure each switch for continuity using the multi circuit tester. If any abnormality is found, replace the respective switch assemblies with a new one. " 09900-25008: Multi circuit tester set NEUTRAL SWITCH IGNITION SWITCH Color Color Position Position Neutral...

  • Page 255: Battery

    ELECTRICAL SYSTEM 8-27 BATTERY SPECIFICATIONS Type designation YTX9-BS Capacity 12 V, 28.8 kC (8 Ah)/10 HR a Anode plates e Stopper b Separator (fiberglass plate) f Filter c Cathode plates g Terminal d Upper cover breather h Safety valve INITIAL CHARGING FILLING ELECTROLYTE Remove the aluminum tape 1 sealing the battery electrolyte filler holes 2.
  • Page 256 8-28 ELECTRICAL SYSTEM Make sure that air bubbles 6 are coming up into each elec- trolyte container, and leave it in this position for more than 20 minutes. NOTE: If no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times.

  • Page 257: Servicing

    ELECTRICAL SYSTEM 8-29 " * For charging the battery, make sure to use a charger specially designed for MF batteries. Otherwise, the battery may be overcharged resulting in shortned service life. * Do not remove the caps while charging. * Position the battery with the cap facing upward while charging.
  • Page 258  ...

  • Page 259: Servicing Information

    SERVICING INFORMATION SERVICING INFORMATION CONTENTS TROUBLESHOOTING .................. 9- 2 ENGINE ....................9- 2 DRIVE TRAIN ..................9- 5 CARBURETOR ..................9- 5 CHASSIS ....................9- 6 BRAKES ....................9- 7 ELECTRICAL ..................9- 8 BATTERY ....................9- 9 WIRING DIAGRAM ..................9-10 WIRING HARNESS, CABLE, AND HOSE ROUTING ........

  • Page 260: Troubleshooting

    SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. 1. Worn cylinder. Replace. 2. Worn piston ring. Replace. 3. Worn valve guide or improper valve seating. Repair or replace. 4.
  • Page 261 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine is noisy. Noise seems to come from the crankshaft 1. Worn or burnt bearing. Replace. 2. Big-end bearing worn or burnt. Replace. 3. Excessive thrust clearance. Replace. Noise seems to come from transmission 1.
  • Page 262 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine idles poorly. 1. Valve clearance out of adjustment. Adjust. 2. Poor seating of valves. Replace. 3. Defective valve guides. Replace. 4. Worn rocker arm or arm shaft. Replace. 5. Defective generator. Replace.

  • Page 263: Drive Train

    SERVICING INFORMATION DRIVE TRAIN Complaint Symptom and possible causes Remedy Power will not trans- 1. Broken drive and driven bevel gear teeth. Replace. mit from the engine to 2. Broken propeller shaft serration. Replace. the rear wheel. 3. Worn or broken rear axle serration. Replace.

  • Page 264: Chassis

    SERVICING INFORMATION CHASSIS Complaint Symptom and possible causes Remedy Handling is too heavy 1. Improper front wheel alignment. Adjust. or stiff. 2. Insufficiently lubricated. Lubricate. 3. Low air pressure in front tires. Adjust. 4. Tie rod ends tending to seize. Replace.

  • Page 265: Brakes

    SERVICING INFORMATION BRAKES Complaint Symptom and possible causes Remedy Poor braking. 1. Insufficient brake fluid. Refill to level mark. (FRONT) 2. Air in brake fluid circuit. Bleed air out. 3. Worn pads. Replace. 4. Worn disc. Replace. Poor braking. 1. Worn shoe linings. Replace.

  • Page 266: Electrical

    SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coil. Replace. sparking. 2. Defective spark plug. Replace. 3. Defective generator. Replace. 4. Defective CDI unit. Replace. 5. Defective pickup coil. Replace. Spark plug is wet or 1.

  • Page 267: Battery

    SERVICING INFORMATION BATTERY Complaint Symptom and possible causes Remedy Sulfation or spots on 1. Cracked battery case. Replace. surfaces of cell 2. Battery has been left in a run-down condition for a long Replace. plates. time. Battery runs down 1. Incorrect charging method. Check the generator, and regu- quickly.

  • Page 268: Wiring Diagram

    9-10 SERVICING INFORMATION WIRING DIAGRAM...

  • Page 269: Wiring Harness, Cable, And Hose Routing

    SERVICING INFORMATION 9-11 WIRING HARNESS, CABLE, AND HOSE ROUTING WIRING HARNESS ROUTING Brake light/Taillight Wiring harness Wiring harness Clamp Handlebar switch Battery Ignition swich Reverse cable Clamp Clamp Parking brake Pilot lamp Ignition coil Left brake switch Set the generator coupler inside of the frame. Clamp Clamp Clamp...
  • Page 270 9-12 SERVICING INFORMATION Ignition switch Handlebar switch (L) Front brake switch Parking brake switch Brake lever switch Clamp Starter cable Forward Set the coupler inside. Clamp Pass the lead wire on the upper bracket. Neutral switch 30ß lead wire 10ß Rear brake lamp switch harness Carburetor...

  • Page 271: Cable Routing

    SERVICING INFORMATION 9-13 CABLE ROUTING Throttle cable Parking brake cable Throttle cable Reverse cable Clamp Brake hose DETAIL E Starter cable Cable guide Reverse cable Parking brake cable FRONT Starter cablle Pass the parking brake cable behind the brake Pass the throttle cable hose.
  • Page 272 9-14 SERVICING INFORMATION Starter cable Wiring harness OUTSIDE Clamp Clamp the starter cable with the wiring harness. Clamp the starter cable FRONT inside of the frame. DETAIL F Parking brake cable Starter cable Reverse cable Pass the starter cable under the frame. Clamp Clamp Do not give...
  • Page 273 SERVICING INFORMATION 9-15 STEERING SHAFT SET-UP Tighten the rear bolts after tightening the front ones. Clearance...

  • Page 274: Carburetor Hose Routing

    9-16 SERVICING INFORMATION CARBURETOR HOSE ROUTING Left Right 45ß Left Right Air vent hose Carburetor Carburetor overflow hose Clamp Clamp...

  • Page 275: Front Brake Hose Routing

    SERVICING INFORMATION 9-17 FRONT BRAKE HOSE ROUTING...

  • Page 276: Rear Brake Breather Hose Routing

    9-18 SERVICING INFORMATION REAR BRAKE BREATHER HOSE ROUTING...

  • Page 277: Fuel Hose Routing

    SERVICING INFORMATION 9-19 FUEL HOSE ROUTING...

  • Page 278: Rear Brake Cam Lever Set-Up

    9-20 SERVICING INFORMATION REAR BRAKE CAM LEVER SET-UP...

  • Page 279: Steering Head Cover Set-Up

    SERVICING INFORMATION 9-21 STEERING HEAD COVER SET-UP Steering head cover Clip Fuel tank breather hose No. 2 Steering head cover bracket...

  • Page 280: Taillight Set-Up

    9-22 SERVICING INFORMATION TAILLIGHT SET-UP Rear fender Taillight Rear reflector Side reflector E-28 ONLY...

  • Page 281: Special Tools

    SERVICING INFORMATION 9-23 SPECIAL TOOLS 09900-00410 09900-06106 09900-06107 09900-06108 09900-09004 Hexagon wrench set Snap ring pliers Snap ring pliers Snap ring pliers Impact driver set 09900-20202 09900-20203 09900-20205 09900-20508 Micrometer Micrometer Micrometer Cylinder gauge set 09900-20101 (1/100 mm, (1/100 mm, (1/1000 mm, (1/100 mm, Vernier calipers...
  • Page 282 9-24 SERVICING INFORMATION 09915-64510 Compression gauge 09913-85210 09918-02410 or 09915-74512 Bearing/oil seal 09918-03810 09915-74511 Oil pressure gauge 09916-10911 installer (Adaptor) Oil pressure gauge adaptor Valve lapper set 09916-14510 09916-14910 09916-21111 09916-24450 09916-22480 Valve spring com- Valve spring com- 09916-24900 Solid pilot Solid pilot pressor pressor attachment...
  • Page 283 SERVICING INFORMATION 9-25 09930-10121 Spark plug wrench 09930-30721 09930-35010 09930-31921 09930-44520 Rotor remover Rotor remover Rotor remover Rotor holder 09930-73150 09950-81910 Output shaft holder Remover NOTE: When ordering a special tool, please confirm whether it is available or not.

  • Page 284: Tightening Torque

    9-26 SERVICING INFORMATION TIGHTENING TORQUE ENGINE ITEM N•m kgf-m lb-ft Cylinder head cover bolt Camshaft sprocket bolt Cylinder head nut (M8) 16.5 Cylinder head nut (M6) Cylinder base nut (M6) Cam chain tensioner mounting bolt Cam chain tension adjuster spring holder bolt Neutral switch bolt Spark plug 13.0...

  • Page 285: Drive Train

    SERVICING INFORMATION 9-27 DRIVE TRAIN ITEM N•m kgf-m lb-ft Final gear case cover bolt 19.0 Pinion gear bearing locknut 10.0 72.5 Rear drive gear oil filler plug 19.0 Rear drive gear oil drain plug 19.0 Rear axle housing set bolt/nut (RH) 43.5 Rear axle housing set bolt/nut (LH) 47.0...

  • Page 286: Tightening Torque Chart

    9-28 SERVICING INFORMATION 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 A A A (mm) N•m kgf-m lb-ft N•m kgf-m lb-ft 0.15...

  • Page 287: Service Data

    SERVICING INFORMATION 9-29 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. (1.3) (1.1) Tappet clearance (when cold) 0.03 0 .08 (0.001 0 .003) 0.08 0 .13 (0.003 0 .005) Valve guide to valve stem 0.010 0 .037 clearance (0.0004 0 .0015) 0.030 0 .057...
  • Page 288 9-30 SERVICING INFORMATION CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 33.780 33.820 33.480 (1.3299 1.3315) (1.3181) 32.990 33.030 32.690 (1.2988 1.3004) (1.2870) Camshaft journal oil clearance 0.036 0.066 0.150 (0.0014 0.0026) (0.0059) Camshaft journal holder I.D. 22.012 22.025 (0.8666...
  • Page 289 SERVICING INFORMATION 9-31 ITEM STANDARD LIMIT Piston ring thickness 0.97 0.99 (0.038 0.039) 1.17 1.19 (0.046 0.047) Piston pin bore 16.002 16.008 16.030 (0.6300 0.6302) (0.6311) Piston pin O.D. 15.992 16.000 15.980 (0.6296 0.6299) (0.6291) CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT...
  • Page 290 9-32 SERVICING INFORMATION DRIVE TRAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3.047 (64/21) Secondary reduction ratio 1.133 (17/15) Final reduction ratio 3.200 (32/10) Gear ratios 3.083 (37/12) 1.933 (29/15) 1.388 (25/18) 1.095 (23/21) 0.913 (21/23) Reverse 2.833 (34/12) Shift fork to groove clearance...
  • Page 291 SERVICING INFORMATION 9-33 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Spark plug NGK: DR7EA Type DENSO: X22ESR-U (0.024 0.028) Spark performance Over 8 (0.3) at 1 atm. Ignition coil resistance Terminal 1.0 Ω Ω Ω Ω Primary 0.05 Terminal Plug cap 10.5 1 9.0 kΩ...
  • Page 292 9-34 SERVICING INFORMATION BRAKE + WHEEL Unit: mm (in) ITEM STANDARD/SPECIFICATION LIMIT Rear brake lever play (0.12 0.20) Rear brake pedal free travel 20 30 (0.79 1.18) Brake disc thickness Front (0.110 0.126) (0.098) Brake disc runout 0.30 Front (0.012) Brake drum I.D.
  • Page 293 SERVICING INFORMATION 9-35 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. Gasoline containing MTBE (MethyI Tertiary E-28, 33 ButyI Ether), less than 10 % ethanol, or less than 5 % methanol with appropriate cosolvents and corrosion inhibitor is permissible.
  • Page 294  ...

  • Page 295: Lt-Z250K5 ( 05-Model)

    LT-Z250K5 ( 05-MODEL) 10-1 LT-Z250K5 ( 05-MODEL) This chapter describes specifications, service data and servicing procedures which differ from those of the LT-Z250K4 ( 04-MODEL). NOTE: * Any differences between the LT-Z250K4 ( 04-MODEL) and LT-Z250K5 ( 05-MODEL) in specifications and service data are indicated with an asterisk mark (*). * Please refer to the chapter 1 through 9 for details which are not given in this chapter.
  • Page 296 10-2 LT-Z250K5 ( 05-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..................1 720 mm (67.7 in) Overall width ..................1 070 mm (42.1 in) Overall height ..................1 090 mm (42.9 in) Wheelbase ..................1 135 mm (44.7 in) Front track ...................
  • Page 297 LT-Z250K5 ( 05-MODEL) 10-3 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. (1.3) (1.1) Tappet clearance (when cold) 0.03 0.08 (0.001 0.003) 0.08 0.13 (0.003 0.005) Valve guide to valve stem 0.010 0.037 clearance (0.0004 0.0015) 0.030 0.057 (0.0012 0.0024) Valve stem deflection...
  • Page 298 10-4 LT-Z250K5 ( 05-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 33.780 33.820 33.480 (1.3299 1.3315) (1.3181) 32.990 33.030 32.690 (1.2988 1.3004) (1.2870) Camshaft journal oil clearance 0.036 0.066 0.150 (0.0014 0.0026) (0.0059) Camshaft journal holder I.D. 22.012 22.025 (0.8666 0.8671) Camshaft journal O.D.
  • Page 299 LT-Z250K5 ( 05-MODEL) 10-5 CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end I.D. 16.006 16.014 16.040 (0.6302 0.6305) (0.6315) Conrod deflection (0.12) Conrod big end side clearance 0.10 0.45 (0.004 0.018) (0.04) Conrod big end width 17.95 18.00 (0.707 0.709) Crank web to web width...
  • Page 300 10-6 LT-Z250K5 ( 05-MODEL) DRIVE TRAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3.047 (64/21) Secondary reduction ratio 1.133 (17/15) Final reduction ratio 3.200 (32/10) Gear ratios 3.083 (37/12) 1.933 (29/15) 1.388 (25/18) 1.095 (23/21) 0.913 (21/23) Reverse 2.833 (34/12) Shift fork to groove clearance...
  • Page 301 LT-Z250K5 ( 05-MODEL) 10-7 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Spark plug NGK: DR7EA Type DENSO: X22ESR-U 0.6 0.7 (0.024 0.028) Spark performance Over 8 (0.3) at 1 atm. Ignition coil resistance Terminal 0.05 1.0 Ω Primary Terminal Plug cap 10.5 19.0 k Ω...
  • Page 302 10-8 LT-Z250K5 ( 05-MODEL) BRAKE + WHEEL Unit: mm (in) ITEM STANDARD/SPECIFICATION LIMIT Rear brake lever play (0.12 0.20) Rear brake pedal free travel 20 30 (0.79 1.18) Brake disc thickness 2.8 3.2 Front (0.110 0.126) (0.098) Brake disc runout 0.30 Front (0.012)
  • Page 303 LT-Z250K5 ( 05-MODEL) 10-9 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. Gasoline containing MTBE (MethyI Tertiary E-28, 33 ButyI Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and...
  • Page 304 10-10 LT-Z250K5 ( 05-MODEL) TIGHTENING TORQUE CHASSIS ITEM N•m kgf-m lb-ft Handlebar clamp bolt 16.5 Steering shaft holder bolt 16.5 Steering shaft nut 35.5 Wishbone arm pivot bolt/nut (upper and lower) 47.0 Wheel hub nut (front) 47.0 Wheel hub nut (rear) 13.8 99.9 Wheel set nut (front and rear)
  • Page 305 LT-Z250K5 ( 05-MODEL) 10-11 FRONT BRAKE HOSE ROUTING...
  • Page 306  ...

  • Page 307: Lt-Z250K6 ( 06-Model)

    LT-Z250K6 ( 06-MODEL) 11-1 LT-Z250K6 ( 06-MODEL) This chapter describes specifications, service data and servicing procedures which differ from those of the LT-Z250K5 ( 05-MODEL). NOTE: * Any differences between the LT-Z250K5 ( 05-MODEL) and LT-Z250K6 ( 06-MODEL) in specifications and service data are indicated with an asterisk mark (*). * Please refer to the chapter 1 through 10 for details which are not given in this chapter.
  • Page 308 11-2 LT-Z250K6 ( 06-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..................1 720 mm (67.7 in) Overall width ..................1 070 mm (42.1 in) Overall height ..................1 090 mm (42.9 in) Wheelbase ..................1 135 mm (44.7 in) Front track ...................
  • Page 309 LT-Z250K6 ( 06-MODEL) 11-3 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. (1.3) (1.1) Tappet clearance (when cold) 0.03 0.08 (0.001 0.003) 0.08 0.13 (0.003 0.005) Valve guide to valve stem 0.010 0.037 clearance (0.0004 0.0015) 0.030 0.057 (0.0012 0.0024) Valve stem deflection...
  • Page 310 11-4 LT-Z250K6 ( 06-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 33.780 33.820 33.480 (1.3299 1.3315) (1.3181) 32.990 33.030 32.690 (1.2988 1.3004) (1.2870) Camshaft journal oil clearance 0.036 0.066 0.150 (0.0014 0.0026) (0.0059) Camshaft journal holder I.D. 22.012 22.025 (0.8666 0.8671) Camshaft journal O.D.
  • Page 311 LT-Z250K6 ( 06-MODEL) 11-5 ITEM STANDARD LIMIT Piston ring thickness 0.97 0.99 (0.038 0.039) 1.17 1.19 (0.046 0.047) Piston pin bore 16.002 16.008 16.030 (0.6300 0.6302) (0.6311) Piston pin O.D. 15.992 16.000 15.980 (0.6296 0.6299) (0.6291) CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT...
  • Page 312 11-6 LT-Z250K6 ( 06-MODEL) DRIVE TRAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3.047 (64/21) Secondary reduction ratio 1.133 (17/15) Final reduction ratio 3.200 (32/10) Gear ratios 3.083 (37/12) 1.933 (29/15) 1.388 (25/18) 1.095 (23/21) 0.913 (21/23) Reverse 2.833 (34/12) Shift fork to groove clearance...
  • Page 313 LT-Z250K6 ( 06-MODEL) 11-7 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Spark plug NGK: DR7EA Type DENSO: X22ESR-U 0.6 0.7 (0.024 0.028) Spark performance Over 8 (0.3) at 1 atm. Ignition coil resistance Terminal 0.05 1.0 Ω Primary Terminal Plug cap 10.5 19.0 k Ω...
  • Page 314 11-8 LT-Z250K6 ( 06-MODEL) BRAKE + WHEEL Unit: mm (in) ITEM STANDARD/SPECIFICATION LIMIT Rear brake lever play (0.12 0.20) Rear brake pedal free travel 20 30 (0.79 1.18) Brake disc thickness 2.8 3.2 Front (0.110 0.126) (0.098) Brake disc runout 0.30 Front (0.012)
  • Page 315 LT-Z250K6 ( 06-MODEL) 11-9 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. Gasoline containing MTBE (MethyI Tertiary E-28, 33 ButyI Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and...

  • Page 316: Lt-Z250K7 ( 07-Model)

    LT-Z250K7 ( 07-MODEL) 12-1 LT-Z250K7 ( 07-MODEL) NOTE: * The specification and service data are the same as the K6-MODEL CONTENTS I NFORMATION LABEL INSTALLATION (For E-33) ........12- 2...
  • Page 317 12- 2 LT-Z250K7 ( 07-MODEL) INFORMATION LABEL INSTALLATION (For E-33) LABEL Frame LH side...

  • Page 318: Lt-Z250K8 ( 08-Model)

    LT-Z250K8 ( 08-MODEL) 13-1 LT-Z250K8 ( 08-MODEL) NOTE: * The specification and service data are the same as the K7-MODEL CONTENTS I NFORMATION LABEL ................13- 2...
  • Page 319 13-2 LT-Z250K8 ( 08-MODEL) INFORMATION LABELS APPLIED SPECIFICATION LABEL or PLATE NAME E-19 E-28 E-33 Certification plate E Information label E Gearshift pattern label E Gearshift pattern label E/ F Tire air pressure label E Tire air pressure label and warning no-passenger label F General warning label E General warning label F Warning no-passenger label E...
  • Page 320 LT-Z250K9 (’09 MODEL) 14-1 LT-Z250K9 (’09 MODEL) 6JKU EJCRVGT FGUETKDGU UGTXKEG URGEKHKECVKQPU UGTXKEG FCVC CPF UGTXKEKPI RTQEGFWTGTU YJKEJ FKHHGT HTQO VJQUG QH VJG .6<- /1&'.  016' #P[ FKHHGTGPEGU DGVYGGP VJG .6<- /1&'. CPF .6<- /1&'. KP URGEKHKECVKQPU CTG ENGCT[ KPFKECVGF YKVJ CP CUVGTKUM OCTM 2NGCUG TGHGT VQ VJG ECRVGTU  VJTQWIJ  HQT FGVCKNU YJKEJ CTG PQV IKXGP KP VJKU EJCRVGT CONTENTS PAGE...

  • Page 321: Lt-Z250K9 ( 09-Model)

    14- 2 LT-Z250K9 ( 09-MODEL) SPECIFICATIONS DIMENSIONS AND CURB MASS Overall length ..................1 720 mm (67.7 in) Overall width..................1 070 mm (42.1 in) Overall height ..................1 090 mm (42.9 in) Wheelbase ..................1 135 mm (44.7 in) Front track ...................
  • Page 322 LT-Z250K9 ( 09 MODEL) 14-3 SERVICE DATA CARBRETOR SPECIFICATION ITEM * E-19 * E-28, 33 ← Carburetor type MIKUNI BSR29 Bore size 29 mm ← (1.14 in) I.D. No. 21G0 21G1 ← Idle r/min 1 500 ± 100 r/min Float height 13.0 ±...
  • Page 323 14- 4 LT-Z250K9 ( 09-MODEL) FUEL TANK CONSTRUCTION 1 Fuel tank 2 Fuel cap 3 Breather hose 4 Gasket 5 Gasket 6 Fuel valve 7 Fuel hose...
  • Page 324 LT-Z250K9 ( 09 MODEL) 14-5 CARBURETOR PILOT SCREW REMOVAL (For E-28, 33) Because harsh cleaning solvents can damage the O-ring seals in the pilot system, the pilot system components should be removed before cleaning. • Use a 1/8” size drill bit with a drill-stop to remove the pilot screw plug.
  • Page 325 14- 6 LT-Z250K9 ( 09-MODEL) INFORMATION LABELS Information label (E-28) Certification label (E-33) Front of frame right side...

This manual is also suitable for:

Lt-z250k5 2005Lt-z250k9 2009250Lt-z250k6 2006Lt-z250k7 2007Lt-z250k8 2008

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