Suzuki FA50 Service Manual
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Suzuki FA50 Service Manual

Suzuki FA50 Service Manual

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  • Page 2 Suzuki Motor Co., Ltd reserves the right to make changes without notice at any time. Quoting, copying or otherwise using any part of this manual without explicit authorization from Suzuki Motor Co., Ltd. is not permitted as all rights to the publication are reserved under copyright law.
  • Page 3 G ROUP IN DEX SERVICIN G P RO CEDU RE...

  • Page 4: Table Of Contents

    GENERAL INFORMAJ'TON GENERAL IN F O R M A T I O N M O D E L I D ENTI FICATION ..............1-2 SPECIFICAT I O N S ..................FUEL A N D O I L RECOM M E N DATION ..........1-5 G E N ERAL NOTES A N D PR ECAUTIONS ...........

  • Page 5: Model Identification

    GENEIUIL JNFOUMATION MODEL IDENTIFICATION R I G HT SIDE VIEW F RA M E N U MB E R The frame serial number is stamped o n the right side of the steering head pipe. LEFT S I D E VIEW ENG I N E NUMBER The engine serial number is located on the left side of the cran kcase.

  • Page 6: Specifications

    GENERAL fNFORAIATTON SPECIFICATIONS DIM E N S I O N S A N D WEIGHT Overall length 1 585 mm (62.4 i n ) Overall width 670 m m (26.4 in) Overa l l height 970 mm (38.2 i n ) 1 040 mm (40.2 i n ) Wheelbase 1 20 m m ( 4.7 i n )
  • Page 7 GLiNER.-\L l./\'l'OR,\J:\'/'/Of\ CHASSIS Telescopic Front suspension 45° (right & left) Swinging arm, oil dampened Rear suspension Steering angle Caster 65°00'' Trail 70 mm (2.76 i n ) Turning radius 1 .4 m (4.6 ft) Front brake Internal expanding I nternal expanding Rear brake Front ti re size 2.25- 1 4 4 P R...

  • Page 8: Fuel And Oil Recommendation

    GJ:NER.AL /,'\'f-'ORAli\ Tf()1\' FUEL AND OIL RECOMMENDATION B e sure to use the specified fuel and oils. The fol lowing are the specifications: FUEL Use only un leaded or l ow-lead type· gaso­ l i ne of at least 95 pump octane Engine o i l tank cap Fuel tank cap method) or 89 octane or higher...

  • Page 9: General Notes And Precautions

    Gb\/:'RAI. 1.1\'l:OR.\l:l 'J IOS GENERAL NOTES AND PRECAUTIONS Observe the following items without fail when d isassembling and reassembl i ng motorcycles. Be sure to replace packings, gaskets, 0 rings, circlips and cotter pins with new ones. • • T i ghten bolts and nuts from the ones of larger diameter to those of sma l ler d iameter, and from inside to out-side d iagonally, with specified tightening torque.

  • Page 10: Technical Features

    GENERAL JNFORMA 1'/0N TECHNICAL FEATURES DESC R I PTION The F A50 has a 49 cc 2-cycle engine with reed valve. The simple construction and rational design of the engine has m i n i m ized the numbe r of i n spection items, thus allowing easy inspection and almost maintenance-free operation.·...
  • Page 11 GI: vr:R IL 1s1:0RM� rJ(),\ REED VALVE A reed valve is used in the intake system. The reed valve has thin, flexible steel pieces and are fitted into the top of the cran kcase. As the p iston moves up and down, the pressure in the crankcase alternately changes to negative and positive, thus causing the reed valve to open and close.
  • Page 12 GENERAL lNJ-'ORAJATIOf\' PISTON AND PISTON R I N G Both 1st and 2nd piston ri n gs are of keystone type, and an expander ring is with the 2nd ring. The keystone ring i s less sticking and has excellent durability. The expander ring absorbs the noise generated by the piston s l i d i n g against the cylinder wall by means of its spring tension, thus reducing ove rall noise.
  • Page 13 n 01 \ 1-10 Gl:: .\" I:RA t J,\TORM.� POWER TRANSMISSION This motorcycle is equipped with an automatic one speed transmission. If the engine revolution •IQ) is i ncreased, the cl utch is connected and the power of the crankshaft is transmitted to the counter shaft Power of the countershaft is transmitted to the final drive shaft...
  • Page 15 1 12 (;/·:t\lilUL lvFOln/:l'fl(),\ KICK STARTER When the brake lever is squeezed, the kick starter lifter lever i s actuated I•, the kick starter l i fter ' ' .2 l shaft rotates and the kick starter lifter moves downward �).
  • Page 16 1-13 GJ,;NJ:RAL JNFORM.-11"/0N " PEI" SYSTEM I n the FA50 ignition system, the system is used. system uses a magneto as the power source, and the capacitor (condenser) momenta ri l y stores a cha rge u p t o hundreds of volts.
  • Page 17 l.E\'ER.tl. /.'\FORM ff/O \ 1-14 Connecting Diagram Engine kill switch Magneto P E I unit Ignition coil Spark plug Wiring Circuit l"' " ' " Spark PEI Unit Condenser charging coil Ignition coil Description As the magneto turns, the voltage generated by the condenser charging coi l is charged to the condenser through the following ci rcu it: Diode D3 Condenser charging coil...

  • Page 19: Periodic Maintenance Schedule

    :VS Pf: CTI ( 'STAI f:'.\' r ON :�ND PERIODIC MAINTENANCE SCHEDULE Vehicles should be inspected after a certain period of running for wear of parts, carbon deposits, elongated cables, etc. Inspections should be made periodically and defects should be repaired or adjusted beforehand to prevent trouble and prolong the motorcycle's service life.

  • Page 21: Maintenance Procedure

    lNSPliC'JJ()N .·IND .-!Djl'STl\11:1\J"/' MAINTENANCE PROCEDURE A I R CLEA N E R Clean at initial miles) 1 000 (600 miles) 3 00 Battery j" case cover Slipper _Element ..� ..• '--UPPER-- §2___ LOWER-� 6N2-2A-4 YuAsA Non flammable Motor o i l •...
  • Page 22 JNSPEC"/'ION AND 11DjUSTMl:iNT BRAKES BRAKE S H O E WEAR Adjust a t initial 1 000 km (600 Check every miles) • k m (2 miles) km (2 every miles) • When applying the front brake, if the e x ­ tended line of the brake cam lever e x ceeds Adjust by turning the adjusting nut so the range on the brake panel, replace the...
  • Page 23 l.\"SPEC'r!ON .-11\iD 4Vjl 'STMl:'N'f • E N G I N E I DLE RPM Finally adjust the throttle cable play. 0.5 -1.0 mm and every 000 km Throttle cable play • miles) (0.02 0_04 in) • Adjust the throttle cable play . •...
  • Page 24 INSPEC/10N l'lND ADJUS"fMENT CYLI N D E R H E A D NUTS FUEL LI N E Retighten at initial 1 000 (600 miles) two years (2 000 miles) every 3 Replace the fuel l i n e every two years. •...
  • Page 26 • l/\'SPT'.CTION /IND ADJUSTAII:.N'f Check spark p l ug for burnt condition. If abnormal, replace the plug as indicated below. Lock nut ©J N i ppon R emarks Denso Spacer Steering stem the standard plug Check inner o r W9FP-UL is apt to get wet, re­...
  • Page 28 USTMEN'J' INSl'FC'J'JON AND .-l DJ 2-11 CHASSIS BOLTS A N D N UTS Retighten at initial 1 (600 miles) and every 3 km (2 miles) These bolts and nuts l i sted below are important safety parts. They must be retightened, as neces­ sary, to the specified torque with a torque wrench .
  • Page 29 SL:R !'ICING PROCEDURc SERVICIN G P RO CEDU RE -- --- CONTENTS 3- 2 E N G I N E R E M OVAL/INSTALLATION ..........3- 3 CYL I N D E R HEAD, CYLIN DER, PISTON ........

  • Page 30: Engine Removal/Installation

    Sl:'R. PROCEDL'RI: I 'ICING ENGINE REMOVAL/INSTALLATION Left side Upper side ® Remove the engine oil tank cap, fuel Remove the fuel line and the vacuum Remove the support bracket. line with the fuel cock set to O N . @ Remove the frame upper cover. •...
  • Page 31 SER VICING PROCEDURE CYLINDER HEAD, CYLINDER, PISTON, PISTON RING ,,__ ..,. . _.- · r �, 1 .2 kg-m 16.0 a.5 1b-111 ® Remove carbon @, <i> Replace gasket 1.5 - 2.0 kg-m ( 1 1 .0 - 1 4. 0 lb-ft) ©...

  • Page 33: Kick Starter, Left Cover

    ® and then insta l l @. When insta l l i n g the kick starter return • Apply Suzuki Super Grease A to the o i l • seal lip a n d t h e kick starter spring.

  • Page 34: Power Transmission

    SER l'ICINC PROCL:D l 'RJ; POWER TRANSMISSION • 09920-30220 Clutch holder Apply thread lock cement. J.o kg·m ( 1 4.5 - 2 1 .5 lb-ft) !-_'- Key W"h" ave washer w"h" W"h" W"h" W"h" Look One way clutch • Circlip opener 09900-06 1 07 •...

  • Page 38: Cran Kshaft

    ® . • When insta l l ing the crankshaft, apply the Crankshaft remover 09920-1 3 1 1 1 SUZUKI Bond No. 1 201 99104-31 1 00 • Be sure to set the spacer when instal l ing the oil pump.
  • Page 39 Sl:'R VICING P/�OCf:'Dl!RE 3-11 C R A N K S HAFT DEFLECTION Service limit 0.05 m m (0.002 in) SMALL END DE FLECTION Service limit 3.0 mm (0.12 in) • S M A L L E N D BORE D I A . Service limit 16.040 m m (0.6315 in) PISTON PIN 0.D.

  • Page 40: Carburetor

    J. 1 2 si:R 1 ·1c1,YG T'Rocr ; n 1 ·1u, CARBURETOR Clean each passage of air and fuel with an air gun. Leaner Idle Richer 3 F 1 3-3 Check for damage and replace if any. Be sure to c l ean i t when overhauling ±...

  • Page 41: Flyw H Eel Magneto

    S/iR VJCJNG PROCEDU RE 3-1 J FLYW H EEL MAGNETO F lywheel holder 09930-401 1 3 Apply thread lock cement Wipe off oil on the taper throughly. Sliding shaft 09930-30102 F i x the stator to a l ign the scribed l ine with Attachment C 09930-301 6 1 the center of the screw hole so that correct...
  • Page 42 J-1 -1 Sl£R I 'ICING PROCEIJ( IRI: Specifications Ignition method: sparks per crankshaft rotation Light capacity: 8. 7 V or less at V or more at 2 8 000 Charging capacity: 2. 5 8 000 A or less at Secondary voltage: kV or more at Ignition coil resistance: 1 8 k n...
  • Page 43 SJ"'R PROCEDURli l 'lCJNG 3-15 STATOR • Pocket tester 09900-25002 Select the knob to RX "x 1 " . • Make a following continuity test. Unit : ( n ) 0 - 1 0 - 1 0 - 1 O F F O F F 90 -110 •...

  • Page 44: Chassis E Lectrical

    3- 1 6 SER i'ICING PROCTiDURli CHASSIS ELECTR ICAL • IGN ITION C O I L Using the pocket tester check the ignition coi l . o - rn. x 1 n Knob Resistance x kn 16 - 1 8 kii position x kn 16 - 1 8 kii...
  • Page 45 VICING SJ-:R PROCJ-:DURH 3- 1 7 PEI UNIT I test lead for F A50 09900-28607 • • main switch to ON. Wire as shown in the figure and turn the It is in good condition if the indicator stays off, replace it. I ight comes on and remains I it.
  • Page 46 SER l 'ICINC PROCFD l .R E J-18 P E I Inspection by Pocket Tester • Positive (+) pointer to touch : Black/Red Red/Black Black/Wh ite Black/Yellow O F F O F F O F F Black/Red � CJ ..I :i O F F 80 - 100 n...
  • Page 47 SER VICING PROCJ;DURE 3- 1 9 RECTI F I E R • I f continuity i s found in range when found when (+) (-) probes are reversed, it connecting as shown in the figure and not is in good condition. If continuity is found i n both cases or no continuity i n either case, replace it.

  • Page 48: Switches

    SE R 1 ·1cJ,\'C l'R OCJ-;D l ' R E J-20 SWITCHES I G NITION SWITCH Pocket tester 09900-25002 • Turn the ignition switch to ON and O F F a s shown in the chart below. I f cont i r;i u i ­ t y i s found, it i s i n good condition.
  • Page 49 Sf;'R VICING PROCEDURE 3-21 • E N G I N E K I L L SWITCH Set the kill switch to O F F position, con­ Ul6111 l ST°' nect B / R wire and ground wire to the pocket tester and check continuity. •...

  • Page 50: Steering

    I 'lCl\'G PJ{ ()CEVl /�I: 3-22 Sl:R STEERING Lock Sp<Jcer Steering stem nut .Check inner or outer races for wear Steel balls • Check inner or outer races for wear. G R EASE Steel balls • • Number of steel balls Upper 2 5 pcs Lower...

  • Page 51: Front Suspension

    3-23 SER. VICING PROCEDURE FRONT SUSPENSION • ..Check the rubber stopper for cracks or damage 2.5 - 3.5 kg-m ( 1 8.5 - 25.5 lb·ft)
  • Page 55 SJ.:R V!CJNG INFORt.1.A. TJON SERV I CI N G I N F O R M A T IO N CONTENTS 4- 2 TROUBLESHOOTING ................4- 5 SPECIAL M ATERI ALS .

  • Page 56: Troubleshooting

    SI:"/{ w; J.\"J'()R1'1 l "/Cl TIO.\' TROUBLESHOOTING H A R D E N G I N E STARTING OR NO ENG I N E STARTING • E N G I N E • Compression leakage from crank chamber • Leakage from cylinder base gasket •...
  • Page 57 SER J'ICJNC /,\'f."OR AL l 'J"JON ENGINE STALLING I m proper idling rpm. • Fouled or worn spark plug • Lean fuel/air mixture • Air screw out of adjustment • Clogged carburetor jet • Clogged fuel hose C logged gaso l i ne tank cap I ncorrect carburetor fuel level Compression leakage from cran kcase (oil seal, mating surface) NOT ENOUGH ENGINE POWER...
  • Page 58 4-.J S l iR l'ICl.VG INFORAI TIO.V E N G I N E OVERH EAT Lean fuel/air mixture • Clogged carburetor jet • Carburetor float level Ignition timing too advance o r retarded Carbon deposit • Cylinder head, piston crown, exhaust port, spark plug Dragging brake Defective o i l pump DEFECTIVE CLUTCH...

  • Page 59: Special Materials

    S U Z U K I , i f used t o re­ Suzuki super grease place parts of S U Z U K I origin in the ma­...

  • Page 60: Special Tools

    Sl:R I "ICING l.l\' l'OR!\l \ "/ 1 0. \ ' SPECIAL TOOLS Snap ring p l i ers (opening type) Shock driver set 09900-06 1 0 7 09900-09002 M icrometer Dial gauge Cylinder gauge set 09900-20201 (0 - 25 mm) mm ) 09900-20606 (0 - 1 0 mm, 09900-20508...
  • Page 61 SJ.iR. I 'ICING l1'\'l· OR1\un JON Clutch holder Spark plug wrench Bearing remover 09920-30220 09930- 1 0 1 1 1 09921-20210 ·�---·/ � - �;:- f' Rotor remover slide shaft Attachment C (27 mm screw) Rotor holder 09930-30 1 0 2 09930-30 1 6 1 09930-40 1 1 3 •...

  • Page 62: Wire And Cable Routing

    'JCJ:\IG INFOl�M,\ TTON -I 8 SF.R I WIRE AND CABLE ROUTING W I R I N G ROUTING ..•...
  • Page 64 � SPEEDOMETER llGHl c;::, •UCU BEAM INOICAlOR LIGHT FRO!\ T BRA)(I LICH SWITCH ' � � � � "' ;;:; � '""""' �"'" -..: """' '"' :,... uE•DttGHT L•o•r G> )> G> )> � ! ! � I t.�AC"ETO U,;tt W I R E COLOR HI Alt HUl\Kl l llill...

  • Page 66: S E Rvice Data

    4-12 SER 1 7C JN(; INFOR/11.l T]().\' S E R V I C E DATA C Y LIND E R + PISTON + PISTON RING U n i t : mm ( i n ) L I M IT I TEM STANDARD 0.055 - 0.085 0.

  • Page 67: Oil Pump

    .'i/:R l '/C/NG INl'ORM:ITION 4-13 CON ROD + C RAN K S H A F T U n i t : m m ( i n ) I T E M STAN D A R D L I M IT 1 6 .003 - 1 6.01 1 1 6.040 Conrod s m a l l e n d l .
  • Page 68 4- 1 4 SJ:R l'ICJNG INl'OR.M/ITION TRANSM I SS I O N Unit: m m ( i n ) L I M I T ITEM STAN DAR D 1 .000 Primary reduction ratio F i nal reduction ratio 5.564 Gear ratios 2.384 Chain 2.333...
  • Page 69 :) lo R. l 'ICING 11\'FORMATION 4- 1 5 C A R B U R E T O R U n i t : m m ( i n ) SPEC I F ICATION ITEM Carburetor type V M 1 2SH M I K U M I Bore size ±...
  • Page 70 4- 1 6 SER I 'TC/NG INJ'ORAll\ 'J'ION Unit· mm (in) E L ECTR I CA L SPE C I F ICATION NOTE ITEM ± Ignition timing 2° B.T.D.C. at 4000 rpm 25° -,- - N G K BP 4 - HA or N -1 Spark plug ( 0.02 0.03...
  • Page 71 4- 1 7 VJ CL NG INFORJ\lfA TJON B R A K E + W H E E L U n i t : m m ( i n ) L I M I T ITEM STANDARD Front brake lever distance 1 .
  • Page 72 Sl: R l "/Cl ."l.'G l.\TORM-'. 'f'ION 4- 1 8 F U E L + O I L ITEM NOTE SPEC I F ICATION Use only unleaded or low-lead type gasoline of at Fuel type R + M method) or least 85 - 95 pump octane ( 89 octane or higher rated by the R esearch method.
  • Page 73 SER l 'IC!NC INJ:-'OR.MA TION 4- 1 9 WATTAGE SPEC I F ICATION ITEM Headlight Tail/Brake l ight 5 . 3/ 1 7 Turn signal l ight Tachometer light - - -- Speedometer light 1 . 5 Turn signal indicator light - --- - High beam ind icator light 1 .7...

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