Suzuki FZ50 1979 Service Manual
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Suzuki FZ50 1979 Service Manual

Suzuki FZ50 1979 Service Manual

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Summary of Contents for Suzuki FZ50 1979

  • Page 2 Suzuki Motor Co. 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: General Information

    GROUP INDEX GENERAL INFORMATION INSPECTION AND ADJUSTMENT SERVICING PROCEDURE SERVICING INFORMATION...

  • Page 4: Table Of Contents

    CE ERJIL INFORMATIO r GENERAL INFORMATION MODEL IDE N TI FICATION ..............SPECIFICATIONS ..................FUEL AND OIL RECOMMEN DATIO N ..........1- 6 GENERAL NOTES A N D PRECAUTIONS ........... TECHNICA L FEATURES ................

  • Page 5: Model Ide N Ti Fication

    GE JERAL JNFORM1l'J10 MO D E L I D E N TIF ICAT I O N RIGHT SIDE VIEW FRAME NUMBER The frame serial n u mber i s stamped o n the right side of the steeri ng head p ipe. LEFT SIDE VIEW ENGINE NUMBER The eng i ne seri al number is l ocated o n the left...

  • Page 6: Specifications

    GENERAL I FORNU11'1 0 SPEC I F I C AT I O N S DIMENSIONS A N D WEIGHT Overal I l ength 1 650 mm ( 65.0 in) Overall width 665 mm ( 26.2 i n) Overall h eight 990 mm ( 39.0 in) Wheelbase 1 120 mm (44.
  • Page 7 150 kPa ( 1.50 kg/cm2, 21 psi) ( N o rmal solo riding) R ear tire pre.ssure ELECTRICAL I g n ition type SUZUKI "P E I " I g nition t i m i ng 20° B.T . D .C. at 4 000 r/m i n Spark plug...

  • Page 8: Fuel And Oil Recommen Datio N

    GENERAL I FORMATIO F U EL A N D O I L R ECO MME N DATI O N Be su re t o use t h e specified fuel a n d o i l s. The fo l l owi ng are t h e spec ificat ions: FUEL Gaso l ine used shou l d be unleaded o r l ow·...
  • Page 9 GE ERAL I "FORi\lll l T IO G E N E RAL NOT ES A N D PR ECAUTIONS O bserve the fol l owing items without fa i l when d isassemb l i ng a nd reassem b l i ng motorcycl es. Be su re to rep lace packi ngs, gaskets, 0 rings, circl ips and cotter p i n s wi th new ones.

  • Page 10: Technica L Features

    GENERAL I TECHNICAL FEAT U RES DESCRIPTION The FZ50 has a 49 cm3 (49 cc), 2-cycle engine with a reed valve. The simple constructi on and rati ona l design of the engine has mini mized the number of inspection i tems, thus allowing easy i n spection and a l most mai ntenance-free operation.

  • Page 11: Reed Valve

    REED VALVE A reed valve is used i n the i nta ke syste m . The reed valve has thin, flexible steel pieces and a re As the piston moves up and d own, the pressure i n the fi tted i nto the top of the cra n kcase.
  • Page 12 Cli1 ERAL INPORMATIO PISTON AND PISTON RIN G Both 1st a n d 2nd piston rings are of keystone type, a nd an e x pander ri ng is with the 2nd ri ng. The keystone ri n g is less sticking and has excellent du ra b i l i ty . The expander ring absorbs the noise generated by the piston sl idi n g against the cylinder wa ll by means of its spring tensi on, thus reduci n g overall n oise.
  • Page 14 CF. ERAL INFORMATION 1-11 The FZ50 i s equ ipped with a ful ly automatic, 2-speed, transm1ss1on . Two, separate, centrifugal clutches a re used to select 1 st and then 2nd gear. At l ower eng ine R PM 's, the low speed clutch (Clutch N o.

  • Page 15: Drive Chain

    1- 12 GENERAL J FORJdATJO DRIVE CHAIN Power is t ra ns mitted from the cou nter shaft to the final· d rive shaft t h rough a d rive cha in. The d rive chai n is mainta ined at t he proper tension by the chain tensioners provided for the upper and lowe r pa rts of the cha i n and is i m m ersed in transmiss i on oil - oi l bath type - ensuring excel lent d u rabi lity.

  • Page 16: Kick Starter

    CE ERAL INFORMA'l10N /./J KICK STARTER When the b ra ke lever is squeezed, the kick starter lifter l ever is actuated, the k i c k starter l i fter shaft rotates and the kick sta rter l i fter moves d ownwa rd . By the movement of the kick starter lifter, the kick sta rter guide is push ed and the guide end is raised .
  • Page 17 1-14 GENERAL Ii FORMATION "PEI" SYSTEM I n the FZSO ign ition system, the P E I system is used. The PE I syste m uses a magneto as the power sou rce, and the capaci tor ( condenser) momenta ri ly stores a cha rge up to hu nd reds of volts.

  • Page 18: Front Fork

    1-16 GENERAL JNFORMATIO STEERING T o ma ke mai ntenance work more efficient steering is now i nsta l led with a s i ngle b ol t. As the bolt is tightened, V shape of the end piece expands ti ll i t contacts the i nside of the head pipe and is fixed there.

  • Page 19: Inspection And Adjustment

    AND ADJUSTME INSPECTION AND ADJUSTMENT PERIO DIC MAINTENANCE SCHEDULE 2 - 2 ....•......2- 3 MAINTENANCE PROCEDURE ............
  • Page 20 JNSPECTIO A D ADJUSTMENT PERI O DIC MA I N TEN AN CE SCHED U LE Veh icles should be i nspected after a certain period of runn ing for wear of parts, ca rbon deposits, e l ongated ca bles, etc. I nspections should be m ade peri odica l l y and defects should be repaired or adjusted beforehand to p revent trouble a n d p ro long the motor c ycle's service l i fe.

  • Page 21: Lubrication Chart

    ADJUSTMENT J 1SJ>EC110J LUBRICATION CHART Rotating and rubbing parts must be l u bricated periodical ly. I nsuffi cient l ubrication wil l cause rapid wear and severe damage may result. Lubricate the fo l l owing parts periodi cal ly. I nterval Every Every...

  • Page 23: Brake Shoe Wear

    I rsJ>ECnON AND tlD} · s rMENT BRAKES BRAKE SHOE WEAR Adjust at in itial C heck every 3 000 k m 000 km and every 3 000 km • When applying the front b rake, i f the ex­ •...
  • Page 24 D AD]US1'ME1 SPECTJO"I A • Finally adjust t h e throttle cable p l ay. ENGINE IDLE R/MIN ( Refer to page 2-1 2.) Adjust at i n i ti a l 1 000 k m 0.5 - 1.0 mm a n d every 3 000 k m Throttle cab le p lay (0.02 - 0.04 i n )

  • Page 25: Cylinder Head And Cylinder

    I 1SPECTIO N AND /lD}USTM ENT FU EL STRAIN ER k g · head nut 0.8 - 8.5 lb-ft tightening torque (6.0 - 000 km Clean at initial 1 000 km nd every CYLINDER HEAD AND CYLINDER If the fuel straine r cup is dirty with sed iment or water, gasoline wil l not f l ow smoothly 6 000 km Remove carbon...
  • Page 26 /lD]UST I SPECTJON tr: 11' • Check whether the mark on the o i l p u m p Checking oil pump capacity control lever i s a l igned with the i ndex Use the special tool, check the pump for capacity by measuring the amount of o i l the mark when t h e th rottle valve is positioned as abo...
  • Page 29 Ai D /lDJUSl'MEN'J" JNSPEC-1101. 2-10 � THROTTLE CABLE Locknut • Loosen the lock nut and adjust the cab le S pacer slack by t u rning adjuster in o r out to ob­ tain the fol lowing slack. Steering stem nut After adju sting slack, tighten the lock nut.

  • Page 30: Transmission Oil

    Ji SPiiCTJO D ADJ 2-11 TIRE TRANSMISSION OIL Change at i n i t i a l 1 000 km and every 3 000 km Tire pressure I f the tire p ressure is too high, the motor­ After a long period of use, the transm ission cycle will tend to ride stiffl y, have poor oi l qualities wi l l deteriorate and qu icken the traction.

  • Page 31: Chassis Bolts And Nuts

    D ADJ 2-12 SPEGT!ON 111 STMENT CHASSIS BOLTS AND NUTS Retighten at in itia l 1 000 km and e 6 000 km These bolts and nuts l isted be l ow are important safety parts. They must be retightened, as n eces­ sary, to the specified torque with a torq ue wrench.

  • Page 32: Flywheel Magneto

    SER VICI re PROCED SERVICING PROCEDURE 3 - 2 ENGINE REMOVAL/INSTALLATION ..•.•.•.•.••..•......•. 3- 3 CYLINDER HEAD, CYLINDER, PISTON ........... KICK STARTER, LEFT COVER ............3- 5 3- 6 POWER TRANSMISSION 3- 1 0 LEFT CRANKCASE ................. 3- 1 1 CRANKSHAFT •........•..•..•........

  • Page 34: Cylinder Head, Cylinder, Piston

    C J>R.OCED RE CYL I N DER HEAD, CYLI N DER, PISTO N , PISTO N R I NG ® Remove carbon Replace gasket kg-m ( 14.0 lb-ft) © R emove carbon of the exh aust p ort and apply oil on the cy l i nder wal l . A rrow mark on the piston crown faces e xhaust side.
  • Page 35 SER VICI 'C PROCEDURE CYLINDER BORE Cylinder gauge 09900-20508 41.060 mm Service Limit (1.6165 in) PISTON DIAMETER Microm eter 09900-20202 40.880 mm Service Limit (1.6094 in) RING END GAP Thickness gauge 09900-20804 0.75 mm Service Limit (0.030 in) RING FREE END GAP 09900-20101 Vernier ca l iper marked...

  • Page 36: Kick Starter, Left Cover

    SfiR VICING PROCED RE K I C K START E R, LEFT COV E R Bearing remover 09921-20210 S l id i ng shaft 09930-30102 shaft Sliding Remover kg·m 0.5 -0.8 (4.0 - 5.5 l b-ft) • When insta l l i ng the kick starter return spring, i nsta l l ®...

  • Page 37: Power Transmission

    SERVICING PROCED POWER T RANS MI S S I ON Clutch holder 09920-30220 • Appl y thread lock cement. 2.0 - 3.0 kg-m (14.5 - 21.5 lb-ft) Wave Rubber Rubber Plastic ring To prevent chain noise To wheel Adjust so that there is no l utch thrust play.
  • Page 38 SER VICING PROCEDURE AUTO M AT I C C L U TCH 2. C LUTC H " LO C K- U P" I NSPECT I ON I NSPECT I O N (C LUTC H NO. 1) Perform this inspection to determine i f the The F Z50 i s equ ipped with a n automatic clutch is e ngaging fu l l y and not slipping clutch and automatic 2 speed transm ission .
  • Page 39 SER VICING l'ROCED R E If the engine r/m in does n ot coi nside with the specified r/m in range then d isassemble the clutch. • Cl utch shoe - inspect the shoes visu a l l y for ch ips, cracki ng, uneven wear, burn ing and check the depth of the grooves on the shoes.
  • Page 40 'R E Sci� VICI G PROCl;D CHAIN 20 P I TC H LEN G TH 3. SECON D G EAR SH I FT PO I NT (C LUTCH NO. 2 ) Service I im 1 73.0 mm (6.83 in) R ide t h e m otor cycle i n a n ormal manner a nd n ote at what road speed the trans·...

  • Page 42: Crankshaft

    3- 1 1 C RA N KSHAFT • I nstall the engi ne ground wire. • C heck for damage and bent reeds. careful not to bend the reed valve stopper. � Grou nd wire Oil pump control cable guide Oil pump •...

  • Page 44: Carburetor

    3 - 1 3 SER VICI C l'ROCED RE C A R B U R ETO R Clean each passage of air and fue l with an a i r gu n. Idl e R icher 301 3-3 Check for damage and rep lace if any. sure to when clean...

  • Page 45: Flywheel Magneto 3 - 1

    C PROCED 3- 1 4 SER JIJ'Cl FLYW H EEL MAG N ETO F lywheel ho lder 09930-401 1 3 Apply thread lock cement Sliding sh a ft 09930-30 1 02 F ix the stator to a l ign the scribed l i ne with Attachment C 09930-301 6 1 the center of the screw hole so that correct...

  • Page 47: Chassis Electrical

    3- 1 6 SER VICING PR OCED STATOR Pocket tester 09900-25002 • Se lect the knob to RX "x 1 " . • Make a fo l lowi ng con t i n u ity test. Unit : lnl 1 80 - O F F O F F C H ASSIS ELECTR I CAL...
  • Page 48 3-1 7 SER VICING PROCED URE E lectro-tester 09900-28 1 06 Main switch • W i re as shown in the figure and turn the m a i n switch to ON. • If a blu ish white spa r k occurs continuous­ ly for about ten m i n utes;...
  • Page 49 SER VICI. re PROCED "RE 3-1 8 P E I I n spection by Pocket Tester Positive pointer to touch : B lack/ Red Red/Black Black/White Black/Yellow B lack/Red O F F O F F O F F I :s 7 k.Q Red/Black 0 - 20 k.Q...
  • Page 50 SER VJCI G l>R OCEDURE 3-1 9 RECTI FIER I f con t i n uity i s fou nd i n n range when • connecti ng as shown in the figure and not found when probes a re reversed, it is in good conditio n .

  • Page 51: Switches

    3-20 SER VICI PR OCED URE SWITCHES IGNITION SWITCH Pocket tester 09900-25002 Turn the ign ition switch to O N and O F F • as shown i n the chart be low. I f conti n u i­ ty is fou nd, it is i n good cond ition. not, rep lace it.
  • Page 52 SER VICI1 C PROCEDURE 3-2 1 FRONT AND REAR BRAKE SWITCH • Place the pocket tester between orange lead wire and white lead wire with the red Fron t Brake Rear Brake tube and squeeze the b rake lever. If con­ tinuity i s found, it is i n good condition.

  • Page 53: Steering

    SER VICI re PR OCF!D RF. 3-22 STEERI NG � • Check i nner or outer races for wea r. '" '°' we" " .© I • N u m ber of steel bal ls · 22 pcs ... . . Upper .

  • Page 54: Front Suspension

    3.23 SER VICI G PROCEDURE FRONT S U S PEN S I O N 1 . 5 - 2.0 kg·m ( 1 1 .0 - 1 4 .0 lb·ft ?';:::� � Check the shock absorber for oil leakage 1 .0 - 1 .5 kg·m ( 7 .

  • Page 55: Wheels And Brakes

    3-24 SER VICI 1G PROCEDURH WHE ELS A N D BRAKES WHEELS F RONT 1 . 5 - k g -m ( 1 1 .0 - 14. 5 1b-f t) CAUTI O N : When applying grease, be sure to apply it th in to avoid damaging the brake shoe and b raking effeciency .
  • Page 57 3-26 SER VICING PROCEDURE WHEE L RUNOUT axial a n d rad ial wheel rim runout of Measure front a n d rear wheels. Servi li mit 2.0 mm (0.08 i n ) I and Radia l ) (Axia Radiai TIRE Measure both f ront and rear tire tread depth .

  • Page 59: Electrical Circuit

    SER .VICI TRO U BLES HOOTI NG HARD ENGINE STARTING OR NO ENG I NE STARTING ENGINE Compression leakage fro m c ra n k chamber • Lea kage from cran kcase mating su rface • Leakage due to defective crankshaft oi I seal •...
  • Page 60 SER II/Cl C I FORMA'J'I01 ENGINE STALLING I mproper i d l i n g r/m i n . 2. Compression l eakage from cran kcase ( o i l seal , mating surface) F o u led o r worn spa r k plug Lean fuel/a i r m ixtu re •...
  • Page 61 SER VICING I FORMA TION ENGINE OVERHEAT Carbon deposit • Cyl i nder head, piston crown, exhaust port, spark p l ug I gnition ti m i ng too advance O i l pump adjustment, defective o i l pump Lean fuel/a i r mixture •...
  • Page 63 SER VJCJNG I FORMA TION S PEC I A L TOO LS P E I Test lead Clutch holder Bearing remover ( I D 1 2mm) 0992 1 -202 1 0 09900·28605 09920·30220 gauge Shock d river set Thickness Snap ring pliers 09900·09002 09900·20804 09900·06 1 07...
  • Page 64 SHR VJCJ C I FORMA TIO Piston pin puller Bearing i nstaller Cra nkshaft remover 0991 3· 75820 099 1 0-3451 0 09920- 1 31 1 1 Spar k plug wrench Rotor remover (shaft) Attachment C (Screw 27m m ) 09930·...
  • Page 66 > Speedometer cable Choke cable Front brake cable Rear brake cable Front brake cable c.,, � :-:: � Horn clamp � Speedometer cable ;:::. . � ...; :;:: """ '°...
  • Page 68 SEJ� VICI C INFORMA TION 4- 1 1 T I G HT E N I N G TORQ U E kg-m I T E M l b-ft Q'TY ENGINE Cylinder head nut 0.8 - 1 . 2 6.0 - 8.5 Exhaust pipe bolt 1 .
  • Page 69 C I f'ORM1I TIO 4- 1 2 SER VICI SERV I C E DATA PISTON + RING + CYLINDER U nit : m m ( in) I TE M STAN DAR D L I M I T Piston - Cyl inder clearance 0.070 - 0.080 (0.0028 - 0.003 1 ) 0.
  • Page 70 VICING I 'FORM/ITIO 4- t 3 CLUTCH Unit (in) I T E M STAN DAR D L I M I T 87.00 - 87. 1 5 87.40 (3.44 1 ) (3.425 - 3.43 1 ) Clu tch wheel l . D . 1 05.00 - 1 05.
  • Page 71 4- 1 4 SER VICING l FORMA TION CAR B U R ETOR U n it : mm (in) ITEM SPEC I F I CAT I ON Idle r/m i n 1 500 ± 1 50 r/m in Carburetor type M I KU N I V M 1 4SH 1 .
  • Page 72 SER VICING JNFORMA TIO 4- 15 BRAKE + WHEEL U nit : mm (in) I T E M STA N D AR D L I M I T & Axle runout ( F ront Rear) 0.25 (0.0 1 0 ) Brake drum l .
  • Page 73 Prepared by SUZUKI MO TOR CO., LTD. Service Depa r t me n t OverSeas Opera t ions Division April, 1 9 79 SR-0560 Printed i n J a pan...

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