Suzuki FZ50 T 1980 Supplementary Service Manual
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Suzuki FZ50 T 1980 Supplementary Service Manual

Suzuki FZ50 T 1980 Supplementary Service Manual

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  • Page 2 SUZUKI MOTOR CO., LTD. Service Department Overseas Operations Division Quoting, copying or otherwise using any put or lhis manual without explicit authorization from Suzuki Motor Co., Ltd. as all permitted rights to the publication are re.served under copyright law.

  • Page 3: Table Of Contents

    CONTENTS VIEW OF SUZUKI FZSO"T" ..............2 SPECIFICATIONS ..................3 TRANSMISSION OIL ................5 "PEI'' SYSTEM ..................FLYWHEEL MAGNETO ................ 7 CHASSIS ELECTRICAL ........SPECIAL MATERIALS ................11 SPECIAL TOOLS ................... 12 WIRE AND CABLE ROUTING ..............

  • Page 5: Specifications

    SPECIFICATIONS DIMENSIONS AND WEIGHT Overall length 1 650 mm (65. 0 in ) Overall width 665 mm (26. 2 in ) Overal I height 990 mm (39.0 in) Wheelbase 1 120 mm (44.1 in) Ground clearance 120 mm ( 4.7 in) Dry mass ( weight ) 59 kg ( 130 lbs )
  • Page 6 CHASSIS Front suspension Bottom link oil dampened Rear suspension Swinging arm Steering angle 45° (right left ) & 63°00" Caster Trail 81 mm (3.19 in) 1. 7 m (5. 6 Turning radius brake Internal expanding Front Rear brake Internal expanding Front tire size 3.

  • Page 7: Transmission Oil

    TRANSMISSION OIL Use a good quality 20 W/4 0 multi-grade m otor oil.

  • Page 8: "Pei" System

    "PEI" SYSTEM In the F250 ignition system, the PEI system is used. The PEI system uses a magneto as the power source, and the capacitor (condenser ) momentarily stores a charge up to hundreds of volts. The charge is instantly discharged, at the specified ignition timing, to the ignition coil primary winding, thus inducing a high surge of voltage in the secondary winding .

  • Page 9: Flywheel Magneto

    FLYWHEEL MAGNETO SPECIFICATIONS Ignition method: sparks per crank shaft rotation Light capacity: 5.5 V or more at 500 r/min 8.5 V or less at 8 000 r/min Charging capacity: 0 . 7 A or more at 000 r/min Secondary voltage: 3.0 A or less at 8 000 r/min Ignition coil resistance: kV or more at 500 - 8 000 r/min...

  • Page 10: Chassis Electrical

    Pocket tester 09900-2 5 002 Select the knob to RX "x 1" . • Make a following continuity test. • Approx. t f!J Unit COLOR CODE APPROX. (fl) B/W-Y B/W-WIA 0.75 BIA - CHASSIS ELECTRICAL IGNITION COIL Using the pocket tester check the ignition •...
  • Page 12 PEI Inspection by Pocket Tester Positive pointer to touch: Black/White Black/Yell ow Black/Red Red/Black 5-7n 4-Sn Black/White I .. Black/Yellow �o > � 4-Sn Black/Red . ., $ �-= 15 - 17 n Red/Black Test conditions The pocket tester's selector knob should be set at k!l"...

  • Page 13: Special Materials

    99000-32040 oQil seals Cable (speedometer! Brake cam shaft Speedometer gears Front shock absorber arm and arm shaft Suzuki super grease "A" 99000·25010 Crankcase mating surface Suzuki bond 1215 99104·31110 Muffler fitting bolt Suzuki lock super " 13 6 3C "...

  • Page 14: Special Tools

    SPECIAL TOOLS Snap ring pliers (opening type) 09900·06107 Micrometer Dial gauge 09900-20201 (O - 25 mm} Cylinder gauge set 09900-20606 10 - 10 mm. 09900-20508 09900·20202 (25 - 50 mm) Torque wrench 09009-21102 to- 120 kg·cm) Thickness gauge 09900·21103 (100-900 kg·cm) 09900·...
  • Page 15 Spark plug wrench Bearing remover Rotor remover slide shaft 09921-20210 09930-10111 09930·30102 Attachment C (27 Steering stem nut wrench screw) Rotor holder 09940-10122 09930-30161 09930·401 13 Steering race and swing arm baring installer Spoke nipple wrench Steering race installer 09941 ·34511 09940-53111 09940·60113 Tire pressure gauge...

  • Page 16: Wire And Cable Routing

    Turn signal relay )> )> :::f...
  • Page 17 (") )> :x:J Front brake cable Rear brake cable " Front fork Rear brake cable pivot Cable guide plate Rear brake cable...

  • Page 18: Wiring Diagram

    :::0 � :;, � T � i::, � � � UNIT MAGNETO crnL WIRE COLOR � GNITION )> •.•....Green REAR BRAKE LIGHT " "' Gr ..... Grev '< o: m '< >- :::0 O ....... Orange �:6� � >- R ..
  • Page 20 Unit· mm (in) CONROD+ CRANKSHAFT ITEM STANDARD LIMIT 16. 003 - 16. 0 1 1 16 . 04 0 Conrod small end l.D. 0. 6300 - 0.6304 ( 0.6315 ) Conrod deflection 0 . 12 4 0. 0 0. 1 Crank web to web width ±...
  • Page 21 Unit: mm lin) TRANSMISSION LIMIT ITEM STANDARD 1.000 Primary reduction ratio Final reduction ratio 8. 696 (31 / 1 3 62 / 17) Gear ratios 2.137 62 / 29 1.421 54 / 38 0.15 0 . 0 5 - 0.10 Shift fork thickness ( 0.006 ) 0.002 - 0.004...
  • Page 22 Unit: mm ( in} ELECTRICAL SPECIFICATION NOTE ITEM Ignition timing ° 4000 r/min. 2· B.T. D.C. at ± Spark plug NGK BP4 HA or NIPPON Type DENSO W14FP-UL 0.6-0.8 0 . 0 24 -0 . 0 31 8/Y - Ground Ignition coil resistance Primary Approx.
  • Page 23 Unit: mm lin) BRAKE+ WHEEL ITE M LIMIT STANDARD 20 - 30 Front brake lever distance 0.8 - 1.2 20 - 30 Rear brake lever distance 0.8 - 1.2 100.7 Brak e drum l.D. Front 3.96 100.7 Rear 3.96 Brake lining thickness 0.06 Wheel rim runout...
  • Page 24 1 . 2 I 1 . 0 US/Imp gal ) reser v e 0.21 I 0. 1 8 US/Imp qt) Engine oil type 2·CYCLE MOTOR SUZUKI SUPER quality LUBRICANT equivalent good synthetic based 2-cycle oil. Engine oil tank capacity 1. 3 I 1.1...

  • Page 25: View Of Suzuki Fzso"X

    VIEW OF SUZUKI FZSO"X" RIGHT SIDE VIEW LEFT SIDE VIEW...

  • Page 26: Ignition Coil

    IGNITION COIL Using the pocket tester check the ignition • coil. Knob Resistance position 0 - i n - B/Y Core xk!1 Core - High tension Approx. 4-6k!1 B/Y - High tension Approx. ·6kD xk!1 TURN SIGNAL LIGHT SWITCH Check the conductivity between the lead terminals on the left handle switch box when the turn signal indicator knob is operated.

  • Page 27: Wiring Diagram

    "' RIGHT HAtmLUAR SWITCH WIRE COLOR RA KE LIG HT ��. �� �& " ICilllTIONCOIL EN GIN E KIL L #i1AGtlE TO COi UNIT ..,, ..BhKk S'IV ITCH TURN SIGNAL RELA V Green ....� rni1 Gray ..

  • Page 28: Service Data

    Unit: mm (in) CYLINDER+ PISTON+ PISTON RING LIMIT ITEM STANDARD 0.120 0 .070 -0 .0 80 Piston to cylinder clearance ( 0 . 0 0 47 ) 0.0028 - 0 .0 0 31 Cylinder bore 41.000 - 41.015 41.060 ( 1.6142 - 1.6148 ) ( 1.
  • Page 29 OIL PUMP SPECIFICATION ITEM 7.000 14 / 2 Oil pump reduction ratio CCI pump discharge rate 1.02 - 1.26 (Full open) ( 0.034 /0.036- 0.043/0.044 US/lmp oz) for 6 minutes at 2000 r/min. Unit: mm (in) CLUTCH ITEM STANDARD LIMIT 87.00 - 87.15 87.40 Clutch wheel l.D.
  • Page 30 Unit: mm (in) CARBURETOR SPECIFICATION ITEM Carburetor type MIKUNI V M 14SH Bore size 14 ( 0 .6) 0 2 421 1.0. r/min. Idle r/min. 1500 ± 22.4 Float height ± 0.0 4 0.88 ± Main jet (M. J.) 57.5 Air jet (A .
  • Page 31 Unit· mm (in} ELECTRICAL NOTE SPECIFICATION ITEM Ignition timing 25 ° B.T.D.C. at 4000 r/min. 2• ± Spark plug NGK BP4HA or NIPPO N Type DE NSO W1 4FP-UL 0.6 - 0 . 8 0 . 0 24 - 0 .031 B/Y - Ground.
  • Page 32 Unit: mm (in) BRAKE+ WHEEL LIMIT ITEM STANDARD 20 - 30 Front brake lever distance 0 . 8 - 1. 2 20 - 30 Rear brake lever distance 0 . 8 - 1. 2 100 . 7 Brake drum l.D. Front 3.96 100.7...
  • Page 33 89 octane or higher rated by the Research method. 4 . 5 Fuel tank including reserve 1.2 / 1.0 US/Imp gal) reserve US/Imp qt) 0 .21 / 0 .18 Engine oil type SUZUKI SUPER 2·CYCLE MOTOR good qualitV LUBRICANT equivalent synthetic based 2-cycle oil.
  • Page 34 Prepared by SUZUKI MOTOR CO.,LTD. Service Department Overseas Oper:ilions Division December, 1980 Manual No. 99000 - 85057-0E3(;ri)SUPPL. Printed in Japan...
  • Page 35 SUZUKI MOTOR CO., LTD.

This manual is also suitable for:

Fz50 x 1981Fz50 n 1979

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