Page 1 S U Z U K I LT-A500F SERVICE MANUAL...
Page 2 CHASSIS actual vehicle exactly in detail. * This manual is written for persons who have enough knowledge, skills and tools, includ- ELECTRICAL SYSTEM ing special tools, for servicing SUZUKI vehi- cles. If you have proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you.
Page 3 HOW TO U S E THIS MANUAL T O L O C A T E W H A T Y O U A R E L O O K I N G F O R : 1. The text of this manual is divided into sections. 2.
Page 4 Apply THREAD LOCK "1342". otherwise specified. 99000-32050 Apply molybdenum oil solution, Apply or use brake fluid. (mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1 : 1) Apply SUZUKI SUPER GREASE "A". Measure in voltage range. 99000-25030 (For USA) 99000-25010 (For the other countries) Apply SUZUKI SILICONE GREASE.
Page 5: Table Of Contents
GENERAL INFORMATION GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE 1- 2 GENERAL PRECAUTIONS 7- 2 SUZUKI LT-A500FY (2000-MODEL) 1- 4 SERIAL NUMBER LOCATION 1- 4 FUEL, OIL, AND ENGINE COOLANT RECOMMENDATIONS 1- 4 FUEL 1- 4 ENGINE OIL 1- 5 DIFFERENTIAL GEAR AND FINAL BEVEL GEAR OIL...
Page 6 1-2 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. A WARNING Indicates a potential hazard that could result in death or injury.
Page 7 GENERAL INFORMATION 1-3 A CAUTION * If parts replacement is necessary, replace the parts with SUZUKI Genuine Parts or their equivalent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order.
Page 8: Suzuki Lt-A500Fy (2000-Model)
) 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. • Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10% eth- anol.
Page 9: Engine Coolant
Use an antifreeze designed for aluminum radiators. SUZUKI recommends the use of SUZUKI COOLANT antifreeze. If this is not available, use an equivalent antifreeze for aluminum radiators.
Page 10 1-6 GENERAL INFORMATION A CAUTION The percentage of antifreeze in the coolant should be between 50 to 60%. If the percentage of antifreeze is above or below this range the coolant's frost protection and rust-inhibiting capa- bilities will be reduced. Always keep the antifreeze content above 50% even if the atmospheric temperature does not go below the freezing point.
Page 11 GENERAL INFORMATION 1-7 INFORMATION L A B E L S APPLIED SPECIFICATION LABEL or PLATE NAME LABEL or PLATE NAME E-03 E-24 E-28 E-33 Certification plate — © Compliance label — © — Information label © — — — Tire air pressure label © ©...
Page 12 1-8 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length 2 005 mm (79.0 in) 2 050 mm (80.7 in) E-17 Overall width 1 170 mm (46.1 in) Overall height 1 185 mm (46.7 in) Wheelbase 1 230 mm (48.4 in) Front track 880 mm (34.6 in) 885 mm (34.8 in)
Page 13 GENERAL INFORMATION 1-9 CHASSIS Independent, double wishbone, coil spring, oil Front suspension damped, spring preload 5-way adjustable 4-link rigid axle, coil spring, oil damped, spring Rear suspension preload 5-way adjustable Inside 38° Steering angle Outside 26° 17 mm (0.67 in) Trail 3.0 m (9.8 ft) Turning radius...
Page 14 1-10 GENERAL INFORMATION COUNTRY AND A R E A C O D E S The following codes stand for the applicable countries and areas. C O D E C O U N T R Y O R A R E A E-03 E-17 Sweden...
Page 15: Table Of Contents
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- 4 VALVE CLEARANCE 2- 5 SPARKPLUG 2- 6 FUEL HOSE THROTTLE CABLE PLAY 2- 7...
Page 16: Engine Oil
PERIODIC MAINTENANCE PERIODIC MAINTENANCE S C H E D U L E 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. Maintenance intervals are expressed in terms of kilometers, miles and months, and are dependent on whichever comes first.
Page 17: Maintenance And Tune-Up Procedures
MAINTENANCE AND TUNE-UP P R O C E D U R E S This section describes the servicing procedures for each item mentioned in the Periodic Maintenance chart. AIR C L E A N E R Clean every 1 000 km (600 miles, 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 18: Exhaust Pipe Nuts And Muffler Bolts
2-4 PERIODIC MAINTENANCE EXHAUST PIPE NUTS AND MUFFLER B O L T S Tighten initially at 200 km (100 miles, 1 month) and every 1 000 km (600 miles, 3 months) thereafter. • Remove the rear fender. (CU 7-7) • Tighten the exhaust pipe nuts © , muffler connection bolt (2), and muffler mounting bolts ®...
Page 19: Specifications
VALVE C L E A R A N C E Inspect initially at 200 km (100 miles, 1 month) and every 2 000 km (1 200 miles, 6 months) thereafter. Excessive valve clearance results in valve noise and insuffi- cient valve clearance results in valve damage and reduced power.
Page 20: Sparkplug
PERIODIC MAINTENANCE S P A R K PLUG Inspect every 2 000 km (1 200 miles, 6 months). Replace every 6 000 km (4 000 miles). • Remove the left front fender side cover. ( C U 7-5) • Disconnect the spark plug cap and remove the spark plug ©...
Page 21: Fuel Hose
PERIODIC MAINTENANCE SPARK PLUG INSTALLATION A C A U T I O N To avoid damaging the cylinder head threads; first, finger tighten the spark plug, and then tighten it to the specified torque using the spark plug wrench. • Insert the spark plug and finger tighten it to the cylinder head and then tighten it to the specified torque.
Page 22: Engine Idle Speed
PERIODIC MAINTENANCE ENGINE IDLE S P E E D Inspect initially at 200 km (100 miles, 1 month) and every 1 000 km (600 miles, 3 months) thereafter. NOTE: Make this adjustment when the engine is hot. • Remove the left front fender side cover. ( C ^ 7-5) •...
Page 23 2.5 L (2.6 US qt, 2.2 Imp qt) Engine overhaul: 3.0 L (3.2 US qt, 2.6 Imp qt) A CAUTION ONLY USE A GENUINE SUZUKI MOTORCYCLE OIL FILTER. Other manufacturer's oil filters may differ in thread specifications (thread diameter and pitch), filtering performance and durability which may lead to engine damage or oil leaks.
Page 24: Differential Gear And Final Bevel Gear Oil
2-10 PERIODIC MAINTENANCE DIFFERENTIAL G E A R AND FINAL B E V E L G E A R OIL Inspect every 2 000 km (1 200 miles, 6 months). Replace every two years. To change the differential gear and final bevel gear oil, locate the vehicle on a level position and carry out the following steps.
Page 25: Engine Coolant
PERIODIC MAINTENANCE 2-11 ENGINE COOLANT Replace the engine coolant every two years. ENGINE COOLANT L E V E L CHECK • Check the engine coolant level by observing the upper © and lower © lines on the engine coolant reservoir. •...
Page 26: Radiator Hoses
2-12 PERIODIC MAINTENANCE RADIATOR H O S E S Inspect every 2 000 km (1 200 miles, 6 months). Inspect the radiator hoses for damage and engine coolant leak- age. If any damages are found, replace the radiator hoses with new ones.
Page 27 PERIODIC MAINTENANCE 2-13 Remove the movable drive face © , movable driven face and drive belt ® . INSPECTION • Inspect the drive belt for wear or damage. If any damages are found, replace the drive belt with a new one. REMOUNTING Remount the drive belt reverse older of removal.
Page 28 2-14 PERIODIC MAINTENANCE • Hold the movable drive face and movable driven face using the special tool and tighten them to the specified torque. IT55L1 09930-40113: Rotor holder H Movable drive face nut: 115 N-m (11.5 kgf-m, 83.0 Ib-ft) Movable driven face nut: 115 N-m (11.5 kgf-m, 83.0 Ib-ft) •...
Page 29 B R A K E S Inspect initially at 200 km (100 miles, 1 month) and every 1 000 km (600 miles, 3 months) thereafter. BRAKE PADS • Remove the front wheels. (CC7 7-9) The extent of brake pad wear can be checked by observing the limit line ©...
Page 30: Brake Fluid
2-16 PERIODIC MAINTENANCE BRAKE SHOES This vehicle is equipped with a brake lining wear limit indicator on the brake panel. At the condition of normal lining wear, an extended line from the index mark on the brake camshaft should be within the range embossed on the brake panel with the brake on.
Page 31: Brake Hoses
PERIODIC MAINTENANCE 2-17 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 cylinder and thus interferes with the full braking perfor- mance of the brake caliper.
Page 32: Tires
2-18 PERIODIC MAINTENANCE T I R E S Inspect every 2 000 km (1 200 miles, 6 months). TIRE TREAD CONDITION Operating the vehicle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of the tire tread reaches the following specification.
Page 33: Suspensions
PERIODIC MAINTENANCE 2-19 STEERING Inspect initially at 200 km (100 miles, 1 month) and every 1 000 km (600 miles, 3 months) thereafter. Steering system should be adjusted properly for smooth manip- ulation of the handlebars and safe running. TOE-IN •...
Page 34: Chassis Nuts And Bolts
2-20 PERIODIC MAINTENANCE CHASSIS NUTS AND B O L T S Tighten initially at 200 km (100 miles, 1 month) and every 1 000 km (600 miles, 3 months) thereafter. Check that all chassis nuts and bolts are tightened to their specified torque. (Refer to page 2-21 for the locations of the following nuts and bolts.) kgf-m Ib-ft...
Page 35 PERIODIC MAINTENANCE 2-21...
Page 36: General Lubrication
2-22 PERIODIC MAINTENANCE G E N E R A L LUBRICATION Lubricate every 1 000 km (600 miles, 3 months). Proper lubrication is important for smooth operation and long life of each working part of the vehicle. Major lubrication points are indicated below. A WARNING Be careful not to apply too much grease to the brake camshaft.
Page 37: Compression Pressure Check
PERIODIC MAINTENANCE 2-23 COMPRESSION P R E S S U R E C H E C K 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 should include compression readings for each maintenance service.
Page 38: Oil Pressure Check
2-24 PERIODIC MAINTENANCE OIL P R E S S U R E C H E C K Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. EffilOil pressure: Above 190 kPa (1.9 kgf/cm , 27.0 psi) Below 250 kPa (2.5 kgf/cm , 36.0 psi)
Page 39: Initial Engagement And Clutch Lock-Up Inspection
PERIODIC MAINTENANCE 2-25 INITIAL ENGAGEMENT AND CLUTCH LOCK-UP INSPECTION The LT-A500F 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 thoroughly check the operation of the drive train.
Page 40: Clutch Lock-Up Inspection
2-26 PERIODIC MAINTENANCE CLUTCH LOCK-UP INSPECTION Perform this inspection to determine if the clutch is engaging fully and not slipping. • Connect a tachometer onto the spark plug lead. • Start the engine. • Shift the range lever to the "High" position. •...
Page 41 ENGINE ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE 3- 2 ENGINE REMOVAL AND REMOUNTING 3- 3 EMGINE REMOVAL 3- 3 ENGINE REMOUNTING 3- 8 ENGINE DISASSEMBLY 3-11 ENGINE COMPONENTS INSPECTION AND SERVICE 3-23 CYLINDER HEAD COVER 3-23 CYLINDER HEAD 3-24 CAMSHAFT/AUTOMATIC...
Page 42 ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN P L A C E 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 L E F T SIDE REMOVAL INSTALLATION...
Page 43 ENGINE ENGINE REMOVAL AND REMOUNTING 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. • Shift the range lever to the "Neutral" position. •...
Page 44 ENGINE • Disconnect the clamp, regulator/rectifier coupler ® remove the regulator/rectifier © . • Remove the carburetor intake pipe. • Disconnect the air cleaner case breather hose. • Remove the air cleaner assembly. Disconnect the starter motor read wire ® and remove the starter motor 0.
Page 45 • Remove the clip 0, gearshift arm bolt (2), and pull out the gearshift arm © . NOTE: Make sure to mark the aligning points of the gearshift arm and camshaft before removing the gearshift arm. • Disconnect the engine coolant temperature switch...
Page 46 ENGINE • Disconnect the speedometer cable. • Disconnect the clamps, neutral switch coupler © , gen- erator couplers ® . • Remove the front propeller shaft joint bolts. • Remove the rear propeller shaft joint bolts. • Disconnect the ignition coil coupler © and ignition coil lead wire @.
Page 47 ENGINE • Remove the engine under plate. • Remove the engine from the right side.
Page 48: Engine Remounting
ENGINE ENGINE REMOUNTING Remount the engine in the reverse order of engine removal. • Install the engine mounting nuts and bolts. NOTE: Temporally tighten the nuts in this stage. 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 49 • Tighten the rear propeller shaft joint bolts to the specified torque. H Rear propeller shaft joint bolt: 23 N m (2.3 kgf-m, 16.5 Ib-ft) • Apply THREAD LOCK "1342" to the front propeller shaft joint bolts, and then tighten it to the specified torque. tJ33 99000-32050: THREAD LOCK "1342"...
Page 50 3-10 ENGINE • Tighten the muffler connection bolt ® to the specified torque. H Muffler connection bolt: 23 N m (2.3 kgf-m, 16.5 Ib-ft) • Apply THREAD LOCK "1342" to the muffler mounting bolt (2) and tighten it to the specified torque. tJ33 99000-32050: THREAD LOCK "1342"...
Page 51: Engine Disassembly
ENGINE 3-11 ENGINE DISASSEMBLY • Remove the cap bolt © and cam chain tension adjuster < Remove the recoil starter. • Remove the Top-Dead-Center (TDC) plug. • Turn the generator rotor until the line (3) on the generator rotor is aligned with the mark (4) on the crankcase. NOTE: When removing the cylinder head cover, the piston must be at TDC of the compression...
Page 52 3-12 ENGINE • Remove the cylinder head cover bolts diagonally and remove the cylinder head cover. • Remove the camshaft end cap © and dowel pins (2). • Flatten the lock washer and remove the two camshaft sprocket bolts. • Remove the camshaft and sprocket. •...
Page 53 • Remove the cylinder head nuts, and then remove the cylin- der head. If the cylinder head does not come off, lightly tap it using a plastic mallet. • Remove the cylinder head gasket 0 and dowel pins (2). • Remove the radiator hose.
Page 54 3-14 ENGINE • Remove the cam chain guide © . • Remove the cylinder base nuts © , and then remove the cyl- inder. If the cylinder does not come off, lightly tap it using a plastic mallet. Remove the cylinder gasket (3) and dowel pins @. •...
Page 55 ENGINE 3-15 Remove the generator rotor cover and exhaust cover stay. Remove the starter driven gear © , starter driven gear shaft (2), starter drive gear @, and starter drive gear shaft 0. • Remove the oil filter using the special tool. IT55LI 09915-40610: Oil filter wrench Remove the drive belt cover.
Page 56 3-16 ENGINE • Hold the movable driven face using the special tool and • Remove the fixed drive face plate and spacer. • Remove the clutch housing case © and clutch housing (2). • Remove the neutral switch 0, switch contacts 0 springs.
Page 57 ENGINE 3-17 Hold the generator rotor using a 36-mm offset wrench and then remove the clutch shoe nut. A CAUTION The clutch shoe nut has left-hand threads. Remove the clutch shoe assembly © and cam chain • Hold the generator rotor using a 36-mm offset wrench and then remove the oil pump drive gear bolt.
Page 58 3-18 ENGINE • Hold the generator rotor using a 36-mm offset wrench and then remove the generator rotor nut. • Screw in the rotor remover attachment until the left surface of the crankshaft seats the attachment. IT55LI 09930-31920: Rotor remover •...
Page 59 ENGINE 3-19 Remove the gearshift cam stoppers. • Remove the left crankcase securing bolts. • Remove the right crankcase securing bolts. © • Separate the crankcase using the special tool. 09920-13120: Crankcase separating tool NOTE: Fit the crankcase separating tool to the right side, so that the tool plate is paralleled with the end face of the crankcase.
Page 60 3-20 ENGINE • Remove the gear shift fork shaft ® , gear shift forks (2), gear shift cam (3), and washers. • Remove the countershaft assembly ® and driveshaft assembly © . • Remove the secondary driven output shaft assembly. NOTE: Refer to chapter 4 when inspecting the secondary driven output shaft.
Page 61 ENGINE 3-21 Remove the balancer shaft. • Remove the circlip, water pump driven gear, pin and washer. • Remove the transmission output shaft housing. Unlock the caulking (as pointed) and remove the transmis- sion output shaft nut using the special tool. 09930-73160: Output shaft holder Remove the transmission output shaft assembly.
Page 62 3-22 ENGINE • Remove the oil sump filter cap 0 and oil sump filter (2).
Page 63 ENGINE COMPONENTS INSPECTION AND S E R V I C E C Y L I N D E R H E A D C O V E R DISASSEMBLY ACAUTIOINT Identify the position of each removed part. Organize the parts in their respective groups (i.e. intake or exhaust) so that they can be installed in their original positions.
Page 64 3-24 ENGINE ROCKER ARM I.D. Measure the rocker arm bore with a caliper gauge. If the inside diameter is not within specification, replace the rocker arm with a new one. 09900-20605: Dial calipers Rocker arm I.D. Standard: 12.000-12.018 mm (0.4724-0.4731 in) REASSEMBLY •...
Page 65 ENGINE 3-25 • Compress the valve springs and remove the valve cotters from the valve stem using the special tools. (T||] 09916-14510: Valve spring compressor 09916-14910: Attachment 09916-84511: Tweezers Remove the valve spring retainer and valve springs. Remove the valve from the other side. •...
Page 66 3-26 ENGINE VALVE HEAD RADIAL RUNOUT Support the valve using a V-block and measure the valve head radial runout using the dial gauge, as shown. If the runout exceeds the service limit, replace the valve with a new one. (TSSL) 0 9 9 0 0 - 2 0 6 0 6 : Dial gauge ( 1 / 1 0 0 mm) 0 9 9 0 0 - 2 0 7 0 1 : Magnetic stand V-block set 0 9 9 0 0 - 2 1 3 0 4 :...
Page 67 VALVE GUIDE SERVICING • Drive the valve guide out toward the camshaft side using the valve guide remover. (T||) 09916-44310: Valve guide remover/installer NOTE: * Discard the removed valve guide subassemblies. * Only oversized valve guides are available as replacement parts.
Page 68 3-28 ENGINE VALVE SEAT WIDTH • Coat the valve seat uniformly with prussian blue. Install the valve and attach a valve lapper onto it. Tap the coated seat with the valve face in a rotating manner, in order to obtain a clear impression of the seating contact.
Page 69 • When installing the solid pilot © , rotate it slightly. • Seat the pilot snugly. Install the 45° cutter (2), attachment (3), and T-handle (4). INITIAL SEAT CUT • Descale and clean up the seat using the 45° cutter. Rotate the cutter one or two turns.
Page 70 3-30 ENGINE TOP NARROWING CUT Contact area too high and • If the contact area is too high on the valve, or if it is too wide, too wide on face of valve use the 15° cutter to lower and narrow the contact area. ©...
Page 71 VALVE SEAT SEALING CONDITION INSPECTION With the valve and valve spring assembled, pour a small quan- tity of gasoline into the intake or exhaust port. Check that no gasoline leaks though the valve seat. If leakage is found, correct the sealing surface. A WARNING Gasoline is highly flammable and explosive.
Page 72 3-32 ENGINE REASSEMBLY • Install each valve spring seat. • Apply molybdenum oil solution to each oil seal and press-fit them into position. ACAUTIOIST Do not reuse the oil seals. • Apply molybdenum oil solution to the valve as shown and then insert them to the valve guides.
Page 73 U 3 Cam chain tensioner bolt: 13 N m (1.3 kgf-m, 9.5 Ib-ft) • Install the intake pipe © . • Install the thermostat and thermostat housing ® . • Apply SUZUKI BOND "1207B" to the engine coolant temper- ature switch (4) and tighten them to the specified torque. For USA HUsZi 99104-31140: SUZUKI BOND "1207B"...
Page 74 3-34 ENGINE CAM WEAR Worn-down cams are often the cause of mistimed valve opera- tion resulting in reduced power output. Measure the cam height © using the micrometer. If the cams are worn to the service limit, replace the camshaft with new a one.
Page 75 ENGINE 3-35 CAMSHAFT RUNOUT Support the valve using V-blocks and measure the camshaft runout using the dial gauge. If the runout exceeds the service limit, replace the camshaft with a new one. rroon 09900-20606: Dial gauge (1/100 mm) 09900-20701: Magnetic stand 09900-21304: V-block set (100 mm) Camshaft runout Service Limit: 0.10 mm (0.004 in)
Page 76 3-36 ENGINE PISTON-RING-TO-GROOVE CLEARANCE Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge. If any clearance reading exceeds the service limit, replace both the piston and piston rings. (T^) 09900-20803: Thickness gauge 09900-20205: Micrometer (0-25 mm) Piston-ring-to-groove clearance Service Limit: 1st:...
Page 77 PISTON PIN AND PIN BORE Measure the piston pin bore diameter using the small bore gauge. If the diameter exceeds the service limit, replace the piston with a new one. IT55LI 0 9 9 0 0 - 2 0 6 0 2 : Dial gauge ( 1 / 1 0 0 0 mm) 0 9 9 0 0 - 2 2 4 0 3 : Small bore gauge ( 1 8 - 3 5 mm) Piston pin bore Service Limit:...
Page 78 3-38 ENGINE C R A N K S H A F T CRANKSHAFT RUNOUT Support the crankshaft using V-blocks and measure the crank- shaft runout using the dial gauge, as shown. If the runout exceeds the service limit, replace the crankshaft with a new one.
Page 79 S T A R T E R C L U T C H • Hold the rotor with a 36-mm offset wrench and remove the hexagon bolts. • Install the starter clutch in the proper direction as shown. NOTE: When installing the starter clutch onto the rotor, make sure the notch ®...
Page 80 3-40 ENGINE M O V A B L E D R I V E F A C E A N D D R I V E N F A C E © Movable drive face plate © Damper (4 pes) Spacer ) Movable drive face nut ©...
Page 81 MOVABLE DRIVE F A C E DISASSEMBLY • Remove the spacer. • Remove the movable drive face plate © and rollers © . ROLLER AND SLIDING S U R F A C E Inspect each roller and their sliding surface for wear or dam- age.
Page 82 • Apply a small amount of SUZUKI SUPER GREASE "A" to the bore and oil seal lip. For USA J S j * 99000-25030: SUZUKI SUPER G R E A S E "A" For the other countries 99000-25010: SUZUKI SUPER G R E A S E "A"...
Page 83 ENGINE 3-43 MOVABLE DRIVEN FACE DISASSEMBLY • Hold the movable driven face assembly using the special tool and vise, and loosen the movable driven face nut using the special tool. A WARNING Do not remove the movable driven face nut before attaching the clutch spring compressor.
Page 84 REASSEMBLY • Install the new O-rings. • Apply SUZUKI SUPER GREASE "A" to the oil seal lips, O- rings and movable driven face inside grease groove. For USA 99000-25030: SUZUKI SUPER G R E A S E "A"...
Page 85 To prevent damaging the oil seal lip from during installation, slide the lip using a 0.1-mm steel sheet as a guide. • Apply SUZUKI SUPER GREASE "A" to the O-ring and pin hole. For USA 99000-25030: SUZUKI SUPER G R E A S E "A"...
Page 86: Drive Belt
3-46 ENGINE • Slowly turn the special tool handle to tighten and align the flats ® at the movable driven face end with the spring plate Tighten the movable driven face nut temporarily. Remove the special tool from the movable driven face assembly.
Page 87 O I L P U M P A CAUTION The oil pump case securing screw is applied with SUZUKI THREAD LOCK SUPER "1303". If an attempt is made to overhaul the oil pump assembly, the screw may be damaged. Only the oil pump unit is available as a replacement.
Page 88 3-48 ENGINE G E A R S H I F T F O R K A N D G E A R GEARSHIFT-FORK-TO-GEARSHIFT-FORK GROOVE CLEARANCE Clearance for each of the two gearshift forks plays an important role in the smoothness and positiveness of the shifting action. Measure the gearshift fork clearance in the groove of its respective gear using the thickness gauge.
Page 89 ENGINE 3-49 T R A N S M I S S I O N DISASSEMBLY Disassemble the transmission gears as shown. © Reverse idle gear Bearing © Washer Reverse driven gear © Spacer Washer © Reverse idle gear shaft Lock washer ©...
Page 90 3-50 ENGINE R E A S S E M B L Y Reassemble the driveshaft in the reverse order of disassembly. Pay attention to the following points: NOTE Before installing the gears, apply engine oil to the inner surface of each gear and bushing. ACAUTIOINT * Never reuse a circlip.
Page 92 3-52 ENGINE • When installing a new circlip, pay attention to the direction of the circlip. Fit it to the side where the thrust is, as shown. The rounded side should be against the gear surface. ® Thrust (B) Sharp edge Fit the claw ©...
Page 93 ENGINE 3-53 B E A R I N G S Wash the bearing with a cleaning solvent and lubricate it with Play motor oil before inspection. Rotate the inner race and check to see that it turns smoothly. If it does not turn quietly and smoothly, or if there are signs of any abnormalities, the bearing is defective and must be replaced with a new one as follows.
Page 94 3-54 ENGINE L E F T DRIVESHAFT BEARING • Remove the left driveshaft bearing using the special tools. (yjj^ 09923-74510: Bearing remover 09930-30102: Sliding hammer A CAUTION Replace the removed bearing with a new one. • Install the left driveshaft bearing using the special tool. IT55LI 09913-70210: Bearing installer set CRANKSHAFT BEARING •...
Page 95 ENGINE 3-55 • Install the right and left output shaft bearings using the spe- cial tool. (TOSL) 09913-70210: Bearing installer set • Apply a small quantity of THREAD LOCK "1342" or "1322" to the bearing retainer screws, and tighten them sequrely. For USA tJ33 99000-32050: THREAD LOCK "1342"...
Page 96 3-56 ENGINE • Install the left balancer shaft bearing using the special tool. 09913-70210: Bearing installer set WATER PUMP BEARING • Remove the circlip © and water pump bearing (2). A CAUTION Replace the removed bearing and circlip with new ones.
Page 97 ENGINE 3-57 • Install the left clutch housing bearing using the special tool. IT55LI 09913-70210: Bearing installer set DRIVE BELT COVER BEARING • Remove the bearing retainer. • Remove the drive belt cover bearing using the special tool. 09921-20220: Bearing remover set A CAUTION Replace the removed bearing with a new one.
Page 98 Replace the removed oil seals with new ones. • Apply SUZUKI SUPER GREASE "A" to the lip of the oil J S I * 99000-25030: SUZUKI SUPER G R E A S E "A" For the other countries ^199000-25010: SUZUKI SUPER G R E A S E "A"...
Page 99 GEARSHIFT SHAFT OIL S E A L • Remove the gearshift shaft oil seal from the left crankcase using the special tool. 09913-50121: Oil seal remover A C A U T I O N Replace the removed oil seal with a new one. •...
Page 100 3-60 ENGINE • Remove the starter cup oil seal using the special tool. • Install the starter cup oil seal using the special tool. IT55LI 09913-70210: Bearing installer set...
Page 101 ENGINE 3-61 ENGINE R E A S S E M B L Y 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.
Page 102 3-62 ENGINE C R A N K S H A F T © Bearing © Crankshaft (R) © Washer © Crank pin © Bearing © Conrod © Crankshaft (L) © Bearing • Determine the width between the webs referring to the figure when rebuilding the crankshaft.
Page 103 ENGINE 3-63 B A L A N C E R S H A F T © Bolt © Washer © Oil pump drive gear ® Pin © Spacer © Bearing ® Circlip ® Spring washer ® Plate ® Balancer driven gear No.2 ®...
Page 104 3-64 ENGINE G E A R S H I F T C A M A N D F O R K © Neutral switch © Washer © Circlip © Washer © Spring © Neutral switch contact © Spring © Gearshft shaft ©...
Page 105 • Apply grease to the lip of oil seals ®. 99000-25160: WATER RESISTANCE G R E A S E • Apply SUZUKI BOND "1207B" to the mating surface of the right crankcase. For USA 4!£3 99104-31140: SUZUKI BOND "1207B"...
Page 106 3-66 ENGINE • Tighten the two 8-mm crankcase bolts © , first, and then the 6-mm bolts to the specified torque. H Crankcase bolt 8 mm: 22 N m (2.2 kgf-m, 16.0 Ib-ft) 6 mm: 11 N m (1.1 kgf-m, 8.0 Ib-ft) NOTE: Install the new gasket onto the crankcase bolt®...
Page 107 ENGINE 3-67 S T A R T E R C L U T C H A N D G E N E R A T O R R O T O R • Remove the grease from the tapered portion of the crank- shaft and the generator rotor.
Page 108 3-68 ENGINE • When installing the oil pump drive gear, align the pin ® with the groove (2). • Hold the generator rotor using the 36-mm offset wrench, and then tighten the oil pump drive gear bolt to the specified torque.
Page 109 ENGINE 3-69 N E U T R A L S W I T C H • Install the springs and switch contacts. • Apply THREAD LOCK SUPER "1303" or "1322" to the threads of the bolts, and then tighten them to the specified torque. For USA •499 99000-32030: THREAD LOCK SUPER "1303"...
Page 110 3-70 ENGINE • Hold the movable drive face and movable driven face using the special tool and tighten them to the specified torque. ITSSLI 09930-40113: Rotor holder H Movable drive face nut: 115 N-m (11.5 kgf-m, 83.0 Ib-ft) Movable driven face nut: 115 N-m (11.5 kgf-m, 83.0 Ib-ft) •...
Page 111 99000-25030: SUZUKI SUPER G R E A S E "A" For the other countries ^ \ 9 9 0 0 0 - 2 5 0 1 0 : SUZUKI SUPER G R E A S E "A" H Starter cup nut: 33 N m (3.3 kgf-m, 24.0 Ib-ft) S P E E D O M E T E R G E A R B O X •...
Page 112 3-72 ENGINE • The 1st and 2nd piston rings should be installed with the mark facing up. • First, install a spacer © into the oil ring groove and then install the two side rails © . The spacer and side rails do not have a designated top and bottom.
Page 113 ENGINE 3-73 P I S T O N A N D C Y L I N D E R Install the piston and cylinder in the reverse order of removal. NOTE: Install the piston with the punch mark © on the piston head facing exhaust side.
Page 114 3-74 ENGINE NOTE: There is a holder for the bottom end of the cam chain guide cast in the crankcase. Make sure the guide (3) is inserted prop- erly or binding of the cam chain and guide may result. C Y L I N D E R H E A D •...
Page 115 ENGINE 3-75 C A M S H A F T / A U T O M A T I C D E C O M P R E S S I O N A S S E M B L Y •...
Page 116 C Y L I N D E R H E A D C O V E R • Thoroughly wipe off oil from the fitting surfaces of the cylin- der head and cover. • Uniformly apply SUZUKI BOND "1216" to the cylinder head cover. For USA 4™3 99104-31160: SUZUKI BOND "1216"...
Page 117 • Turn the adjusting screw clockwise with a flat-bladed screw driver until the push rod is locked. • Fit a new gasket to the chain tension adjuster body. A CAUTION^ Use a new gasket to prevent oil leakage. • Install the chain tension adjuster body to the cylinder, and then tighten the two alien bolts to the specified torque.
Page 118 3-78 ENGINE R E C O I L S T A R T E R © Bearing © Oil seal © Spacer © O-ring © O-ring © Gasket © Stater cup © Nut ® Nut ® Ratchet set ® Reel ©...
Page 119 • After installing the spiral spring, engage the part © of the reel with the part @ of the spiral spring. • Apply SUZUKI SUPER GREASE "A" to the shaft and ratchet. For USA 99000-25030: SUZUKI SUPER G R E A S E "A"...
Page 120 SHAFT DRIVE AND DIFFERENTIAL SHAFT DRIVE AND DIFFERENTIAL CONTENTS SECONDARY BEVEL GEARS 4- 2 CONSTRUCTION 4- 2 REMOVAL 4- 3 DISASSEMBLY 4- 3 INSPECTION 4- 5 REASSEMBLY 4- 5 SHIM ADJUSTMENT 4- 7 FINAL ASSEMBLY AND REMOUNTING 4- 9 REASSEMBLY INFORMATION 4-10 DIFFERENTIAL BEVEL GEARS...
Page 121 SHAFT DRIVE AND DIFFERENTIAL SECONDARY B E V E L G E A R S C O N S T R U C T I O N © Front propeller shaft joint yoke © Washer © Plate ® Plate © O-ring ©...
Page 122 SHAFT DRIVE AND DIFFERENTIAL R E M O V A L • Remove the engine. ( C r 3-3 to 3-7) • Separate the crankcase. (c^ 3-11 to 3-19) • Remove the front and rear secondary driven output shaft. • Remove the transmission output shaft. 3-21) •...
Page 123 SHAFT DRIVE AND DIFFERENTIAL • Remove the C-rings. • Remove the bearing by hitting the area © of the front drive output yoke using the copper hammer, as shown. • Separate the front drive output yoke and propeller shaft joint yoke.
Page 124 SHAFT DRIVE AND DIFFERENTIAL I N S P E C T I O N Insert the universal joint to the bearing and check the play by turning the universal joint, as shown. If excessive play is noted, replace the bearing with a new one. Inspect the universal joint and outer surface of the bearing for scuffing, wear and damage.
Page 125 SHAFT DRIVE AND DIFFERENTIAL REAR SECONDARY DRIVEN OUTPUT SHAFT • Tighten the new rear output joint nut to the specified torque. Rear output joint nut: 100 N m (10.0 kgf-m, 72.5 Ib-ft) • Bend the collar of the nut © into the notch in the shaft. FRONT SECONDARY DRIVEN OUTPUT SHAFT •...
Page 126 SHAFT DRIVE AND DIFFERENTIAL SHIM ADJUSTMENT BACKLASH NOTE: When measuring the backlash or checking tooth contact, it is not necessary that the universal joint be installed and that thread lock be applied to the secondary driven output shaft nut. • Install the transmission output shaft. {[^T 3-61) •...
Page 127 SHAFT DRIVE AND DIFFERENTIAL TOOTH C O N T A C T © After backlash adjustment is carried out, the tooth contact must be checked. Pay attention to the following procedures: • Remove the secondary driven output shaft assembly from the crankcase.
Page 128 SHAFT DRIVE AND DIFFERENTIAL FINAL A S S E M B L Y AND REMOUNTING • After adjusting the gear backlash and tooth contact correctly, remove the secondary driven output shaft and transmission output shaft. • Clean off any machinist's dye or paste from the gear teeth, and lubricate the teeth with engine oil.
Page 129 4-10 SHAFT DRIVE AND DIFFERENTIAL REASSEMBLY INFORMATION kgf-m Ib-ft ITEM © 10.0 72.5 ® 10.0 72.5 List of s h i m s ® available for the secondary List of s h i m s ® available for the secondary drive driven gear.
Page 130 SHAFT DRIVE AND DIFFERENTIAL 4-11 DIFFERENTIAL B E V E L G E A R S CONSTRUCTION © Rear propeller shaft joint yoke © Universal joint ® C-ring © Washer © Front propeller shaft joint yoke © Plate ® Plate ©...
Page 131 4-12 SHAFT DRIVE AND DIFFERENTIAL REMOVAL • Drain the differential gear oil. {{^T 2-10) • Remove the front suspension. (CI7 7-29) • Remove the differential gear case covers. • Remove the front drive shaft using the special tools. ( ^ L ] 09930-30102: Sliding hammer 09924-21940: Wheel hub remover 09924-21930: Drive shaft remover •...
Page 132 SHAFT DRIVE AND DIFFERENTIAL 4-13 • Remove the differential gear case mounting stay. DISASSEMBLY DIFFERENTIAL DRIVE GEAR HOUSING • Remove the C-rings. • Remove the bearing by hitting the copper hammer on the position © of the front propeller shaft joint yoke. •...
Page 133 4-14 SHAFT DRIVE AND DIFFERENTIAL • Remove the O-ring and shims. A CAUTIOINT Replace the removed O-ring with a new one. • Loosen the differential drive bevel gear nut by holding the yoke using the vise. • Remove the differential drive bevel gear yoke and differential drive bevel gear.
Page 134 SHAFT DRIVE AND DIFFERENTIAL 4-15 DIFFERENTIAL DRIVEN BEVEL GEAR AND DIFFERENTIAL ASSEMBLY • Remove the driven bevel gear bearing case. • Remove the cam cover. • Remove the washer © and spring (2). • Remove the cam and washer.
Page 135 4-16 SHAFT DRIVE AND DIFFERENTIAL • Remove the sliding dog and shift fork. • Remove the driven gear and shims. • Remove the differential assembly and shims. NOTE: Do not disassemble the differential assembly. INSPECTION DIFFERENTIAL DRIVE B E V E L GEAR HOUSING Inspect the removed parts for the following abnormalities.
Page 136 SHAFT DRIVE AND DIFFERENTIAL 4-17 Inspect the universal joint and outer surface of the bearing for scuffing, wear and damage. If any damages are found, replace the bearing with a new one. DIFFERENTIAL DRIVEN B E V E L GEAR AND DIFFERENTIAL ASSEMBLY Check the inner race play of the bearing by hand while it is in the differential case.
Page 137 4-18 SHAFT DRIVE AND DIFFERENTIAL Inspect the oil seal for wear or damages. If excessive wear is found, replace the oil seal with a new one. • Remove the oil seals using the special tool. IT55LI 09913-50121: Oil seal remover A C A U T I O N Replace the removed oil seal with a new one.
Page 138 SHAFT DRIVE AND DIFFERENTIAL 4-19 • Install a new spacer. A CAUTION^ Replace the removed spacer with a new one. • Tighten the differential drive bevel gear nut to the specified torque. [J] Differential drive bevel gear nut: 120 N m (12.0 kgf-m, 87.0 Ib-ft) Measure the bearing preload.
Page 139 4-20 SHAFT DRIVE AND DIFFERENTIAL DIFFERENTIAL DRIVEN B E V E L GEAR AND DIFFERENTIAL ASSEMBLY • Install a new driven bevel gear bearing using the special tool. 09913-70210: Bearing installer set NOTE: When installing the bearing, tap on the punched mark side of the bearing with the bearing installer.
Page 140 SHAFT DRIVE AND DIFFERENTIAL 4-21 • Install the differential assembly into the differential driven bevel gear housing. • Place the removed shims on the differential bevel gear hub. • Install the differential driven bevel gear on the differential • Install the removed shim on the drive bevel gear housing. •...
Page 141 4-22 SHAFT DRIVE AND DIFFERENTIAL BACKLASH Measure the backlash of the differential gear using the dial gauge, as shown. Take backlash readings at several places while turning the flange slightly in each direction and securely holding the differential driven gear. Read the total backlash on the dial gauge.
Page 142 SHAFT DRIVE AND DIFFERENTIAL 4-23 Measure the height © of the bearing inner race surface and bearing case flange using the straightedge and special tools. IT55LI 09900-20602: Dial gauge (1/100 mm) 09900-20701: Magnetic stand 09900-21203: Surface plate 09900-21304: V-block set (100 mm) Measure the height ©...
Page 143 4-24 SHAFT DRIVE AND DIFFERENTIAL TOOTH CONTACT © After backlash adjustment is carried out, the tooth contact must be checked. Pay attention to the following procedures: • Remove the differential driven bevel gear. • Clean and degrease several teeth on the differential driven bevel gear and apply a coating of machinist's layout dye or paste to the teeth.
Page 144 • Apply SUZUKI SUPER GREASE "A" to the O-rings. For USA ^ 1 9 9 0 0 0 - 2 5 0 3 0 : SUZUKI SUPER G R E A S E "A" For the other countries 99000-25010: SUZUKI SUPER G R E A S E "A"...
Page 145 4-26 SHAFT DRIVE AND DIFFERENTIAL • Align the punch mark © of camshaft with punched mark © of cam. • Install the dog and shift fork into the driven gear bearing case. • Install the driven gear bearing case, and then tighten the securing bolts to the specified torque.
Page 146 • Apply SUZUKI SUPER GREASE "A" to the universal joint. For USA ^ \ 9 9 0 0 0 - 2 5 0 3 0 : SUZUKI SUPER G R E A S E "A" For the other countries %£M\99000-25010: SUZUKI SUPER G R E A S E "A"...
Page 147 4-28 SHAFT DRIVE AND DIFFERENTIAL R E A S S E M B L Y INFORMATION kgf-m Ib-ft ITEM ® 16.5 16.5 © 16.5 12.0 87.0 © 32.5 Jt§H List of shims ( List of shims ® List of shims ( Shim thickness (mm) Part No.
Page 148 SHAFT DRIVE AND DIFFERENTIAL 4-29 FINAL B E V E L G E A R S CONSTRUCTION © Final gear bearing case (R) O-ring © Oil seal © Bearing Shim © Final bevel gear set © Washer Shim © Final bevel gear case Bearing O-ring Final bearing case (L)
Page 149 4-30 SHAFT DRIVE AND DIFFERENTIAL REMOVAL AND DISASSEMBLY • Drain the final bevel gear-oil. (CCT 2-10) • Remove the rear axle shaft. (£OT 7-54) • Disconnect the final bevel gear case breather hose. Remove the rear propeller shaft joint bolt. Remove the final drive shaft housing.
Page 150 SHAFT DRIVE AND DIFFERENTIAL 4-31 • Hold the final drive shaft coupling using the special tool and then remove the final drive gear nut. IT55LI 09924-61810: Final drive gear coupling holder • Remove the washer © and final drive shaft coupling © . •...
Page 151 4-32 SHAFT DRIVE AND DIFFERENTIAL Remove the bearing case bolts. • Separate the final gear bearing case using the suitable 5-mm bolts. • Remove the shims © and final driven bevel gear ( Remove the shims (3) and washer @. INSPECTION Inspect the final drive shaft and ball joint assembly for wear or damage.
Page 152 SHAFT DRIVE AND DIFFERENTIAL 4-33 BEARINGS Check the inner race play of the bearing by hand while it is in the case. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. If anything unusual is found, replace the bearing with a new one.
Page 153 4-34 SHAFT DRIVE AND DIFFERENTIAL OIL S E A L Inspect the oil seal for wear or damages. If any damages are found, replace the oil seal with a new one. • Remove the right final driven gear oil seal. (CJr 4-33) •...
Page 154 SHAFT DRIVE AND DIFFERENTIAL 4-35 • Install the new left final driven gear bearing using the special tool. IT55L1 09913-70210: Bearing installer set • Install the new oil seals using the special tool. ( ^ J 09913-70210: Bearing installer set •...
Page 155 4-36 SHAFT DRIVE AND DIFFERENTIAL BACKLASH • Install the final drive bevel gear, gear stopper and final drive gear nut. {{^T 4-39) NOTE: At this time, it is not necessary to install the O-ring. Measure the backlash of the final drive gear using the dial gauge, as shown.
Page 156 SHAFT DRIVE AND DIFFERENTIAL 4-37 Measure the height © of the mating surface of the gear case and driven gear back side using the straightedge and special tool. ( ^ ] 09900-20602: Dial gauge 09900-20701: Magnetic stand 09900-21203: Surface plate 09900-21304: V-block set Decide the proper shim thickness (§) by the following formula.
Page 157 4-38 SHAFT DRIVE AND DIFFERENTIAL TOOTH CONTACT © After backlash adjustment is carried out, the tooth contact must be checked. Pay attention to the following procedures: • Remove the final driven bevel gear. • Clean and degrease several teeth on the final driven bevel gear and apply a coating of machinist's layout dye or paste to teeth.
Page 158 • Apply SUZUKI SUPER GREASE "A" to the O-rings. For USA /S§H99000-25030: SUZUKI SUPER G R E A S E "A" For the other countries 99000-25010: SUZUKI SUPER G R E A S E "A" • Apply THREAD LOCK SUPER "1303" or "1322" to the bear- ing case bolt and tighten them to the specified torque.
Page 159 99000-25030: SUZUKI SUPER G R E A S E "A" For the other countries 99000-25010: SUZUKI SUPER G R E A S E "A" • Apply SUZUKI BOND "1207B" to the mating surface of the final drive shaft housing. For USA HhsZI 99104-31140: SUZUKI BOND"1207B"...
Page 160 SHAFT DRIVE AND DIFFERENTIAL 4-41 R E A S S E M B L Y INFORMATION ITEM kgf-m Ib-ft ® 16.5 11.0 79.5 © 16.5 10.0 72.5 ® 16.5 List of shims List of shims ( List of shims ( Shim thickness (mm) Part No.
Page 161 FUEL AND LUBRICATION SYSTEM FUEL AND LUBRICATION SYSTEM CONTENTS FUEL TANK 5- 2 CONSTRUCTION 5- 2 FUEL LINE INSPECTION 5- 2 REMOVAL 5- 2 REMOUNTING 5- 3 FUEL VALVE 5- 4 REMOVAL AND INSPECTION 5- 4 FUEL STRAINER 5- 4 REMOUNTING 5- 4 FUEL LEVEL GAUGE...
Page 162 FUEL AND LUBRICATION SYSTEM F U E L TANK CONSTRUCTION © Fuel tank cap © Fuel tank ® Fuel level gauge © Fuel valve © Fuel hose © Breather hose F U E L LINE INSPECTION Inspect the fuel lines, fuel tank, and fuel tank cap for damage and fuel leakage.
Page 163 FUEL AND LUBRICATION SYSTEM • Remove the fuel tank. REMOUNTING Remount the fuel tank in the reverse order of removal.
Page 164: Removal And Inspection
FUEL AND LUBRICATION SYSTEM F U E L VALVE REMOVAL AND INSPECTION • Remove the fuel tank. ( d F 5-2 and 5-3) • Remove the fuel valve. A WARNING * Gasoline is highly flammable and explosive. Keep heat, sparks, and flames away from gasoline. * Replace the removed O-ring with a new one to pre- vent fuel leakage.
Page 165 FUEL AND LUBRICATION SYSTEM F U E L L E V E L GAUGE REMOVAL • Remove the fuel tank cover. (c^T 7-5 and 7-6) • Remove the fuel level gauge. A WARNING Gasoline is very explosive. Extreme care must be taken.
Page 166 FUEL AND LUBRICATION SYSTEM CARBURETOR CONSTRUCTION © Top cap Pilot jet Holder © Spring Pilot screw © Jet needle Float Gasket @ Diaphragm/Piston valve Float pin Side cap © Needle jet Gasket Throttle cable guide © Pilot air jet Float chamber Throttle stop screw ©...
Page 167 FUEL AND LUBRICATION SYSTEM SPECIFICATIONS SPECIFICATION ITEM ITEM E-03, 24, 28 E-33 Carburetor type MIKUNI BST34SS < — Bore size 34 mm < — 09FA 09FB I.D. No. 1 500 ± 100 r/min Idle r/min <r- 13.0 ± 0.5 mm Float height <...
Page 168 FUEL AND LUBRICATION SYSTEM REMOVAL • Remove the fuel tank. ( C U 5-2 and 5-3) • Loosen the carburetor clamp screws. • Disconnect the starter cable. • Remove the carburetor side cap © . • Disconnect the throttle cable (2). •...
Page 169 FUEL AND LUBRICATION SYSTEM Remove the spring © , stopper plate ), jet needle ® , and diaphragm @. • Remove the float chamber. • Remove the O-ring. A CAUTIOISr Replace the removed O-ring with a new one to prevent fuel leakage.
Page 170 5-10 FUEL AND LUBRICATION SYSTEM • Remove the following parts. © Valve seat ® Main jet © Pilot jet 0 Pilot screw © Needle jet © Pilot air jet NOTE: Before removing the pilot screw 0 , its setting must be deter- mined.
Page 171 FUEL AND LUBRICATION SYSTEM 5-11 CLEANING A WARNING Some carburetor cleaning chemicals, especially dip- type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer's instructions on proper use, handling and storage. • Clean all jets with a spray-type carburetor cleaner and dry them using compressed air.
Page 172 5-12 FUEL AND LUBRICATION SYSTEM INSPECTION Check the following items for any damage or clogging. If any damages are found, replace the damaged parts with new ones. * Pilot jet * Valve seat *Main jet * Piston valve *Main air jet * Starter (enricher) jet * Pilot air jet * O-ring...
Page 173 FUEL AND LUBRICATION SYSTEM 5-13 R E A S S E M B L Y Reassemble the carburetor in the reverse order of disassem- bly. Pay attention to the following points. PILOT SCREW • After cleaning, install the pilot screw © to the original setting by turning the screw in until it lightly seats, and then backing it out the same number of turns counted during disassembly.
Page 174: Lubrication System
5-14 FUEL AND LUBRICATION SYSTEM LUBRICATION SYSTEM ENGINE LUBRICATION S Y S T E M CHART Zl CD Eg S £ Z O O I — I — >! w w < Y— < o > O CD < — <...
Page 175 COOLING SYSTEM COOLING SYSTEM CONTENTS COOLING SYSTEM 6- 2 DESCRIPTION. 6- 2 CONSTRUCTION 6- 3 ENGINE COOLANT 6- 5 RADIATOR, COOLING FAN, AND ENGINE COOLANT RESERVOIR 6- 6 INSPECTION 6- 6 REMOVAL 6- 7 REMOUNTING 6- 8 COOLING FAN THERMO SWITCH 6- 9 REMOVAL 6- 9...
Page 176: Cooling System
COOLING SYSTEM COOLING SYSTEM DESCRIPTION The engine is cooled by engine coolant set in forced circulation through jackets formed in the cylinder and cylinder head, and through the radiator. For the water pump, a high-capacity centrifugal pump is used. The radiator is a tube-and-fin type made of aluminum material, which is characterized by lightness in weight and good heat dissipation.
Page 177 COOLING SYSTEM CONSTRUCTION © Radiator cap © Radiator inlet hose © Radiator outlet hose © Water pump inlet hose © Water pump outlet hose © Radiator bypass hose © Water hose joint pipe © Reservoir cap ® Reservoir ® Inlet hose ®...
Page 179 COOLING SYSTEM ENGINE COOLANT (°F) (°C) ( k g f / c r r r ) At the time of manufacture, the cooling system is filled with a 50:50 mixture of distilled water and ethylene glycol antifreeze. This mixture will provide optimum corrosion and heat protec- tion, and will protect the cooling system from freezing at above •M - 3 1 °C (-24T).
Page 180 COOLING SYSTEM RADIATOR, COOLING FAN, AND ENGINE COOLANT RESERVOIR INSPECTION RADIATOR Before removing the radiator and draining the engine coolant, check the following. Check the cooling system for leaks with a radiator tester © . Remove the radiator cap and connect the radiator tester to the filler.
Page 181 COOLING SYSTEM COOLING FAN • Remove the front fender. ( C r * 7-6) • Disconnect the cooling fan coupler. Test the cooling fan motor for load current using an ammeter connected as shown. The voltmeter is for making sure that the battery applies 12 volts to the motor.
Page 182 COOLING SYSTEM • Remove the radiator. • Remove the cooling fan. • Disconnect the engine coolant reservoir hoses. • Remove the engine coolant reservoir. REMOUNTING Remount the radiator, cooling fan, and engine coolant reservoir in the reverse order of removal. After remounting the radiator, be sure to add engine coolant, ( c ^ 2-11)
Page 183 COOLING SYSTEM COOLING FAN THERMO SWITCH The cooling fan is secured behind the radiator by four bolts and is automatically controlled by the thermo switch. The thermo switch remains open when the temperature of the engine coolant is low, but closes when the temperature reaches approximately 88°C (190T) setting the cooling fan in motion.
Page 184 Pay attention to the following points: • Apply SUZUKI SUPER GREASE "A" to the O-ring. For USA 99000-25030: SUZUKI SUPER G R E A S E "A" For the other countries %£M\99000-25010: SUZUKI SUPER G R E A S E "A"...
Page 185 Install the engine coolant temperature switch in the reverse order of removal. Pay attention to the following points: • Apply SUZUKI BOND "1207B" to the thread portion of the engine coolant temperature switch and tighten it to the spec- ified torque.
Page 186 6-12 COOLING SYSTEM THERMOSTAT REMOVAL • Remove the left side front fender side cover. 7-5) • Remove the center exhaust pipe cover. 3-3) • Drain the engine coolant. ([""7" 2-11) A WARNING * Do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor.
Page 187 For USA J?!*99000-25030: SUZUKI SUPER G R E A S E "A" For the other countries 5 f n 99000-25010: SUZUKI SUPER G R E A S E "A" • After installing the thermostat, be sure to add engine coolant. 2-11)
Page 188: Water Pump
6-14 COOLING SYSTEM WATER PUMP R E M O V A L A N D D I S A S S E M B L Y • Drain the engine coolant, (CT* 2-11) A WARNING Do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor.
Page 189 • Install the water pump bearings using the special tool. irSSh 09913-70210: Bearing installer set • Apply SUZUKI SUPER GREASE "A" to the new O-rings. For USA 99000-25030: SUZUKI SUPER G R E A S E "A" For the other countries 99000-25010: SUZUKI SUPER G R E A S E "A"...
Page 190: Brakes
CHASSIS CONTENTS EXTERIOR PARTS 7- 2 CONSTRUCTION 7- 2 REMOVAL 7- 4 REMOUNTING 7- 8 FRONT AND REAR WHEELS 7- 9 CONSTRUCTION 7- 9 REMOVAL 7- 9 REMOUNTING 7- 9 TIRES 7-10 TIRE REPLACEMENT 7-10 FRONT DRIVE SHAFT 7-12 CONSTRUCTION 7-12 REMOVAL 7-12...
Page 191: Exterior Parts
CHASSIS EXTERIOR PARTS C O N S T R U C T I O N Fuel tank cover © Front fender side cover © Front carrier © © Front fender © Radiator cover © Front mudguard © Front mudflap © Mudflap inner...
Page 192 CHASSIS...
Page 193 CHASSIS REMOVAL SEAT • Remove the seat © . FRONT CARRIER • Remove the front carrier © . FRONT GRIP BAR • Remove the differential case cover ® . • Disconnect the clamps and headlight couplers. • Remove the front grip bar (2).
Page 194 CHASSIS RADIATOR COVER • Remove the front grip bar. {^ZT 7-4) • Remove the radiator cover © . • Remove the lid © . FRONT FENDER SIDE COVERS • Remove the seat. ( C U 7-4) • Remove the selection lever knob © . •...
Page 195 CHASSIS • Remove the air cleaner duct mounting bolt. • Remove the fuel tank cover © . FRONT FENDER • Remove the seat, front carrier, front grip bar, radiator cover, front fender side covers, and fuel tank cover, ( d r * 7-4 to 7-6) •...
Page 196 CHASSIS REAR FENDER • Remove the front fender side covers, fuel tank cover, and rear carrier. (£~T 7-5 and 7-6) > • Remove the front seat hook plate © and rear seat hook plate ® . • Remove the battery © . NOTE: Disconnect the 0 battery lead wire, first •...
Page 197 CHASSIS R E M O U N T I N G Remount the seat, front carrier, front grip bar, radiator cover, lid, front fender side covers, fuel tank cover, front fender, rear carrier, and rear fender in the reverse order of removal. Pay attention to the following point: •...
Page 198 CHASSIS FRONT AND REAR W H E E L S C O N S T R U C T I O N R E M O V A L • Place the vehicle on level ground. • Remove the wheel set nuts. •...
Page 199 7-10 CHASSIS TIRES T I R E R E P L A C E M E N T • Remove the front and rear wheels. 7-9) • After removing the air valve cap, release the tire pressure by depressing the valve. •...
Page 200 • Inflate the tire to seat the tire bead. ESSJ Maximum tire bead seat pressure Front: 250 kPa (2.5 kgf/cm ,36 psi) Rear: 250 kPa (2.5 kgf/cm ,36 psi) A CAUTION Place the tire under a protective tire cage or similar protective covering device before inflating the tire.
Page 201: Front Drive Shaft
7-12 CHASSIS FRONT DRIVE SHAFT C O N S T R U C T I O N © Front drive shaft assembly © Differential side joint set © side boot set Differential © Snap ring © Circlip © Differential side outer boot clamp ©...
Page 202 • Remove the boot band of the differential side joint (double offset joint). • Slide the boot toward the center of the front drive shaft and remove the snap ring from the outer race. • Separate the outer race from the front drive shaft. •...
Page 203 7-14 CHASSIS INSPECTION AND REASSEMBLY Inspect the boots for wear or damage. If any damages are found, replace the boots with new ones. Inspect the circlip, snap ring, and boot bands for wear or dam- age. If any damages are found, replace the circlip, snap ring, and boot bands with new ones.
Page 204 • Install the circlip to the cage. • Apply grease to the entire surface of the cage and the inside of the outer race. Position Differential side Wheel side Grease — 80 g Quantity 45 g NOTE: The tube of joint grease is included in the wheel side boot set or wheel side joint assembly of spare parts.
Page 205 7-16 CHASSIS • After fitting the boot on the outer race, insert a screw driver into the boot on the outer race side and allow air to enter the boot so that the air pressure in the boot becomes the same as the atmospheric pressure at the positions indicated in the illustration.
Page 206: Brake Hose No
CHASSIS 7-17 FRONT B R A K E C O N S T R U C T I O N © Master cylinder reservoir cap © Diaphragm © Master cylinder clamp © Boot © Piston/cup set © Cup © Spring ©...
Page 207 7-18 CHASSIS B R A K E P A D R E P L A C E M E N T • Remove the front wheel, ( d / 7-9) • Remove the brake caliper mounting bolts © and brake pad mounting pins (2).
Page 208 CHASSIS 7-19 B R A K E F L U I D R E P L A C E M E N T • Place the vehicle on a level surface and keep the handlebar straight. • Remove the master cylinder reservoir cap and diaphragm. •...
Page 209 7-20 CHASSIS • Remove the brake pads. ( O 7-18) • Remove the brake caliper holder © . WMKM • Remove the spring • Place a rag over the brake caliper pistons to prevent them from popping out and then force out the pistons using com- pressed air.
Page 210 PISTON S E A L S • Install the piston seals © and dust seals © as shown. BRAKE CALIPER HOLDER • Apply SUZUKI SILICON GREASE to the brake caliper holder. 99000-25100: SUZUKI SILICONE G R E A S E...
Page 211 7-22 CHASSIS # Tighten the brake pad mounting pins © , brake caliper mounting bolts (2), and brake hose union bolt ® to the spec- ified torque. H Brake pad mounting pin: 18 N-m (1.8 kgf-m, 13.0 Ib-ft) Brake caliper mounting bolt: 26 N m (2.6 kgf-m, 19.0 Ib-ft) Brake hose union bolt: 23 N-m (2.3 kgf-m, 16.5 Ib-ft)
Page 212 • Remove the brake disc. B R A K E D I S C I N S P E C T I O N • Remove the front wheel. (CCT 7-9) Check the brake disc for cracks or damage and measure the thickness using the micrometer.
Page 213 7-24 CHASSIS • Apply SUZUKI SUPER GREASE "A" to the wheel hub spline. FOR USA ^>99000-25030: SUZUKI SUPER G R E A S E "A" For the other countries Jffn99000-25010: SUZUKI SUPER G R E A S E "A" • Apply THREAD LOCK SUPER "1360" to the brake disc bolts and tighten them to the specified torque.
Page 214 M A S T E R C Y L I N D E R R E M O V A L A N D D I S A S S E M B L Y • Place a rag underneath the brake hose union bolt on the master cylinder to catch any spilt brake fluid.
Page 215 7-26 CHASSIS • Remove the piston/secondary cup, primary cup, and spring. © Secondary cup © Piston © Primary cup ® Spring M A S T E R C Y L I N D E R I N S P E C T I O N MASTER CYLINDER Inspect the master cylinder bore for any scratches or damage.
Page 216 When remounting the master cylinder on the handlebar, align the master cylinder holder's mating surface © with the punch mark © on the handlebar and tighten the upper clamp bolt first. H Master cylinder clamp bolt: 10 N m (1.0 kgf-m, 7.0 Ib-ft) ®...
Page 217: Front Suspension
7-28 CHASSIS FRONT SUSPENSION C O N S T R U C T I O N © Front shock absorber Upper wishbone arm © Bushing © Steering knuckle Inner dust seal Spacer ® Hub bearing Outer dust seal ® Washer Lower wishbone arm ©...
Page 218 CHASSIS 7-29 R E M O V A L A N D D I S A S S E M B L Y • Remove the wheel hub with brake disc. [ZZF 7-22) • Remove the brake hose retainer. • Remove the cotter pin and tie rod end nut. A C A U T I O N Replace the removed cotter pin with a new one.
Page 219 7-30 CHASSIS • Remove the drive shaft cover. • Remove the steering knuckle end bolt by holding its end side using a vise. • Remove the brake disc cover. I N S P E C T I O N FRONT SHOCK ABSORBER Inspect the shock absorber for oil leakage or damage.
Page 220 WISHBONE ARM Inspect the wishbone arm for wear or damage. If any damages are found, replace the wishbone arm with a new one. DRIVE SHAFT COVER Inspect the drive shaft cover for wear or damage. If any dam- ages are found, replace the drive shaft cover with a new one. BRAKE DISC COVER Inspect the brake disc cover for wear or damage.
Page 221 7-32 CHASSIS DUST S E A L Inspect the dust seal lips for wear or damage. If any damages are found, replace the dust seal with a new one. • Remove the steering knuckle dust seal using the special tool. IT55L1 09913-50121: Oil seal remover A C A U T I O N Replace the removed dust seal with a new one.
Page 222 For USA ^ 1 9 9 0 0 0 - 2 5 0 3 0 : SUZUKI SUPER G R E A S E "A" For the other countries ^ 1 9 9 0 0 0 - 2 5 0 1 0 : SUZUKI SUPER G R E A S E "A"...
Page 223 7-34 CHASSIS • Install the steering knuckle dust seal using the special tool. ( ^ L ) 09913-70210: Bearing installer set • Apply THREAD LOCK SUPER "1303" or "1322" to the steer- ing knuckle end bolt, and then tighten it to the specified torque. For USA t i 3 99000-32030: THREAD LOCK SUPER "1303"...
Page 224 • Tighten the tie rod end nut to the specified torque. H Tie rod end nut: 32 N m (3.2 kgf-m, 23.0 Ib-ft) NOTE: After installing the tie rod end nut, insert a new cotter pin into the tie rod end. FRONT SHOCK ABSORBER STANDARD POSITION: 2/5...
Page 225 7-36 CHASSIS STEERING C O N S T R U C T I O N © Speedometer upper cover © Speedometer lower cover © Handlebar upper clamp ® Handlebar © Handlebar lower clamp © Steering shaft ® Steering shaft holder ©...
Page 226 CHASSIS 7-37 R E M O V A L A N D D I S A S S E M B L Y • Remove the front fender. 7-6) • Remove the front wheel. 7-9) • Remove the master cylinder assembly. 7-25) •...
Page 227 7-38 CHASSIS • Separate the tie rod ends ® , nuts © and ), and tie rods 0. A CAUTION The locknuts (2) have left-hand threads. • Remove the cotter pin and steering shaft nut. A CAUTION Replace the removed cotter pins with new ones. •...
Page 228 I N S P E C T I O N Inspect the removed parts for the following abnormalities. * Handlebar distortion * Handlebar clamp wear DUST S E A L S Inspect the dust seals for wear or damage. If any damages are found, replace the dust seals with new ones.
Page 229 For USA ^ 1 9 9 0 0 0 - 2 5 0 3 0 : SUZUKI SUPER G R E A S E "A" For the other countries ^ 1 9 9 0 0 0 - 2 5 0 1 0 : SUZUKI SUPER G R E A S E "A"...
Page 230 CHASSIS 7-41 TIE ROD • Tighten the tie rod end nuts to the specified torque. H Tie rod end nut: 32 N m (3.2 kgf-m, 23.0 Ib-ft) NOTE: After installing the tie rod end nuts, install the new cotter pins into the tie rod end.
Page 231 7-42 CHASSIS 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) (CZT • Place 75 kg (165 lbs) of weight on the seat. •...
Page 232 CHASSIS 7-43 FRONT WHEEL, FRONT B R A K E , FRONT SUSPENSION, AND STEERING REASSEMBLING INFORMATION kgf-m Ib-ft ITEM kgf-m Ib-ft ITEM © 16.5 © 10.0 72.5 16.5 36.0 © ® 35.5 36.0 ® ® 47.0 43.5 ® ® 105.0 23.0 14.5...
Page 233 7-44 CHASSIS REAR B R A K E C O N S T R U C T I O N © Dust seal © Brake drum cover © Well hub (right side) © Brake drum © Brake shoe © Brake camshaft ©...
Page 234 CHASSIS 7-45 • Disconnect the rear brake breather hose.
Page 235 7-46 CHASSIS • Remove the rear brake panel. • Remove the O-ring. ill!!! •111 • Remove the brake cam lever bolt © , cam lever © , and spring ® . • Remove the brake camshaft. I N S P E C T I O N BRAKE DRUM Inspect the brake drum and measure the brake drum inside diameter to determine the extent of wear.
Page 236 R E A S S E M B L Y A N D R E M O U N T I N G Reassemble and remount the rear brake in the reverse order of removal and disassembly. Pay attention to the following points: • Apply SUZUKI SUPER GREASE "A" to the brake camshaft, pin and O-ring. For USA 99000-25030: SUZUKI SUPER G R E A S E "A"...
Page 237 • Apply SUZUKI SUPER GREASE "A" to the wheel hub spline. For USA ^ f n 99000-25030: SUZUKI SUPER G R E A S E "A" For the other countries JlSW99000-25010: SUZUKI SUPER G R E A S E "A"...
Page 238 • Tighten the rear wheel set nut © to the specified torque. H Rear wheel set nut: 50 N m (5.0 kgf-m, 36.0 Ib-ft) • Tighten the rear hub nut © to the specified torque by apply- ing the rear brake. H Rear hub nut: 100 N m (10.0 kgf-m, 72.5 Ib-ft) NOTE: * First, remount the rear wheels and lower the jack, and then...
Page 239: Rear Suspension
7-50 CHASSIS REAR SUSPENSION C O N S T R U C T I O N © Rear shock absorber assembly © Rear axle housing (right side) © Rear axle housing (left side) ® Bushing © Bushing © Bushing © Bushing Rear suspension arm (RH) Rear suspension arm (RH)
Page 240 R E M O V A L A N D D I S A S S E M B L Y • Remove the rear wheel. (CU 7-9) • Remove the rear shock absorber. • Disconnect the rear brake lever cable © and remove the clamps ©...
Page 241 7-52 CHASSIS BUSHING Inspect the bushings for wear or damage. If any damages are found, replace the respective bushings with new ones. • Apply THREAD LOCK SUPER "1303" or "1322" to the outer surface of the bushing when replacing the suspension arm bushings.
Page 242 CHASSIS 7-53 REAR A X L E SHAFT C O N S T R U C T I O N © Circlip © Bearing © Rear axle shaft (right side) © Rear axle housing (right side) © Final bevel gear case cover ©...
Page 243 7-54 CHASSIS R E M O V A L A N D D I S A S S E M B L Y • Remove the rear brake. ( C r 7-44 to 7-46) • Remove the rear suspension (d7 7-51) = >...
Page 244 CHASSIS 7-55 REAR AXLE SHAFT Inspect the rear axle shaft for distortion or damages. If any damages are found, replace the rear axle shaft with a new one. DUST S E A L Inspect the dust seal lip for wear or damage. If any damages are found, replace the dust seal with a new one.
Page 245 R E A S S E M B L Y A N D R E M O U N T I N G Reassemble and remount the rear axle in the reverse order of removal and disassembly. Pay attention to the following points: • Apply SUZUKI SUPER GREASE "A" to the hub bearings and dust seals before installing them. For USA ;fl*99000-25030: SUZUKI SUPER G R E A S E "A"...
Page 246 CHASSIS 7-57 • Apply SUZUKI SUPER GREASE "A" to the rear axle shaft spline. For USA JSI* 99000-25030: SUZUKI SUPER G R E A S E "A" For the other countries 99000-25010: SUZUKI SUPER G R E A S E "A"...
Page 247 7-58 CHASSIS REAR WHEEL, REAR B R A K E , REAR SUSPENSION, AND REAR A X L E SHAFT REASSEMBLING INFORMATION...
Page 248 CHASSIS 7-59 SHIFT L E V E R S C O N S T R U C T I O N • Remove the selection shift lever bracket.
Page 249 7-60 CHASSIS • Remove the selection shift lever. • Remove the selection shift lever holder. • Remove the O-rings and spacer. A CAUTION^ Replace the removed O-rings with new ones. INSPECTION Inspect the selection shift lever assembly for wear or damage. If any damages are found, replace the selection shift lever assembly with a new one.
Page 250 Pay attention to the following point: • Apply SUZUKI SUPER GREASE "A" to the selection shift lever holder, spacer, mating surface of the selection shift lever, and O-rings.
Page 251 Reassemble and remount the range lever in the reverse order of removal and disassembly. Pay attention to the following point: • Apply SUZUKI SUPER GREASE "A" to the spacer, mating surface of the range lever, and O-rings. For USA 99000-25030: SUZUKI SUPER G R E A S E "A"...
Page 252 99000-25030: SUZUKI SUPER G R E A S E "A" For the other countries ^ 1 9 9 0 0 0 - 2 5 0 1 0 : SUZUKI SUPER G R E A S E "A" • Attach the selection lever cable, washer, and E-ring to the selection lever.
Page 253 7-64 CHASSIS • Install the selection lever cable © into the cable stopper © located on the frame. Then, finger tighten the selection lever cable adjusting nuts © to hold it in place. NOTE: Make sure the selection lever cable is positioned so that the cable stopper ©...
Page 254 For USA ^ 1 9 9 0 0 0 - 2 5 0 3 0 : SUZUKI SUPER G R E A S E "A" For the other countries ^ 1 9 9 0 0 0 - 2 5 0 1 0 : SUZUKI SUPER G R E A S E "A"...
Page 255 7-66 CHASSIS • Install the range lever cable © into the cable stopper ® located on the frame. Then, finger tighten the range lever cable adjusting nuts @ to hold it in place. NOTE: Make sure the range lever cable is positioned so that the cable stopper ®...
Page 256 ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING CONNECTORS 8- 2 COUPLERS 8- 2 CLAMPS 8- 2 FUSES SEMI-CONDUCTOR EQUIPPED PARTS 8- 2 BATTERY 8- 3 CONNECTING THE BATTERY WIRING PROCEDURE USING THE MULTI CIRCUIT TESTER 8- 4 LOCATION OF ELECTRICAL COMPONENTS 8- 5 CHARGING SYSTEM...
Page 257: 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 258: Connecting The Battery
ELECTRICAL SYSTEM BATTERY • The MF battery used in this vehicle does not require mainte- nance (e.g., electrolyte level inspection, distilled water replenishment). • During normal charging, no hydrogen gas is produced. How- ever, if the battery is overcharged, hydrogen gas may be produced.
Page 259 ELECTRICAL SYSTEM USING THE MULTI CIRCUIT T E S T E R • Properly use the multi circuit tester © and © probes. Improper use can cause damage to the vehicle and tester. • If the voltage and current values are not known, begin mea- suring in the highest range.
Page 260 ELECTRICAL SYSTEM LOCATION OF E L E C T R I C A L COMPONENTS © Battery © Ignition coil © Ignition switch © Speedometer © Handlebar switch © Starter motor ® Neutral switch © Regulator/rectifier...
Page 261 ELECTRICAL SYSTEM ® Cooling fan ® Cooling fan thermo switch © Engine coolant temperature switch © Fuse box ® Neutral relay @ CDI unit © Main fuse © Starter relay Generator...
Page 262: Charging System
ELECTRICAL SYSTEM CHARGING SYSTEM DESCRIPTION The charging system consists of a generator, regulator/rectifier, and battery. The AC current, which is gen- erated by the generator, is converted by the regulator/rectifier into DC current. The regulator/rectifier is one unit which has two functions. The regulator prevents overcharging of the battery by grounding the exces- sive AC current.
Page 263 ELECTRICAL SYSTEM TROUBLESHOOTING Battery runs down quickly. Accessories Check accessories which use excessive • Remove accessories are installed amounts of electricity. No accessories Check the battery for current leak- Current leaks • Short circuit of the wire age. ( C ^ 8-9) harness •...
Page 264 INSPECTION BATTERY CURRENT L E A K A G E • Turn the ignition switch to the "OFF" position. • Remove the seat, (dr 7-4) • Disconnect the © battery lead wire. Measure the current between the © battery terminal and the ©...
Page 265 8-10 ELECTRICAL SYSTEM STATOR COIL RESISTANCE • Remove the rear fender, ( d r 7-7) • Disconnect the stator coil lead wire coupler. Measure the resistance between the three lead wires using the multi circuit tester. If the resistance is not within the specified value, replace the stator coil with a new one.
Page 266 ELECTRICAL SYSTEM 8-11 REGULATOR/RECTIFIER • Remove the rear fender. ({OT 7-7) • Disconnect the regulator/rectifier couplers © . 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.
Page 267: Starter System
8-12 ELECTRICAL SYSTEM STARTER SYSTEM DESCRIPTION The starter system consists of the following components: the starter motor, starter relay, neutral relay, neu- tral switch, starter button, engine stop switch, ignition switch, and battery. Pressing the starter button (on the left handlebar switch) energizes the starter relay, causing the contact points to close, thus, completing the circuit from the starter motor to the battery.
Page 268 ELECTRICAL SYSTEM 8-13 Measure the starter relay voltage at the starter relay connectors (between Y/B © No voltage • • t y ignition switch F a u | and B/W © ) when the starter button is • Faulty engine stop switch pushed.
Page 269 8-14 ELECTRICAL SYSTEM • Disassemble the starter motor, as shown. © Housing end (outside) Brush holder Brush spring © Brush terminal set © O-ring © Starter motor case © O-ring Armature Washer set Housing end (inside) O-ring ® S T A R T E R MOTOR INSPECTION CARBON BRUSHES Inspect the carbon brushes for abnormal wear, cracks, or smoothness in the brush holder.
Page 270 A CAUTION" Replace the removed O-rings with new ones to pre- vent oil leakage and moisture. • Apply SUZUKI SUPER GREASE "A" to the lip of the oil seal. For USA Jif*99000-25030: SUZUKI SUPER G R E A S E "A"...
Page 271 8-16 ELECTRICAL SYSTEM S T A R T E R R E L A Y INSPECTION • Remove the rear fender. (CCP 7-7) • Remove the starter relay cover. • Disconnect the starter motor lead wire, battery lead wire, and starter relay coupler at the starter relay.
Page 272 ELECTRICAL SYSTEM 8-17 NEUTRAL R E L A Y INSPECTION • Remove the rear fender. ((XT 7-7) • Disconnect the neutral relay from the starter relay holder. Apply 12 V to terminals © and © ( © to © and © to © ) and check the continuity between ®...
Page 273: Ignition System
8-18 ELECTRICAL SYSTEM IGNITION SYSTEM DESCRIPTION In the capacitor discharged ignition system, the battery's electrical energy charges the capacitor. This energy is released in a single surge at the specified ignition timing point and the current flows through the primary side of the ignition coil. A high voltage is induced in the secondary windings of the ignition coil, resulting in a strong spark between the spark plug gap.
Page 274 ELECTRICAL SYSTEM 8-19 Measure the ignition coil primary peak voltage. (CZT 8-20) Inspect the spark plug. Correct NOTE: The ignition coil peak voltage ( C r 2-6 and 2-7) inspection method is applicable only with the multi circuit tester and the peak volt adaptor. Correct Incorrect Faulty spark plug...
Page 275 8-20 ELECTRICAL SYSTEM INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the front fender, ( d r * 7-6) • Remove the spark plug cap. • Connect a new spark plug to spark plug cap and ground it to the cylinder head. NOTE: Make sure the spark plug cap and spark plug are connected properly and the battery is fully-charged.
Page 276 ELECTRICAL SYSTEM 8-21 IGNITION COIL RESISTANCE • Remove the fuel tank. ( d r * 5-2 and 5-3) • Disconnect the ignition coil lead wire, coupler, and remove the ignition coil. Measure the ignition coil resistance in both the primary and secondary windings using the multi circuit tester.
Page 277 8-22 ELECTRICAL SYSTEM • Repeat the above procedure a few times and measure the highest pickup coil and power source coil peak voltage. Tester knob indication: Voltage ( ~ ) WM Pickup coil peak voltage: More than 0.5 V Power source coil peak voltage: More than 0.7 V PICKUP COIL AND POWER SOURCE COIL RESISTANCE •...
Page 278 ELECTRICAL SYSTEM 8-23 SPEEDOMETER REMOVAL • Remove the front fender. (£Zr 7-6) > • Remove the lower meter cover. • Disconnect the speedometer cable © , speedometer coupler © , and ignition switch coupler ® . • Remove the upper meter cover. •...
Page 279 8-24 ELECTRICAL SYSTEM DISASSEMBLY • Disassemble the speedometer, as shown. CD-" © Speedometer © Damper ® Braket © Pilot box reflector © Upper case pilot box © Pilot lens ® Bulb © Bulb ® Socket assembly...
Page 280 ELECTRICAL SYSTEM 8-25 L A M P S HEADLIGHT Headlight bulb: 12 V 30/30 W 12 V 35/36.5 W..E-17 A CAUTIOINT 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 •...
Page 281 8-26 ELECTRICAL SYSTEM TAILLIGHT Taillight bulb: 12 V Brake light/Taillight: 7/3,4W ..E-17 A CAUTION" 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 •...
Page 282 ELECTRICAL SYSTEM 8-27 SWITCHES Measure each switch for continuity using a tester. If any abnormality is found, replace the respective switch assemblies with a new one. IGNITION SWITCH ^ \ < 3 o l o r P o s i t i o n " " - ^ Light ( - $ - ) Light ( - $ - ) —...
Page 283: Initial Charging
8-28 ELECTRICAL SYSTEM BATTERY REMOVAL • Remove the battery. (cCr* 7-7) SPECIFICATIONS Type designation FTH16-BS-1 Capacity 12V, 50.4kC(14Ah)/10HR ® Anode plates ® Stopper © Separator (fiberglass plate) © Filter © Cathode plates © Terminal (3) Upper cover breather © Safety valve INITIAL CHARGING FILLING E L E C T R O L Y T E •...
Page 284 ELECTRICAL SYSTEM 8-29 Make sure the air bubbles © rise to the top of each electro- lyte container and leave the electrolyte container in this posi- tion for more than 20 minutes. NOTE: If air bubbles do not rise from any one of the filler ports, tap the bottom of the electrolyte container two or three times.
Page 285 8-30 ELECTRICAL SYSTEM SERVICING Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, clean the battery terminals with sandpaper.
Page 286 SERVICING INFORMATION CONTENTS TROUBLESHOOTING 9- 2 ENGINE SHAFT DRIVE 9- 5 CARBURETOR 9- 5 CHASSIS 9- 6 BRAKES 9- 7 ELECTRICAL 9- 8 BATTERY 9- 9 WIRING DIAGRAM 9-10 WIRE HARNESS, CABLE AND HOSE ROUTING 9-12 WIRE HARNESS ROUTING 9-12 CABLE ROUTING 9-14 DIFFERENTIAL AND FINAL BEVEL GEAR HOSE ROUTING...
Page 287 SERVICING INFORMATION TROUBLESHOOTING ENGINE S y m p t o m and p o s s i b l e c a u s e s R e m e d y Complaint E n g i n e will not start C o m p r e s s i o n too low 1.
Page 288 SERVICING INFORMATION Complaint S y m p t o m a n d p o s s i b l e c a u s e s R e m e d y E n g i n e is noisy. E x c e s s i v e valve chatter 1.
Page 289 SERVICING INFORMATION R e m e d y Complaint S y m p t o m a n d p o s s i b l e c a u s e s Replace. 1. W o r n or d a m a g e d clutch shoes. Slipping clutch.
Page 290 SERVICING INFORMATION SHAFT DRIVE Complaint S y m p t o m a n d p o s s i b l e c a u s e s R e m e d y 1. Broken secondary drive and driven gear teeth. Replace.
Page 291 SERVICING INFORMATION CHASSIS Complaint S y m p t o m a n d p o s s i b l e c a u s e s R e m e d y 1. Improper front wheel alignment. Adjust. Handling is too heavy 2.
Page 292 SERVICING INFORMATION B R A K E S S y m p t o m a n d p o s s i b l e c a u s e s R e m e d y Complaint 1. Insufficient brake fluid. Refill to level mark.
Page 293 SERVICING INFORMATION E L E C T R I C A L R e m e d y S y m p t o m a n d p o s s i b l e c a u s e s Complaint Replace.
Page 294 SERVICING INFORMATION BATTERY R e m e d y Complaint S y m p t o m a n d p o s s i b l e c a u s e s Replace. 1. Cracked battery case. Sulfation or s p o t s on 2.
Page 295 9-10 SERVICING INFORMATION WIRING DIAGRAM JflJJuIlilJJlJ E-03,24,28 and 33 j ! | S ! f H l 1 !i iiiiiiiiiliSjiiiifiim l„^ai«:j;Slll£llSlSlllgg...
Page 296 SERVICING INFORMATION 9-11 lllijliil E-17 iiilMiiIIillIMIMiiiii 5 5 i ? - uj « S i S «: S l^i^oii;S§lIllalSlllI?g • L I S...
Page 297 9-12 SERVICING INFORMATION WIRE HARNESS, C A B L E , AND HOSE ROUTING WIRE HARNESS ROUNTING Clamp Clamp /Wiring harness Handlebar switch (L) Clamp Ignition switch Clamp Handlebar switch \Wiring harness Speedometer Clamp 'Horn button (E-24) Emergency switch (E-17) \Wiring harness / ©...
Page 298 SERVICING INFORMATION 9-13 ^ • J 1 2 0 7 B ] Engine ground lead wire Starter motor lead wire Right crankcase Clamp Generator lead wire Generator lead wire Neutral switch...
Page 299 9-14 SERVICING INFORMATION C A B L E ROUTING Rear brake lever cable ^Throttle cable Brake hose Pass the throttle cable behind the brake hose and rear brake lever cable. Speedometer cable Rear brake lever cable Water pump inlet hose Clamp Rear brake Rear brake lever cable...
Page 300 SERVICING INFORMATION 9-15...
Page 301 9-16 SERVICING INFORMATION...
Page 302 SERVICING INFORMATION 9-17 REAR BRAKE BREATHER HOSE ROUTING...
Page 303 9-18 SERVICING INFORMATION F U E L S Y S T E M HOSE ROUTING Steering head cover...
Page 304 SERVICING INFORMATION 9-19...
Page 305 9-20 SERVICING INFORMATION FRONT B R A K E HOSE ROUTING Throttle cable Fix the grommet of brake hose to the hose clamp Brake hose After touching the brake hose union to the stopper, tighten the union bolt to the specified torque.
Page 306 SERVICING INFORMATION 9-21...
Page 307 9-22 SERVICING INFORMATION S P E C I A L TOOLS 09900-00410 Hexagon w r e n c h 09900-06106 09900-06107 09900-06108 09900-09004 S n a p ring pliers Impact driver s e t S n a p ring pliers S n a p ring pliers 09900-20508 09900-20202...
Page 308 SERVICING INFORMATION 9-23 0 9 ^ ^ ^ ^ ^ ^ ^ C o m p r e s s i o n g a u g e s e t 09915-74510 09916-10911 09913-84510 09915-40610 09915-63310 Oil filter w r e n c h Oil p r e s s u r e g a u g e V a l v e lapper s e t Bearing installer...
Page 309 9-24 SERVICING INFORMATION 09924-61810 09924-21930 09924-74520 09924-52420 Final drive gear 09924-21940 Drive shaft remover Bearing installer Holder coupling holder Wheel hub remover 09930-31920 09930-40113 09924-84510 09930-30102 09930-30721 Rotor remover Rotor holder B e a r i n g installer s e t Sliding h a m m e r Rotor remover 09941-54911...
Page 310: Tightening Torque
SERVICING INFORMATION 9-25 TIGHTENING TORQUE ENGINE kgf-m Ib-ft ITEM Cylinder head cover bolt Camshaft sprocket bolt 11.0 Cylinder head bolt 27.5 6 mm oyunaer neaa nui 18.0 8 mm Cylinder base nut Cam chain tensioner bolt Cam chain tension adjuster bolt Cam chain tension adjuster cap bolt Spark plug Valve clearance adjuster locknut...
Page 311 9-26 SERVICING INFORMATION DIFFERENTIAL ITEM kgf-m Ib-ft Front differential gear oil drain plug 16.5 Front differential gear selection cam stopper 16.5 Front differential gear case mounting nut 32.5 Front drive bevel gear nut 87.0 12.0 Front drive bevel gear housing bolt 16.5 Front driven bevel gear bearing case bolt 16.5...
Page 312: Tightening Torque Chart
SERVICING INFORMATION 9-27 kgf-m Ib-ft ITEM 36.0 Rear wheel set nut Rear brake cam lever nut Rear brake pedal nut Rear brake drum cover bolt 16.5 Rear shock absorber mounting nut (Upper) 43.5 40.0 bolt (Lower) 58.0 Rear suspension arm pivot nut 43.5 Rear suspension arm rear nut and bolt 36.0...
Page 313 9-28 SERVICING INFORMATION SERVICE DATA Unit: mm (in) VALVE + GUIDE ITEM STANDARD LIMIT 30.6 Valve diam. (1.20) 27.0 (1.06) Valve clearance (when cold) 0.05 - 0.10 (0.002 - 0.004) 0.17 - 0.22 (0.007 - 0.009) Valve guide to valve stem 0.010 - 0.037 (0.0004 - 0.0015) clearance...
Page 314 SERVICING INFORMATION 9-29 Unit: mm (in) CAMSHAFT + CYLINDER HEAD ITEM LIMIT STANDARD 33.450 - 33.490 33.150 Cam height (1.3169 - 1.3185) (1.3051) 33.520 - 33.560 33.220 (1.3197 - 1.3213) (1.3079) Camshaft journal oil clearance 0.032 - 0.066 0.150 0 22 (0.0013 - 0.0026) (0.0059) 0.028 - 0.059...
Page 315 9-30 SERVICING INFORMATION LIMIT STANDARD ITEM Piston ring groove width 1.01 - 1.03 (0.0398 - 0.0406) 1.21 - 1.23 (0.0476 - 0.0484) 2.51 - 2.53 (0.0988 - 0.0996) 0.97 - 0.99 Piston ring thickness (0.0382 - 0.0390) 1.17 - 1.19 (0.0461 - 0.0469) 23.002 - 23.008 23.030...
Page 316 SERVICING INFORMATION 9-31 Unit: mm (in) Except ratio TRANSMISSION + DRIVE BELT ITEM STANDARD LIMIT Reduction ratio Variable change (2.555 - 0.706) Secondary reduction ratio 1.133 (17/15) Final reduction ratio Front 3.600 (36/10) Rear 3.600 (36/10) Transmission re- 6.406 (40/16 x 41/16) duction ratio High 3.523 (33/24 x 41/16)
Page 317 9-32 SERVICING INFORMATION CARBURETOR SPECIFICATION ITEM ITEM E-03, 24, 28 E-17 E-33 Carburetor type MIKUNI BST34SS Bore size 34 mm <— I.D. No. 09FA 09FC 09FB Idle r/min. 1 500 ± 100 r/min. <— 13.0 ± 0.5 mm Float height <—...
Page 318 SERVICING INFORMATION 9-33 WATTAGE Unit:W SPECIFICATION ITEM ITEM E-03, 24, 28, 33 E-17 Headlight 30 x 2 pes. 35 x 2 pes. 30 x 2 pes. 36.5 x 2 pes. Taillight 5 x 2 pes. — " Brake light/Taillight 7/3.4 x 2 pes. —...
Page 319 9-34 SERVICING INFORMATION TIRE PRESSURE COLD INFLATION kgf/cm NOTE TIRE PRESSURE LOAD CAPACITY LOAD CAPACITY FRONT 0.35 REAR 0.30 UP TO 172 kg (380 lbs) UP TO 172 kg (380 lbs) VEHICLE LOAD CAPACITY LIMIT: 172 kg (380 lbs) FUEL + OIL ITEM SPECIFICATION NOTE...
Page 320 LT-A500FK1 ('01-MODEL) LT-A500FK1 ('01-MODEL) FOREWORD This chapter describes service data, servicing procedures which differ from those of the LT- A500FY ('OO-MODEL). NOTE: * Any differences between LT-A500FY (VO-MODEL) and LT-A500FK1 ('01-MODEL) in speci- fications and service data are clearly indicated with the asterisk marks (*). * Please refer to the chapter 1 through 9 for details which are not given in this chapter.
Page 321 10-2 LT-A500FK1 ('01-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length 2 005 mm (79.0 in 2 050 mm (80.7 in E-17 Overall width 1 170 mm (46.1 in Overall height 1 185 mm (46.7 in 1 175 mm (46.3 in E-17 Wheelbase 1 230 mm (48.4 in...
Page 322 LT-A500FK1 ('01-MODEL) 10-3 CHASSIS Front suspension Independent, double wishbone, coil spring, oil damped, spring preload 5-way adjustable Rear suspension 4-link rigid axle, coil spring, oil damped, spring preload 5-way adjustable Steering angle Inside 38° Outside 26° Trail 17 mm (0.67 in) Turning radius 3.0 m (9.8 ft) Front brake...
Page 323 10-4 LT-A500FK1 ('01-MODEL) SERVICE DATA Unit, mm (in) VALVE + GUIDE ITEM STANDARD LIMIT Valve diam. 30.6 (1.20) 27.0 (1.06) Valve clearance (when cold) 0 . 0 5 - 0 . 1 0 (0.002 - 0.004) 0 . 1 7 - 0 . 2 2 (0.007 - 0.009) Valve guide to valve stem 0 .
Page 324 LT-A500FK1 ('01-MODEL) 10-5 Unit: mm (in) CAMSHAFT + CYLINDER HEAD ITEM STANDARD LIMIT 33.450 - 33.490 33.150 Cam height (1.3169 - 1.3185) (1.3051) 33.520 - 33.560 33.220 ( 1 . 3 1 9 7 - 1.3213) (1.3079) 0.032 - 0.066 0.150 Camshaft journal oil clearance <p22...
Page 325: Oil Pump
10-6 LT-A500FK1 ('01-MODEL) ITEM LIMIT STANDARD Piston ring groove width 1.01 - 1.03 (0.0398 - 0.0406) 1.21 - 1.23 (0.0476 - 0.0484) 2.51 - 2.53 (0.0988 - 0.0996) Piston ring thickness 0.97 - 0.99 (0.0382 - 0.0390) 1 . 1 7 - 1 . 1 9 (0.0461 - 0.0469) Piston pin bore 23.002 - 23.008...
Page 326 LT-A500FK1 ('01-MODEL) 10-7 Unit: mm (in) Except ratio TRANSMISSION + DRIVE BELT LIMIT ITEM STANDARD Reduction ratio 'Variable change (2.876 - 0.703) Secondary reduction ratio 1.133 (17/15) Final reduction ratio Front 3.600 (36/10) Rear 3.600 (36/10) Transmission re- 6.406 (40/16 x 41/16) duction ratio High 3.523 (33/24 x 41/16)
Page 327 10-8 LT-A500FK1 ('01-MODEL) CARBURETOR SPECIFICATION ITEM ITEM E-03, 24, 28 E-17 E-33 Carburetor type MIKUNI BST34SS <e- <- 34 mm Bore size <— <— I.D. No. 09FA 09FC 09FB Idle r/min. 1 500 ± 100 r/min. <- Float height 13.0 ± 0.5 mm <- (0.51 ±...
Page 328 LT-A500FK1 ('01-MODEL) 10-9 U n i t W WATTAGE SPECIFICATION ITEM ITEM E-17 E-24 E-03, 28, 33 30 x 2 pes. 35 x 2 pes. Headlight Headlight 36.5 x 2 pes. 30 x 2 pes. 5 x 2 pes. 5 x 2 pes. Taillight _______ 7/3.4 x 2 pes.
Page 329 10-10 LT-A500FK1 ('01-MODEL) TIRE PRESSURE COLD INFLATION kgf/cm NOTE TIRE PRESSURE LOAD CAPACITY LOAD CAPACITY FRONT 0.35 REAR 0.30 UP TO 172 kg (380 lbs) UP TO 172 kg (380 lbs) VEHICLE LOAD CAPACITY LIMIT: 172 kg (380 lbs) FUEL + OIL ITEM SPECIFICATION NOTE...
Page 330: Periodic Maintenance Chart
LT-A500FK1 ('01-MODEL) 10-11 PERIODIC MAINTENANCE CHART ^ ^ - ^ ^ ^ ^ ^ - ^ ^ ^ ^ ^ - ^ ^ ^ Interval Interval Interval 1 000 2 000 miles 1 200 Item Item Item months Air cleaner Exhaust pipe nuts and muffler bolts Valve clearance Spark plug...
Page 331: Maintenance Procedures
10-12 LT-A500FK1 ('01-MODEL) MAINTENANCE PROCEDURES SPARK ARRESTER A CAUTION Clean every 2 000 km (1 200 miles, 6 months). Remove the muffler end cover. • Remove the spark arrester. ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ "...
Page 332 LT-A500FK1 ('01-MODEL) 10-13...
Page 333 10-14 LT-A500FK1 ('01-MODEL) FINAL BEVEL GEARS CONSTRUCTION ^4l322| ( § ) « - | T 3 0 3 | / Final gear bearing case (R) O-ring Oil seal Bearing © Shim Final bevel gear set ® Washer Shim Final bevel gear case Bearing Oil seal Bearing...
Page 334 LT-A500FK1 ('01-MODEL) 10-15 REMOVAL AND DISASSEMBLY • Remove the rear axle housings and axle shafts. • Drain the final bevel gear oil. • Disconnect the final drive shaft boot ©. • Remove the final bevel gear case assembly (2). • Remove the final drive shaft housing. •...
Page 335 10-16 LT-A500FK1 f 01-MODEL) • Hold the final drive shaft coupling using the special tool and then remove the final drive gear nut. IT55LI 09924-61810: Final drive gear coupling holder. Remove the washer © and final drive shaft coupling ® ®...
Page 336 LT-A500FK1 ('01-MODEL) 10-17 • Remove the final gear right case bolts. INSPECTION Inspect the final drive shaft for wear or damage. If any damages are found, replace the final drive shaft.
Page 337 10-18 LT-A500FK1 ('01-MODEL) BEARINGS AND OIL S E A L S INSPECTION Play - — P l a y Check the inner race play of the bearing by hand while it is in the case. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation.
Page 338 LT-A500FK1 ('01-MODEL) 10-19 Install the final driven gear bearing using the special tool. 09913-70210: Bearing installer set • Install the new final driven gear oil seal using the special tool. 09913-70210: Bearing installer set • Install the new final drive pilot bearing using the special tool. 09924-84521: Bearing installer set FINAL GEAR RIGHT C A S E BEARING AND OIL S E A L •...
Page 339 10-20 LT-A500FK1 ('OI-MODEL) Remove the drive bevel gear bearig using the vise and attach- ing a suitable tool on the drive shaft and then tapping the tool with hammer. A CAUTION Replace the removed oil seal with a new one. •...
Page 340 LT-A500FK1 ('01-MODEL) 10-21 FINAL GEAR BEARING C A S E SHIM CLEARANCE Measure the clearance ® between the driven gear and bearing. Pay attention to the following points: Measure the height ® of the bearing inner race surface and bear- ing case flange using the special tools and straightedge.
Page 341 10-22 LT-A500FK1 ('01-MODEL) TOOTH CONTACT After backlash adjustment is carried out, the tooth contact must be checked. Pay attention to the follwing procedures: • Remove the final driven bevel gear. • Clean and degrease several teeth on the final driven bevel gear and apply a coating of machinist's layout dye or paste to teeth.
Page 342 • Install new O-rings to the final gear right case and stopper. • Apply SUZUKI SUPER GREASE "A" to the O-rings. For USA J f f n 99000-25030: SUZUKI SUPER G R E A S E "A" For the other countries 99000-25010: SUZUKI SUPER G R E A S E "A"...
Page 343 99000-25030: SUZUKI SUPER G R E A S E "A" For the other countries ^ a H 99000-25010: SUZUKI SUPER G R E A S E "A" • Install the oil seal collar using the special tool. 09913-70210: Bearing installer set NOTE: Set the suitable tool ®...
Page 344 • Tighten the final drive shaft housing nut to the specified torque. H Final drive shaft housing nut: 23 N-m (2.3 kgf-m, 16.5 Ib-ft) • Apply SUZUKI SUPER GREASE "A" to the spline of the final drive shaft. REMOUNTING Remount the final bevel gear case assembly in the reverse order...
Page 345 10-26 LT-A500FK1 ('01-MODEL) REASSEMBLY INFORMATION kgf-m Ib-ft ITEM ® 16.5 © 11.0 79.5 © 16.5 10.0 72.5 List of shims List of shims List of shims ® Part No. Shim thickness (mm) Part No. Shim thickness (mm) Shim thickness (mm) Part No.
Page 346: Wiring Diagram
LT-A500FK1 ('01-MODEL) 10-27 WIRING DIAGRAM F o r E - 0 3 , 2 4 , 2 8 , 3 3 SS2IS51I*" °>0)O ? OJ m > v; v; v; v: -* C ra = o g ro ro"a^= ^ J g 3 = g £ £ m m m o o o c r ^ >...
Page 347 10-28 LT-A500FK1 ('01-MODEL) For E-17 5 ^ v-_v>_v«_v- s > 0)0)0)0)g a) a) > > ° o o o o o a) a > « = c c c "l . - S o _o m m a a o c c ^ > - m m m m m m m o o o o a : ^ > - > - ^ LU <...
Page 348: Cooling System Hose Routing
LT-A500FK1 ('01-MODEL) 10-29 COOLING SYSTEM HOSE ROUTING •g ~o -Q "co " t o c o 0 cn o T 3 " £ 1 C O 0 0 o o o o X - Q c t f 0 0 0 0 £- s¬...
Page 349 Prepared by S U Z U K I MOTOR CORPORATION Motorcycle Service Department 2nd Ed, December, 2000 1st Ed, July, 1999 Part NO.99500-44032-01E Printed in Japan...
Page 350 SUZUKI MOTOR CORPORATION Printed in Japan ( T K ) Y K1...

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