Suzuki LT-F500F 2002 Service Manual
  1. Manuals
  2. Brands
  3. Suzuki Manuals
  4. Offroad Vehicle
  5. LT-F500F 2002
  6. Service manual

Suzuki LT-F500F 2002 Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the LT-F500F 2002 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Suzuki LT-F500F 2002

Summary of Contents for Suzuki LT-F500F 2002

  • Page 2 FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI LT-F500F and procedures for its inspection, service, and overhaul of its main compo- GENERAL INFORMATION nents. Other information considered as generally known is not included. PERIODIC MAINTENANCE Read the GENERAL INFORMATION section to familiarize yourself with the vehicle and its mainte- nance.
  • Page 3 HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily.
  • Page 4 Apply molybdenum oil solution. Apply or use brake fluid. (mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 : 1) Apply SUZUKI SUPER GREASE “A”. Measure in voltage range. 99000-25030 (USA) 99000-25010 (Others) Measure in resistance range.

  • Page 5: Table Of Contents

    GENERAL INFORMATION GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE .............. 1- 2 GENERAL PRECAUTIONS ..............1- 2 SUZUKI LT-F500FK3 (2003-MODEL) ..........1- 4 SERIAL NUMBER LOCATION ............1- 4 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION ....1- 4 FUEL .................... 1- 4 ENGINE OIL.................. 1- 5 FRONT AND REAR DRIVE GEAR OIL ........

  • Page 6: Warning/Caution/Note

    GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. Indicates a potential hazard that could result in death or injury.
  • Page 7 GENERAL INFORMATION " * If parts replacement is necessary, replace the parts with SUZUKI Genuine Parts or their equiv- alent. * 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-F500Fk3 (2003-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% etha- nol.

  • Page 9: Engine Oil

    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: Break-Ln Procedures

    GENERAL INFORMATION " 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: Information Labels

    GENERAL INFORMATION INFORMATION LABELS APPLIED SPECIFICATION LABEL or PLATE NAME E-03 E-28 E-33 ¡ ¡ — Certification plate ¡ — — Information label ¡ ¡ ¡ Tire air pressure label ¡ — — Tire air pressure label and warning no-passenger label ¡...

  • Page 12: Specifications

    GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length............2 095 mm (82.5 in) Overall width ............1 170 mm (46.1 in) Overall height............1 200 mm (47.2 in) Wheelbase ............1 270 mm (50.0 in) Ground clearance ..........250 mm ( 9.8 in) Seat height............
  • Page 13 GENERAL INFORMATION CHASSIS Front suspension..........Independent, double wishbone, coil spring, oil damped Rear suspension ..........Swingarm type, coil spring, oil damped Front wheel travel..........180 mm (7.1 in) Rear wheel travel ..........200 mm (7.9 in) Caster..............3.3° Trail ..............17 mm (0.67 in) Toe-in ..............

  • Page 14: Country And Area Codes

    1-10 GENERAL INFORMATION COUNTRY AND AREA CODES The following codes stand for the applicable countries and areas. CODE COUNTRY OR AREA E-03 E-28 Canada E-33 California (USA)
  • Page 15 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 SPARK PLUG ................2- 6 FUEL LINE ...................2- 7 THROTTLE CABLE PLAY ............2- 8 ENGINE IDLE SPEED ..............2- 8...

  • Page 16: Periodic Maintenance Schedule

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the vehicle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometers, miles and months, and are dependent on whichever comes first. NOTE: More frequent servicing may be performed on vehicles that are use under severe conditions.

  • Page 17: Maintenance And Tune-Up Procedures

    PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item mentioned in the Periodic Maintenance chart. AIR CLEANER Clean every 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

    PERIODIC MAINTENANCE * Inspect the air cleaner element for tears. A torn ele- ment must be replaced. * If driving under dusty conditions, clean the air cleaner element more frequently. The surest way to accelerate engine wear is to operate the engine with- out the element or with torn element.

  • Page 19: Valve Clearance

    PERIODIC MAINTENANCE VALVE CLEARANCE 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 insufficient valve clearance results in valve damage and reduced power. Check the intake and exhaust valve clearances at the distances indicated above and adjust the valve clearances to specification, if necessary.

  • Page 20: Spark Plug

    • Apply grease to the O-rings and install the O-rings valve inspection caps. • Tighten the valve inspection cap bolts/nuts to the specified torque. & 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) # Valve inspection cap bolt/nut: 10 N·m (1.0 kgf-m, 7.0 lb-ft) SPARK PLUG Inspect every 2 000 km (1 200 miles, 6 months).

  • Page 21: Fuel Line

    PERIODIC MAINTENANCE SPARK PLUG GAP Measure the spark plug gap using a thickness gauge. If the spark plug gap is out of specification, adjust the gap. $ Standard Spark plug gap: 0.7 – 0.8 mm (0.028 – 0.031 in) % 09900-20803: Thickness gauge 0.7 –...

  • Page 22: Throttle Cable Play

    PERIODIC MAINTENANCE THROTTLE CABLE PLAY Inspect initially at 200 km (100 miles, 1 month) and every 1 000 km (600 miles, 3 months) thererafter. Adjust the throttle cable play A as follows. • Loosen the locknut 1 of the throttle cable. •...

  • Page 23: Engine Oil And Oil Filter

    PERIODIC MAINTENANCE ENGINE OIL AND OIL FILTER Replace initially at 200 km (100 miles, 1 month) and every 2 000 km (1 200 miles, 6 months) thereafter. The oil should be changed while the engine is warm. Oil filter replacement at the above intervals, should be done together with the engine oil change.
  • Page 24 Oil and filter change: 3.6 L (3.8 US qt, 3.2 lmp qt) Engine overhaul: 4.0 L (4.2 US qt, 3.5 lmp qt) ONLY USE A GENUINE SUZUKI MOTORCYCLE OIL FILTER. Other manufacture’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 25: Differential Gear And Final Bevel Gear Oil

    PERIODIC MAINTENANCE 2-11 DIFFERENTIAL GEAR AND FINAL BEVEL GEAR OIL Inspect every 2 000 km (1 200 miles, 6 months). Replace every 2 years. To change the differential gear and final bevel gear oil, locate the vehicle on a level position and carry out the following steps. Use SAE #90 hypoid gear oil which is rated GL-5 under the API classification system.

  • Page 26: Engine Coolant

    2-12 PERIODIC MAINTENANCE • Place an oil pan below the final gear case, and then drain the oil by removing the drain plug 2 and filler cap 3. • Tighten the drain plug 2 to the specified torque. # Final bevel gear oil drain plug: 33 N·m (3.3 kgf-m, 24.0 lb-ft) •...

  • Page 27: Radiator Hoses

    PERIODIC MAINTENANCE 2-13 • Remove the radiator cap 2 and engine coolant reservoir cap • Remove the right inner fender. ("7-6) • Place a pan below the water pump, and then drain the engine coolant by removing the drain plug 4. * Do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor.

  • Page 28: Clutch

    • Apply grease to the O-ring and install the O-ring clutch adjuster cap. • Install the clutch adjuster cap. & 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) SPARK ARRESTER Clean every 2 000 km (1 200 miles, 6 months).

  • Page 29: Brakes

    PERIODIC MAINTENANCE 2-15 BRAKES FRONT 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 and the right rear wheel. ("7-11) The extent of brake pads wear can be checked by observing the limit line 1 on the side of brake pads.

  • Page 30: Brake Fluid

    2-16 PERIODIC MAINTENANCE Rear brake lever • After adjusting the brake pedal, check the rear brake lever play. The brake lever play B as measured at the lever holder should be between 3 – 5 mm (0.1 – 0.2 in) when the lever is lightly pulled in towards the grip.
  • Page 31 PERIODIC MAINTENANCE 2-17 AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion absorb a large proportion of the pressure developed by the master cylin- der and thus interferes with the full braking performance of the brake caliper.

  • Page 32: Brake Hoses

    2-18 PERIODIC MAINTENANCE BRAKE HOSES Inspect every 2 000 km (1 200 miles, 6 months). Replace every 4 years. • Check the brake hoses for leakage, cracks, wear and dam- age. If any damages are found, replace the brake hoses with new ones.

  • Page 33: Steering System

    PERIODIC MAINTENANCE 2-19 To minimize the possiblility of tire damage from over-inflation, we strongly recommended that a man- ual type air pump be used rather than a high pressure air compressor as found in service stations. When fill- ing air into the tires, never exceed 70 kPa (0.7 kgf/cm², 10 psi).

  • Page 34: Suspensions

    2-20 PERIODIC MAINTENANCE SUSPENSIONS Inspect every 2 000 km (1 200 miles, 6 months). • Support the vehicle using a jack and wooden blocks. • Remove the front and rear wheels. ("7-11) • Inspect the suspension arm and bushing for scratches, wear, or damage.

  • Page 35: Chassis Nuts And Bolts

    PERIODIC MAINTENANCE 2-21 CHASSIS NUTS AND BOLTS 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 2-22 for the loca- tions of the following nuts and bolts.) Item N·m...
  • Page 36 2-22 PERIODIC MAINTENANCE...

  • Page 37: General Lubrication

    PERIODIC MAINTENANCE 2-23 GENERAL LUBRICATION Lubricate every 1000 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. & 1Steering shaft holder 5Drive shaft joint spline Grease 2Brake lever holder and throttle lever...

  • Page 38: Compression Pressure Check

    2-24 PERIODIC MAINTENANCE COMPRESSION PRESSURE CHECK The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership shoud include compression readings for each maintenance service. $ Compression pressure: Standard: 1 000 kPa (10.0 kgf/cm², 142 psi) Service Limit: 800 kPa (8.0 kgf/cm², 114 psi)

  • Page 39: Oil Pressure Check

    PERIODIC MAINTENANCE 2-25 OIL PRESSURE CHECK Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. $ Oil pressure: Above 120 kPa (1.2 kgf/cm², 17.0 psi) at 3 000 r/min, Oil temp. at 60°C (140°F) Below 160 kPa (1.6 kgf/cm², 23.0 psi) Low or high oil pressure can indicate any of the following conditions: LOW OIL PRESSURE...

  • Page 40: Initial Engagement And Clutch Lock-Up Inspection

    2-26 PERIODIC MAINTENANCE INITIAL ENGAGEMENT AND CLUTCH LOCK-UP INSPECTION The LT-F500F 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 41: Clutch Lock-Up Inspection

    PERIODIC MAINTENANCE 2-27 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 high-tension code. • Start the engine. • Shift the range lever to the “High” position. •...

  • Page 42: Parking Inspection

    2-28 PERIODIC MAINTENANCE PARKING INSPECTION Depress the rear brake pedal and shift the shift lever 1 into “P” (Parking). Inspect the rear wheel for locking by moving the vehi- cle back and forth. If the rear wheel is unlocked, inspect the rear drive. ("4-28) If it is unable to shift into “P”, adjust the parking interlock cable.
  • Page 43 ENGINE ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ...3- 2 ENGINE LEFT SIDE ..............3- 2 ENGINE RIGHT SIDE ..............3- 2 ENGINE CENTER ................3- 2 ENGINE REMOVAL AND INSTALLATION .........3- 3 ENGINE REMOVAL ..............3- 3 ENGINE INSTALLATION .............3- 8 ENGINE DISASSEMBLY ..............3-12 ENGINE TOP SIDE ..............3-12 ENGINE BOTTOM SIDE ..............3-16...

  • Page 44: Engine Components Removable With Engine In Place

    ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and installed without removing the engine from the frame. Refer to the page listed in each section for removal and installation instructions. ENGINE LEFT SIDE PARTS REMOVAL INSTALLATION...

  • Page 45: Engine Removal And Installation

    ENGINE ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal procedure. • Drain engine oil. (!2-9) •...
  • Page 46 ENGINE • Remove the engine under cover 1. • Remove the carburetor. (!5-8) • Disconnect the breather hose 2 that connects the oil retun tank and the engine. • Disconnect the engine ground lead wire 3 and starter motor lead wire 4. •...
  • Page 47 ENGINE • Remove the reverse switch. • Disconnect the gearshift arm A and reverse gear cable B. • Disconnect the spark plug cap C. • Disconnect the engine coolant temperature switch lead wire • Remove the muffler. • Remove the exhaust pipe. •...
  • Page 48 ENGINE • Remove the right footrest. • Remove the brake pedal. • Remove the propeller shaft flange coupling bolts, front and rear.
  • Page 49 ENGINE • Remove the engine mounting bolts and nuts. • Remove the engine mounting bracket A. • Remove the engine from the right side.

  • Page 50: Engine Installation

    ENGINE ENGINE INSTALLATION Remount the engine in the reverse order of engine removal. Pay attention to the following points: NOTE: * The engine mounting nuts are self-locking. * Once the nut has been removed, it is no longer of any use. Be sure to use new nuts, and then tighten them to the specified torque.
  • Page 51 ENGINE • Install the propeller shaft, front and rear. NOTE: FRONT Align the match marks on the front propeller shaft so that the yoke A would be aligned with the yoke B as shown in illustra- tion. Match mark • Apply THREAD LOCK SUPER “1303” to the propeller shaft flange coupling bolts and tighten them to the specified torque.
  • Page 52 3-10 ENGINE • Adjust the brake pedal height as shown. % Brake pedal height A Standard: 5 – 15 mm (0.2 – 0.6 in) Brake pedal (!2-15) • Install the new gasket and tighten the exhaust pipe nuts tem- porally. •...
  • Page 53 • Tighten the locknut 2 by holding the adjuster screw 3. # Locknut 1: 8 N·m (0.8 kgf-m, 5.7 lb-ft) Locknut 2: 23 N·m (2.3 kgf-m, 16.5 lb-ft) • Apply SUZUKI SUPER GREASE “A” to the O-ring and install the clutch adjuster cap. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A”...

  • Page 54: Engine Disassembly

    3-12 ENGINE ENGINE DISASSEMBLY ENGINE TOP SIDE SPARK PLUG • Remove the spark plug. ( 09930-10121: Spark plug wrench set • Remove the valve timing inspection plug 1. • Turn the crankshaft and align the “TDC” line A on the genera- tor rotor with the index mark B on the crankcase.
  • Page 55 ENGINE 3-13 • Remove the gear position switch. RECOIL STARTER • Remove the recoil starter. CYLINDER HEAD COVER • Remove the valve inspection caps. • Remove the cylinder head cover. CAMSHAFT • Remove the camshaft end cap 1.
  • Page 56 3-14 ENGINE • Flatten the lock washer. • Remove the cam chain sprocket bolts and lock washer. • Remove the camshaft 1 and camshaft sprocket 2. " Do not drop the cam chain 3 into the crankcase. • Remove the C-ring 4. "...
  • Page 57 ENGINE 3-15 • Remove the cylinder head bolts diagonally. • Remove the cylinder head. NOTE: If the cylinder head does not come off, lightly tap it with a plastic hammer. • Remove the dowel pins and gasket 1. CYLINDER • Remove the cam chain guide 1. •...

  • Page 58: Engine Bottom Side

    3-16 ENGINE • Remove the dowel pins and gasket 3. PISTON • Remove the piston by removing the piston pin circlip 1. NOTE: Place a rag under the piston so as not to drop the piston pin cir- clip into the crankcase. ENGINE BOTTOM SIDE SPEEDOMETER GEARBOX •...
  • Page 59 ENGINE 3-17 • Remove the generator rotor cover. TRANSFER • Remove the starter driven gear 1, the spacer 2, the starter idle gear 3, the washer 4, the transfer idle gear 5, the washer 6, the transfer No. 2 gear 7, the washer 8 and the transfer output gear 9.
  • Page 60 3-18 ENGINE NEUTRAL SWITCH • Remove the neutral switch. • Remove the O-ring 1, spring 2 and pin 3. CLUTCH COVER • Remove the clutch adjuster cap. • Remove the clutch cover. • Remove the washer 1, clutch release arm 2 and clutch release roller guide 3.
  • Page 61 ENGINE 3-19 • Unlock the clutch shoe nut. CLUTCH • While holding the generator rotor with the special tool, remove the clutch shoe nut. ( 09930-44541: Rotor holder " Clutch shoe nut has left-hand threads. • Remove the clutch release plate 1. •...
  • Page 62 3-20 ENGINE • Remove the clutch sleeve hub nut with the special tool. ( 09920-53730: Clutch sleeve hub holder • Remove the clutch shoe assembly and primary driven gear assembly. CAM CHAIN • Remove the cam chain. GEARSHIFT • Remove the gearshift cam plate guide 1. •...
  • Page 63 ENGINE 3-21 GEARSHIFT CAM STOPPER • Remove the cam stopper nut 1, the gearshift cam stopper 2 and spring 3. OIL PUMP DRIVE GEAR • Remove the oil pump drive gear bolt by holding the oil pump driven gear with the special tool. ( 09930-40113: Rotor holder •...
  • Page 64 3-22 ENGINE GENERATOR • Remove the generator rotor bolt with the special tool. ( 09930-44541: Rotor holder • Remove the generator rotor with the special tool. ( 09930-30721: Rotor remover • Remove the key 1. • Remove the starter driven gear 2. •...
  • Page 65 ENGINE 3-23 • Remove the right crankcase bolts. • Separate the crankcase with the special tool. NOTE: * The crankcase separator plate is parallel with the end face of the crankcase. * The crankshaft must remain in the left crankcase half. ( 09920-13120: Crankcase separator DRIVE TRAIN/GEARSHIFT CAM •...
  • Page 66 3-24 ENGINE • Remove the output shaft assembly. BALANCER • Remove the balancershaft driven gear 1 and balancershaft CRANKSHAFT • Remove the crankshaft with the special tool. ( 09920-13120: Crankcase separator...

  • Page 67: Engine Components Inspection And Servicing

    ENGINE 3-25 ENGINE COMPONENTS INSPECTION AND SERVICING CYLINDER HEAD COVER DISASSEMBLY " Be sure to identify each removed part as to its loca- tion, and lay the parts out in groups designated as “Exhaust”, “Intake”, so that each will be restored to the original location during assembly.

  • Page 68: Cylinder Head

    3-26 ENGINE ROCKER ARM I.D. When checking the valve rocker arm, the inside diameter of the valve rocker arm and wear of the camshaft contacting surface should be checked. % Rocker arm I.D. Standard: 12.000 – 12.018 mm (0.4724 – 0.4731 in) ( 09900-20605: Dial calipers REASSEMBLY NOTE:...
  • Page 69 ENGINE 3-27 • Remove the intake pipe. • Remove the thermostat. • Remove the cam chain tensioner bolt 3. • Compress the valve spring and remove the valve cotters from the valve stem with the special tools. ( 09916-14510: Valve spring compressor 09916-14910: Attachment 09916-84511: Tweezers •...
  • Page 70 3-28 ENGINE • Remove the oil seal with long-nose pliers. • Remove the valve spring seat. NOTE: Removal of valves completes ordinary disassembling work. If valve guides have to be removed for replacement after inspect- ing the related parts, carry out the steps shown in the valve guide servicing.
  • Page 71 ENGINE 3-29 VALVE FACE WEAR Visually inspect each valve face for wear or damage. If any abnormal wear is found, replace the respective valve with a new one. Measure the valve head thickness T. If the valve head thickness is not within the specified value, replace the value with a new one.
  • Page 72 3-30 ENGINE • Re-finish the valve guide holes in the cylinder head with the reamer and handle. ( 09916-34580: Valve guide reamer (10.8 mm) 09916-34542: Reamer handle " When refinishing or removing the reamer from the valve guide hole, always turn it clockwise. •...
  • Page 73 ENGINE 3-31 % Valve seat width W Standard: 0.9 – 1.1 mm (0.035 – 0.043 in) ( 09916-10911: Valve lapper set If either requirement is not met, correct the seat by servicing it as follows: VALVE SEAT SERVICING The valve seats for intake and exhaust valves are machined to two different angles.
  • Page 74 3-32 ENGINE • Install the 45° cutter, attachment and T-handle. INITIAL SEAT CUT • Using the 45° cutter, descale and clean up the seat. Rotate the cutter one or two turns. • Measure the valve seat width W after every cut. •...
  • Page 75 ENGINE 3-33 FINAL SEAT CUT The contact area too low and too • If the contact area W is too low or too narrow, use the 45° cut- narrow on face of valve ter to raise and widen the contact area. NOTE: After cutting the 15°...
  • Page 76 3-34 ENGINE VALVE STEM END CONDITION Inspect the valve stem end face for pitting and wear. If pitting or wear of the stem end face are present, the valve stem end may be resurfaced, providing that the length 1 will not be reduced to less than the service limit.
  • Page 77 ENGINE 3-35 • Insert the valves, with their stems coated with molybdenum oil solution all around and along the full stem length without any break. * MOLYBDENUM OIL SOLUTION " When inserting each valve, take care not to damage the lip of the stem seal. •...

  • Page 78: Camshaft

    3-36 ENGINE • Apply SUZUKI SUPER GREASE “A” to the O-ring and install the intake pipe. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the thermostat. (!6-12) • Install the thermostat cover. • Apply SUZUKI BOND “1207B”/“1215” to the engine coolant temperature switch 5 and tighten it to the specified torque.
  • Page 79 To properly measure the oil clearance with plastigauge, all gas- ket material must be removed from fitting surfaces of cylinder head and cover. Do not apply SUZUKI BOND “1216B” until after the oil clearance has been determined. • Tighten the cylinder head cover bolts evenly and diagonally to the specified torque.

  • Page 80: Cam Chain Tension Adjuster

    3-38 ENGINE CAM CHAIN TENSION ADJUSTER CAM CHAIN TENSION ADJUSTER Insert the - screwdriver into the slotted end of cam chain ten- sion adjuster and turn it clockwise to lessen the tension and release the - screwdriver. Then check the push rod movement. If the push rod is stuck or spring mechanism failed, replace the cam chain tension adjuster with a new one.

  • Page 81: Piston

    ENGINE 3-39 PISTON PISTON DIAMETER Using a micrometer, measure the piston outside diameter at the place shown in Fig. If the measurement is less than the limit, replace the piston. % Piston diameter Service Limit: 87.380 mm (3.4402 in) 15 mm (0.6 in) ( 09900-20204: Micrometer (75 –...
  • Page 82 3-40 ENGINE PISTON RING FREE END GAP AND END GAP Before installing piston rings, measure the free end gap of each ring using vernier calipers. Next, fit the ring in the cylinder, and measure each ring end gap using a thickness gauge. If any ring has an excess end gap, replace the ring.

  • Page 83: Conrod/Crankshaft

    ENGINE 3-41 CONROD/CRANKSHAFT CONROD SMALL END I.D. Using a caliper gauge, measure the conrod small end inside diameter. % Conrod small end I.D. Service Limit: 23.040 mm (0.9071 in) ( 09900-20605: Dial calipers (10 – 34 mm) 09900-22403: Small bore gauge (18 – 35 mm) If the conrod small end inside diameter exceeds the above men- tioned limit, replace the conrod.

  • Page 84: Clutch

    3-42 ENGINE CLUTCH CLUTCH DRIVE PLATES NOTE: Wipe off engine oil from the clutch drive plates with a clean rag. • Measure the thickness of drive plates with a vernier calipers. • If each drive plate is not within the standard range, replace it with a new one.
  • Page 85 ENGINE 3-43 CLUTCH SHOES Inspect the clutch shoes for chips, cracks, uneven wear, and heat discoloration. Also, check the depth of the grooves on the clutch shoes. If there is no groove at any part of the shoes, replace the shoes as a set. NOTE: The clutch shoes must always be changed as a set.
  • Page 86 3-44 ENGINE • Apply THREAD LOCK SUPER “1303” to the bolts, and then tighten them to the specified torque with a offset wrench. # Starter clutch bolt: 26 N·m (2.6 kgf-m, 19.0 lb-ft) $ 99000-32030: THREAD LOCK SUPER “1303” ( 09930-44541: Rotor holder •...

  • Page 87: Transmission

    ENGINE 3-45 TRANSMISSION DISASSEMBLY • Disassemble the transmission as shown. Reverse gear dog Countershaft Reverse driven gear 4th drive gear " 1st driven gear 3rd drive gear 4th driven gear 5th drive gear 3rd driven gear 2nd drive gear 5th driven gear Reverse idle gear &...
  • Page 88 3-46 ENGINE REASSEMBLY Assemble the transfer in the reverse order of disassembly. Pay attention to the following points: NOTE: * Always use new snap rings. * Before installing the gears, coat lightly engine oil to the shafts and gears. " * Never reuse a snap ring.
  • Page 89 ENGINE 3-47 Reverse idle shaft Countershaft Driveshaft • When installing the bushings, align the shaft hole with the bushing hole.

  • Page 90: Gearshift Fork

    3-48 ENGINE GEARSHIFT FORK SHIFT FORK TO GROOVE CLEARANCE Using a thickness gauge, check the shifting fork clearance in the groove of its gear. The clearance for each of the three shifting forks plays an impor- tant role in the smoothness and positiveness of shifting action. If the clearance exceeds the limit, replace the fork or its gear, or both.

  • Page 91: Transfer Gearshift Cam

    ( 09924-84521: Bearing installer set NOTE: The stamped mark on the oil seal faces outside. • Apply a small quantity of the SUZUKI SUPER GREASE “A” to the oil seal lip. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
  • Page 92 3-50 ENGINE DISASSEMBLY • Disassemble the transfer gearshift cam as shown. REASSEMBLY • Install the snap ring 1, spring 2 and gearshift cam 3. NOTE: The convex side of the gearshift cam 3 face lower side. • Install the spring 4, washer 5 and snap ring 6.

  • Page 93: Oil Pump

    OIL PUMP " The oil pump case securing screw is applied with SUZUKI THREAD LOCK “1342”. If an attempt is made to overhaul the pump assembly, the screw may be damaged. Only the oil pump unit is available as a replacement.
  • Page 94 3-52 ENGINE GEARSHIFT CAM STOPPER • Apply a small quantity of THREAD LOCK “1342” to the thread and tighten the gearshift cam stopper to the specified torque. & 99000-32050: THREAD LOCK “1342” # Gearshift cam stopper: 10 N·m (1.0 kgf-m, 7.0 lb-ft) DRIVE BEVEL GEAR DISASSEMBLY •...
  • Page 95 ENGINE 3-53 • Remove the output shaft with a plastic mallet. DRIVE BEVEL GEAR REASSEMBLY • Install the output shaft with a plastic mallet. • Install the shim 1. • Install the drive bevel gear and washer 2. • Hold the output shaft with the special tool. ( 09930-73150: Output shaft holder •...
  • Page 96 3-54 ENGINE • Stake the nut with a center punch. BEARING INSPECTION Play Play Rotate the bearing inner race by finger to inspect for abnormal play, noise and smooth rotation while the bearings are in the crankcase. Replace the bearing in the following procedure if there is any- thing unusual.
  • Page 97 ENGINE 3-55 • Remove the bearing with the special tool. ( 09921-20210: Bearing remover 1 09923-74510: Bearing remover 2 09941-64511: Bearing remover 3 09930-30104: Sliding shaft NOTE: If there is no abnormal noise, the bearing removal is not neces- sary. BEARING REASEMBLY •...

  • Page 98: Generator Cover

    3-56 ENGINE • Install the bearing retainers. NOTE: When installing the bearing retainers, apply a small quantity of THREAD LOCK to the screws. & 09900-32050: THREAD LOCK “1342” OIL PRESSURE REGULATOR • Remove the oil pressure regulator 1. • When installing the oil pressure regulator 1, tighten it to the specified torque.
  • Page 99 ENGINE 3-57 • Remove the oil seal retainer. • Remove the oil seal 1 with the special tool. ( 09913-50121: Oil seal remover • Remove the spacer 2. • Remove the bearing with the special tool. ( 09921-20240: Bearing remover set NOTE: If there is no abnormal noise, the bearing removal is not neces- sary.
  • Page 100 3-58 ENGINE REASSEMBLY • Install the bearing 1 with the special tool. ( 09913-70210: Bearing installer set NOTE: The sealed side of the bearing must face to crankcase. • Install the bearing with the special tool. ( 09913-70210: Bearing installer set...
  • Page 101 ENGINE 3-59 • Apply SUZUKI SUPER GREASE “A” to the bearing, O-ring and oil seal lip. • Install the oil seal with the special tool. ( 09913-70210: Bearing installer set NOTE: When installing the oil seals, the stamped mark on the oil seal faces to the special tool.

  • Page 102: Clutch Cover

    3-60 ENGINE CLUTCH COVER DISASSEMBLY • Remove the clutch release mechanism. INSPECTION Rotate the rollers 1 by hand to inspect for an abnormal noise and a smooth rotation. Replace the clutch release roller assem- bly if there is anything unusual. REASSEMBLY •...

  • Page 103: Recoil Starter

    ENGINE 3-61 RECOIL STARTER O-ring Starter cup " Starter cup nut Ratchet set Reel Spiral spring Rope assembly DISASSEMBLY • After removing the nut 1, take out the recoil starter related parts from the housing. 1 Nut 6 Spring 2 Friction plate 7 Spacer 3 Ratchet guide 8 Pin...
  • Page 104 Wear hand and eye protection when installing the reel, since the spring may quickly unwind and cause an injury. • Apply SUZUKI SUPER GREASE “A” to the spiral spring. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) •...
  • Page 105 ENGINE 3-63 • Pull the rope and check that the ratchet is pushed out.

  • Page 106: Drive Train (Inboard Side)

    3-64 ENGINE DRIVE TRAIN (INBOARD SIDE) FRONT/REAR OUTPUT SHAFT Front output shaft Rear output shaft " Drive bevel gear Shims (s) Driven bevel gear Shim (s) 45 N·m 4.5 kgf-m 32.5 lb-ft 100 N·m 100 N·m 10.0 kgf-m (10.0 kgf-m, 72.5 lb-ft) 72.5 lb-ft 100 N·m (10.0 kgf-m, 72.5 lb-ft)
  • Page 107 ENGINE 3-65 REMOVAL • Remove the transmission assemblies. (!3-23) • Remove the front output shaft 1 and rear output shaft 2. • After removing the drive bevel gear nut 3, remove the drive bevel gear 4. (!3-52) • Separate the front and rear output shafts. DISASSEMBLY Rear output shaft •...
  • Page 108 3-66 ENGINE • Remove the washer 1, bearing 2 and driven bevel gear 3. • Remove the C-rings from the universal joint. " Replace the removed C-ring with a new one. • Remove the bearings by tapping with the special tool and hammer.
  • Page 109 ENGINE 3-67 • With the rear output shaft held immovable with a vise, remove the nut. " Replace the removed nut with a new one. • Remove the washer 1, joint yoke 2, oil seal 3, bearig 4 and shim 5. "...
  • Page 110 3-68 ENGINE • Using a chisel and unlock the nut. • With the front output shaft held immovable with a vise, remove the nut. " Replace the removed nut with a new one. • Remove the washer 1, joint yoke 2, oil seal 3 and bearing "...
  • Page 111 The bearing knock-pin A should be positioned inside. • Apply grease to the lip of the oil seal. • Install the oil seal to the joint yoke. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) NOTE:...
  • Page 112 • Apply grease to the bearing and its dust seal lip. • Install the universal joint and bearings with the special tool. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) ( 09913-70210: Bearing installer set...
  • Page 113 The bearing knock-pin A should be positioned inside. • Apply grease to the lip of the oil seal. • Install the oil seal to the joint yoke. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) NOTE:...
  • Page 114 • Install the universal joint and bearings with the special tool. (!3-70) • Install the C-rings by tapping with a copper hammer. (!3-70) ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) ( 09913-70210: Bearing installer set NOTE: Reassemble the universal joint in the same manner as the rear one.

  • Page 115: Shim Adjustment

    ENGINE 3-73 SHIM ADJUSTMENT BACKLASH • Install the drive bevel gear. (!3-52) • Place the front and rear output shafts on the crankcase and hold bearings with the special tool. ( 09921-21910: Bearing holder • Set a dial gauge as shown on the drive bevel gear. Measure the backlash by turning the drive bevel gear shaft in each direction, reading the total backlash on the dial gauge.
  • Page 116 3-74 ENGINE TOOTH CONTACT After backlash adjustment is carried out, the tooth contact must be checked. Pay attention to the following procedures: • Remove the front and rear output shafts from the crankcase. • Clean and degrease several teeth of the drive and driven bevel gears.
  • Page 117 ENGINE 3-75 FINAL ASSEMBLY • After adjusting the gear backlash and tooth contact correctly, remove the front and rear output shafts and drive bevel gear. • Clean off any machinist’s dye or paste from the gear teeth, and lubricate the teeth with engine oil. •...

  • Page 118: Reassembly Information

    3-76 ENGINE REASSEMBLY INFORMATION List of shims available for the drive bevel gear side. Shim thickness Part No. 0.25+0.25=0.50 mm (0.0197 in) 24935-19B00-025: 0.25 mm (0.0098 in) 0.25+0.30=0.55 mm (0.0217 in) 0.30+0.30=0.60 mm (0.0236 in) 24935-19B00-030: 0.30 mm (0.0118 in) 0.30+0.35=0.65 mm (0.0256 in) 0.35+0.35=0.70 mm (0.0276 in) 0.25+0.25+0.25=0.75 mm (0.0295 in)

  • Page 119: Crankshaft

    ENGINE 3-77 CRANKSHAFT DISASSEMBLY Crankshaft (R) Washer " Crank pin Bearing Conrod Washer Crankshaft (L) REASSEMBLY • Determine the width between the webs referring to the figure when rebuilding the crankshaft. % Crank web to web width Standard: 70.9 – 71.1 mm (2.791 – 2.799 in)

  • Page 120: Engine Reassembly

    3-78 ENGINE ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassembly. Pay special attention to the following points: NOTE: Apply engine oil to each running and sliding part before reas- sembling. ENGINE BOTTOM SIDE CRANKSHAFT • When mounting the crankshaft in the crankcase, it is neces- sary to pull its left end into the crankcase with the special tool.

  • Page 121: Gearshift Cam And Fork

    ENGINE 3-79 GEARSHIFT CAM AND FORK 10 N . m (1.0 kgf . m, 7.0 lb-ft) 19 N . m (1.9 kgf . m, 13.5 lb-ft) Reverse shift cam Reverse gearshift arm " Reverse gearshift fork Gearshift fork No. 1 Gearshift fork shaft Gearshift cam stopper &...
  • Page 122 3-80 ENGINE • Install the driveshaft and countershaft. • Install the reverse idle gear shaft 1. • Install the snap ring 2, washer 3 and spacer 4. • Install the reverse idle gear 5 and washer 6. • Install the reverse dog 7 on the driveshaft.
  • Page 123 ENGINE 3-81 • Fit the gearshift forks No. 1 8, No. 2 9, and reverse gearshift fork 0 into the gearshifting grooves. NOTE: Three kinds of gearshifting forks are used. They resemble each other very closely in external appearance and configuration. 8: Gearshift fork No.
  • Page 124 3-82 ENGINE • Install the gearshifting fork shafts F. • After installing the gearshift forks and gears, turn the gearshift cam and check to see that gears engage positively. NOTE: After the gearshifting fork shafts and gearshifting forks have been fitted, confirm that gear change is normal while turning the countershaft and driveshaft.
  • Page 125 ENGINE 3-83 • Apply SUZUKI BOND “1207B/1215” to the mating surface of the right crankcase. + 99104-31140: SUZUKI BOND “1207B” (USA) , 99000-31110: SUZUKI BOND “1215” (Others) • Assemble the crankcase within few minutes. • Tighten the crankcase securing bolts for right side.
  • Page 126 3-84 ENGINE NEUTRAL SWITCH • After positioning the spring and switch contact 1, install the switch body with a new O-ring 2. GENERATOR • Install the washer 1. • Install the starter driven gear 2. • Install the key 3. NOTE: Degrease the tapered portion of the generator rotor assembly and also the crankshaft.
  • Page 127 ENGINE 3-85 • Install the washer 1 and pin 2. • Install the oil pump driven gear by installing the snap ring. OIL PUMP DRIVE GEAR • Install the spacer 1 and pin 2. • Install the oil pump drive gear 3 and washer 4. NOTE: Flange side of the gear is positioned inside.
  • Page 128 3-86 ENGINE • Install the spring to the gearshift cam shaft properly. • Install the gearshift cam shaft assembly while aligning the spring ends with the stopper pin 2. • Install the gearshift cam plate guide 3.
  • Page 129 ENGINE 3-87 CLUTCH 100 N·m (10.0 kgf-m, 72.5 lb-ft) 130 N . m (13.0 kgf . m, 94.0 lb-ft) Clutch release roller Washer Washer Clutch release roller guide Clutch sleeve hub Clutch shoe nut Clutch release arm Clutch driven plate Washer Bearing Clutch drive plate...
  • Page 130 3-88 ENGINE • Install the clutch drive plates and driven plates one by one onto the clutch sleeve hub 1. • Install the clutch pressure plate 2. • Install the collar 3 onto the primary driven gear assembly. • Install the clutch sleeve hub assembly into the primary driven gear assembly.
  • Page 131 ENGINE 3-89 • Install the primary driven gear assembly together with the clutch wheel. • Install the washer 6 and clutch sleeve hub nut. NOTE: INSIDE The convex side of the washer faces outside. OUTSIDE Washer • Tighten the clutch sleeve hub nut to the specified torque with the special tool.
  • Page 132 3-90 ENGINE • Tighten the clutch shoe nut to the specified torque while hold- ing the generator rotor with the special tool. " The clutch shoe nut has left-hand threads. # Clutch shoe nut: 130 N·m (13.0 kgf-m, 94.0 lb-ft) ( 09930-44541: Generator rotor holder •...
  • Page 133 • Tighten the locknut 4 by holding the adjuster screw 5. # Locknut 3: 8 N·m (0.8 kgf-m, 5.7 lb-ft) Locknut 4: 23 N·m (2.3 kgf-m, 16.5 lb-ft) • Apply SUZUKI SUPER GREASE “A” to the O-ring and install the clutch adjuster cap. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA)

  • Page 134: Transfer

    3-92 ENGINE TRANSFER " * Never reuse a snap ring. After a snap ring has been removed from a shaft, the removed snap ring should be discarded and a new snap ring must be installed. * When installing a new snap ring, care must taken not to expand the end gap larger than required to slip the snap ring over the shaft.
  • Page 135 ENGINE 3-93 Countershaft Driveshaft...
  • Page 136 3-94 ENGINE Knob " Shift lever assy Lever stopper plate Gearshift cam Gearshift shaft & Gearshift fork Gear fork shaft...
  • Page 137 ENGINE 3-95 TRANSFER • Install the spacer 1. • Install the output gear 2 and washer 3. • Install the spacer 4. • Install the bushing by aligning the hole A with the hole B on the shaft. • Install the transfer No. 1 gear 5. •...
  • Page 138 3-96 ENGINE • Install the spacer C. • Install the transfer idle gear D and washer E. • Install the transfer gearshift shaft F and washer G. • Install the transfer gearshift fork H and shaft I. STARTER DRIVEN GEAR/IDLE GEAR •...
  • Page 139 # Transfer shift cam stopper bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) STARTER CUP • Apply SUZUKI SUPER GREASE “A” to the O-ring and lip of the oil seal. • Install the starter cup. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A”...
  • Page 140 ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the washer, speed sensor shaft and rotor. • Apply SUZUKI SUPER GREASE “A” to the O-ring and washer. • Install the washer and cap. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A”...

  • Page 141: Engine Top Side

    ENGINE 3-99 ENGINE TOP SIDE PISTON • Install the piston rings in the order of oil ring, 2nd ring and 1st ring. • The first member to go into the oil ring groove is a spacer 1. After placing the spacer, fit the two side rails 2. NOTE: Side designations, top and bottom, are not applied to the spacer and side rails: Those can be positioned each either way.
  • Page 142 3-100 ENGINE • Apply a light coat of molybdnum oil solution to the piston pin. * MOLYBDNUM OIL SOLUTION • Install the piston and piston pin. NOTE: When installing the piston, the dent A on the piston head is located to the exhaust side. •...
  • Page 143 ENGINE 3-101 " When installing the cylinder and cylinder head, pull the cam chain upward, or the chain will be caught between the crankcase and cam drive sprocket. • Fit the dowel pins and new cylinder head gasket 3. " Use a new gasket to prevent gas leakage.
  • Page 144 3-102 ENGINE CAMSHAFT • Align the line A on the generator rotor with the index mark B on the crankcase. " Pull the cam chain upward, or the chain will be caught between crankcase and cam drive sprocket. • Align the marks A on the camshaft so that they are parallel with the surface of the cylinder head.
  • Page 145 • Install the dowel pins to the cylinder head. • Apply engine oil to the cam face and camshaft journal. • Apply SUZUKI BOND “1216B” to the mating surface of the cylinder head cover. (!3-104) • Fit the camshaft end cap 1.
  • Page 146 3-104 ENGINE LIQUID GASKET APPLYING PLACE 1216B LOCATION OF CYLINDER HEAD COVER BOLT NOTE: * Fit the gasket to the bolt...
  • Page 147 # Spring holder bolt: 8 N·m (0.8 kgf-m, 5.7 lb-ft) • Adjust the valve clearance. (!2-5) • Apply grease to the new O-rings and install the valve inspec- tion caps. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
  • Page 148 3-106 ENGINE • Tighten valve timing inspection plug 4 to the specified torque. # Valve timing inspection plug: 23 N·m (2.3 kgf-m, 16.5 lb-ft) RECOIL STARTER • Temporarily install the recoil starter. GEARSHIFT LEVER • Install the shift lever position switch 1 and snap ring 2. •...
  • Page 149 ENGINE 3-107 • Install the spark plug. ( 09930-10121: Spark plug wrench set...
  • Page 150 DRIVE TRAIN DRIVE TRAIN CONTENTS DRIVE TRAIN ..................4- 2 FRONT DRIVING SYSTEM ............4- 2 FRONT DRIVE (DIFFERENTIAL) REMOVAL ......4- 3 FRONT DRIVE (DIFFERENTIAL) DISASSEMBLY .....4- 3 FRONT DRIVE (DIFFERENTIAL) INSPECTION ......4- 7 FRONT DRIVE (DIFFERENTIAL) REASSEMBLY ......4-10 FRONT DRIVE (DIFFERENTIAL) INSTALLATION .....4-16 SHIM ADJUSTMENT ..............4-17 REASSEMBLY INFORMATION ..........4-20 REAR DRIVING SYSTEM ..............4-21...

  • Page 151: Drive Train

    DRIVE TRAIN DRIVE TRAIN FRONT DRIVING SYSTEM Front drive (differential) gear case Shim(s), RH " Differential assy Shim(s), LH Front drive (differential) gear case cover 2WD/4WD shifting motor & 2WD/4WD shifting pinion 2WD/4WD shifting rack 2WD/4WD shifting fork 2WD/4WD shifting sleeve 4WD switch 2WD switch Bevel pinion gear...

  • Page 152: Front Drive (Differential) Removal

    DRIVE TRAIN FRONT DRIVE (DIFFERENTIAL) REMOVAL • Remove the front fender and front wheels. (!7-6 and 7-11) • Drain the differential gear oil. (!2-11) • Remove the front suspension. (!7-33) • Hold the inboard joint 1 of the drive shaft and tug the drive shaft horizontally.
  • Page 153 DRIVE TRAIN 2WD/4WD SHIFTING PINION AND SWITCH • Remove the 4WD switch 1 and 2WD switch 2. • Remove the 2WD/4WD shifting pinion 3. 2WD/4WD SWITCHES INSPECTION !8-24. FRONT DRIVE (DIFFERENTIAL) GEAR CASE • Remove the front drive (differential) gear case cover bolts in a crisscross pattern.
  • Page 154 DRIVE TRAIN • Remove the oil seals out of the gear case and its cover with the special tool. # 09913-50121: Oil seal remover NOTE: If there is no abnormal condition, the oil seal removal is not nec- essary. " The removed oil seal must be replaced with a new one.
  • Page 155 DRIVE TRAIN • Remove the snap ring. • Remove the bearing with the special tool. # 09913-50121: Oil seal remover NOTE: If there is no abnormal condition, the bearing removal is not nec- essary. " The removed bearing must be replaced with a new one.

  • Page 156: Front Drive (Differential) Inspection

    DRIVE TRAIN • Remove the pinion gear pilot bearing with the special tools. # 09921-20240: Bearing remover set 09917-50410: Bearing remover NOTE: If there is no abnormal condition, the bearing removal is not nec- essary. " The removed bearing must be replaced with a new one.
  • Page 157 DRIVE TRAIN UNIVERSAL JOINT YOKE Inspect the splines of universal joint for wear or damage. If any defects are found, replace the universal joint yoke with a new one. Inspect the universal joint and outer surface of the bearing for scuffing, wear and damage.
  • Page 158 DRIVE TRAIN Check the outer race play and smooth rotation of the bearing by hand while it is on the pinion gear shaft. Inspect the pinion gear for wear or damage. If the pinion gear is damaged, inspect the ring gear. If any defects are found, replace the bearing and gear with the new ones.

  • Page 159: Front Drive (Differential) Reassembly

    4-10 DRIVE TRAIN DIFFERENTIAL BEARING/BEVEL RING GEAR Check the outer race play and smooth rotation of the bearing by hand while it is on the differential. Inspect the ring gear for wear or damage. If the ring gear is damaged, inspect the pinion gear also. If any defects are found, replace the bearings and ring gear with the new ones.
  • Page 160 • Apply grease to the new oil seal lips. # 09913-70210: Bearing installer set $ 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) BEVEL PINION GEAR BEARING • Drive the bearing onto the shaft with the special tool.
  • Page 161 # 09913-70210: Bearing installer set • Apply grease to the seal lip groove. $ 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Apply 4 – 5 gram of water resistance grease to the outside of seal lip groove.
  • Page 162 • Apply sealant to the shifting fork shaft plug 1 and tighten it to the specified torque. & 99104-31140: SUZUKI BOND “1207B” (USA) ' 99000-31110: SUZUKI BOND “1215” (Others) ( Shifting fork shaft plug: 15 N·m (1.5 kgf-m, 11.0 lb-ft)
  • Page 163 • Install the differential assembly to the gear case. • Install the dowel pin and apply a sealant to the mating surface of the case. & 99104-31140: SUZUKI BOND “1207B” (USA) ' 99000-31110: SUZUKI BOND “1215” (Others) NOTE: After the backlash and tooth contact have been checked or adjusted, apply a sealant to the mating surface of the case.
  • Page 164 • Apply sealant to the 2WD/4WD switches and tighten them to the specified torque. & 99104-31140: SUZUKI BOND “1207B” (USA) ' 99000-31110: SUZUKI BOND “1215” (Others) ( 2WD/4WD switch: 22 N·m (2.2 kgf-m, 16.0 lb-ft) 2WD/4WD SHIFTING MOTOR •...

  • Page 165: Front Drive (Differential) Installation

    • Install a new stopper ring into its groove in the splines. • Apply grease to the splines of the drive shafts and install the drive shafts to the front drive (differential) gear case. $ 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) "...

  • Page 166: Shim Adjustment

    DRIVE TRAIN 4-17 SHIM ADJUSTMENT BACKLASH • Install the removed left and right side shims and differential assembly. • Assemble the gear case cover. (!4-14) NOTE: At this time, it is not necessary to apply a sealant to the mating surface of the gear case.
  • Page 167 4-18 DRIVE TRAIN LEFT SIDE SHIM SELECTION • Install the removed right side shim(s) and differential assem- bly. • Put a few pieces of solder (O.D.: 1.2 – 1.5 mm × L: 6 mm) on the bearing outer race, as shown. NOTE: * Do not install the left side shim(s) at this time.
  • Page 168 DRIVE TRAIN 4-19 TOOTH CONTACT After backlash adjustment and left side shim selection are car- ried out, the tooth contact must be checked. Pay attention to the following points: • Remove the differential ring gear. • Clean and degrease several teeth on the ring gear and pinion gear, and then apply a coating of machinist’s layout dye or paste to several teeth of the pinion gear.

  • Page 169: Reassembly Information

    4-20 DRIVE TRAIN REASSEMBLY INFORMATION Mating surfaces 23 N . m (2.3 kgf-m, 16.5 lb-ft) Left side of ring gear shim(s) Right side of ring gear shim(s) 4 – 5 gram Threaded parts...

  • Page 170: Rear Driving System

    DRIVE TRAIN 4-21 REAR DRIVING SYSTEM 33 N·m (3.3 kgf-m, 24.0 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft) 20 N·m (2.0 kgf-m, 14.5 lb-ft) 33 N·m (3.3 kgf-m, 24.0 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft) 100 N·m (10.0 kgf-m, 72.5 lb-ft) 23 N·m 23 N·m (2.3 kgf-m,...

  • Page 171: Rear Drive Removal

    4-22 DRIVE TRAIN REAR DRIVE REMOVAL • Drain the gear oil. (!2-11) • Remove the rear wheels. (!7-11) • Remove the rear brake caliper. • Make sure that the parking cam lever is in “P” position. • Remove the parking cam lever. •...

  • Page 172: Rear Drive Disassembly

    DRIVE TRAIN 4-23 REAR DRIVE DISASSEMBLY PARKING/REAR DRIVE SHAFT • Remove the parking cam stopper and cover. • Remove the parking camshaft assembly. • Remove the parking pawl lever shaft plug 1. • Remove the parking pawl lever 2 by removing its shaft. •...
  • Page 173 4-24 DRIVE TRAIN • Remove the snap ring and washer from the drive shaft. • Remove the drive shaft and waterproof seal by tapping with a plastic mallet. • Remove the parking gear by removing the snap rings. • Remove the oil seal with the special tool. # 09913-50121: Oil seal remover NOTE: If there is no abnormal condition, the oil seal removal is not nec-...
  • Page 174 DRIVE TRAIN 4-25 • Remove the snap ring. • Remove the bearing out of the drive shaft housing with the special tool. # 09913-70210: Bearing installer set NOTE: If there is no abnormal condition, the bearing removal is not nec- essary.
  • Page 175 4-26 DRIVE TRAIN • Remove the bearing locknut with the special tool. # 09924-41830: Bearing lock nut wrench " The removed locknut must be replaced with a new one. • Remove the pinion gear assembly and shims out of the case. •...
  • Page 176 DRIVE TRAIN 4-27 • Remove the bearing out of the cover with the special tool. # 09913-70210: Bearing installer set NOTE: If there is no abnormal condition, the bearing removal is not nec- essary. " The removed bearing must be replaced with a new one.

  • Page 177: Rear Drive Inspection

    4-28 DRIVE TRAIN • Remove the pinion gear pilot bearing with the special tools. # 09921-20240: Bearing remover set 09917-50410: Bearing remover NOTE: If there is no abnormal condition, the bearing removal is not nec- essary. " The removed bearing must be replaced with a new one.
  • Page 178 DRIVE TRAIN 4-29 Inspect the oil seal for wear or damage. Check the inner race play and smooth rotation of the bearing by hand while it is in the case. If any defects are found, replace the oil seal and bearing with the new ones.
  • Page 179 4-30 DRIVE TRAIN Check the gear case and case cover bearings for wear or dam- age. If any wear or damage is found, replace the bearing with a new one. BEARING REMOVAL !4-27, 28. Check the breather rubber case for wear or damage. Also check that the joint of the rubber case fits tightly.

  • Page 180: Rear Drive Reassembly

    • Install the new oil seals into the gear case and case cover with the special tool. • Apply grease to the new oil seal lips. # 09913-70210: Bearing installer set $ 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
  • Page 181 4-32 DRIVE TRAIN BEVEL PINION GEAR SHAFT BEARING/LOCKNUT • Drive the bearing onto the shaft with the special tool. # 09913-70210: Bearing installer set BEVEL PINION GEAR/SHIM [FINAL ASSEMBLY] • Install the shims, pinion gear assembly and bearing lock- nut. •...
  • Page 182 • Coat a new O-ring with grease and apply sealant to the mat- ing surface of the cover, then install the gear case cover. $ 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) & 99104-31140: SUZUKI BOND “1207B” (USA) ' 99000-31110: SUZUKI BOND “1215”...
  • Page 183 4-34 DRIVE TRAIN • Apply grease to the seal lip groove. $ 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Apply 4 – 5 gram of water resistance grease to the outside of seal lip groove.
  • Page 184 • Install the new oil seal to the parking cam cover with the spe- cial tool, and then apply grease to the seal lip. # 09913-70210: Bearing installer set $ 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the parking pawl lever and parking camshaft assembly.

  • Page 185: Rear Drive Installation

    1. • Tighten the parking cam stopper 1 to the specified torque. ( Parking cam stopper: 23 N·m (2.3 kgf-m, 16.5 lb-ft) $ 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) REAR DRIVE INSTALLATION Install the rear drive in the reverse order of removal. Pay atten- tion to the following points: •...
  • Page 186 DRIVE TRAIN 4-37 • Install the rear drive gear case under cover. • Tighten the axle housing mounting bolts to the specified torque. ( Axle housing mounting bolt: 60 N·m (6.0 kgf-m, 43.5 lb-ft) • When installing the parking cam lever, align the punched marks on the shaft and lever.

  • Page 187: Shim Adjustment

    4-38 DRIVE TRAIN SHIM ADJUSTMENT BACKLASH • Install the pinion gear assembly, removed shim(s) and new bearing locknut. (!4-32) • Tighten the bearing locknut to the specified torque. (!4-32) NOTE: At this time, it is not necessary to stake the bearing locknut. (!4-32) •...
  • Page 188 DRIVE TRAIN 4-39 RIGHT SIDE SHIM SELECTION • After the backlash has been checked or adjusted, put a few pieces of solder (O.D.: 1.2 – 1.5 mm × L: 6 mm) on the ring gear back side, as shown. NOTE: * Do not install the right side shim(s) at this time.
  • Page 189 4-40 DRIVE TRAIN TOOTH CONTACT After backlash adjustment and right shim selection are carried out, the tooth contact must be checked. Pay attention to the fol- lowing procedures: • Remove the ring gear. • Clean and degrease several teeth on the ring gear and pinion gear, and then apply a coating of machinist’s layout dye or paste to several teeth of the pinion gear.

  • Page 190: Reassembly Information

    DRIVE TRAIN 4-41 REASSEMBLY INFORMATION 30 N . m (3.0 kgf-m, 21.5 lb-ft) 5 – 7 gram 4 – 5 gram Mating surfaces 23 N . m (2.3 kgf-m, 16.5 lb-ft) Mating surfaces Mating surfaces 110 N . m Pinion gear shim(s) (11.0 kgf-m, 79.5 lb-ft) Right side of ring gear shim(s)
  • Page 191 4-42 DRIVE TRAIN...
  • Page 192 FUEL SYSTEM FUEL SYSTEM CONTENTS FUEL TANK ..................5- 2 CONSTRUCTION ................. 5- 2 FUEL LINE INSPECTION ............5- 3 REMOVAL ..................5- 3 REMOUNTING ................5- 3 FUEL VALVE ..................5- 4 REMOVAL AND INSPECTION ............ 5- 4 FUEL STRAINER ................. 5- 4 REMOUNTING ................5- 4 FUEL LEVEL GAUGE ................

  • Page 193: Fuel Tank

    FUEL SYSTEM FUEL TANK CONSTRUCTION Fuel level gauge Breather hose Fuel tank cap Fuel tank assy Bolt Spacer Cushion rear Cushion front Fuel hose Fuel valve Bolt...

  • Page 194: Fuel Line Inspection

    FUEL SYSTEM FUEL LINE INSPECTION Inspect the fuel lines, fuel tank, and fuel tank cap for damage and fuel leakage. If any damages are found, replace the defec- tive parts with new ones. REMOVAL • Remove the seat, fuel tank covers and fuel tank top cover. (!7-5) •...

  • Page 195: Fuel Valve

    FUEL SYSTEM FUEL VALVE REMOVAL AND INSPECTION • Remove the fuel tank. (!5-3) • Remove the fuel valve 1. " Gasoline is highly flammable and explosive. Keep heat, sparks and flames away from gasoline. FUEL STRAINER If the fuel strainer is dirty with sediment or rust, fuel will not flow smoothly and loss in engine power may result.

  • Page 196: Fuel Level Gauge

    FUEL SYSTEM FUEL LEVEL GAUGE REMOVAL • Remove the fuel tank top cover. (!7-5) • Remove the fuel level gauge cap 1. " * Gasoline is highly flammable and explosive. * Keep heat, sparks and flames away from gasoline. • Remove the fuel level gauge. INSPECTION Inspect the float of the fuel gauge assembly moves smoothly.

  • Page 197: Carburetor

    FUEL SYSTEM CARBURETOR CONSTRUCTION Cover assy Spring retainer Jet Needle Diaphragm assy Spring Hose Cover Starter plunger Spring Guide holder Diaphragm assy Spring Cover Float chamber Slow jet Hose O-ring Needle jet holder Main jet Needle valve Float pin Throttele stop screw Pilot screw Float Gasket...

  • Page 198: Specifications

    FUEL SYSTEM SPECIFICATIONS SPECIFICATION ITEM E-03, 28 E-33 ← Carburetor type KEIHIN CVK36 ← Bore size 36 mm I.D. No. 03GF 03GG ← Idle r/min 1 300 ± 100 r/min Float height 17.0 ± 1.0 mm ← (0.67 ± 0.04 in) ←...

  • Page 199: Removal

    FUEL SYSTEM REMOVAL • Remove the fuel tank. (!5-3) • Loosen the carburetor clamp screws. • Remove the carburetor side cap 1. • Disconnect the throttle cable 2. • Remove the carburetor. • Disconnect the starter cable.

  • Page 200: Disassembly

    FUEL SYSTEM DISASSEMBLY • Remove the fuel hose 1, air vent hoses 2 and vacuum hose • Remove the coasting enrichment valve cover 4, spring 5, coasting enrichment valve 6 and O-ring 7. • Remove the top cap. Do not use compressed air on the carburetor body before removing the diaphragm;...
  • Page 201 5-10 FUEL SYSTEM • Remove the throttle stop screw 1. • Remove the O-ring 2. Replace the removed O-ring with a new one to prevent fuel leakage. • Remove the float pin 3, float 4 and needle valve 5.
  • Page 202 FUEL SYSTEM 5-11 • Remove the following parts. 1 Main jet and needle jet holder 2 Slow jet 3 Starter jet 4 Pilot screw NOTE: Before removing the pilot screw 4, its setting must be deter- mined. Slowly turn the pilot screw clockwise and count the num- ber of turns until it is lightly seated.

  • Page 203: Cleaning

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

  • Page 204: Reassembly

    FUEL SYSTEM 5-13 NEEDLE VALVE INSPECTION If foreign matter is caught between the valve seat and the nee- dle valve, the gasoline will continue flowing and overflow. If the valve seat and needle valve are worn beyond the permissible limits, similar trouble will occur. Conversely, if the needle valve sticks, the gasoline will not flow into the float chamber.

  • Page 205: Remounting

    THROTTLE STOP SCREW • Apply the grease to thread part of the throttle stop screw, then install the throttle stop screw to the carburetor. & 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) REMOUNTING Remount the carburetor assembly in the reverse order of removal.
  • Page 206 COOLING AND LUBRICATION SYSTEM COOLING AND LUBRICATION SYSTEM CONTENTS ENGINE COOLANT ................6- 2 COOLING CIRCUIT ................6- 3 COOLING CIRCUIT INSPECTION ..........6- 3 RADIATOR AND HOSES ..............6- 4 RADIATOR REMOVAL ..............6- 4 RADIATOR REMOUNTING ............6- 4 RADIATOR RESERVOIR TANK REMOVAL AND REMOUNTING ................6- 4 RADIATOR CAP INSPECTION ...........6- 5 RADIATOR INSPECTION AND CLEANING .......6- 5...

  • Page 207: Engine Coolant

    COOLING AND LUBRICATION SYSTEM ENGINE COOLANT At the time of manufacture, the cooling system is filled with a 50:50 mixture of distilled water and ethylene glycol anti-freeze. Anti-freeze Freezing point This 50:50 mixture will provide the optimum corrosion protection density and excellent heat protection, and will protect the cooling system –30˚C (–24˚F) from freezing at temperatures above –31°C (–24°F).

  • Page 208: Cooling Circuit

    COOLING AND LUBRICATION SYSTEM COOLING CIRCUIT ENGINE COOLANT RESERVOIR THERMOSTAT TEMPERATURE CYLINDER HEAD TANK SWITCH CYLINDER COOLING FAN THERMO RADIATOR SWITCH WATER PUMP COOLING CIRCUIT INSPECTION Before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. •...

  • Page 209: Radiator And Hoses

    COOLING AND LUBRICATION SYSTEM RADIATOR AND HOSES RADIATOR REMOVAL • Remove the front fender. (#7-6) • Drain engine coolant by removing the drain plug. • Disconnect the cooling fan motor lead wire coupler 1 and cooling fan thermo-switch lead wire coupler 2. •...

  • Page 210: Radiator Cap Inspection

    COOLING AND LUBRICATION SYSTEM RADIATOR CAP INSPECTION • Remove the radiator cap lid. • Fit the cap 1 to the radiator cap tester 2. • Build up pressure slowly by operating the tester. Make sure that the pressure build-up stops at 95 – 125 kPa (0.95 – 1.25 kgf/cm², 13.5 –...

  • Page 211: Radiator Hose Inspection

    COOLING AND LUBRICATION SYSTEM RADIATOR HOSE INSPECTION • Remove the front fender. (#7-6) • Any radiator hose found in a cracked condition or flattened must be replaced. • Any leakage from the connecting section should be corrected by proper tightening.

  • Page 212: Cooling Fan

    COOLING AND LUBRICATION SYSTEM COOLING FAN REMOVAL • Remove the front fender. (#7-6) • Drain engine coolant. (#6-4) • Remove the radiator. (#6-4) • Remove the cooling fan. • Remove the cooling fan motor. INSPECTION • Remove the radiator cap lid. •...

  • Page 213: Installation

    COOLING AND LUBRICATION SYSTEM INSTALLATION • Install the cooling fan motor and cooling fan. % Cooling fan motor mounting screw: 8 N·m (0.8 kgf-m, 6.0 lb-ft) % Cooling fan nut: 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Install the radiator. (#6-4) •...

  • Page 214: Cooling Fan Thermo-Switch

    COOLING AND LUBRICATION SYSTEM COOLING FAN THERMO-SWITCH REMOVAL • Remove the front fender. (#7-6) • Drain a small amount of engine coolant. (#6-4) • Disconnect the cooling fan thermo-switch lead wire coupler • Remove the cooling fan thermo-switch 2. INSPECTION •...

  • Page 215: Engine Coolant Temperature Switch

    1 and the column thermometer 2 with a pan. INSTALLATION • Apply sealant to the thread portion of the engine coolant tem- perature switch. ) 99104-31140: SUZUKI BOND “1207B” (USA) * 99000-31110: SUZUKI BOND “1215” (Others) • Tighten the engine coolant temperature switch to the speci- fied torque.

  • Page 216: Thermostat

    COOLING AND LUBRICATION SYSTEM 6-11 THERMOSTAT REMOVAL • Remove the fuel tank cover. (#7-5) • Drain a small amount of engine coolant. (#6-4) • Place a rag under the thermostat case. • Remove the thermostat case. • Remove the thermostat. INSPECTION Inspect the thermostat pellet for signs of cracking.
  • Page 217 6-12 COOLING AND LUBRICATION SYSTEM NOTE: The hole A of the thermostat faces upside. • After installing the thermostat, be sure to add engine coolant. (#2-12) • Tighten the thermostat case bolts to the specified torque. • Install the fuel tank cover. (#7-5) % Thermostat case bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

  • Page 218: Water Pump

    COOLING AND LUBRICATION SYSTEM 6-13 WATER PUMP REMOVAL • Remove the right inner fender. (#7-6) • Remove the right mud guard. (#7-8) • Drain engine coolant. (#6-4) • Disconnect the water hoses. • Remove the water pump cover bolts. • Remove the impeller securing bolt with a water pump plier. •...

  • Page 219: Disassembly

    6-14 COOLING AND LUBRICATION SYSTEM MECHANICAL SEAL Visually inspect the mechanical seal for damage, with particular attention given to the sealing face. Replace the mechanical seal that shows indications of leakage. Also replace the seal ring if necessary. DISASSEMBLY • Remove the mechanical seal ring 1 and seal 2. The removed mechanical seal and seal must be replaced with new ones.

  • Page 220: Reassembly And Installation

    * Install the oil seal taking care about its direction. (#6-17) • Apply grease to the oil seal. & 09913-70210: Bearing installer set + 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the water pump shaft by using the suitable size socket wrench.
  • Page 221 6-16 COOLING AND LUBRICATION SYSTEM • Tighten the impeller securing bolt to the specified torque with a water pump plier. % Impeller securing bolt: 15 N·m (1.5 kgf-m, 11.0 lb-ft) NOTE: The seal lip side 1 must face to impeller. •...

  • Page 222: Lubrication System

    COOLING AND LUBRICATION SYSTEM 6-17 O-ring Seal washer Mechanical seal & Shaft " Impeller Oil seal Water pump shaft bolt Joint Impeller washer 15 N . m (1.5 kgf-m, 11.0 lb-ft) LUBRICATION SYSTEM OIL PRESSURE #2-25 OIL FILTER #2-10 OIL PRESSURE REGULATOR #3-56 OIL SUMP FILTER #3-51...

  • Page 223: Engine Lubrication System Chart

    6-18 COOLING AND LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM CHART...

  • Page 224: Engine Lubrication System

    COOLING AND LUBRICATION SYSTEM 6-19 ENGINE LUBRICATION SYSTEM Oil jet...
  • Page 225 CHASSIS CHASSIS CONTENTS EXTERIOR PARTS ........................7- 2 CONSTRUCTION ......................7- 2 REMOVAL ........................7- 4 REMOUNTING ........................7-10 FRONT AND REAR WHEELS ....................7-11 CONSTRUCTION ......................7-11 REMOVAL ........................7-11 REMOUNTING ........................7-11 TIRES ............................7-12 TIRE REPLACEMENT ...................... 7-12 FRONT DRIVE SHAFT ......................

  • Page 226: Exterior Parts

    CHASSIS EXTERIOR PARTS CONSTRUCTION Fuel tank top cover Front fender Front inner fender (RH) Front inner fender (LH) Front grill upper Front grip bar Front grill lower Front box Front carrier Muffler cover...
  • Page 227 CHASSIS Rear carrier Rear fender Fuel tank cover Mud guard Battery holder plate Rear box...

  • Page 228: Removal

    CHASSIS REMOVAL SEAT • Remove the seat. FRONT CARRIER • Remove the front carrier. GRILL UPPER/LOWER COVERS • Remove the grill lower cover 1. • Remove the front carrier. (!Abobe) • Remove the grill upper cover 2. FRONT GRIP BAR •...
  • Page 229 CHASSIS • Remove the front grip bar. FUEL TANK COVERS • Remove the seat. (!7-4) • Remove the air cleaner duct mounting screw 1. • Remove the fuel tank covers. NOTE: Before removing the fuel tank covers, do not attempt to uncou- ple the fuel tank covers.
  • Page 230 CHASSIS FRONT FENDER • Remove the seat. (!7-4) • Remove the front grip bar. (!7-4) • Remove the fuel tank covers. (!7-5) • Remove the gearshift lever knob 1. • Remove the right and left mud guard fasteners/screws. • Remove the right inner fender 2. •...
  • Page 231 CHASSIS • Remove the left inner fender 4. • Remove the front fender. FRONT BOX • Remove the front box cap 1. • Remove the front box mounting screw. • Turn the front box 2 counterclockwise and remove it. • Remove the front box holder 3. •...
  • Page 232 CHASSIS MUD GUARD • Remove the muffler cover 1. (Right side) ✩: hooked part • Remove the mud guard 2. REAR CARRIER • Remove the rear carrier 1.
  • Page 233 CHASSIS REAR FENDER • Remove the fuel tank covers. (!7-5) • Remove the rear carrier. (!7-8) • Remove the battery 1 and its tray. • Remove the starter motor relay 2 and fuse box/neutral relay 3 from the rear fender. •...

  • Page 234: Remounting

    7-10 CHASSIS REMOUNTING Remounting the exterior parts in reverse order of removal. Pay attention the following points: REAR CARRIER • Apply THREAD LOCK “1342” to the rear carrier mounting bolts. " 99000-32050: THREAD LOCK “1342”...

  • Page 235: Front And Rear Wheels

    CHASSIS 7-11 FRONT AND REAR WHEELS CONSTRUCTION Wheel set nut ITEM N·m kgf-m lb-ft 36.0 REMOVAL • Place the vehicle on level ground. • Support the vehicle with a jack or wooden block. • Remove the wheel set nuts. • Remove the front and rear wheels. REMOUNTING Remount the wheels in the reverse order of removal.

  • Page 236: Tires

    7-12 CHASSIS TIRES TIRE REPLACEMENT • Remove the front and rear wheels. (!7-11) • After removing the air valve cap, release the tire pressure by depressing the valve. • Dismount the bead from the rim completely as shown. • Separate the tire from the rim by using a set of tire levers and rim protectors.
  • Page 237 CHASSIS 7-13 • When installing each tire, make sure the arrow A on the tire points in the direction of rotation. Also, make sure the outer side of the wheel rim is facing outward. NOTE: For inspecting the tire refer to page 2-18. Inspect the valve core, before installation.

  • Page 238: Front Drive Shaft

    7-14 CHASSIS FRONT DRIVE SHAFT CONSTRUCTION Circlip Differential side joint set Differential side boot set Snap ring Circlip Differential side outer boot clamp Differential side inner boot clamp Wheel side inner boot clamp Wheel side outer boot clamp Boot set REMOVAL •...
  • Page 239 CHASSIS 7-15 • Clean the front drive shaft. • Remove the boot bands of the differential side joint (double offset joint). • Slide the boot toward to the center of the front drive shaft and remove the stopper ring from the outer race. •...
  • Page 240 7-16 CHASSIS • Remove the inner race with a bearing puller. • Remove the boot. Do not disassemble the wheel side joint (double offset joint). If any damages are found, replace the wheel side joint with a new one. NOTE: * Wash the disassembled parts (except for the boot).
  • Page 241 CHASSIS 7-17 • Install the snap ring to the cage. • Apply grease to the entire surface of the cage and the inside of the outer race. Position Wheel side Differential side Grease Quantity 40 g (1.4 oz) 55 g (1.9 oz) NOTE: The tube of joint grease is included in the wheel side boot set or wheel side joint assembly of spare parts.

  • Page 242: Remounting

    7-18 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 243: Front Brake

    CHASSIS 7-19 FRONT BRAKE CONSTRUCTION Master cylinder reservior cap Master cylinder mounting bolt Diaphragm Brake hose union bolt Master cylinder clamp Brake pipe nut Boot Air bleeder valve Piston/cup set Brake caliper mounting bolt Brake pad mounting pin Spring Caliper holder pin Master cylinder Caliper holder pin Brake hose No.1...

  • Page 244: Brake Pad Replacement

    7-20 CHASSIS BRAKE PAD REPLACEMENT • Remove the front wheel. (!7-11) • Remove the brake caliper mounting bolts 1 and brake pad mounting pins 2. • Remove the brake pads. * Do not operate the brake lever during or after brake pad removal.

  • Page 245: Brake Fluid Replacement

    CHASSIS 7-21 BRAKE FLUID REPLACEMENT • Place the vehicle on a level surface and keep the handlebar straight. • Remove the master cylinder reservoir cap and diaphragm. • Suck up the old brake fluid as much as possible. • Fill the reservoir with new brake fluid. ' Specification and classification: DOT 4 •...
  • Page 246 7-22 CHASSIS • Remove the spring 1. • Place a rag over the brake caliper pistons to prevent them from popping out and then force out the pistons using com- pressed air. Do not use high pressure air to prevent brake caliper piston damage.

  • Page 247: Brake Caliper Inspection

    CHASSIS 7-23 BRAKE CALIPER INSPECTION BRAKE CALIPER Inspect the brake caliper cylinder wall for nicks, scratches or other damage. If any damages are found, replace the brake cal- iper with a new one. BRAKE CALIPER PISTON Inspect the brake caliper piston for any scratches or other dam- age.

  • Page 248: Brake Caliper Reassembly And Remounting

    • Tighten the pin 1 to the caliper holder 2 to the specified torque. # Caliper holder pin: 18 N·m (1.8 kgf-m, 13.0 lb-ft) • Apply SUZUKI SILICON GREASE to the brake caliper holder pin. ( 99000-25100: SUZUKI SILICONE GREASE...
  • Page 249 CHASSIS 7-25 • Apply SUZUKI SILICON GREASE to the pin 3. ( 99000-25100: SUZUKI SILICON GREASE • Install the pin 4, washer 5 and caliper holder 6 to the cali- per. • Apply THREAD LOCK SUPER “1360” to the pin 4.

  • Page 250: Brake Disc Removal And Disassembly

    7-26 CHASSIS BRAKE DISC REMOVAL AND DISASSEMBLY • Remove the front wheel. (!7-11) • Remove the cotter pin. Replace the removed cotter pin with a new one. • Loosen the axle nut 1 by applying the front brake. • Remove the axle nut 1 and spring washer 2. •...

  • Page 251: Brake Disc Inspection

    Reassemble and remount the brake disc in the reverse order of removal and disassembly. Pay attention to the following points: • Apply SUZUKI SUPER GREASE “A” to the wheel hub spline. + 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) •...

  • Page 252: Master Cylinder Removal And Disassembly

    7-28 CHASSIS • Install the wheel hub. When installing the wheel hub, make sure the spacer 1 is properly positioned. • Install the front caliper. (!7-25) CORRECT INCORRECT • Install the spring washer 2 as its convex side A faces to the front hub nut.
  • Page 253 CHASSIS 7-29 • Remove the brake lever 1 and brake switch 2. • Remove the reservoir cap 3 and diaphragm 4. • Drain the brake fluid. • Pull the dust boot 5 out and remove the circlip 6. • Remove the piston/secondary cup, primary cup and spring. 7 Secondary cup 8 Piston 9 Primary cup...

  • Page 254: Master Cylinder Inspection

    7-30 CHASSIS MASTER CYLINDER INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or damage. If any damages are found, replace the master cylinder with a new one. PISTON AND RUBBER PARTS Inspect the piston surface, primary cup, secondary cup and dust seal for any scratches, wear or damage.
  • Page 255 CHASSIS 7-31 When remounting the master cylinder on the handlebars, align the master cylinder holder's mating surface 1 with the punch mark 2 on the handlebar and tighten the upper clamp bolt first. # Master cylinder clamp bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) A Master cylinder B Master cylinder upper clamp bolt C Handlebar...

  • Page 256: Front Suspension

    7-32 CHASSIS FRONT SUSPENSION CONSTRUCTION Front shock absorber Upper wishbone arm " Bushing Steering knuckle Inner dust seal Spacer & Hub bearing Outer dust seal Lower wishbone arm Bushing Disc cover Front disc Front hub Shock absorber mounting upper bolt Shock absorber mounting lower nut Wishbone arm pivot nut Steering knuckle pinch bolt...

  • Page 257: Removal And Disassembly

    CHASSIS 7-33 REMOVAL AND DISASSEMBLY • Remove the wheel hub with brake disc. (!7-26) • Remove the brake hose clamp. • Remove the drive shaft cover. • Remove the cotter pin and tie rod end nut. Replace the removed cotter pin with a new one. •...
  • Page 258 7-34 CHASSIS • Remove the front grip lower cover. (!7-4) • Remove the front grip mounting bolts for helping to remove the lower wishbone arm mounting bolt. • Loosen the upper wishbone arm pivot bolts/nuts and lower shock absorber mounting bolt/nut. •...

  • Page 259: Inspection

    CHASSIS 7-35 INSPECTION FRONT SHOCK ABSORBER Inspect the shock absorber for oil leakage or damage. If any damages are found, replace the front shock absorber with a new one. WISHBONE ARM Inspect the wishbone arms for damage. If any damages are found, replace the wishbone arm with a new one.
  • Page 260 7-36 CHASSIS DRIVE SHAFT COVER Inspect the drive shaft cover for damage. If any damages are found, replace the drive shaft cover with a new one. BRAKE DISC COVER Inspect the brake disc cover for damage. If any damages are found, replace the brake disc cover with a new one.
  • Page 261 CHASSIS 7-37 HUB BEARINGS Inspect the inner race play of the hub bearing by hand while it is in the steering knuckle. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. If there is anything unusual, replace the bearing with a new one.

  • Page 262: Reassembly And Remounting

    Reassemble and remount the front suspension in the reverse order of removal and disassembly. Pay attention to the following points: • Apply SUZUKI SUPER GREASE “A” to the hub bearings and the lip of the dust seals before installing them. + 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A”...
  • Page 263 CHASSIS 7-39 • Install the knuckle end to the wishbone arm by using the spe- cial tools. * 09913-70210: Bearing installer set • Install the new snap ring securely. • Apply THREAD LOCK SUPER “1303” or “1322” to the wish- bone arm pivot bolts, and then tighten the nuts 1 to the spec- ified torque.
  • Page 264 7-40 CHASSIS • Apply THREAD LOCK SUPER “1303” or “1322” to the steer- ing knuckle pinch bolts, and then tighten them to the specified torque. , 99000-32030: THREAD LOCK SUPER “1303” (USA) - 99000-32110: THREAD LOCK SUPER “1322” (Others) # Steering knuckle pinch bolt: 50 N·m (5.0 kgf-m, 36.0 lb-ft) •...

  • Page 265: Steering

    CHASSIS 7-41 STEERING CONSTRUCTION Handlebar upper clamp Handlebars " Handlebar lower clamp Steering shaft Steering shaft holder Dust seal & Cable guide Bushing Dust seal O-ring Dust seal Tie rod end (inside) Tie rod end (outside) Handlebar cover bracket Handlebar cover Handlebar clamp bolt Steering shaft holder bolt Steering shaft nut...

  • Page 266: Removal And Disassembly

    7-42 CHASSIS REMOVAL AND DISASSEMBLY • Remove the front fender. (!7-6) • Remove the front wheel. (!7-11) • Remove the master cylinder assembly. (!7-28) • Remove the throttle lever case. • Disconnect the rear brake cable 1 and remove the handlebar switch 2.
  • Page 267 CHASSIS 7-43 • Remove the handlebar clamp bolts and handlebars assembly. • Disconnect the brake hose from the clamp. • Remove the cotter pins and tie rod end nuts. • Remove the tie rods. Replace the removed cotter pins with new ones. •...

  • Page 268: Inspection

    7-44 CHASSIS • Remove the steering shaft holder bolts. Replace the removed clips with new ones. • Remove the steering shaft 0. • Remove the dust seals A from the steering shaft. • Remove the dust seal B and O-ring C from the frame. Replace the removed O-ring with a new one.
  • Page 269 CHASSIS 7-45 STEERING SHAFT AND HOLDER Inspect the steering shaft for distortion or bends. If any damages are found, replace the steering shaft with a new one. Inspect the two steering shaft holders for wear or damage. If any damages are found, replace the steering shaft holders with new ones.

  • Page 270: Reassembly And Remounting

    Pay attention to the following points: STEERING SHAFT • Apply SUZUKI SUPER GREASE “A” to the O-ring and dust seals before remounting the steering shaft. + 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) •...
  • Page 271 CHASSIS 7-47 • Tighten the steering shaft holder bolts to the specified torque. # Steering shaft holder bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) NOTE: Make sure that the wiring harness, cables and brake hose rout- ing are proper. (!9-12 to -20) TIE ROD •...

  • Page 272: Toe-In Adjustment

    7-48 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) • Place 75 kg (165 lbs) of weight on the seat. Forward •...

  • Page 273: Front Wheel, Front Brake, Front Suspension And Steering Reassembling Information

    CHASSIS 7-49 FRONT WHEEL, FRONT BRAKE, FRONT SUSPENSION AND STEERING REASSEMBLING INFORMATION...

  • Page 274: Rear Brake

    7-50 CHASSIS REAR BRAKE CONSTRUCTION Reservoir tank cap Reservoir tank " Reservoir hose ITEM N·m kgf-m lb-ft Connector 23.0 16.5 O-ring Brake hose 10.0 & Piston/cup set 32.0 23.0 Push rod Boot Spring Brake pad Caliper holder Caliper Insulator Piston Dust seal Oil seal Brake hose union bolt...

  • Page 275: Brake Pad Replacement

    CHASSIS 7-51 BRAKE PAD REPLACEMENT • Remove the right rear wheel. (!7-11) • Remove the brake caliper mounting bolts 1. • With pushing the caliper holder 2, remove the brake pads. * Do not operate the brake lever during or after brake pad removal.

  • Page 276: Brake Fluid Replacement

    7-52 CHASSIS BRAKE FLUID REPLACEMENT • Place the vehicle on a level surface. • Remove the seat and fuel tank covers. (!7-4 and 7-5) • Remove the master cylinder reservoir cap and diaphragm. • Suck up the old brake fluid as much as possible. •...
  • Page 277 CHASSIS 7-53 • Remove the spring 3 and insulator 4. • Remove the brake caliper holder 5 and rubber parts 6. • 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 278: Brake Caliper Inspection

    7-54 CHASSIS BRAKE CALIPER INSPECTION BRAKE CALIPER Inspect the brake caliper cylinder wall for nicks, scratches or other damage. If any damages are found, replace the brake cal- iper with a new one. BRAKE CALIPER PISTON/INSULATOR Inspect the brake caliper piston and insulator for any scratches or other damage.

  • Page 279: Brake Caliper Reassembly And Remounting

    * Apply brake fluid to all of the seals, brake caliper bores and pistons before reassembly. PISTON SEALS • Install the piston seal 1 and dust seal 2 as shown. BRAKE CALIPER HOLDER • Apply SUZUKI SILICON GREASE to the pin. ( 99000-25100: SUZUKI SILICON GREASE...
  • Page 280 7-56 CHASSIS • Assemble the caliper holder and the caliper. NOTE: Make sure that the boots must be set into the holder pin’s grooves securely. • Install the piston, insulator and spring. • Install the pads to the caliper. (!7-51) •...

  • Page 281: Brake Disc Removal And Disassembly

    CHASSIS 7-57 BRAKE DISC REMOVAL AND DISASSEMBLY • Remove the right rear wheel. (!7-11) • Remove the cotter pin. Replace the removed cotter pin with a new one. • Loosen the axle nut 1 by applying the rear brake. • Remove the rear brake caliper. (!7-51) •...

  • Page 282: Brake Disc Reassembly And Remounting

    Reassemble and remount the brake disc in the reverse order of removal and disassembly. Pay attention to the following points: • Apply SUZUKI SUPER GREASE “A” to the wheel hub spline. + 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) •...

  • Page 283: Master Cylinder Removal And Disassembly

    CHASSIS 7-59 MASTER CYLINDER REMOVAL AND DISASSEMBLY • Place a rag underneath the brake hose union bolt on the mas- ter cylinder to catch any spilt brake fluid. Remove the brake hose union bolt 1 and disconnect the brake hose. •...

  • Page 284: Master Cylinder Inspection

    7-60 CHASSIS • Remove the piston/secondary cup, primary cup and spring. A Secondary cup B Piston C Primary cup D Spring MASTER CYLINDER INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or damage. If any damages are found, replace the master cylinder with a new one.

  • Page 285: Master Cylinder Reassembly And Remounting

    * Apply brake fluid to the master cylinder bore and all the component to be inserted into the bore. ' Specification and classification: DOT 4 • Apply the SUZUKI MOLY PASTE to the push rod. . 99000-25140: SUZUKI MOLY PASTE • Install the push rod.
  • Page 286 7-62 CHASSIS • Connect the reservoir hose 5 to the connector 6. • Tighten the master cylinder mounting bolts 7 to the specified torque. • Connect the brake hose to the master cylinder. (Rear brake hose routing: !9-21) • Tighten the brake hose union bolt 8 to the specified torque. # Rear master cylinder mounting bolt: 10 N·m (1.0 kgf-m, 7.3 lb-ft) Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

  • Page 287: Rear Suspension

    CHASSIS 7-63 REAR SUSPENSION CONSTRUCTION ITEM N·m kgf-m lb-ft 25.5 Rear shock absorber 43.5 Swingarm 10.0 72.5 " Spacer Dust seal 10.0 72.5 Bearing 0.95 Rear shock absorber mounting upper nut Rear shock absorber mounting lower nut Swingarm pivot locknut Swingarm pivot bolt (LH) Swingarm pivot bolt (RH)

  • Page 288: Removal

    7-64 CHASSIS REMOVAL • Remove the mud guards (left and right). (!7-8) • Remove the rear wheels. (!7-11) • Remove the rear caliper. (!7-51) • Remove the rear drive gear case and rear axle housings. (!4-22) • Disconnect the rear brake hose from the clamp and guide. •...

  • Page 289: Inspection And Disassembly

    CHASSIS 7-65 • Remove the pivot spacers 5. INSPECTION AND DISASSEMBLY DUST SEAL AND SPACERS Inspect the spacer and dust seal for wear or damage. If any damages are found, replace them with new ones. SWINGARM BEARING • Remove the dust seals with the special tool. •...

  • Page 290: Reassembly And Remounting

    When installing the bearing plate, make sure that the bulge of bearing plate faces inside. • Apply SUZUKI SUPER GREASE “A” to the swingarm bear- ings and lips of dust seals, then install them into the swingarm with the special tool.
  • Page 291 CHASSIS 7-67 • Tighten the swingarm pivot bolts temporarily. • Tighten the left side swingarm pivot bolt to the specified torque first, and then tighten the right side bolt with special tool. # Swingarm pivot bolt (LH): 100 N·m (10.0 kgf-m, 72.5 lb-ft) Swingarm pivot bolt (RH): 9.5 N·m (0.95 kgf-m, 7.0 lb-ft) * 09900-18710: Hexagon socket (12 mm) •...

  • Page 292: Rear Axle

    7-68 CHASSIS REAR AXLE CONSTRUCTION Dust seal Snap ring " Bearing Rear axle housing (RH) O-ring Rear axle housing (LH) & Rear axle (RH) Rear axle (LH) Rear drive gear case cover Trailer towing Rear axle housing bolt Rear axle housing mounting nut ITEM N·m kgf-m...

  • Page 293: Removal

    CHASSIS 7-69 REMOVAL • Place the vehicle on level ground. • Remove the rear wheel. (!7-11) • Remove the rear caliper. (!7-51) • Remove the rear wheel hub. (!7-57) • Loosen the rear axle housing bolts 1. • Remove the rear drive gear case cover bolts 2. •...
  • Page 294 7-70 CHASSIS DUST SEAL Inspect the dust seal’s lip for wear or damage. If any damages are found, replace the dust seal with a new one. • Remove the dust seal using the special tool. * 09913-50121: Oil seal remover HUB BEARING Inspect the inner race play of the hub bearing by hand while it is in the rear axle housing.

  • Page 295: Reassembly And Remounting

    Reassembly and remounting the rear axle in reverse order of removal and disassmebly. Pay attention to the following points: • Apply SUZUKI SUPER GREASE “A” to the hub bearings and dust seals before installing them. + 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A”...
  • Page 296 7-72 CHASSIS • Install the rear axle shaft and rear axle housing to the rear drive gear case. • Apply THREAD LOCK SUPER “1303” to the rear axle hous- ing bolts 4. • Install the trailer towing 5 and tighten the rear axle housing bolts 4 to the specified torque.

  • Page 297: Rear Wheel, Rear Brake, Rear Suspension, Rear Swingarm And Rear Axle Shaft Reassembling Information

    CHASSIS 7-73 REAR WHEEL, REAR BRAKE, REAR SUSPENSION, REAR SWIN- GARM AND REAR AXLE SHAFT REASSEMBLING INFORMATION...

  • Page 298: Gearshift Lever

    7-74 CHASSIS GEARSHIFT LEVER CONSTRUCTION 2.0 N·m (0.2 kgf-m, 1.5 lb-ft) 29 N·m 2.9 kgf-m, 21.0 lb-ft 29 N·m (2.9 kgf-m, 21.0 lb-ft) Boot Upper cover Lower cover Knob Button Gearshift lever assy Reverse gear cable Bracket Cable stopper Parking cable...

  • Page 299: Removal And Disassembly

    CHASSIS 7-75 REMOVAL AND DISASSEMBLY • Remove the front fender. (!7-6) • Disconnect the parking switch coupler 1. • Remove the boot 2. • Remove the E-ring and disconnect the reverse gear cable 3 from the reverse arm 4. Do not apply lateral force to the cable end. Excessive bending of cable may result in damage of flexible joint of cable •...

  • Page 300: Inspection

    7-76 CHASSIS • Loosen the locknut 9 and disconnect the parking interlock cable 0. • Remove the gearshift lever assembly. INSPECTION GEARSHIFT LEVER ASSEMBLY Inspect the gearshift lever assembly for wear or damage. If any damage are found, replace the gear shift lever assembly. NOTE: Do not disassemble the gearshift lever assembly.

  • Page 301: Reassembly And Remounting

    Reassemble and remount the gearshift lever in the reverse order of removal and disassembly. Pay attention to the following points: • Apply SUZUKI SUPER GREASE “A” to the each pivot, sliding area and lock pins. + 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A”...
  • Page 302 7-78 CHASSIS • Apply SUZUKI SUPER GREASE “A” to the gearshift lever Left Right rod. + 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Turn the gearshift lever rod 1 so that the rod length A would be 23 mm (0.9 in) as shown in the illustration.

  • Page 303: Cables

    CHASSIS 7-79 CABLES REMOVAL AND INSTALLATION REVERSE GEAR CABLE Before removing the reverse gear cable, keep the gearshift lever in the “R” position. • Remove the tank covers, left inner fender and left mud guard. (!7-5 to -8) • Disconnect the reverse gear cable 1 from the reverse arm 2 by removing the E-ring and clip.
  • Page 304 7-80 CHASSIS • Install the reverse gear arm 5 onto its shaft so that the setting angle becomes approx. 42° from the horizontal to the “R” position. • Install the reverse switch. Make sure the installation angle of the reverse gear arm is accurate.
  • Page 305 CHASSIS 7-81 • Remove the clip. NOTE: Flatten the locked parts A with a long nose pliers. • Remove the clip. • Remove the parking cable 1 with the parking cam arm. • Release the cable adjuster lock. (!7-83) • Connect the parking cam arm 3 to the parking cable 4. •...
  • Page 306 7-82 CHASSIS • Pass the parking cable 4 through the guides. • Install the clip 5. • Install the parking cable 4 to the parking arm 2. • Adjust the cable play. (!7-83) Do not apply lateral force to the cable end. Excessive bending of cable may result in damage of flexible joint of cable...

  • Page 307: Cable Play Adjustment

    CHASSIS 7-83 CABLE PLAY ADJUSTMENT PARKING INTERLOCK CABLE Before adjusting the parking interlock cable play, adjust the rear brake pedal height and rear brake lever play properly. (!2- • Shift the shift lever into “D”. • Loosen the locknuts 1. •...
  • Page 308 7-84 CHASSIS REVERSE GEAR CABLE AND PARKING CABLE Before installing the cable, release the cable adjuster lock. • Slide the lock cover 1 on the cable adjuster. • Push out the lock piece 2 to an extent where the adjuster 3 slides smoothly.
  • Page 309 ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ..............8- 2 CONNECTORS ................8- 2 COUPLERS .................. 8- 2 CLAMPS ..................8- 2 FUSES ..................8- 2 SEMI-CONDUCTOR EQUIPPED PARTS ........8- 2 BATTERY ..................8- 3 CONNECTING THE BATTERY ........... 8- 3 WIRING PROCEDURE ..............

  • Page 310: 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 311: Battery

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

  • Page 312: Location Of Electrical Components

    ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS Battery Front brake switch Main fuse 2WD/4WD selection button Starter relay Ignition switch Fuse box Power source Neutral relay Rear brake switch Parking brake switch Ignition coil Handlebar switch (L)
  • Page 313 ELECTRICAL SYSTEM Cooling fan ( 6-7) 2WD switch Cooling fan thermo-switch ( 6-9) Engine coolant temp. switch ( 6-10) Parking position switch Generator Starter motor Speed sensor Regulator/rectifier CDI unit 2WD/4WD selecting relay Neutral switch 2WD/4WD motor Reverse switch 4WD switch Gear switch...

  • Page 314: Charging System

    ELECTRICAL SYSTEM CHARGING SYSTEM Ignition switch Main fuse Battery Generator Regulator/rectifier 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 leaks. Current leaks •...
  • Page 315 ELECTRICAL SYSTEM Measure the continuity of the generator coil. No continuity • Faulty generator coil or 8-9) disconnected lead wires Continuity Measure the generator no-load voltage. Incorrect • Faulty generator 8-9) Correct Inspect the regulator/rectifier. Incorrect • Faulty regulator/rectifier 8-10) Correct Incorrect Inspect the wires.

  • Page 316: Inspection

    ELECTRICAL SYSTEM INSPECTION BATTERY CURRENT LEAKAGE • Remove the seat. (!7-4) • Turn the ignition switch to the “OFF” position. • Disconnect the - battery lead wire. Measure the current between - battery terminal and the - bat- tery lead wire using the multi circuit tester. If the reading exceeds the specified value, leakage is evident.
  • Page 317 ELECTRICAL SYSTEM GENERATOR COIL RESISTANCE • Remove the fuel tank cover. (!7-5) • Disconnect the generator coupler. Measure the resistance between the three lead wires. If the resistance is not specified value, replace the stator coil with a new one. Also, check that the generator core is insulated.
  • Page 318 8-10 ELECTRICAL SYSTEM REGULATOR/RECTIFIER • Remove the rear fender. (!7-9) • Remove the regulator/rectifier. Measure the voltage between the terminals using the multi cir- cuit tester, as indicated in the table below. If the voltage is not within the specified value, replace the regu- lator/rectifier with a new one.

  • Page 319: Starter System

    ELECTRICAL SYSTEM 8-11 STARTER SYSTEM Starter Ignition Engine button switch stop switch Fuse Fuse Neutral relay Starter motor Neutral indicator light B/Bl Starter relay Bl/B Neutral switch Parking brake switch TROUBLESHOOTING Starter motor will not run. Check if the starter motor runs when its terminal is connected The transfer is in neutral.

  • Page 320: Starter Motor Removal And Disassembly

    8-12 ELECTRICAL SYSTEM Check the starter relay. Incorrect • Faulty starter relay 8-15) Correct • Improper starter relay contact The starter motor runs when the transfer gear position is in neutral, but does not run when the transfer gear position is in any position other than neutral, with the parking brake lever grasp firmly. Incorrect •...

  • Page 321: Starter Motor Inspection

    ELECTRICAL SYSTEM 8-13 • Disassembly the starter motor, as shown. Housing end (outside) Brush holder Brush spring O-ring Brush terminal set Starter motor case Washer set Armature Washer set Housing end (inside) O-ring STARTER MOTOR INSPECTION CARBON BRUSHES Inspect the carbon brushes for abnormal wear, cracks, or smoothness in the brush holder.

  • Page 322: Starter Motor Reassembly And Remounting

    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. . 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) •...

  • Page 323: Starter Relay Inspection

    ELECTRICAL SYSTEM 8-15 • Apply SUZUKI SUPER GREASE “A” to the O-ring . . 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Connect the starter lead wire and the engine ground lead wire. (!9-14) STARTER RELAY INSPECTION •...

  • Page 324: Neutral Relay Inspection

    8-16 ELECTRICAL SYSTEM Measure the relay coil resistance between the terminals using the multi circuit tester. If the resistance is not within the specified value, replace the starter relay with a new one. # 09900-25008: Multi circuit tester set ) Tester knob indication: Resistance (Ω Ω Ω Ω ) &...

  • Page 325: Ignition System

    ELECTRICAL SYSTEM 8-17 IGNITION SYSTEM Ignition Engine switch stop switch Fuse Fuse CDI unit Wave form Ignition power arrangment source circuit circuit DC-DC Ignition converter coil Battery Driver Generator Wave form arrangment Spark plug circuit Transfer Neutral/ Parking switch parking brake switch switch...
  • Page 326 8-18 ELECTRICAL SYSTEM Measure the ignition coil primary peak voltage. ( 8-19) Inspect the spark plug. Correct NOTE: The ignition coil peak voltage 2-7) inspection method is applicable only with the multi circuit tester and the peak volt adaptor. Correct Incorrect Incorrect •...

  • Page 327: Inspection

    ELECTRICAL SYSTEM 8-19 INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the fuel tank cover. (!7-5) • Remove the spark plug cap. • Connect a new spark plug to spark plug cap and ground it to the cylinder head. NOTE: Make sure that the spark plug cap and spark plug are connected properly and the battery is fully-charged.
  • Page 328 8-20 ELECTRICAL SYSTEM IGNITION COIL RESISTANCE • Remove the fuel tank cover. (!7-5) • Disconnect the ignition coil lead wire and spark plug cap, and remove the ignition oil. Measure the ignition coil resistance in both the primary and sec- ondary windings using the multi circuit tester.

  • Page 329: 2Wd/4Wd Selecting System

    ELECTRICAL SYSTEM 8-21 2WD/4WD SELECTING SYSTEM DESCRIPTION The 2WD/4WD selecting system consists of the following components: the 2WD/4WD selecting button, 2WD switch, 4WD switch, 2WD/4WD selecting relay, 2WD/4WD motor and battery. TO SHIFT FROM 2-WHEEL DRIVE TO 4-WHEEL DRIVE: Depress the 2WD/4WD selecting button with the ignition switch in ON position. Depressing this switch causes current A to flow as shown, energizing the 2WD/4WD selecting relay coil.

  • Page 330: Troubleshooting

    8-22 ELECTRICAL SYSTEM TROUBLESHOOTING Does not shift to 2WD/4WD (2WD/4WD motor will not run.) Turn on the ignition switch. Listen for a click Check the 2WD/4WD motor. Clicks from the 2WD/4WD selecting relay when the 8-23) 2WD/4WD selecting button is pushed. Does not run Runs No click...

  • Page 331: Inspection

    ELECTRICAL SYSTEM 8-23 INSPECTION 2WD/4WD MOTOR • Remove the left inner fender. (!7-7) • Disconnect the 2WD/4WD motor coupler 1. • Remove the 2WD/4WD motor 2. Connect the 12 V battery to the 2WD/4WD motor lead wires as shown. If the motor does not run, replace the motor assembly with a new one.
  • Page 332 8-24 ELECTRICAL SYSTEM First check the insulation between B and C and between A and C terminals with the tester. Apply 12 V to the terminals as shown in Fig-1, and check the continuity between B and C. Apply 12 V to the terminals as shown in Fig-2, and check the continuity between A and C.

  • Page 333: Speedometer

    ELECTRICAL SYSTEM 8-25 SPEEDOMETER PARTS NAMES Parking indicator light Reverse indicator light Neutral indicator light High beam indicator light Engine coolant temperature indicator light Gear position Speedometer Clock/hour Odometer/tripmeter (A, B) ODO/TRIP button Clock/Hour button...

  • Page 334: Operating Procedure

    8-26 ELECTRICAL SYSTEM OPERATING PROCEDURE INITIAL DISPLAY When the ignition switch is set to ON, all LCD and engine cool- ant temperature indicator light light up for two seconds. NOTE: If the power supply is cut (e.g., when the battery is replaced); * The odometer, tripmeter and clock are displayed after the ini- tial display appears.
  • Page 335 ELECTRICAL SYSTEM 8-27 CLOCK Displays the time (hour and minutes) on a 12-hour clock. Setting the time Hold down the button over two seconds and then flashing the minute display. 2 Select the correct minutes by min. pressing the button. Decide the minutes by pressing the ODO/TRIP button, and then flashing the hour display.

  • Page 336: Inspection

    8-28 ELECTRICAL SYSTEM INSPECTION SPEEDOMETER • Remove the speedometer assembly. (!7-42) • Apply 12 V to the terminals and check that the indicators are turned on. Battery + Battery - Battery + Battery - ITEM ITEM LCD (Gear position, 4WD, A &...
  • Page 337 The highest tester reading voltage (12 V) while testing is same as the total voltage of four batteries. • Apply SUZUKI SUPER GREASE “A” to the speed sensor O- ring before installing it. . 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A”...

  • Page 338: Lamps

    8-30 ELECTRICAL SYSTEM LAMPS HEADLIGHT AND AUXILIARY LIGHT Headlight bulb: 12 V 30/30 W Auxiliary light: 12 V 40 W (Right & Left) If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.
  • Page 339 ELECTRICAL SYSTEM 8-31 AUXILIARY LIGHT BULB REPLACEMENT • Remove the auxiliary light cover 1. • Remove the auxiliary light 2. • Remove the socket 3 with lead wire. • Disconnect the lead wire coupler 4. • Install the new bulb assembly in the reverse order of removal.

  • Page 340: Brake Light/Taillight

    8-32 ELECTRICAL SYSTEM BRAKE LIGHT/TAILLIGHT Brake light/taillight: 12 V 21/5 W 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 • Remove the brake light/taillight assembly backward. ✡...

  • Page 341: Switches

    ELECTRICAL SYSTEM 8-33 SWITCHES Measure each switch for continuity using a multi circuit tester. If any abnormality is found, replace the respective switch assemblies with a new one. # 09900-25008: Multi circuit tester set IGNITION SWITCH PARKING POSITION SWITCH Color Color Position Position...
  • Page 342 8-34 ELECTRICAL SYSTEM NEUTRAL SWITCH • Remove the fuel tank cover. (!7-5) • Disconnect the neutral switch coupler 1. Measure neutral switch for continuity using a multi circuit tester. If there is no continuity, replace the neutral switch with a new one.

  • Page 343: Battery

    ELECTRICAL SYSTEM 8-35 BATTERY SPECIFICATIONS Type designation FTH16-BS Capacity 12 V, 50.4 kC (14 Ah)/10 HR a Anode plates e Stopper b Separator (fiberglass plate) f Filter c Cathode plates g Terminal d Upper cover breather h Safty valve INITIAL CHARGING FILLING ELECTROLYTE •...
  • Page 344 8-36 ELECTRICAL SYSTEM NOTE: If no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the container from the battery. • After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the bat- tery.

  • Page 345: Servicing

    ELECTRICAL SYSTEM 8-37 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 346 SERVICING INFORMATION SERVICING INFORMATION CONTENTS TROUBLESHOOTING ................ 9- 2 ENGINE ..................9- 2 DRIVE TRAIN ................9- 6 CARBURETOR ................9- 6 CHASSIS ..................9- 7 BRAKES ..................9- 8 RADIATOR (COOLING SYSTEM) ..........9- 8 ELECTRICAL ................9- 9 BATTERY ..................

  • Page 347: Troubleshooting

    SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. 1. Worn cylinder. Replace. 2. Worn piston ring. Replace. 3. Worn valve guide or improper valve seating. Repair or replace. 4.
  • Page 348 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine is noisy. Excessive valve chatter 1. Excessive valve clearance. Adjust. 2. Weak or broken valve spring. Replace. 3. Worn rocker arm and rocker arm shaft. Replace. Noise seems to come from the piston 1.
  • Page 349 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Slipping clutch. 1. Clutch control out of adjustment or loss of play. Adjust. 2. Weakened clutch springs. Replace. 3. Worn clutch shoes. Replace. 4. Worn or distorted pressure plate. Replace. 5. Distorted clutch plates, driven and drive. Replace.
  • Page 350 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Exhaust smoke is 1. Excessive amount of engine oil. Check level and drain. dirty or thick. 2. Worn piston ring or cylinder. Replace. 3. Worn valve guide. Replace. 4. Scored or scuffed cylinder wall. Replace.

  • Page 351: Drive Train

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

  • Page 352: Chassis

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

  • Page 353: Brakes

    SERVICING INFORMATION BRAKES Complaint Symptom and possible causes Remedy Poor braking. 1. Insufficient brake fluid. Refill to level mark. 2. Air in brake fluid circuit. Bleed air out. 3. Worn pads. Replace. 4. Too much play on brake pedal. Adjust. Insufficient brake 1.

  • Page 354: Electrical

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

  • Page 355: Battery

    9-10 SERVICING INFORMATION BATTERY Complaint Symptom and possible causes Remedy Sulfation or spots on 1. Cracked battery case. Replace. surfaces of cell 2. Battery has been left in a run-down condition for a long Replace. plates. time. Battery runs down 1.

  • Page 356: Wiring Diagram

    SERVICING INFORMATION 9-11 WIRING DIAGRAM...

  • Page 357: Wiring Harness, Cable, And Hose Routing

    9-12 SERVICING INFORMATION WIRING HARNESS, CABLE, AND HOSE ROUTING WIRING HARNESS ROUTING Fix the wiring harness clamp to the frame. To headlight (LH) To headlight (RH) Cooling fan thermo-switch To power source Wiring harness To headlight (RH) Engine coolant temperature switch Fix the wiring harness clamp to the frame.
  • Page 358 SERVICING INFORMATION 9-13 Battery terminal Battery terminal Rear fender Starter relay Clamp Reverse switch Main fuse Neutral switch Generator Wiring harness Pass the wiring harness above the ground wire and starter motor lead wire, and set them to the groove of the rear fender.
  • Page 359 9-14 SERVICING INFORMATION...

  • Page 360: Cable Routing

    SERVICING INFORMATION 9-15 CABLE ROUTING Clamp Front brake switch Starter cable 2WD/4WD selecting button Rear brake cable Throttle cable Throttle cable Cable guide Clamp Pass the throttle cable and the starter cable through the cable guide. Pass the parking cable Pass the throttle cable front of the rear brake cable.

  • Page 361: Carburetor Hose Routing

    9-16 SERVICING INFORMATION CARBURETOR HOSE ROUTING Insert the air vent hose into the fuel tank cover. Air vent hose Air vent hose Face the clamp Face the clamp Carburetor screw head left side. screw head up ward.
  • Page 362 SERVICING INFORMATION 9-17 Brake hose Breather hose No.2 Pass the breather hose No.2 the right of the brake hose. Fuel tank Steering shaft Radiator Breather hose No.1 Breather hose No.2 Fuel tank Clamp the breather hose No.2 at 20 mm (0.8 in) from hose end. 20mm (0.8 in) Connect the breather hose No.2...

  • Page 363: Cooling System Hose Routing

    9-18 SERVICING INFORMATION COOLING SYSTEM HOSE ROUTING...

  • Page 364: Front Driving System

    SERVICING INFORMATION 9-19 FRONT DRIVING SYSTEM...

  • Page 365: Front Brake Hose Routing

    9-20 SERVICING INFORMATION FRONT BRAKE HOSE ROUTING...

  • Page 366: Rear Brake Hose Routing

    SERVICING INFORMATION 9-21 REAR BRAKE HOSE ROUTING...

  • Page 367: Oil Return Tank Hose Routing

    9-22 SERVICING INFORMATION OIL RETURN TANK HOSE ROUTING...

  • Page 368: Special Tools

    SERVICING INFORMATION 9-23 SPECIAL TOOLS 09900-00410 09900-06106 09900-06107 09900-06108 09900-09004 Hexagon wrench set Snap ring pliers Snap ring pliers Snap ring pliers Impact driver set 09900-20202 09900-20204 09900-20205 09900-18710 Micrometer Micrometer Micrometer Hexagon socket 09900-20101 (1/100 mm, (1/100 mm, (1/1000 mm, (12 mm) Vernier calipers 25–50 mm)
  • Page 369 9-24 SERVICING INFORMATION 09900-22403 09900-25008 Small bore gauge Multi circuit tester 09900-26006 09910-32812 09913-50121 (18–35 mm) Tachometer Crankshaft installer Oil seal remover 09915-64512 Compression gauge 09913-70210 09915-40610 09915-63310 09915-74511 09916-10911 Bearing installer set Oil filter wrench Adaptor Oil pressure gauge Valve lapper set 09916-14910 09916-21111...
  • Page 370 SERVICING INFORMATION 9-25 09920-13120 09920-53730 09917-50410 Crankcase separat- Clutch sleeve hub 09921-20210 09921-20240 Bearing remover ing tool holder Bearing remover Bearing remover set 09924-41830 09921-21910 09923-74510 09924-21940 Bearing locknut 09924-84510 Bearing holder Bearing remover Wheel hub remover wernch Bearing installer set 09930-10121 09930-30190 09924-84521...

  • Page 371: Tightening Torque

    9-26 SERVICING INFORMATION TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lb-ft Cylinder head cover bolt Camshaft sprocket bolt 11.0 Cylinder head bolt 27.5 6 mm Cylinder head nut 8 mm 18.0 Cylinder base nut Cam chain tensioner bolt Cam chain tension adjuster mounting bolt Cam chain tension adjuster spring holder bolt Spark plug Valve clearance adjuster locknut...

  • Page 372: Differential

    SERVICING INFORMATION 9-27 DIFFERENTIAL ITEM N·m kgf-m lb-ft Front drive (differential) gear oil drain plug 23.0 Front drive (differential) gear oil filler plug 25.5 Front drive (differential) gear case mounting nut 32.5 Front drive (differential) gear case bolt 16.5 Front propeller shaft flange coupling bolt 32.5 Rear drive shaft housing nut 16.5...

  • Page 373: Tightening Torque Chart

    9-28 SERVICING INFORMATION TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt A A A A (mm) N·m kgf-m lb-ft N·m kgf-m lb-ft 0.15...

  • Page 374: Service Data

    SERVICING INFORMATION 9-29 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. 30.6 — (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 –...
  • Page 375 9-30 SERVICING INFORMATION CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 33.430 – 33.484 33.130 (1.3161 – 1.3183) (1.3043) 33.500 – 33.554 33.200 (1.3189 – 1.3210) (1.3071) Camshaft journal oil clearance Right & 0.032 – 0.066 0.150 Center (0.0013 –...
  • Page 376 SERVICING INFORMATION 9-31 ITEM STANDARD LIMIT 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) 1.17 –...
  • Page 377 9-32 SERVICING INFORMATION DRIVE TRAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 2.032 (63/31) — Secondary reduction ratio 1.133 (17/15) — Final reduction ratio Front 3.600 (36/10) — Rear 3.600 (36/10) — Transfer gear ratio 2.419 (22/23 × 27/17 × 43/27) —...
  • Page 378 SERVICING INFORMATION 9-33 ITEM STANDARD/SPECIFICATION LIMIT OFF→ → → → ON Engine coolant temp. indicator light Approx. 115 °C (239 °F) thermo-switch operating temperature ON→ → → → OFF Approx. 108 °C (226 °F) OFF→ → → → ON Approx. 88 °C (190 °F) Cooling fan thermo-switch operating temperature ON→...
  • Page 379 9-34 SERVICING INFORMATION ITEM SPECIFICATION NOTE Battery Type designation FTH16-BS Capacity 12 V 50.4 kC (14 Ah)/10 HR Fuze size Main 30 A Power source 10 A Headlight (HI) 10 A Headlight (LO) 10 A Ignition 15 A 10 A WATTAGE Unit: W ITEM...
  • Page 380 SERVICING INFORMATION 9-35 ITEM STANDARD/SPECIFICATION LIMIT Turning radius 3.0 m (9.8 ft) Toe-in (with 75 kg, 165 lbs) 7 ± 4 (0.30 ± 0.16) Chamber 0.45° Caster 3.3° Wheel rim size Front 12 × 6.0 AT — Rear 12 × 7.5 AT —...
  • Page 381 Prepared by August, 2002 Part No. 99500-44050-01E Printed in Japan...
  • Page 382 Printed in Japan...

Table of Contents

Save PDF