Suzuki DR-Z70 Service Manual
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Suzuki DR-Z70 Service Manual

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  • Page 1 9 9 5 0 0 - 4 0 0 3 0 - 0 3 E...
  • Page 2 FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI DR-Z70 and procedures for its inspec- tion/service and overhaul of its main components. GENERAL INFORMATION Other information considered as generally known is not included. Read the GENERAL INFORMATION section to...
  • 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. (mixture of engine oil and SUZUKl Measure in diode test range. MOLY PASTE in a ratio of 1 : 1) Apply SUZUKI SUPER GREASE “ A ” or equivalent grease. Measure in continuity test range. 99000-25010 Apply SUZUKI BOND “...

  • Page 5: Table Of Contents

    1-1 GENERAL INFORMATION GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE .................1- 2 GENERAL PRECAUTIONS................1- 2 SUZUKI DR-Z70K8 (’08-MODEL) ..............1- 4 SERIAL NUMBER LOCATION..............1- 4 FUEL AND OIL RECOMMENDATION ............1- 5 FUEL (FOR USA AND CANADA)............1- 5 FUEL (FOR OTHER COUNTRIES)............1- 5 ENGINE OIL (FOR USA).................1- 5 ENGINE OIL (FOR OTHER COUNTRIES) ..........1- 5...

  • 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 equiva- lent. * 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 and orientation.

  • Page 8: Suzuki Dr-Z70K8 ('08-Model)

    GENERAL INFORMATION SUZUKI DR-Z70K8 (’08-MODEL) RIGHT SIDE LEFT SIDE • Difference between illustration and actual motorcycle may exist depending on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the right side of the steering head pipe.

  • Page 9: Fuel And Oil Recommendation

    Suzuki recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or equivalent engine oil. Use of SF/SG or SH/SJ in API with MA in JASO. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an alternative according to the following chart.

  • Page 10: Information Labels

    GENERAL INFORMATION INFORMATION LABELS APPLIED SPECIFICATION LABEL or PLATE NAME Noise label – Information label – Fuel caution label – Manual notice Label – General warning label E General warning label F – Manufacturer label – Compliance label E – ICES Canada label –...

  • Page 11: Specifications

    GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length................1 320 mm (52.0 in) Overall width ................580 mm (22.8 in) Overall height................790 mm (31.1 in) Wheelbase ................935 mm (36.8 in) Ground clearance ..............135 mm (5.3 in) Seat height................

  • Page 12: Chassis

    GENERAL INFORMATION CHASSIS Front suspension..............Inverted telescopic, coil spring Rear suspension ..............Swingarm type, coil spring, oil damped Front fork stroke ..............96 mm (3.8 in) Rear wheel travel ..............76 mm (3.0 in) Caster..................25 ° 20 ’ Trail ..................35 mm (1.38 in) Steering angle .................

  • Page 13: Periodic Maintenance

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE .............2- 2 PERIODIC MAINTENANCE CHART .............2- 2 LUBRICATION POINTS .................2- 3 MAINTENANCE AND TUNE-UP PROCEDURES ........2- 4 AIR CLEANER ..................2- 4 EXHAUST PIPE BOLTS AND MUFFLER MOUNTING NUT ....2- 5 VALVE CLEARANCE ................2- 6 SPARK PLUG ..................2- 8 SPARK ARRESTER ................2- 9 FUEL LINE .....................2- 9...

  • Page 14: 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 motorcycle operating at peak performance and economy. NOTE: More frequent servicing may be performed on motorcycles that are used under severe conditions. PERIODIC MAINTENANCE CHART Interval Initially...

  • Page 15: Lubrication Points

    PERIODIC MAINTENANCE LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. Side-stand pivot and spring hook Drive chain Throttle cable Front brake lever holder Brake pedal pivot Kick starter lever NOTE:...

  • Page 16: Maintenance And Tune-Up Procedures

    PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements. AIR CLEANER Inspect each time the motorcycle is ridden and clean as necessary. If the air cleaner element is clogged with dust, intake resistance will be increased, with a resultant decrease in power output and increase in fuel consumption.

  • Page 17: Exhaust Pipe Bolts And Muffler Mounting Nut

    PERIODIC MAINTENANCE • Reinstall the cleaned or new air cleaner element in the reverse order of removal. The open mesh A of the air cleaner element must be faced outside. The surest way to accelerate engine wear is to operate the engine without the element or to use a torn ele- ment.

  • Page 18: Valve Clearance

    PERIODIC MAINTENANCE VALVE CLEARANCE Inspect initially at 1 month and every 6 months there- after. REMOVAL • Remove the spark plug. ( 2-8) • Remove the camshaft sprocket cover 1 . • Remove the valve inspection caps 2 . • Remove the TDC plug 3 and generator cover plug 4 . INSPECTION The valve clearance specification is different for intake and exhaust valves.
  • Page 19 PERIODIC MAINTENANCE • Turn the crankshaft to bring the “Top” line A on the generator rotor to the center of hole on the generator cover and also to bring the mark B on the camshaft sprocket with the concave line C of the cylinder head as shown. •...

  • Page 20: Spark Plug

    PERIODIC MAINTENANCE SPARK PLUG Inspect every 6 months. Replace every 12 months. REMOVAL • Disconnect the spark plug cap 1 and remove the spark plug HEAT RANGE • Check spark plug heat range by observing electrode color. If the electrode of the spark plug is wet appearing or dark color, replace the spark plug with hotter type one.

  • Page 21: Spark Arrester

    PERIODIC MAINTENANCE INSTALLATION Before using a spark plug wrench, carefully turn the spark plug by finger into the threads of the cylinder head to prevent damage. • Tighten the spark plug to the specified torque. Spark plug: 11 N·m (1.1 kgf-m, 8.0 lb-ft) 09930-10121: Spark plug wrench set SPARK ARRESTER Clean every 6 months.

  • Page 22: Engine Oil

    PERIODIC MAINTENANCE 2-10 ENGINE OIL ENGINE OIL REPLACEMENT Replace initially at 1 month and every 6 months there- after. • Engine oil should be changed while the engine is warm. • Place the motorcycle on the side-stand. • Place an oil pan below the engine. Drain oil by removing the engine oil drain plug 1 .

  • Page 23: Throttle Cable Play

    2-11 PERIODIC MAINTENANCE THROTTLE CABLE PLAY Inspect initially at 1 month and every 6 months there- after. Adjust the throttle cable play A as follows. • Pull the throttle adjuster cover 1 . • Loosen the lock-nut 2 of the throttle cable. •...

  • Page 24: Drive Chain

    If any defects are found, the drive chain must be replaced. NOTE: When replacing the drive chain, replace the drive chain and sprockets as a set. The standard drive chain is D.I.D 428. SUZUKI recom- mends to use this standard drive chain as a replace- ment. CHECKING •...
  • Page 25 2-13 PERIODIC MAINTENANCE ADJUSTING • Place the motorcycle on the side-stand. • Loosen or tighten both chain adjusters 1 until the chain has 25 – 35 mm (1.0 – 1.4 in) of slack at the middle of the chain between the engine and rear sprockets as shown. The refer- ence marks 2 must be at the same position on the scale to ensure that the front and rear wheels are correctly aligned.

  • Page 26: Brakes

    PERIODIC MAINTENANCE 2-14 BRAKES Inspect initially at 1 month and every 6 months there- after. FRONT BRAKE LEVER PLAY • Adjust the brake lever position. • Adjust the free travel A to 15 – 25 mm (0.6 – 1.0 in) by turn- ing the adjusting nut 1 .

  • Page 27: Spoke Nipples

    2-15 PERIODIC MAINTENANCE TIRE PRESSURE If the tire pressure is too high or too low, steering will be adversely affected and tire wear will increase. Therefore, main- tain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows. Cold inflation tire pressure Front: 100 kPa (1.0 kgf/cm², 14 psi) Rear: 125 kPa (1.25 kgf/cm², 18 psi)

  • Page 28: Steering

    PERIODIC MAINTENANCE 2-16 STEERING Inspect initially at 1 month and every 6 months there- after. The steering should be adjusted properly for smooth turning of handlebars and safe operation. Overtight steering prevents smooth turning of the handlebars and too loose steering will cause poor stability.

  • Page 29: Chassis Bolts And Nuts

    2-17 PERIODIC MAINTENANCE CHASSIS BOLTS AND NUTS Tighten initially at 1 month and every 6 months thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to the locations of the fol- lowing bolts and nuts on the motorcycle.) ITEM N·m kgf-m...

  • Page 30: Compression Pressure Check

    PERIODIC MAINTENANCE 2-18 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 should include compression readings for each maintenance service. COMPRESSION PRESSURE SPECIFICATION Standard Limit...

  • Page 31: Oil Pressure Check

    2-19 PERIODIC MAINTENANCE OIL PRESSURE CHECK Check the oil pressure periodically. This will give a good indication of the condition of the moving parts. OIL PRESSURE SPECIFICATION 15 – 40 kPa (0.15 – 0.40 kgf/cm², 2.1 – 5.7 psi) at 3 000 r/min, Oil temp. at 60 °C (140 °F). If the oil pressure is lower or higher than specification, the following causes may be considered.

  • Page 32: Automatic Clutch Inspection

    PERIODIC MAINTENANCE 2-20 AUTOMATIC CLUTCH INSPECTION This motorcycle is equipped with an automatic clutch. The engagement of the clutch is governed by engine RPMs and cen- trifugal mechanism located in the clutch. To insure proper performance and longer lifetime of the clutch assembly it is essential that the clutch engages smoothly and gradually.
  • Page 33 3-1 ENGINE ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE ......................3- 2 ENGINE REMOVAL AND INSTALLATION ..........3- 3 ENGINE REMOVAL ................3- 3 ENGINE INSTALLATION ...............3- 6 ENGINE DISASSEMBLY ................3- 9 ENGINE COMPONENTS INSPECTION AND SERVICE ......3-21 CYLINDER HEAD ..................3-21 CYLINDER ....................3-32 PISTON AND PISTON PIN ..............3-32 CAM CHAIN TENSION ADJUSTER ............3-34...

  • Page 34: Engine Components Removable With The Engine In Place

    ENGINE ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to page listed in each section for removal and reinstallation instructions. ENGINE CENTER PARTS REMOVAL INSTALLATION Cylinder head...

  • Page 35: 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. • Remove the battery. ( 6-6) • Remove the fuel tank side cover. ( 5-3) •...
  • Page 36 ENGINE • Disconnect the starter motor coupler 7 . • Disconnect the generator coupler 8 and neutral switch cou- pler 9 . • Disconnect the ground wire 0 . • Remove the footrest A . • Remove the gearshift lever B .
  • Page 37 ENGINE • Remove the engine sprocket cover C . • Remove the engine sprocket E with the drive chain F by removing the snap ring D . NOTE: If it is difficult to remove the engine sprocket, loosen the axle nut and chain adjusting nuts to provide additional chain slack.

  • Page 38: Engine Installation

    ENGINE ENGINE INSTALLATION Install the engine in the reverse order of engine removal. • Install the engine mounting bolts and nuts as shown in the fol- lowing illustration. • Tighten the engine mounting nuts to the specified torque. NOTE: The engine mounting nuts are self-locking. Once the nuts have been removed, they are no longer of any use.
  • Page 39 ENGINE • Install the exhaust pipe gasket 3 . The removed gasket must be replaced with a new one to prevent exhaust gas leakage. • Tighten the exhaust pipe bolts to the specified torque. Exhaust pipe bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) •...
  • Page 40 ENGINE • After installing the engine, properly route the wire harness, cables, and hoses. Refer to the wire and cable routing sec- tions. ( 7-13) • Refer to the following sections to adjust the respective items to specification. * ENGINE OIL ( 2-10) * THROTTLE CABLE PLAY ( 2-11)

  • Page 41: Engine Disassembly

    ENGINE ENGINE DISASSEMBLY Identify the position of each removed part. Organize the parts in their respective groups so that they can be reinstalled in their original positions. KICK STARTER LEVER • Remove the kick starter lever. CRANKCASE BREATHER HOSE • Remove the crankcase breather hose. SPARK PLUG •...
  • Page 42 ENGINE 3-10 CYLINDER HEAD • Remove the TDC plug 1 and generator cover plug 2 . • Remove the camshaft sprocket cover 3 and gasket. • Turn the crankshaft bring the “Top” line A on the generator rotor to the center of hole on the generator cover. NOTE: At the above condition, the piston is at TDC of compression stroke and also the mark B on the camshaft sprocket with the...
  • Page 43 3-11 ENGINE • Hold the push rod with the - screw driver. • Remove the cam chain tension adjuster 5 . • Remove the gasket 6 . • Remove the camshaft sprocket washer 7 and camshaft sprocket 8 . • Remove the cylinder head base bolt. •...
  • Page 44 ENGINE 3-12 CYLINDER • Remove the dowel pins 1 , cylinder head gasket 2 , O-ring 3 and cam chain guide 4 . • Remove the cylinder base nut 5 . • Remove the cylinder 6 . NOTE: If the cylinder does not come off easily, lightly tap it with a plastic mallet.
  • Page 45 3-13 ENGINE GENERATOR COVER • Remove the generator cover 1 . • Remove the dowel pins 2 and gasket 3 . CLUTCH COVER • Remove the clutch cover 1 . • Remove the dowel pins 2 and gasket 3 . OIL SUMP FILTER •...
  • Page 46 ENGINE 3-14 OIL FILTER CASE • Remove the oil filter cover 1 with the special tool. 09920-53740: Clutch sleeve hub holder • Remove the oil filter case nut 2 with the special tool. 09930-44530: Rotor holder • Remove the washer 3 and oil filter case 4 . FIRST CLUTCH •...
  • Page 47 3-15 ENGINE • Remove the snap ring 2 . • Remove the gearshifting clutch assembly 3 . OIL PUMP • Remove the oil pump 1 . • Remove the dowel pins 2 . OIL PUMP DRIVE GEAR • Remove the oil pump drive gear 1 and pin 2 . GEARSHIFT CAM STOPPER •...
  • Page 48 ENGINE 3-16 • Remove the gearshift cam pins 5 . • Remove the gearshift cam stopper 6 . GEARSHIFT SHAFT • Remove the release ball outer guide 1 . • Remove the release ball 2 . • Remove the gearshift shaft 3 and spacer 4 . •...
  • Page 49 3-17 ENGINE • Remove the washer 6 and gearshift arm stopper 7 . GEARSHIFT CAM RETAINER • Remove the gearshift cam retainer 1 . GENERATOR ROTOR AND STARTER CLUTCH • Hold the crankshaft with the special tool. 09930-44530: Rotor holder •...
  • Page 50 ENGINE 3-18 CAM CHAIN • Remove the cam chain 1 . STARTER IDLE GEAR • Remove the snap ring 1 , washer 2 and starter idle gear 3 . • Remove the starter idle gear shaft 4 . CRANKCASE • Remove the crankcase bolts. •...
  • Page 51 3-19 ENGINE • Remove the dowel pins 1 . • Remove the oil breather separator 2 . TRANSMISSION • Remove the gearshift fork shafts 1 and gearshift cam 2 . • Remove the gearshift fork No. 1 3 and No. 2 4 . •...
  • Page 52 ENGINE 3-20 KICK STARTER SHAFT • Remove the washer 1 . • Remove the kick starter shaft 2 by turning the shaft. • Remove the kick starter guide 3 and kick starter stopper 4 . CRANKSHAFT • Remove the crankshaft with the special tool. 09920-13120: Crankcase and shaft remover...

  • Page 53: Engine Components Inspection And Service

    3-21 ENGINE ENGINE COMPONENTS INSPECTION AND SERVICE CYLINDER HEAD DISASSEMBLY Identify the position of each removed part. Organize the parts in their respective groups (i.e., intake or exhaust) so that they can be installed in their original locations. • Remove the cam chain tensioner 1 . •...
  • Page 54 ENGINE 3-22 • Remove the intake and exhaust rocker arms 6 . • Remove the camshaft 7 . • Compress the valve spring with the special tools. • Remove the two cotter halves 8 . 09916-14510: Valve spring compressor 09916-14521: Attachment 09916-84511: Tweezers •...
  • Page 55 3-23 ENGINE • Remove the valve oil seal B and valve spring seat C . ROCKER ARM SHAFT O.D. Measure the diameter of rocker arm shaft. Rocker arm shaft O.D. (IN. & EX.): Standard: 9.981 – 9.990 mm (0.3930 – 0.3933 in) 09900-20205: Micrometer (0 –...
  • Page 56 ENGINE 3-24 VALVE FACE WEAR The thickness of the valve face decreases as the face wears. Visually inspect each valve face for wear and replace any valve with an abnormally worn face. Measure the valve face thickness T . If it is out of specification, replace the valve with a new one. Valve head thickness (IN.
  • Page 57 3-25 ENGINE VALVE STEM DEFLECTION • Lift the valve about 10 mm from the valve seat. • Measure the valve stem deflection in two directions, “X” and “Y”, perpendicular to each other, by positioning the dial gauge as shown. • If the deflection measured exceeds the limit, then determine whether the valve or the guide should be replaced with a new one.
  • Page 58 ENGINE 3-26 • Cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 – 150 °C (212 – 302 °F) with a hot plate. Do not use a burner to heat the valve guide hole to prevent cylinder head distortion.
  • Page 59 3-27 ENGINE VALVE SEAT SERVICING • The valve seats 1 for both the intake valve 2 and exhaust valve 3 are machined to three different angles. The seat con- tact surface is cut at 30°. INTAKE SIDE EXHAUST SIDE ← Seat angle 15°, 45°...
  • Page 60 ENGINE 3-28 VALVE SPRING INSPECTION The force of the coil spring keeps the valve seat tight. Weak- ened spring results in reduced engine power output, and often accounts for the chattering noise coming from the valve mecha- nism. • Inspect the valve spring for proper strength by measuring its free length and also by the force required to compress it.
  • Page 61 3-29 ENGINE • Press in the new right bearing to the camshaft with the special tool. 09913-70210: Bearing installer The sealed cover of bearing must face outside. CAM SPROCKET INSPECTION Check the cam sprocket teeth for wear or damage. If any defects are found, replace the cam sprocket and cam chain as a set.
  • Page 62 ENGINE 3-30 • Install the valve spring with the small-pitch portion A facing cylinder head bottom. UP ward B Large-pitch portion C Paint • Be sure that the rounded lip E of the cotter fits snugly into the groove D in the stem end. •...
  • Page 63 • Tighten the cylinder head right cover bolts 4 securely. INTAKE PIPE • Install the intake pipe O-ring 1 . • Apply SUZUKI SUPER GREASE “A” to the intake pipe O-ring The removed O-ring must be replaced with a new one. 99000-25010: SUZUKI SUPER GREASE “A”...

  • Page 64: Cylinder

    ENGINE 3-32 CAM CHAIN TENSIONER • Install the cam chain tensioner 1 and washer 2 . • Tighten the cam chain tensioner bolt 3 to the specified torque. Cam chain tensioner bolt: 8 N·m (0.8 kgf-m, 6.0 lb-ft) CYLINDER CYLINDER DISTORTION Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance reading at several places as indicated.
  • Page 65 3-33 ENGINE PISTON TO CYLINDER CLEARANCE • Subtract the piston diameter from the cylinder bore diameter. • If the piston-to-cylinder clearance exceeds the service limit, rebore the cylinder and use an oversize piston or replace both the piston and cylinder. Piston to cylinder clearance: Service Limit: 0.120 mm (0.0047 in) PISTON PIN AND PIN BORE...

  • Page 66: Cam Chain Tension Adjuster

    ENGINE 3-34 PISTON RING FREE END GAP AND PISTON RING END GAP • Measure the piston ring free end gap using the vernier cali- pers. • Next, fit the piston ring squarely into the cylinder and measure the piston ring end gap using the thickness gauge. •...

  • Page 67: Cam Chain Guide

    3-35 ENGINE CAM CHAIN GUIDE INSPECTION Check the cam chain guide for wear or damage. If any defects are found, replace the cam chain guide with a new one.

  • Page 68: Conrod And Crankshaft

    ENGINE 3-36 CONROD AND CRANKSHAFT 1 Oil pump drive gear 3 Crankshaft, LH 5 Bearing 2 Crankshaft, RH 4 Conrod 6 Crank pin CONROD SMALL END I.D. Using a caliper gauge, measure the conrod small end inside diameter. Conrod small end I.D.: Service Limit: 13.040 mm (0.5134 in) 09900-20605: Dial calipers If the conrod small end bore inside diameter exceeds the limit,...
  • Page 69 3-37 ENGINE CONROD DEFLECTION AND CONROD BIG END SIDE CLEARANCE Wear on the big end of the conrod can be estimated by checking the movement of the small end of the conrod. This method can also check the extent of wear on the parts of the conrod’s big end.

  • Page 70: Oil Pump

    It is available only as an assembly. REASSEMBLY • Reassemble the oil pump in the reverse order of disassembly. Apply SUZUKI SUPER GREASE “A” to the O-rings 1 . 99000-25010: SUZUKI SUOER GREASE “A” or equivalent • Install the O-rings 1 .

  • Page 71: Transmission

    3-39 ENGINE TRANSMISSION DISASSEMBLY • Disassemble the transmission gears as shown in the illustration. 1 1st driven gear 4 Countershaft 7 2nd drive gear 2 3rd driven gear 5 3rd drive gear 3 Driveshaft 6 Sliding dog REASSEMBLY Assemble the countershaft and driveshaft in the reverse order of disassembly. Pay attention to the following points: NOTE: Before installing the gears, apply engine oil to the bearing and inner surface of the each gear.
  • Page 72 ENGINE 3-40 • When installing a new snap ring, pay attention to the direction of the snap ring. Fit the snap ring to the side where the thrust Thrust is as shown in the illustration. The rounded side should be against the gear surface.

  • Page 73: Gearshift Cam

    3-41 ENGINE GEARSHIFT CAM Inspect the gearshift cam wear or damage. If any defects are found, replace the gearshift cam with a new one. GEARSHIFT FORKS GEARSHIFT FORK-TO-GROOVE CLEARANCE Measure the gearshift fork clearance in the groove of its respec- tive gear using the thickness gauge.

  • Page 74: Gearshifting Clutch

    ENGINE 3-42 GEARSHIFTING CLUTCH CONSTRUCTION 1 Push piece 4 Clutch driven plate No.2 7 Clutch pressure plate 2 Clutch sleeve hub 5 Primary driven gear 8 Clutch spring 3 Clutch driven plate No.1 6 Clutch drive plate DISASSEMBLY • Campress the clutch spring using the special tool and remove the snap ring 1 .
  • Page 75 3-43 ENGINE Clutch drive and driven plate claw width Service Limit (drive): 15.15 mm (0.596 in) (driven): 11.3 mm (0.44 in) 09900-20101: Vernier calipers REASSEMBLY Reassemble the gearshifting clutch in the reverse order of disas- sembly. Pay attention to the following points: •...
  • Page 76 ENGINE 3-44 • Install the clutch driven plate No.1 9 . • When installing the clutch drive plate 0 , face its claw A downward as shown. • Install the clutch pressure plate B . • Install the clutch spring C and spacer D . •...

  • Page 77: First Clutch

    3-45 ENGINE FIRST CLUTCH CLUTCH SHOES INSPECTION Inspect the clutch shoes for chips, cracks, uneven wear and burning. Check the depth of grooves on the shoe. If there in no groove at any part of the shoe, replace the clutch shoe assem- bly.
  • Page 78 ENGINE 3-46 DISASSEMBLY • Remove the starter driven gear. • Holding the generator rotor with the special tool, remove the starter clutch bolts 1 . 09930-44530: Rotor holder • Remove the starter clutch 2 from the rotor. INSPECTION Inspect the starter clutch for damage and excessive wear. If any defects are found, replace the starter clutch with a new one.

  • Page 79: Generator Cover

    3-47 ENGINE GENERATOR COVER DISASSEMBLY • Remove the generator lead wire clamp 1 , stator coil 2 , pick-up coil 3 and grommet 4 . REASSEMBLY Reassemble the generator cover in the reverse order of disas- sembly. Pay attention to the following points: •...
  • Page 80 09913-70210: Bearing installer set The removed oil seals must be replaced with new ones. • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the O-ring 3 .

  • Page 81: Crankcase

    3-49 ENGINE • When installing the release arm 4 align the tongue A of release arm plate with the groove B . • Install the spacer 5 and lock-nut 6 and tighten the lock-nut CRANKCASE BEARING INSPECTION • Rotate the inner race by finger to inspect for abnormal play, noise and smooth rotation while the bearings are in the crank- case.
  • Page 82 ENGINE 3-50 LEFT CRANKCASE OIL SEAL REMOVAL • Remove the oil seals 1 with the special tool. 09913-50121: Oil seal remover RIGHT CRANKCASE BEARING INSTALLATION • Install the bearings with the special tool. 09913-70210: Bearing installer set Bearing 1 : 52 Attachment Bearing 2 : 40 Attachment Bearing 3 : 35 Attachment NOTE:...
  • Page 83 LEFT CRANKCASE OIL SEAL INSTALLATION • Install the oil seals 1 to the left crankcase with the special tool. • Apply SUZUKI SUPER GREASE “A” to the oil seal lip. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent 09913-70210: Bearing installer set The removed oil seals must be replaced with new ones.

  • Page 84: Engine Reassembly

    ENGINE 3-52 ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassembly. The following steps require special attention or precautionary measures should be taken. NOTE: Apply engine oil to each running and sliding part before reas- sembling. CRANKSHAFT • When installing the crankshaft into the left crankcase, it is necessary to pull its left end into the left crankcase with the special tools.
  • Page 85 3-53 ENGINE • If the thrust clearance is not within specification, measure the thickness of shim with a micrometer and select the proper size of shim shown below. • The shim size is printed on the shim surface. • After selecting the proper size of shim, place it on the right crankshaft.

  • Page 86: Kick Starter

    ENGINE 3-54 KICK STARTER 1 Kick starter lever 3 Kick starter shaft 5 Kick starter return spring 2 Kick starter drive gear 4 Kick starter • Install the kick starter stopper 1 and kick starter guide 2 . • Align the punched mark A on the kick starter with the punched mark B on the kick starter shaft.

  • Page 87: Transmission

    3-55 ENGINE • Install the kick starter return spring 1 , kick starter shaft 2 and kick starter spring hook end 3 onto the left crankcase boss. TRANSMISSION • Install the countershaft assembly 1 and driveshaft assembly • Install the gearshift forks. 3 : Gearshift fork No.

  • Page 88: Oil Breather Separator

    • Install the dowel pins 1 into the left half of the crankcase. • Apply engine oil to the conrod big end and transmission gears. • Apply SUZUKI BOND “1215” to the mating surface of the right crankcase as shown. 99000-31110: SUZUKI BOND “1215”...

  • Page 89: Starter Idle Gear

    3-57 ENGINE STARTER IDLE GEAR • Install the starter idle gear shaft 1 . • Install the starter idle gear 2 , washer 3 and snap ring 4 . NOTE: Apply engine oil to the starter idle gear and shaft. Removed snap ring must be replaced with a new one.

  • Page 90: Gearshift

    ENGINE 3-58 • Install the generator rotor 6 . • Hold the generator rotor 6 with the special tool. • Tighten the generator rotor nut 7 to the specified torque. 09930-44530: Rotor holder Generator rotor nut: 55 N·m (5.5 kgf-m, 40.0 lb-ft) GEARSHIFT 1 Gearshift cam guide 9 Release arm...
  • Page 91 3-59 ENGINE GEARSHIFT CAM RETAINER • Install the gearshift cam retainer. GEARSHIFT SHAFT • Apply THREAD LOCK SUPER “1322” to the gearshift arm stopper bolt 1 and tighten it to the specified torque. 99000-32110: THREAD LOCK SUPER “1322” Gearshift arm stopper bolt: 19 N·m (1.9 kgf-m, 13.5 lb-ft) •...

  • Page 92: Oil Pump And Drive Gear

    • Install the pin 1 and oil pump drive gear 2 . • Install the dowel pins 3 . • Apply SUZUKI SUPER GREASE “A” to the O-rings 4 . • Install the O-rings 4 . 99000-25010: SUZUKI SUPER GREASE “A”...

  • Page 93: Gearshifting Clutch

    3-61 ENGINE • Install the oil pump 5 . GEARSHIFTING CLUTCH • Install the gearshifting clutch assembly 1 . • Install the snap ring 2 . The removed snap ring must be replaced with a new one. • Install the clutch push piece 3 .

  • Page 94: First Clutch And Oil Filter Case

    ENGINE 3-62 FIRST CLUTCH AND OIL FILTER CASE 1 Oil filter cover 4 Primary drive gear 2 Oil filter case A Oil filter case nut ITEM N·m kgf-m lb-ft 3 Clutch shoe assembly 45.5 FIRST CLUTCH • Install the clutch shoe assembly 1 with its grooves A diago- nally to the crankshaft oil hole B as shown.
  • Page 95 3-63 ENGINE • Install the O-ring 2 and washer 3 . • Apply SUZUKI SUPER GREASE “A” to the O-ring 2 . 99000-25010: SUZUKI SUPER GREASE “A” or equivalent The removed O-ring must be replaced with a new one. NOTE: Install the washer 3 as shown in the illustration.

  • Page 96: Clutch Cover

    ENGINE 3-64 CLUTCH COVER • Install the dowel pins 1 and gasket 2 . The removed gasket must be replaced with a new one to prevent oil leakage. • Install the clutch cover 3 and tighten its bolts to the specified torque.

  • Page 97: Neutral Switch

    3-65 ENGINE NEUTRAL SWITCH • Install the spring 1 and neutral switch contact 2 . • Apply SUZUKI SUPER GREASE “A” to the O-ring 3 . 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the neutral switch 4 .

  • Page 98: Piston

    ENGINE 3-66 • Face the stamped mark upward when assembling. • Position the gaps of the three rings as shown. • 2nd ring • Upper side rail • Lower side rail NOTE: Before inserting piston into the cylinder, check that the gaps are so located.

  • Page 99: Cylinder

    3-67 ENGINE CYLINDER • Apply engine oil to the sliding surface of the piston, piston rings, conrod big end and cylinder wall. • Install the dowel pins 1 and cylinder gasket 2 . The removed gasket must be replaced with a new one. •...

  • Page 100: Camshaft Sprocket

    ENGINE 3-68 • Tighten the cylinder nut 8 and cylinder head bolt 9 to the specified torque. Cylinder head bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) Cylinder nut: 10 N·m (1.0 kgf-m, 7.0 lb-ft) CAMSHAFT SPROCKET • Turn the crankshaft until the “Top” line A on the generator rotor is aligned with the center of the hole in the generator cover.

  • Page 101: Valve Clearance Inspection Cap And Camshaft Sprocket Cover

    Be sure to check the valve clearance. ( 2-6 and -7) VALVE CLEARANCE INSPECTION CAP AND CAMSHAFT SPROCKET COVER • Apply SUZUKI SUPER GREASE “A” to the O-ring. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent The removed O-ring must be replaced with a new one.

  • Page 102: Tdc Plug And Generator Cover Cap

    TDC plug: 11 N·m (1.1 kgf-m, 8.0 lb-ft) STARTER MOTOR • Install the O-ring 1 to the starter motor. • Apply SUZUKI SUPER GREASE “A” to the O-ring 1 . 99000-25010: SUZUKI SUPER GREASE “A” or equivalent The removed O-ring must be replaced with a new one.
  • Page 103 4-1 FUEL SYSTEM FUEL SYSTEM CONTENTS FUEL TANK AND FUEL VALVE ..............4- 2 CONSTRUCTION ..................4- 2 REMOVAL ....................4- 3 FUEL FILTER INSPECTION AND CLEANING ........4- 3 FUEL HOSE INSPECTION ..............4- 4 REMOUNTING ..................4- 4 CARBURETOR....................4- 5 CONSTRUCTION ..................4- 5 SPECIFICATIONS...................4- 6 I.D.

  • Page 104: Fuel Tank And Fuel Valve

    FUEL SYSTEM FUEL TANK AND FUEL VALVE CONSTRUCTION 1 Fuel tank breather hose 4 Fuel valve 2 Fuel tank cap 5 Fuel hose ITEM N·m kgf-m lb-ft 3 Fuel tank A Fuel valve bolt 0.45...

  • Page 105: Removal

    FUEL SYSTEM REMOVAL * Gasoline is highly flammable and explosive. * Keep heat, spark and flame away. • Remove the seat and fuel tank side covers. ( 5-3) • Turn the fuel valve to the “OFF” position. • Disconnect the fuel hose 1 from the fuel valve. •...

  • Page 106: Fuel Hose Inspection

    FUEL SYSTEM FUEL HOSE INSPECTION 2-9) REMOUNTING Remount the fuel tank and fuel valve in the reverse order of removal. Pay attention to the following points: • Install the new fuel valve gasket 1 . The removed gasket must be replaced with a new one to prevent fuel leakage.

  • Page 107: Carburetor

    FUEL SYSTEM CARBURETOR CONSTRUCTION 1 Carburetor top cap 9 O-ring G Main jet 2 Gasket 0 Air screw H Pilot jet 3 Spring A O-ring I Float 4 Spring seat B Throttle stop screw J Gasket 5 O-ring C Needle valve seat K Float chamber 6 Jet needle D Needle...

  • Page 108: Specifications

    FUEL SYSTEM SPECIFICATIONS ITEM SPECIFICATION Carburetor type MIKUNI VM13SH Bore size 13 mm (0.5 in) I.D. No. 14H0 Idle r/min 1 600 ± 100 r/min Float height 23.4 ± 1.0 mm (0.92 ± 0.04 in) Main jet (M.J) Jet needle (J.N) 3L43 Needle jet (N.J) E-5M...

  • Page 109: Disassembly

    FUEL SYSTEM DISASSEMBLY • Remove the starter plunger 1 . • Remove the throttle valve 2 and spring 3 from the throttle cable. • Remove the spring seat 4 . • Remove the jet needle 5 , washer 6 and spring 7 from the throttle valve 2 .
  • Page 110 FUEL SYSTEM • Remove the gasket 0 . • Remove the float pin A . • Remove the float B . • Remove the needle valve C . • Remove the needle valve seat D . • Remove the main jet E , needle jet holder F and needle jet •...

  • Page 111: Cleaning

    FUEL SYSTEM AIR SCREW REMOVAL Because harsh cleaning solvents can damage the O-ring seals in the pilot system, the pilot system components should be Drill-stop removed before cleaning. Plug • Use a 1/8 ″ size drill bit with a drill-stop to remove the air Carburetor screw plug.

  • Page 112: Inspection And Adjustment

    FUEL SYSTEM 4-10 INSPECTION AND ADJUSTMENT CARBURETOR PARTS Check the following items for any damage or clogging. If they are clogged, clean the fuel passage. * Pilot jet * Gasket and O-rings * Main jet * Pilot passageway * Starter plunger * Starter passageway * Float * Needle jet...

  • Page 113: Reassembly And Remounting

    4-11 FUEL SYSTEM REASSEMBLY AND REMOUNTING Reassemble and install the carburetor in the reverse order of removal and disassembly. Pay attention to the following points: • Install the needle valve seat 1 . The removed O-ring must be replaced with a new one. •...
  • Page 114 Align the slit B of the throttle valve 4 with the projec- tion C on the carburetor body. • Install the O-rings 5 . • Apply SUZUKI SUPER GREASE “A” to the O-rings 5 . 99000-25010: SUZUKI SUPER GREASE “A” or equivalent The removed O-rings must be replaced with new ones.

  • Page 115: Lubrication System

    4-13 FUEL SYSTEM LUBRICATION SYSTEM OIL PRESSURE 2-19 OIL FILTER CASE 3-14 OIL SUMP FILTER 3-38 OIL PUMP 3-38 ENGINE LUBRICATION SYSTEM CHART CAM FACE CAMSHAFT CAM CHAIN INTAKE EXHAUST CYLINDER ROCKER ROCKER HEAD CONROD SMALL CYLINDER CYLINDER OIL ORIFICE WALL OIL FILTER CLUTCH COVER...
  • Page 116 CHASSIS CHASSIS CONTENTS EXTERIOR PARTS ..................5- 2 FASTENER REMOVAL AND INSTALLATION ........5- 2 REMOVAL ....................5- 2 REASSEMBLY ..................5- 3 FRONT WHEEL AND FRONT BRAKE ............5- 4 CONSTRUCTION ...................5- 4 REMOVAL ....................5- 4 INSPECTION AND DISASSEMBLY ............5- 6 REASSEMBLY ..................5- 7 REMOUNTING ..................5- 9 FRONT FORK ....................5-10 CONSTRUCTION ...................5-10...

  • Page 117: Exterior Parts

    CHASSIS EXTERIOR PARTS FASTENER REMOVAL AND INSTALLATION FASTENER Removal • Depress the head of fastener center piece 1 . • Pull out the fastener a . Installation • Let the center piece stick out toward the head so that the pawls 2 close.

  • Page 118: Reassembly

    CHASSIS FUEL TANK COVER • Remove the fuel tank side cover bolt 1 . • Remove the fasteners 2 . • Remove the fuel tank side cover 3 . • Remove the fuel tank cap 4 . • Remove the fuel tank upper cover 5 . NOTE: Install the fuel tank cap after removing the fuel tank upper cover.

  • Page 119: Front Wheel And Front Brake

    CHASSIS FRONT WHEEL AND FRONT BRAKE CONSTRUCTION 1 Front axle 8 Spring 2 Spacer (R) 9 Brake shoe 3 Dust seal 0 Brake camshaft 4 Bearing (R) A Brake panel 5 Spacer B Brake cam lever ITEM N·m kgf-m lb-ft 6 Front wheel rim A Front axle nut 38.5...

  • Page 120: Spacer

    CHASSIS • Support the motorcycle with a jack or wooden block. Make sure that the motorcycle is securely supported. • Remove the front axle 7 and spacer 8 . • Remove the front wheel with the front brake panel. • Remove the front brake panel 9 . •...

  • Page 121: Inspection And Disassembly

    CHASSIS INSPECTION AND DISASSEMBLY WHEEL BEARING Inspect the wheel bearing plays while they are in the wheel. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation. Replace the bearings in the following procedure if there is any- thing unusual.

  • Page 122: Reassembly

    REASSEMBLY Reassemble and install the front wheel in the reverse order of removal and disassembly. Pay attention to the following points: FRONT WHEEL • Apply SUZUKI SUPER GREASE “A” to the wheel bearings. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
  • Page 123 Removed bearing • Install the dust seal using the special tool. 09913-70210: Bearing installer set • Apply SUZUKI SUPER GREASE “A” to the dust seal lip. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent The removed dust seal must be replaced with a new one.

  • Page 124: Remounting

    • Tighten the brake cam lever nut to the specified torque. Brake cam lever nut: 3 N·m (0.3 kgf-m, 2.0 lb-ft) • Apply SUZUKI SUPER GREASE “A” to the brake cam and pin, and install the brake shoes. 99000-25010: SUZUKI SUPER GREASE “A”...

  • Page 125: Front Fork

    5-10 CHASSIS FRONT FORK CONSTRUCTION 1 Spring joint 3 Front fork spring 2 Stopper (rubber) 4 Inner tube...

  • Page 126: Removal

    CHASSIS 5-11 REMOVAL • Remove the front number plate. ( 5-3) • Remove the front fork cover. ( 5-3) • Remove the front wheel. ( 5-4) • Remove the dust seal 1 . • Remove the snap ring 2 . •...

  • Page 127: Inspection

    5-12 CHASSIS DISASSEMBLY • Remove the spring joint 1 , front fork spring 2 and stoppers Do not remove the pin 4. INSPECTION FRONT FORK SPRING Measure the fork spring free length. If it is shorter than the ser- vice limit, replace it with a new one. Front fork spring free length Service Limit: 154 mm (6.1 in) STOPPER...

  • Page 128: Reassembly And Remounting

    • Install the front fork spring 1 , stoppers 2 and spring joint 3 . • Install the front fork spring. NOTE: The close-pitch end A of spring must face downward. Downward • Apply SUZUKI SUPER GREASE “A” (approx. 40 ml) to the inner parts and spring. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
  • Page 129 5-14 CHASSIS • Align the projection A on the spring joint with the slot B on the outer tube. • Install the snap ring as shown in the illustration. Outer tube After installing the snap ring, always insure that it is Rounded part completely seated in its groove and securely fitted.

  • Page 130: Steering

    CHASSIS 5-15 STEERING CONSTRUCTION 1 Front fork upper bracket 7 Inner race (lower) 2 Steering stem nut 8 Outer race (lower) 3 Dust seal 9 Front fork outer tube 4 Outer race (upper) 0 Handlebars ITEM N·m kgf-m lb-ft 5 Steering bearing A Front fork upper bracket bolt 32.5 6 Inner race (upper)
  • Page 131 5-16 CHASSIS • Remove the starter cable 1 . • Remove the throttle case 2 and throttle grip 3 . • Remove the handlebars 4 . • Remove the front fork upper bracket 5 . • Remove the steering stem nut 6 using the special tool. 09940-14911: Steering nut socket wrench NOTE: Hold the front fork by hand to prevent falling.

  • Page 132: Inspection

    CHASSIS 5-17 • Remove the outer racer 8 . • Remove the upper and lower bearings 9 . INSPECTION Inspect the removed parts for the following abnormalities. * Handlebars distortion * Race wear and brinelling * Bearing wear or damage * Distortion of the steering stem If any abnormal condition are found, replace defective parts with new ones.

  • Page 133: Reassembly And Remounting

    • Install the lower outer race using the special tool. 09940-51410: Steering bearing installer 09913-70210: Bearing installer set BEARING • Apply SUZUKI SUPER GREASE “A” to the upper and lower bearings. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent STEERING STEM •...
  • Page 134 Handlebars set bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) HANDLEBAR RIGHT SIDE PARTS • Install the throttle cable. • Apply SUZUKI SUPER GREASE “A” to the throttle cable end. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • When installing the throttle case, align the throttle cable holder edge B with the throttle case C .
  • Page 135 5-20 CHASSIS HANDLEBAR LEFT SIDE PARTS • Apply handle grip bond onto the handlebars before installing the handlebar left grip. Handle grip bond Handlebars • When installing the left handlebar grip, align the “ ” mark F with the punched mark G on handlebars. •...

  • Page 136: Rear Wheel And Rear Brake

    CHASSIS 5-21 REAR WHEEL AND REAR BRAKE CONSTRUCTION 1 Chain adjuster 0 Brake shoe 2 Rear axle spacer A Brake camshaft 3 Rear sprocket B Brake panel 4 Dust seal C Brake cam lever 5 Bearing D Rear axle 6 Spacer A Rear axle nut ITEM N·m...

  • Page 137: Removal

    5-22 CHASSIS REMOVAL • Remove the rear brake adjusting nut 1 . • Loosen the lock-nuts and chain adjusters 2 right and left. • Support the motorcycle with a jack or wooden block. • Remove the rear axle nut 3 and rear axle 4 . •...

  • Page 138: Inspection And Disassembly

    REASSEMBLY AND REMOUNTING Reassemble and remount the rear wheel in the reverse order of removal and disassembly. Pay attention to the following points: REAR WHEEL • Apply SUZUKI SUPER GREASE “A” to the wheel bearings. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
  • Page 139 • Install the dust seal using the special tool. 09913-70210: Bearing installer set • Apply SUZUKI SUPER GREASE “A” to the dust seal lip. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent The removed dust seal must be replaced with a new one.
  • Page 140 CHASSIS 5-25 REAR BRAKE 5-8 and 5-9) • Align the boss 1 on the swingarm with the slot 2 on the brake panel. • Tighten the rear axle nut to the specified torque. Rear axle nut: 54 N·m (5.4 kgf-m, 39.0 lb-ft) •...

  • Page 141: Rear Suspension

    5-26 CHASSIS REAR SUSPENSION CONSTRUCTION 1 Rear shock absorber 5 Chain buffer 2 Swingarm pivot shaft A Swingarm pivot nut ITEM N·m kgf-m lb-ft 3 Bushing B Rear shock absorber mounting nut 30.5 4 Swingarm 36.0...

  • Page 142: Removal And Disassembly

    CHASSIS 5-27 REMOVAL AND DISASSEMBLY REAR SHOCK ABSORBER • Support the motorcycle with a jack or wooden block. • Remove the seat. ( 5-3) • Remove the rear shock absorber mounting nut (upper and lower). • Remove the rear shock absorber 1 . •...

  • Page 143: Inspection

    5-28 CHASSIS • Remove the chain cover 6 . • Remove the chain guide 7 . • Remove the chain buffer 8 . INSPECTION REAR SHOCK ABSORBER Inspect the rear shock absorber for oil leakage or other damage. If any oil leakage or damages are found, replace the rear shock absorber with a new one.
  • Page 144 CHASSIS 5-29 • Using appropriate steel tube 1 and vise, remove the bushing • Using an appropriate size steel tubes and vise, install the swingarm bushing. NOTE: Align the surface A of bushing 3 with swingarm inner surface SWINGARM Inspect the swingarm for damage. If any defects are found, replace the swingarm with a new one.

  • Page 145: Reassembly And Remounting

    5-30 CHASSIS SWINGARM PIVOT SHAFT Measure the swingarm pivot shaft runout using the dial gauge. If the pivot shaft exceeds the service limit, replace it with a new one. 09900-20607: Dial gauge (1/100 mm) 09900-20701: Magnetic stand 09900-21304: V-block (100 mm) Swingarm pivot shaft runout Service Limit: 0.6 mm (0.02 in) REASSEMBLY AND REMOUNTING...
  • Page 146 ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ................6- 2 CONNECTOR..................6- 2 COUPLER ....................6- 2 CLAMP ....................6- 2 FUSE .......................6- 2 SEMI-CONDUCTOR EQUIPPED PART ..........6- 3 BATTERY ....................6- 3 WIRING PROCEDURE................6- 3 USING THE MULTI-CIRCUIT TESTER ..........6- 3 LOCATION OF ELECTRICAL COMPONENTS ..........6- 4 CHARGING SYSTEM ..................6- 5 TROUBLESHOOTING ................6- 5 INSPECTION ...................6- 6...

  • Page 147: Cautions In Servicing

    ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTOR • When connecting a connector, be sure to push it in until a click is felt. Click • Inspect the connector for corrosion, contamination and break- age in its cover. COUPLER Click • With a lock type coupler, be sure to release the lock when dis- connecting, and push in fully to engage the lock when con- necting.

  • Page 148: Semi-Conductor Equipped Part

    ELECTRICAL SYSTEM SEMI-CONDUCTOR EQUIPPED PART • Be careful not to drop the part which has a semi-conductor INCORRECT built in such as a CDI unit and regulator/rectifier. • When inspecting these parts, follow the instructions carefully. Failure to follow the proper procedure can cause damage to these parts.

  • Page 149: Location Of Electrical Components

    ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS Regulator/rectifier Generator Fuse (10 A) Battery Starter relay CDI unit Starter motor Ignition coil Ignition switch Starter button Engine stop switch...

  • Page 150: Charging System

    ELECTRICAL SYSTEM CHARGING SYSTEM Regulator/ rectifier Fuse Battery Generator TROUBLESHOOTING NOTE: * Make sure that the fuse is not blown and the battery is fully-charged before diagnosing. Battery runs down quickly. Step 1 1) Check accessories which use excessive amounts of electricity. Are accessories installed? Remove accessories.

  • Page 151: Inspection

    ELECTRICAL SYSTEM Step 5 1) Inspect the regulator/Rectifier. ( 6-8) Is the regulator/rectifier OK? Go to Step 6. Faulty regulator/rectifier. Step 6 1) Inspect wire harness. Is the wire harness OK? Faulty battery. • Short circuit of wire harness. • Poor contact of couplers. Battery overcharges.
  • Page 152 ELECTRICAL SYSTEM GENERATOR COIL RESISTANCE • Disconnect the generator coupler 1 . Measure the resistance between the B/R lead wire and ground using the multi-circuit tester. If the resistance is not within the specified value, replace the generator coil with a new one. 09900-25008: Multi-circuit tester set Tester knob indication: Resistance (Ω) Generator coil resistance:...
  • Page 153 ELECTRICAL SYSTEM REGULATOR/RECTIFIER • Disconnect the regulator/rectifier coupler 1 . • Remove the regulator/rectifier 2 . 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 regulator/rectifier with a new one.

  • Page 154: Starter System

    ELECTRICAL SYSTEM STARTER SYSTEM Starter relay CDI unit Neutral Starter switch motor Battery Starter Engine Ignition button stop switch switch TROUBLESHOOTING NOTE: * Make sure that the fuse is not blown and the battery is fully-charged before diagnosing. Starter motor will not run. Step 1 1) Check that the transmission is in neutral and the engine stop switch is in the “RUN”...

  • Page 155: Starter Motor Removal

    6-10 ELECTRICAL SYSTEM Step 4 1) Check the starter relay. ( 6-15) Is the starter relay OK? Poor contact of the starter relay. Faulty starter relay. Starter motor runs but does not crank the engine. Check the starter clutch. ( 3-45) STARTER MOTOR REMOVAL •...

  • Page 156: Starter Motor Disassembly

    ELECTRICAL SYSTEM 6-11 STARTER MOTOR DISASSEMBLY 1 O-ring 2 Housing end 3 Armature 4 Starter motor case • Remove the O-ring 1 . • Remove the housing end 2 .

  • Page 157: Starter Motor Inspection

    6-12 ELECTRICAL SYSTEM • Remove the O-ring 3 . • Remove the armature 4 . STARTER MOTOR INSPECTION CARBON BRUSH Inspect the brushes for abnormal wear, cracks, or smoothness in the brush holder. If any defects are found, replace the housing end assembly with a new one.

  • Page 158: Starter Motor Reassembly And Installation

    INSTALLATION Reassemble and installation the starter motor in the reverse order of disassembly. Pay attention to the following points: • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal and bearing. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent •...
  • Page 159 The removed O-rings must be replaced with new ones. • Install the O-ring 4 . The removed O-ring must be replaced with a new one. • Apply SUZUKI SUPER GREASE “A” to the O-ring. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent •...

  • Page 160: Starter Relay Inspection

    ELECTRICAL SYSTEM 6-15 STARTER RELAY INSPECTION • Remove the seat. ( 5-2) • Remove the starter relay 1 . • First check the insulation between C and D terminals with the multi-circuit tester. • Then apply 12 V to A and B terminals and check for continu- ity between the C and D terminals.

  • Page 161: Ignition System

    6-16 ELECTRICAL SYSTEM IGNITION SYSTEM Ignition coil CDI unit Spark plug Neutral B/Bl switch Ignition Engine Starter switch stop button switch Regulator/ rectifier Fuse B/Bl Battery Generator TROUBLESHOOTING NOTE: * Make sure the fuse is not blown and the battery is fully-charged before diagnosing. * Make sure the transmission is in neutral and the engine stop switch is in the “RUN”...
  • Page 162 ELECTRICAL SYSTEM 6-17 Step 3 1) Measure the ignition coil primary peak voltage. ( 6-18) NOTE: This inspection method is applicable only with the multi-circuit tester and the peak volt adaptor. Is the peak voltage OK? Go to Step 4. Go to Step 5.

  • Page 163: Inspection

    6-18 ELECTRICAL SYSTEM INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the spark plug cap 1 . • Connect a new spark plug 2 to the spark plug cap and ground it on the cylinder head. NOTE: Make sure that the spark plug cap and spark plug are connected properly.
  • Page 164 ELECTRICAL SYSTEM 6-19 IGNITION COIL RESISTANCE • Remove the spark plug cap. ( 6-18) • Disconnect the ignition coil lead wires 1 , 2 and remove the ignition coil 3 . Measure the ignition coil resistance in both the primary and sec- ondary windings using the multi-circuit tester.

  • Page 165: Switches

    6-20 ELECTRICAL SYSTEM PICK-UP COIL RESISTANCE generator Measure the resistance between the lead wire and ground using coupler the multi-circuit tester. If the resistance is not within the specified B/Bl value, the pick-up coil must be replaced. 09900-25008: Multi-circuit tester set Tester knob indication: Resistance (Ω) Pick-up coil resistance: Generator...

  • Page 166: Battery

    ELECTRICAL SYSTEM 6-21 BATTERY SPECIFICATIONS Type designation YT4B-BS Capacity 12 V, 8.28 kC (2.3 Ah)/10 HR INITIAL CHARGING Filling electrolyte • Remove the aluminum tape 1 sealing the battery electrolyte filler holes. NOTE: When filling electrolyte, the battery must be removed from the motorcycle and must be put on the level ground.

  • Page 167: Servicing

    6-22 ELECTRICAL SYSTEM NOTE: If no air bubbles are coming up from a filler port, tap the bottom of the 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 168: Recharging Operation

    ELECTRICAL SYSTEM 6-23 RECHARGING OPERATION • Using the multi-circuit tester, check the battery voltage. If the voltage reading is 12.0 V (DC) or less, recharge the battery with a battery charger. A Charging period B Stop charging * When recharging the battery, remove the battery from the motorcycle.
  • Page 169 7-1 SERVICING INFORMATION SERVICING INFORMATION CONTENTS TROUBLESHOOTING...................7- 2 ENGINE ....................7- 2 CLUTCH ....................7- 5 CARBURETOR ..................7- 5 CHASSIS ....................7- 6 BRAKES....................7- 7 ELECTRICAL ..................7- 8 BATTERY ....................7- 9 WIRING DIAGRAM .................7-10 WIRING HARNESS, CABLE AND HOSE ROUTING........7-11 WIRING HARNESS ROUTING ...............7-11 CABLE ROUTING ...................7-13 CARBURETOR HOSE ROUTING............7-14 FUEL HOSE AND FUEL TANK BREATHER HOSE ROUTING ....7-15...

  • Page 170: Troubleshooting

    SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not Compression too low start, or is hard to 1. Valve clearance out of adjustment. Adjust. start. 2. Worn valve guides or poor seating of valves. Repair or replace. 3.
  • Page 171 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Noisy engine. Noise seems to come from timing chain 1. Stretched chain. Replace. 2. Worn sprocket. Replace. 3. Not working tension adjuster. Repair or replace. Noise seems to come from clutch 1. Worn splines of countershaft or hub. Replace.
  • Page 172 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine runs poorly 1. Weakened valve spring. Replace. in high speed range. 2. Worn camshaft. Replace. 3. Valve timing out of adjustment. Adjust. 4. Too narrow spark plug gap. Adjust. 5. Ignition not advanced sufficiently due to poorly Replace CDI unit.

  • Page 173: Clutch

    SERVICING INFORMATION CLUTCH Complaint Symptom and possible causes Remedy Slipping First clutch 1. Excessively worn clutch shoes. Replace. clutch. 1. Clutch out of adjustment. Adjust. Gear shifting clutch 2. Excessively worn clutch plates. Replace. Dragging First clutch 1. Erratic clutch weight movement. Replace.

  • Page 174: Chassis

    SERVICING INFORMATION CHASSIS Complaint Symptom and possible causes Remedy Heavy steering. 1. Overtightened steering stem nut. Adjust. 2. Broken bearing in steering stem. Replace. 3. Distorted steering stem. Replace. 4. Not enough pressure in tires. Adjust. Wobbly handlebars. 1. Loss of balance between right and left front forks. Ripair or replace.

  • Page 175: Brakes

    SERVICING INFORMATION BRAKES Complaint Symptom and possible causes Remedy Insufficient brake 1. Worn shoes or drum. Replace. 2. Excessive brake lever play and brake pedal play. Adjust. power. 3. Friction surfaces of shoes are dirty with oil or Replace. dust. 4.

  • Page 176: Electrical

    SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coil or CDI unit. Replace. 2. Defective spark plug. Replace. sparking. 3. Defective pick-up coil or generator coil. Replace. 4. Open-circuited wiring connections. Check and repair. Spark plug soon 1.

  • Page 177: Battery

    SERVICING INFORMATION BATTERY Complaint Symptom and possible causes Remedy “Sulfation”, acidic 1. Cracked battery case. Replace the battery. 2. Battery has been left in a run-down condition for Replace the battery. white powdery sub- stance or spots on a long time. surface of cell plates.

  • Page 178: Wiring Diagram

    SERVICING INFORMATION 7-10 WIRING DIAGRAM...

  • Page 179: Wiring Harness, Cable And Hose Routing

    7-11 SERVICING INFORMATION WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Clamp Wiring harness Wiring harness Wiring harness Neutral switch Clamp Generator Clamp Clamp Clamp Clamp Wiring harness Wiring harness Clamp Ignition switch Starter motor Ignition coil Clamp To handlebar switch Wiring harness Neutral switch Generator...
  • Page 180 SERVICING INFORMATION 7-12 Pick-up coil lead wire Pick-up coil 10 N·m (1.0 kgf-m, 7.0 lb-ft) 4.5 N·m (0.45 kgf-m, 3.5 lb-ft) 10 N·m (1.0 kgf-m, 7.0 lb-ft)

  • Page 181: Cable Routing

    7-13 SERVICING INFORMATION CABLE ROUTING Cut the tip of clamp Cable guide Clamp as shown Max. 3 mm Front brake cable White tape Starter cable Throttle cable Front brake cable Handlebar switch lead Clip wire Front number plate Starter cable Clip Throttle cable Handlebar switch...

  • Page 182: Carburetor Hose Routing

    SERVICING INFORMATION 7-14 CARBURETOR HOSE ROUTING Pass the crankcase breather hose right side of the air Carburetor air Yellow mark (upper side) cleaner drain hose. vent hose Crankcase breather hose White mark (upper side) Generator lead wire Air cleaner drain hose Carburetor overflow hose Clamp Air cleaner clamp...

  • Page 183: Fuel Hose And Fuel Tank Breather Hose Routing

    7-15 SERVICING INFORMATION FUEL HOSE AND FUEL TANK BREATHER HOSE ROUTING Fuel tank breather hose Fuel tank cap Fuel tank Caburetor ripple Install the white mark on the fuel hose to upside. Fuel hose Fuel valve To carburetor Clamp Face the tip of clip to the lower. Fuel tank cushion Cut the tip of clamp approx.

  • Page 184: Handlebar Installation

    SERVICING INFORMATION 7-16 HANDLEBAR INSTALLATION Align the “ ” mark on the grip with the pumched mark on the handlebars. 110 mm Handlebar pad Handlebars Clamp Forward 15 mm...

  • Page 185: Side-Stand Installation

    7-17 SERVICING INFORMATION SIDE-STAND INSTALLATION 40 N·m (4.0 kgf-m, 29.0 lb-ft) Side-stand 10 N·m (1.0 kgf-m, 7.0 lb-ft) REAR BRAKE PEDAL INSTALLATION Cotter pin Brake pedal return spring Brake pedal...

  • Page 186: Fuel Tank Upper Cover Cushion Installation

    SERVICING INFORMATION 7-18 FUEL TANK UPPER COVER CUSHION INSTALLATION Fuel tank upper cover Cusion Cushion FUEL TANK SIDE COVER CUSHION INSTALLATION Fuel tank side cover 5 mm Cushion...

  • Page 187: Special Tools

    7-19 SERVICING INFORMATION SPECIAL TOOLS 09900-20101 09900-20202 09900-20205 09900-20602 09900-20102 Micrometer Micrometer 09900-20530 Dial gauge (25 – 50 mm) (1/1 000 mm, 0 – 25 mm) Vernier calipers Cylinder gauge set (1/1 000 mm, 1 mm) 09900-20605 09900-20607 Dial calipers Dial gauge 09900-20701 09900-20803...
  • Page 188 SERVICING INFORMATION 7-20 09915-74533 09916-14521 09915-74511 Oil pressure gauge 09916-10911 09916-14510 Valve lifter Oil pressure gauge adaptor Valve lapper set Valve lifter attachment 09916-34542 09916-34570 09916-34580 09916-44310 Valve guide reamer Valve guide reamer Valve guide reamer Valve guide 09916-84511 handle (5.0 mm) (10.8 mm) remover/installer...

  • Page 189: Tightening Torque

    7-21 SERVICING INFORMATION TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lb-ft Engine mounting nut 22.5 Exhaust pipe bolt Exhaust cover bolt Muffler mounting nut 16.5 Spark arrester bolt Intake pipe nut 0.55 Engine sprocket cover bolt Spark plug Cam chain tensioner bolt Cylinder nut Cylinder head nut Cylinder head bolt...

  • Page 190: Chassis

    SERVICING INFORMATION 7-22 CHASSIS ITEM N·m kgf-m lb-ft Handlebars set bolt 16.5 Front fork upper bracket bolt 32.5 Front axle nut 38.5 Brake cam lever nut (Front and Rear) Spoke nipple Footrest mounting bolt 16.5 Side-stand bolt Side-stand nut 29.0 Swingarm pivot nut 30.5 Rear shock absorber mounting nut (Upper and Lower)

  • Page 191: Service Data

    7-23 SERVICING INFORMATION SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. 22.5 — (0.89) 19.0 — (0.75) Valve clearance (when cold) 0.04 – 0.07 — (0.0016 – 0.0028) 0.05 – 0.10 — (0.0020 – 0.0039) Valve guide to valve stem 0.025 –...
  • Page 192 SERVICING INFORMATION 7-24 CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT 1 100 kPa Compression pressure 1 300 – 1 700 kPa (11 kgf/cm², (13 – 17 kgf/cm², 185– 242 psi) 156 psi) Piston to cylinder clearance 0.025 –...
  • Page 193 7-25 SERVICING INFORMATION CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end I.D. 13.006 – 13.014 13.040 (0.5120 – 0.5124) (0.5134) Conrod deflection — (0.12) Conrod big end side clearance 0.10 – 0.45 (0.004 – 0.018) (0.04) Conrod big end width 13.95 –...
  • Page 194 SERVICING INFORMATION 7-26 DRIVE TRAIN + DRIVE CHAIN Unit: mm (in) (Except ratio) ITEM STANDARD LIMIT Primary reduction ratio 3.823 (65/17) — Final reduction ratio 2.538 (33/13) — Gear ratios 3.400 (34/10) — 1.812 (29/16) — 1.200 (24/20) — Gearshift fork to groove clearance 0.1 –...
  • Page 195 7-27 SERVICING INFORMATION ELECTRICAL Unit: mm (in) ITEM STANDARD/SPECIFICATION NOTE Spark plug NGK: CR7HSA Type DENSO: U22FSR-U 0.6 – 0.7 (0.024 – 0.028) Spark performance Over 8 (0.3) at 1 atm. Ignition coil resistance Terminal – 0.1 – 0.8 Ω Primary Terminal Plug cap –...
  • Page 196 SERVICING INFORMATION 7-28 BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Front brake lever play 15 –25 — (0.6 – 1.0) Rear brake pedal free travel 15 – 20 — (0.6 – 0.8) Brake drum I.D. Front — 80.7 (3.18) Rear —...
  • Page 197 7-29 SERVICING INFORMATION TIRE PRESSURE COLD INFLATION kgf/cm TIRE PRESSURE FRONT REAR 1.25 FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane ( ) or 91 octane or higher rated by the R + M Research Methrod.
  • Page 198 Prepared by May, 2007 Part No.99500-40030-03E Printed in USA...
  • Page 199 Printed in USA...

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