Suzuki GSX1200 1999 Service Manual
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Suzuki GSX1200 1999 Service Manual

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  • Page 2 FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI GSX1200 and procedures for its inspection/service and overhaul of its main com- GENERAL INFORMATION ponents. Other information considered as generally known is not included. PERIODIC MAINTENANCE Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance.
  • 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 oil. Use engine oil unless Measure in voltage range. otherwise specified. Apply molybdenum oil solution (mixture of engine oil and SUZUKI MOLY Measure in resistance range. PASTE in a ratio of 1:1). Apply SUZUKI SUPER GREASE “A”. Measure in current range.

  • Page 5: Table Of Contents

    GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE ............. 1- 2 GENERAL PRECAUTIONS ............. 1- 2 SUZUKI GSX1200X (’99-MODEL) ........... 1- 4 SERIAL NUMBER LOCATION ............1- 4 FUEL AND OIL RECOMMENDATION ..........1- 4 FUEL ..................... 1- 4 ENGINE OIL .................. 1- 5 BRAKE FLUID ................

  • Page 6: Warning/Caution/Note

    1-2 GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. Indicates a potential hazard that could result in death or injury.
  • Page 7 GENERAL INFORMATION 1-3 " * 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 Gsx1200X ('99-Model)

    1-4 GENERAL INFORMATION SUZUKI GSX1200X (’99-MODEL) LEFT RIGHT * Difference between photograph and actual motorcycle depends 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: Engine Oil

    GENERAL INFORMATION 1-5 ENGINE OIL Use a premium quality 4-stroke motor oil to ensure longer ser- vice life of your motorcycle. Use only oils which are rated SF or SG under the API service classification. MULTIGRADE The recommended viscosity is SAE 10W-40. If an SAE 10W-40 motor oil is not available, select an alternative according to the right chart.

  • Page 10: Information Labels

    1-6 GENERAL INFORMATION INFORMATION LABELS...

  • Page 11: Specifications

    GENERAL INFORMATION 1-7 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ............... 2 140 mm Overall width ..............780 mm Overall height ............... 1 100 mm Wheelbase ..............1 465 mm Ground clearance ............125 mm Seat height ..............795 mm Dry mass ...............
  • Page 12 1-8 GENERAL INFORMATION CHASSIS Front suspension ............Telescopic, coil spring, oil damped Rear suspension ............Swingarm type, gas/oil damped, coil spring, spring pre-load 5-way adjustable, compression damping force 4-way adjustable Steering angle .............. 34° (right & left) Caster ................25° 50’ Trail ................

  • Page 13: Country Or Area Codes

    GENERAL INFORMATION 1-9 COUNTRY OR AREA CODES The following codes stand for the applicable country(-ies) and area(-s). CODE COUNTRY or AREA E-04 France E-22 Germany E-25 Netherlands E-34 Italy, Belgium (E-21), Spain (E-53)
  • Page 14 PERIODIC MAINTENANCE 2-1 PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE ........... 2- 2 PERIODIC MAINTENANCE CHART ..........2- 2 LUBRICATION POINTS ..............2- 3 MAINTENANCE AND TUNE-UP PROCEDURES ......2- 4 VALVE CLEARANCE ..............2- 4 SPARK PLUG .................. 2- 5 EXHAUST PIPE BOLT AND MUFFLER BOLT .......

  • Page 15: Periodic Maintenance Schedule

    2-2 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. Mileages are expressed in terms of kilometer and time for your convenience. NOTE: More frequent servicing may be performed on motorcycles that are used under severe conditions.

  • Page 16: Lubrication Points

    PERIODIC MAINTENANCE 2-3 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. !"Clutch lever holder !"Drive chain #"Center stand pivot and spring hook #"Gearshift lever pivot and footrest pivot #"Side-stand pivot and spring hook !"Brake lever holder #"Brake pedal pivot and footrest pivot...

  • Page 17: Maintenance And Tune-Up Procedures

    2-4 PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements. VALVE CLEARANCE Inspect Initially at 1 000 km (1 month) and Every 12 000 km (12 months). • Remove the seat and fuel tank. ($4-3) •...

  • Page 18: Spark Plug

    Cam Position Intake Camshaft Exhaust Camshaft • When installing the cylinder head cover, apply SUZUKI BOND NO.1207B to the head cover groove and cam end caps. ($3- ' 99000-31140: SUZUKI BOND NO. 1207B • Tighten the cylinder head cover bolts to the specified torque.

  • Page 19: Exhaust Pipe Bolt And Muffler Bolt

    2-6 PERIODIC MAINTENANCE CARBON DEPOSIT Check to see the carbon deposit on the plug. If the carbon is deposited, remove it with a spark plug cleaner machine or carefully using a tool with a pointed end. SPARK PLUG GAP Measure the plug gap with a thickness gauge if it is correct. If not, adjust it to the following gap.

  • Page 20: Air Cleaner Element

    PERIODIC MAINTENANCE 2-7 AIR CLEANER ELEMENT Inspect Every 6 000 km (6 months) and Replace Every 18 000 km (18 months). • Remove the seat and document tray. • Remove the air cleaner element by removing the screws. • Carefully use air hose to blow the dust from the cleaner ele- ment.

  • Page 21: Engine Oil And Oil Filter

    (thread diameter and pitch), filtering performance and durability, which could cause engine damage or oil leaks. Suzuki automo- bile genuine oil filter is also not usable for the motor- cycles.

  • Page 22: Fuel Hose

    PERIODIC MAINTENANCE 2-9 • Fit the drain plug 1 securely, and pour fresh oil through the oil filler. The engine will hold about 3.3 L of oil. Use an API classifi- cation of SF or SG oil with SAE 10W/40 viscosity. •...

  • Page 23: Engine Idle Speed

    2-10 PERIODIC MAINTENANCE ENGINE IDLE SPEED Inspect Initially at 1 000 km (1 month) and Every 6 000 km (6 months) thereafter. NOTE: Make this adjustment when the engine is hot. • Connect a tachometer. • Start up the engine and set its speed at anywhere between 1 100 and 1 300 r/min.

  • Page 24: Clutch

    PERIODIC MAINTENANCE 2-11 CLUTCH (CLUTCH FLUID) Inspect Every 12 000 km (12 months). Replace fluid Every 2 years. (CLUTCH HOSE) Inspect Every 6 000 km (6 months). Replace hose Every 4 years. CLUTCH FLUID LEVEL • Keep the motorcycle upright and place the handlebars straight. •...

  • Page 25: Drive Chain

    2-12 PERIODIC MAINTENANCE DRIVE CHAIN Inspect Initially at 1 000 km (1 month) and Every 6 000 km (6 months) thereafter. Clean and lubricate Every 1 000 km. Visually check the drive chain for the possible defects listed be- low. (Support the motorcycle by a center stand, turn the rear wheel slowly by hand with the transmission shifted to Neutral.) Grease * Loose pins...
  • Page 26 * Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the “O”-rings (or seals). * The standard drive chain is RK50GSVZ1. SUZUKI rec- ommends that this standard drive chain should be used for the replacement.

  • Page 27: Brake

    2-14 PERIODIC MAINTENANCE BRAKE (BRAKE) Inspect Initially at 1 000 km (1 month) and Every 6 000 km (6 months) thereafter. (BRAKE HOSE AND BRAKE FLUID) Inspect Every 6 000 km (6 months). Replace hoses Every 4 years. Replace fluid Every 2 years. BRAKE FLUID LEVEL •...
  • Page 28 PERIODIC MAINTENANCE 2-15 BRAKE PEDAL HEIGHT • Loosen the lock nut 1 and rotate the push rod 2 to locate the brake pedal 45 mm A below the top face of the footrest. • Retighten the lock nut 1 to secure the push rod 2 in the proper position.
  • Page 29 2-16 PERIODIC MAINTENANCE AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the brake cali- per.

  • Page 30: Tire

    The standard tire fitted on this motorcycle is 120/70 ZR17 (58W) for front (BRIDGESTONE BT-54F J) and 170/60 ZR17 (72W) for rear (BRIDGESTONE BT-54R J). The use of tires other than those specified may cause instability. It is highly recommended to use a SUZUKI Genuine Tire.

  • Page 31: Steering

    2-18 PERIODIC MAINTENANCE STEERING Inspect Initially at 1 000 km (1 month) and Every 12 000 km (12 months) thereafter. Taper roller type bearings are used on the steering system for better handling. Steering should be adjusted properly for smooth turning of handlebars and safe running.

  • Page 32: Chassis Bolt And Nut

    PERIODIC MAINTENANCE 2-19 CHASSIS BOLT AND NUT Tighten Initially at 1 000 km (1 month) and Every 6 000 km (6 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-20 for the locations of the following nuts and bolts on the motorcycle.) N .
  • Page 33 2-20 PERIODIC MAINTENANCE...

  • Page 34: Compression Pressure Check

    PERIODIC MAINTENANCE 2-21 COMPRESSION PRESSURE CHECK The compression 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 35: Oil Pressure Check

    2-22 PERIODIC MAINTENANCE OIL PRESSURE CHECK Check periodically the oil pressure in the engine to judge roughly the condition of the moving parts. OIL PRESSURE SPECIFICATION Above 300 kPa (3.0 kgf/cm at 3 000 r/min., Oil temp. at 60°C (140°F) Below 600 kPa (6.0 kgf/cm If the oil pressure is lower or higher than the specification, the following causes may be considered.
  • Page 36 ENGINE 3-1 ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ................3- 2 ENGINE REMOVAL AND REINSTALLATION ........3- 3 ENGINE REMOVAL ............... 3- 3 ENGINE REINSTALLATION ............3- 8 ENGINE DISASSEMBLY ..............3-11 ENGINE COMPONENTS INSPECTION AND SERVICE ....3-23 CYLINDER HEAD .................

  • Page 37: Engine Components Removable With Engine In Place

    3-2 ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to the page listed in each section for removal and reinstallation instructions. ENGINE CENTER See page Exhaust pipe/muffler ......

  • Page 38: Engine Removal And Reinstallation

    ENGINE 3-3 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 seat and frame covers. (!5-2 and -3) •...
  • Page 39 3-4 ENGINE • Remove the clamp 1. • Disconnect the throttle position sensor lead wire coupler 2. • Slightly move the air cleaner box backward. • Remove the carburetor assembly by disconnecting the starter cable 3 and throttle cables 4. •...
  • Page 40 ENGINE 3-5 • Remove the two wire clamps. • Disconnect the starter motor lead wire 1. • Disconnect the generator lead wire 2 and coupler 3. • Remove the gearshift lever by removing its mounting bolt. • Remove the engine sprocket cover by removing the bolts. "...
  • Page 41 3-6 ENGINE • Remove the oil cooler hose union bolts 1. • Remove the oil cooler by removing the mounting bolts 2. • Remove the eight exhaust pipe bolts. • Remove the muffler mounting bolts.
  • Page 42 ENGINE 3-7 • Remove the exhaust pipe/muffler assembly. The gasket retainers 1 are installed in the #1 and #4 exhaust pipes. NOTE: When installing a new exhaust pipe/muffler connector, clean any old dried sealer from the exhaust pipe and from inside the muffler and the exhaust gas sealer should be applied to both the inside and outside of the exhaust pipe/muffler connector.

  • Page 43: Engine Reinstallation

    3-8 ENGINE ENGINE REINSTALLATION Reinstall the engine in the reverse order of engine removal. • Insert the two long bolts from left side. Install the brackets, spacer, bolts and nuts properly, as shown in the following illustration. 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 tighten them to the specified torque.
  • Page 44 ENGINE 3-9 • Locate the carburetor clamps, as shown in the illustration. Carburetor clamp position (Engine side) L.H. R.H. Carburetor clamp position (Air cleaner side) • Replace the carburetor air vent hoses 1 and breather hose 2 to the exact positions. 2 Breather hose 1 Air vent hoses...
  • Page 45 3-10 ENGINE • Install the gearshift lever to the gearshift shaft in the correct position. • Tighten the engine sprocket nut to the specified torque and bend up the lock washer to lock the nut. • Tighten the rear axle nut, exhaust pipe clamp bolts, exhaust pipe mounting bolt and muffler mounting bolt to the specified torque.

  • Page 46: Engine Disassembly

    ENGINE 3-11 ENGINE DISASSEMBLY • Remove the oil filter 1 by using the special tool. $ 09915-40610: Oil filter wrench NOTE: Refer to page 3-74 for installation procedures. • Remove the left and right oil hoses 2 by removing the bolts. $ 09911-73730: 5 mm “T”...
  • Page 47 3-12 ENGINE • Remove the ten camshaft journal holders by removing the bolts. NOTE: Be sure to loosen camshaft journal holder bolts evenly by shifting the wrench diagonally. • Remove the two camshafts; intake and exhaust. • Remove the cam chain guide 1. •...
  • Page 48 ENGINE 3-13 • Remove the left and right oil pipes 1. • Remove the cylinder nut 2. • Firmly grip both ends of the cylinder block and lift it straight up. If the block does not come off, lightly tap on the finless portions of the block with a plastic mallet to make the gasketed joint loose.
  • Page 49 3-14 ENGINE • Remove the starter motor by removing the bolts. • Remove the generator by removing the bolts. • Remove the signal generator rotor by removing the bolt. $ 09900-00410: Hexagon wrench set • Disconnect the oil pressure switch lead wire 1. •...
  • Page 50 ENGINE 3-15 • Remove the clutch pressure plate lifter 1 by removing the circlip. $ 09900-06108: Snap ring pliers • After removing the clutch pressure plate lifter, remove the thrust washer 2, bearing 3 and clutch push piece 4, and pull out the clutch push rods, 5 and 6.
  • Page 51 3-16 ENGINE • Remove the clutch diaphragm springs 1, clutch diaphragm spring seat 2 and clutch pressure plate 3. • Screw two 6-mm bolts into the threaded of the clutch sleeve hub as shown. • Remove the clutch drive and driven plates along with the clutch sleeve hub.
  • Page 52 ENGINE 3-17 • Draw out the gearshift shaft 1, and then remove the cam driven gear 2. $ 09900-09003: Impact driver set NOTE: When removing the cam driven gear 2 , do not lose the gearshift pawl 3 , pin 4 and spring 5 . •...
  • Page 53 3-18 ENGINE • Loosen the starter clutch mounting bolt with the special tool. ! 09920-34840: Starter clutch holder NOTE: When removing the starter clutch assembly from the crankshaft, do not remove the starter clutch mounting bolt after loosening because it is used in conjuction with the special tool. •...
  • Page 54 ENGINE 3-19 • Remove the plug 1 on the upper crankcase. • Remove the upper crankcase tightening bolts and nut. ! 09911-73730: 5 mm “T” type hexagon wrench • Remove the oil pan by removing the bolts. • Remove the shim 2 and O-ring 3. •...
  • Page 55 3-20 ENGINE • Remove the lower crankcase tightening bolts and nut. • Remove the main oil gallery plug A. • When removing the crankshaft tightening bolts, loosen them in the descending order of numbers assigned to these bolts. NOTE: * Two allen bolts are used for tightening crankshaft at the portion * When installing the main oil gallery plug A , replace the O-ring with new one and tighten it to the specified torque.
  • Page 56 ENGINE 3-21 • Remove the crankshaft assembly from the upper crankcase. NOTE: Bear in mind that the crankshaft thrust bearings C are located between shaft and case. • Remove the two dampers 1 and cam chain tensioner 2. • Remove the O-rings, 3 and 4. •...
  • Page 57 3-22 ENGINE • Unhook the gearshift cam stopper spring from the lower crank- case. • Remove the circlip 1 from the gearshift cam, then draw out the gearshift cam from the other side. ! 09900-06107: Snap ring pliers NOTE: When replacing the gearshift cam stopper bolt 2 , apply a small quantity of THREAD LOCK “1342”...

  • Page 58: Engine Components Inspection And Service

    ENGINE 3-23 ENGINE COMPONENTS INSPECTION AND SERVICE CYLINDER HEAD SERVICE Be sure to identify each removed part as to its location, and lay the parts out in groups designated as “No.1”, “No.2”, “Exhaust”, “Inlet”, so that each will be restored to the original location during assembly.
  • Page 59 3-24 ENGINE CYLINDER HEAD DISTORTION Decarbonize the combustion chambers. Check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading at several places indicated. If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder head.

  • Page 60: Cylinder Head

    ENGINE 3-25 VALVE STEM WEAR If the valve stem is worn down to the limit, as measured with a micrometer, where the clearance is found to be in excess of the limit indicated, replace the valve; if the stem is within the limit, then replace the guide.
  • Page 61 3-26 ENGINE VALVE SEAT WIDTH • Coat the valve seat uniformly with Prussian blue. Fit the valve and tap the coated seat with the valve face in a rotating manner, in order to obtain a clear impression of the seating contact. In this operation, use the valve lapper to hold the valve head.
  • Page 62 ENGINE 3-27 • When installing the solid pilot 1, rotate it slightly. • Seat the pilot snugly. Install the 45° cutter 2, attachment 3 and T-handle 4. INITIAL SEAT CUT • Using the 45° cutter, descale and clean up the seat. Rotate the W W W W W cutter one or two turns.
  • Page 63 3-28 ENGINE 15° FINAL SEAT CUT Contact area too low and too • If the contact area is too low or too narrow, use the 45° cutter to narrow on face of valve raise and widen the contact area. NOTE: After cutting the 15°...
  • Page 64 ENGINE 3-29 VALVE SEAT SEALING CONDITION INSPECTION With the valve and valve spring assembled, pour a small quantity of gasoline into the intake or exhaust port. Check that no gasoline leaks though the valve seat. If leakage is found, correct the sealing surface. Always use extreme caution when handling gasoline.
  • Page 65 3-30 ENGINE • Locate the plate A on the cylinder head of exhaust side. ROCKER ARM AND SHAFT ROCKER ARM SHAFT OUTSIDE DIAMETER INSPECTION On the sliding surface, take two measurements, at right angle to each other. If the outside diameter measured is less than the standard value, replace the shaft.
  • Page 66 • Insert the valves, with their stems coated with mixed engine oil/moly paste all around and along the full stem length without any break. When inserting each valve, take care not to damage the lip of the oil seal. ( 99000-25140: SUZUKI MOLY PASTE...
  • Page 67 3-32 ENGINE • Install the valve springs with the small-pitch portion A facing cylinder head. B Large-pitch portion. • Put on the valve spring retainer, and using the valve lifter, press down the springs, fit the cotter halves to the stem end, and re- lease the lifter to allow the cotter 1 to wedge in between re- tainer and stem.

  • Page 68: Camshaft

    ENGINE 3-33 CAMSHAFT Both camshafts should be checked for runout and also for wear of cams and journals if the engine has been noted as giving abnor- mal noise or vibration or lack power output. Any of these condi- tions may be caused by camshafts worn down or distorted to the service limit.
  • Page 69 3-34 ENGINE CAMSHAFT JOURNAL WEAR Determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place. Use the plastigauge 1 to read the clearance at the widest por- tion, which is specified as follows: ! Camshaft-Journal oil clearance (IN &...

  • Page 70: Cam Chain Tension Adjuster

    ENGINE 3-35 CAMSHAFT RUNOUT Measure the runout with a dial gauge. Replace the camshaft if the runout exceeds the limit. ! Camshaft runout (IN & EX) Service Limit: 0.1 mm " " " 09900-20606: Dial gauge (1/100 mm, 10 mm) "...
  • Page 71 If they are found to be damaged, replace them with new ones. NOTE: When replacing the cam chain guides A and B , apply SUZUKI THREAD LOCK SUPER ‘‘1303’’ to threads of bolt and screws. % 99000-32030: THREAD LOCK SUPER ‘‘1303’’...

  • Page 72: Piston

    ENGINE 3-37 CYLINDER BORE Measure the cylinder bore diameter at six places. If any one of the measurements exceeds the limit, overhaul the cylinder and re- place the piston with an oversize piston. The remaining cylinders must be also rebored accordingly. Otherwise, the imbalance might cause excess vibration.

  • Page 73: Piston Ring

    3-38 ENGINE ! Piston ring groove width 1st & 2nd: 1.01 – 1.03 mm Standard : 2.01 – 2.03 mm ! Piston ring thickness Standard 1st: 0.975 – 0.990 mm 2nd: 0.970 – 0.990 mm PISTON RING FREE END GAP AND PISTON RING END GAP Before installing piston rings, measure the free end gap of each ring using vernier calipers.

  • Page 74: Piston Pin

    ENGINE 3-39 PISTON PIN AND PIN BORE Using a small bore gauge, measure the piston pin bore inside diameter, and using a micrometer, measure the piston pin outside diameter. If the difference between these two measurements is more than the limits, replace both piston and piston pin. ! Piston pin bore I.D.
  • Page 75 3-40 ENGINE CONROD-CRANK PIN BEARING SELECTION • Remove the bearing cap nuts, and tap the bearing cap lightly with plastic hammer to remove the bearing cap. • Remove the rods, and mark them to identify the cylinder posi- tion. • Inspect the bearing surfaces for any sign of fusion, pitting, burn, or flaws.

  • Page 76: Conrod

    ENGINE 3-41 • Check the corresponding crank pin O.D. code number 2 , “1”, “2” or “3”. Bearing selection table Crank pin O.D. 2 Code Green Black Brown Conrod I.D. 1 Black Brown Yellow Conrod I.D. specification Code I.D. specification 41.000 –...
  • Page 77 3-42 ENGINE • Apply mixed engine oil/moly paste to the crank pin and bearing surface. ( 99000-25140: SUZUKI MOLY PASTE • When mounting the conrod on the crankshaft, make sure that numeral figure 1 of the conrod faces rearward. • Tighten the bearing cap nuts with specified torque.
  • Page 78 ENGINE 3-43 • Remove the lower crankcase, and measure the width of com- pressed plastigauge in the usual manner. ! Crank journal bearing oil clearance Standard: 0.020 – 0.044 mm Service Limit: 0.08 mm • If the width at the widest part exceeds the limit, replace the set of bearings with new ones by referring to the selection table.

  • Page 79: Crankshaft

    3-44 ENGINE Bearing thickness specification (Grooved bearing with oil hole ..For lower case) Upper Color (Part No.) Thickness Green 1.486 – 1.490 mm ( 12229-06B00-0A0 ) Black 1.490 – 1.494 mm Lower ( 12229-06B00-0B0 ) Brown 1.494 – 1.498 mm ( 12229-06B00-0C0 ) Yellow 1.498 –...
  • Page 80 ENGINE 3-45 • If the right-side thrust bearing is within the standard range, rein- sert the right-side thrust bearing and remove the left-side thrust bearing. • As shown in the illustration, use a thickness gauge to measure the clearance before inserting of the left-side thrust bearing, and select a left-side thrust bearing from the selection table.

  • Page 81: Clutch

    3-46 ENGINE CLUTCH INSPECTION CLUTCH DIAPHRAGM SPRING Measure the free height of each diaphragm spring with a vernier calipers. If each diaphragm spring height is not within the speci- fied limit, replace it with a new one. " " " "...

  • Page 82: Oil Pump

    ENGINE 3-47 CLUTCH RELEASE CYLINDER DISASSEMBLY • Remove the gearshift lever and engine sprocket cover. ( # 3-5) • Remove the clutch hose by removing the union bolt 1. • Remove the air bleeder valve 2. • Remove the clutch release cylinder by removing the mounting bolts 3 and piston retainer screws 4.

  • Page 83: Transmission

    3-48 ENGINE TRANSMISSION DISASSEMBLY • Disassemble the transmission gears as shown in the illustration. & 115 N . m (11.5 kgf-m) 1 Low driven gear 2 4th driven gear 3 3rd driven gear 4 Top driven gear 5 2nd driven gear 6 Driveshaft 7 Countershaft/Low drive gear 8 4th drive gear...
  • Page 84 * Before installing the oil seal, apply grease to the oil seal lip. ( 99000-25140: SUZUKI MOLY PASTE ) 99000-25010: SUZUKI SUPER GREASE ‘‘A’’ * Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded, a new circlip must be installed.
  • Page 85 3-50 ENGINE...
  • Page 86 ENGINE 3-51 GEARSHIFT FORK-GROOVE CLEARANCE Using a thickness gauge, check the gearshift fork clearance in the groove of its gear. The clearance for each of the three gearshift forks plays an impor- tant role in the smoothness and positiveness of the shifting ac- tion.
  • Page 87 3-52 ENGINE STARTER CLUTCH INSPECTION Install the starter driven gear onto the starter clutch and turn the starter driven gear by hand to inspect the starter clutch for a smooth movement. The gear turns one direction only. If a large resistance is felt to rotation, inspect the starter clutch for damage or inspect the starter clutch contacting surface of the starter driven gear for wear or damage.

  • Page 88: Engine Reassembly

    ENGINE 3-53 ENGINE REASSEMBLY The engine is reassembled by carrying out the steps of disassembly in the reversed order, but there are a number of steps which demand special descriptions or precautionary measures. NOTE: Apply engine oil to each running and sliding part before reassembling. NOTE: When installing the gearshift cam stopper plate A , align the pin groove B with the pin C as shown in the figure.
  • Page 89 3-54 ENGINE • Fit the O-rings, 1 and 2, and dowel pins 3 to the correct posi- tions, as shown in the illustrations. Replace the O-rings with new ones to prevent oil leak- age. • Install the oil pump to the lower crankcase with three bolts and tighten them to the specified torque.
  • Page 90 • Clean the mating surfaces of the crankcases before matching the upper and lower ones. • Install the dowel pins to the upper crankcase. • Apply SUZUKI BOND NO. 1207B to the mating surface of the lower crankcase in the following procedure. &...
  • Page 91 3-56 ENGINE BOND “1207B” should be applied to the following locations. The line of BOND...
  • Page 92 ENGINE 3-57 • Fix the right oil pipe A with No. 1 bolt. • Fit the copper washers to the No. 9 and No. A bolts. • Locate two allen bolts at position B and ten 8-mm bolts. • Tighten the crankshaft tightening 8-mm bolts in the ascending order of numbers assigned to these bolts, tightening each bolt a little at a time to equalize the pressure.
  • Page 93 3-58 ENGINE • Fit a new gasket and install the oil pan. Tighten the oil pan bolts to the specified torque. # Oil pan bolt: 14 N . m (1.4 kgf-m) NOTE: Fit a new gasket to the oil pan bolt A correctly position as shown. Use a new gasket to prevent oil leakage.
  • Page 94 ENGINE 3-59 • Install the washer 1, pin 2, oil pump driven gear 3 and washer • Fix the oil pump driven gear with the circlip. ( 09900-06107: Snap ring pliers • Install the thrust washer 5 onto the countershaft. NOTE: Flat surface of washer is positioned outside.
  • Page 95 3-60 ENGINE • Install the clutch sleeve hub onto the countershaft. • Insert the clutch drive plates and driven plates one by one into the clutch sleeve hub in the prescribed order, No.2 drive plate first. Direction of inside DRIVE PLATE: Two kinds of the drive plate, No.1 and No.2, are equipped in the clutch system, they can be distin- guished by the inside diameter.
  • Page 96 ENGINE 3-61 • Install the diaphragm spring holder 1 with three screws. • Install the lock washer 2. • Tighten the clutch sleeve hub nut to the specified torque by using the torque wrench and clutch pressure plate holder. ( 09920-34820: Clutch pressure plate holder # Clutch sleeve hub nut: 150 N·m (15.0 kgf-m) •...
  • Page 97 3-62 ENGINE Diaphragm springs Diaphragm spring holder 150 N . m (15.0 kgf-m) • Coat SUZUKI BOND NO.1207B lightly to the mating surfaces A between upper and lower crankcases. & & & & & 99000-31140: SUZUKI BOND NO. 1207B • Install the dowel pins, a new gasket and clutch cover.
  • Page 98 • Make sure to fit the slot 1 on the back surface of the signal generator rotor over the locating pin 2 at the end of crankshaft. NOTE: SUZUKI BOND NO.1207B should be applied to the groove of the signal generator lead wire grommet 3 . &...
  • Page 99 # Starter clutch mounting bolt: 150 N . m (15.0 kgf-m) ( 09920-34840: Starter clutch holder • Install the starter idle gear 1 and its shaft 2. • Coat SUZUKI BOND NO.1207B lightly to the mating surfaces between upper and lower crankcases. &...
  • Page 100 • Install the starter motor with two bolts. # Starter motor mounting bolt: 6 N . m (0.6 kgf-m) NOTE: * Apply SUZUKI SUPER GREASE “A” to the starter motor O- ring. * Apply a small quantity of THREAD LOCK “1342” to the two bolts.
  • Page 101 90AB Black 189 mm Front NOTE: When reinstalling the cylinder stud bolt 7 , apply SUZUKI BOND NO.1207B lightly to the stud bolt thread. # Cylinder stud bolt: 16 N·m (1.6 kgf-m) & & 99000-31140: SUZUKI BOND NO. 1207B &...
  • Page 102 Replace the O-rings and gasket with new ones to prevent oil leakage and gas leakage. • Fit the new O-rings 2 onto the oil pipes and apply SUZUKI SUPER GREASE “A” to the O-rings. • Install the right and left oil pipes.
  • Page 103 NOTE: Just before placing the camshaft on the cylinder head, apply mixed engine oil/moly paste to its journals fully, taking care not to leave any dry spot. Apply engine oil to the camshaft journal holders. % 99000-25140: SUZUKI MOLY PASTE...
  • Page 104 ENGINE 3-69 • The exhaust camshaft can be distinguished from that of the intake by the embossed letters “EX” (for exhaust) as against letters “IN” (for intake). Similarly, the right end can be distin- guished by the notch 1 at the right end. •...
  • Page 105 3-70 ENGINE 24th pin 1st pin...
  • Page 106 ENGINE 3-71 • Each camshaft journal holder is identified with a cast-on letter. Install the dowel pins to each camshaft journal holder. • Fasten the camshaft journal holders evenly by tightening the camshaft journal holder bolts sequentially. (Try to equalize the pressure by shifting the wrench in the above manner, to fasten the shafts evenly.) NOTE: Damage to head or camshaft journal holder thrust surfaces may result if the camshaft journal holders are not drawn down evenly.
  • Page 107 Turn the crankshaft and check that all the moving parts such as cam follower, camshaft, work properly. Be sure to check and adjust the valve clearance. $ 2-3) • Coat SUZUKI BOND NO.1207B lightly to the mating surfaces between upper and lower crankcases as shown in the Fig. & &...
  • Page 108 • Before installing the cylinder head cover gaskets on the cylin- der head cover, apply SUZUKI BOND NO.1207B to the grooves of the head cover. • Apply SUZUKI BOND NO.1207B to the four cam end caps of the gasket as shown in the Fig. &...
  • Page 109 3-74 ENGINE • Install the left and right oil hoses and tighten their mounting bolts to the specified torque. Replace the O-rings (A A A A A and B B B B B ) with new ones to prevent oil leakage. # Oil hose mounting bolt: 10 N .
  • Page 110 FUEL AND LUBRICATION SYSTEM 4-1 FUEL AND LUBRICATION SYSTEM CONTENTS FUEL SYSTEM ................... 4- 2 FUEL TANK ..................4- 3 REMOVAL..................4- 3 REMOUNTING ................4- 3 FUEL PUMP ..................4- 3 FUEL PUMP MECHANISM ............. 4- 3 REMOVAL..................4- 4 INSPECTION ...................

  • Page 111: Fuel System

    4-2 FUEL AND LUBRICATION SYSTEM FUEL SYSTEM The fuel pump is operated by an electro-magnetic force and its electrical energy is supplied from the battery. The fuel sent under pressure by the fuel pump flows into the float chamber when the float of the carburetor has dropped and the needle valve is open.

  • Page 112: Fuel Tank

    FUEL AND LUBRICATION SYSTEM 4-3 FUEL TANK REMOVAL • Remove the seat (!5-2) • Remove the fuel tank mounting bolts 1. • Turn the fuel valve to “OFF” position and disconnect the fuel hose 2. " Gasoline is highly flammable and explosive. Keep heat, sparks and flames away from gasoline.

  • Page 113: Removal

    4-4 FUEL AND LUBRICATION SYSTEM REMOVAL • Remove the seat. (!5-2) • Remove the document tray. • Remove the frame covers. (!5-3) • Disconnect the fuel pump lead wire coupler 1. • Remove the battery holder 2. • Disconnect the ignitor lead wire couplers. •...
  • Page 114 FUEL AND LUBRICATION SYSTEM 4-5 Connect the battery to the fuel pump and measure the pump discharge amount for one minute using kerosene and measuring cylinder, as shown in the right illustration. Fuel pump Battery + + + + + to Brown/white Battery Battery - - - - - to Black/white $ Discharge amount: More than 600 ml/min...

  • Page 115: Fuel Valve

    4-6 FUEL AND LUBRICATION SYSTEM FUEL VALVE “ON” position “OFF” position “RES” position REMOVAL • Remove the fuel tank. (! 4-3) • Remove the fuel valve by removing the mounting bolts.

  • Page 116: Inspection And Cleaning

    FUEL AND LUBRICATION SYSTEM 4-7 " * Gasoline is very explosive. Extreme care must be taken. * The gaskets 1 1 1 1 1 and O-ring 2 2 2 2 2 must be replaced with the new ones to prevent fuel leakage. INSPECTION AND CLEANING If the fuel filter is dirty with sediment or rust, fuel will not flow smoothly and loss in engine power may result.

  • Page 117: Carburetor

    4-8 FUEL AND LUBRICATION SYSTEM CARBURETOR CONSTRUCTION 1 Top cap 9 Pilot jet G Float chamber N Fuel joint pipe 2 Spring 0 Needle valve ass’y H Throttle stop screw O Hose 3 Spring seat A Float I Vacuum inlet cap P Starter (enricher) plate 4 Jet needle B Float pin...

  • Page 118: Specification

    FUEL AND LUBRICATION SYSTEM 4-9 SPECIFICATION ITEM SPECIFICATION KEIHIN CVK32 Carburetor type 32 mm Bore size 03F6 I.D. No. Idle r/min. 1 200 ± 100 r/min. Fuel level 32 ± 1.0 mm Float height 17 ± 1.0 mm Main jet (M.J.) Jet needle (J.N.)

  • Page 119: Diaphragm And Piston Operation

    4-10 FUEL AND LUBRICATION SYSTEM DIAPHRAGM AND PISTON OPERATION The carburetor is a variable-venturi type, whose venturi cross sectional area is increased or decreased automatically by the piston valve 1. The piston valve moves according to the negative pressure present on the downstream side of the venturi A.

  • Page 120: Slow System

    FUEL AND LUBRICATION SYSTEM 4-11 SLOW SYSTEM This system supplies fuel during engine operation when the throttle valve 1 is closed or slightly opened. The fuel from the float chamber 2 is metered by the pilot jet 3 where it mixes with air coming in through the pilot air jet 4.

  • Page 121: Main System

    4-12 FUEL AND LUBRICATION SYSTEM MAIN SYSTEM As the throttle valve 1 is opened, engine speed rises and negative pressure in the venturi A increases. This causes the piston valve 2 to move upward. The fuel in the float chamber 3 is metered by the main jet 4. The metered fuel enters the needle jet 5, mixes with the air admitted through the main air jet 6 and forms an emulsion.

  • Page 122: Starter (Enricher) System

    FUEL AND LUBRICATION SYSTEM 4-13 STARTER (ENRICHER) SYSTEM Pulling the starter (enricher) plunger 1 causes fuel to be drawn into the starter circuit from the float chamber 2. The starter jet 3 meters this fuel. The fuel then flows into the fuel pipe 4 and mixes with the air coming from the float chamber 2.

  • Page 123: Removal

    4-14 FUEL AND LUBRICATION SYSTEM REMOVAL • Remove the fuel tank. (!4-3) • Remove the frame covers. (!5-3) • Remove the left and right air cleaner box covers 1. • Remove the left and right air cleaner box mounting bolts. •...

  • Page 124: Disassembly

    FUEL AND LUBRICATION SYSTEM 4-15 DISASSEMBLY Before disassembly, prepare a clean and well lit work place where carburetor components can be laid out neatly and will not get lost. Study the service manual carburetor diagram and familiarize yourself with component locations and the different fuel circuits and their routing through the carburetor.
  • Page 125 4-16 FUEL AND LUBRICATION SYSTEM • Remove the upper 1 and lower 2 carburetor set plates. • Separate the carburetor assembly. # 09900-09004: Impact driver set • Remove the top cap 3. " Do not use compressed air on the carburetor body, be- fore removing the diaphragm;...
  • Page 126 FUEL AND LUBRICATION SYSTEM 4-17 • Remove the float chamber 1. # 09900-09004: Impact driver set • Remove the float 2 and needle valve 3. " Do not use a wire to clean the valve seat. • Remove the O-ring 4. "...

  • Page 127: Carburetor Cleaning

    4-18 FUEL AND LUBRICATION SYSTEM • Remove the throttle valve 1 by removing the screws. " These two screws are locked by their ends being punched. Once they are removed, they will be damaged. CARBURETOR CLEANING Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully.

  • Page 128: Carburetor Inspection

    FUEL AND LUBRICATION SYSTEM 4-19 CARBURETOR INSPECTION Check the following items for any damage or clogging. * Pilot jet * Jet needle * Main jet * Valve seat * Main air jet * Piston valve * Pilot air jet * Starter (enricher) jet * Needle jet air bleeding hole * Gasket and O-ring * Float...

  • Page 129: Reassembly And Installation

    4-20 FUEL AND LUBRICATION SYSTEM REASSEMBLY AND INSTALLATION Reassemble and remount the carburetors in the reverse order of removal and disassembly. Pay attention to the following points: THROTTLE VALVE Turn the throttle stop screw and throttle valve synchronizing screw until the throttle valve’s bottom end 1 is aligned with the fore- most by-pass port 2 as shown.
  • Page 130 FUEL AND LUBRICATION SYSTEM 4-21 CARBURETOR ENGAGEMENT Position the throttle valve control lever A between the throttle valve synchronizing screw and spring as shown. THROTTLE POSITION SENSOR POSITIONING Install the throttle position sensor as described below. • Measure the resistance between the throttle position sen- sor terminals as shown in the illustration.

  • Page 131: Carburetor Synchronization

    4-22 FUEL AND LUBRICATION SYSTEM CARBURETOR CLAMP POSITIONING Locate the carburetor clamps as shown in the following illustration. Carburetor clamp position (Engine side) R.H. L.H. Carburetor clamp position (Air cleaner side) CARBURETOR AIR VENT HOSE ROUTING Locate the air vent hoses, as shown in the following illustration. Breather hose Air vent hoses After all of the work has been completed, install the carburetor...
  • Page 132 FUEL AND LUBRICATION SYSTEM 4-23 CALIBRATING THE CARBURETOR BALANCER • Start the engine and let it run at idle until it is warmed up. • Stop the engine. • Remove the vacuum inlet cap 1 from the carburetor. (#1 or #4) •...

  • Page 133: Lubrication System

    4-24 FUEL AND LUBRICATION SYSTEM CARBURETOR SYNCHRONIZATION Remove all of the vacuum inlet caps, before synchronizing the carburetors. Connect the carburetor balancer hoses to these vacuum inlets and then adjust the carburetors as follows. • Start the engine and keep it running at 1 750 r/min. Observe the tachometer reading.

  • Page 134: Engine Lubrication System Chart

    FUEL AND LUBRICATION SYSTEM 4-25 ENGINE LUBRICATION SYSTEM CHART...

  • Page 135: Engine Lubrication System

    4-26 FUEL AND LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM...

  • Page 136: Cylinder Head Cooling System Chart

    FUEL AND LUBRICATION SYSTEM 4-27 CYLINDER HEAD COOLING SYSTEM CHART...

  • Page 137: Cylinder Head Cooling System

    4-28 FUEL AND LUBRICATION SYSTEM CYLINDER HEAD COOLING SYSTEM...

  • Page 138: Engine Oil Cooling System

    FUEL AND LUBRICATION SYSTEM 4-29 ENGINE OIL COOLING SYSTEM ' 10 N . m (1.0 kgf-m) 1 Oil cooler ass’y 2 Oil cooler cover 3 Oil cooler hose (RH) 4 Oil cooler hose (LH) 5 Oil cooler hose union bolt 6 Oil cooler mounting bolt 7 Oil cooler guard ' 10 N .
  • Page 139 CHASSIS 5-1 CHASSIS CONTENTS SEAT, FRAME COVER AND SEAT TAIL COVER ............5- 2 CONSTRUCTION ....................5- 2 REMOVAL ......................5- 2 REMOUNTING ....................... 5- 3 FRONT WHEEL ......................5- 4 CONSTRUCTION ....................5- 4 REMOVAL ......................5- 6 INSPECTION AND DISASSEMBLY ..............5- 7 REASSEMBLY AND REMOUNTING ..............

  • Page 140: Seat, Frame Cover And Seat Tail Cover

    5-2 CHASSIS SEAT, FRAME COVER AND SEAT TAIL COVER CONSTRUCTION 1 Seat 2 Passenger grab handle 3 Seat tail cover 4 Seat lock set REMOVAL SEAT • Remove the seat with the ignition key.

  • Page 141: Remounting

    CHASSIS 5-3 FRAME COVERS • Remove the seat. (! 5-2) • Remove the frame cover mounting screws (left side and right side). • Remove the left and right frame covers by pulling on the hooked parts. : hooked part SEAT TAIL COVER •...

  • Page 142: Front Wheel

    5-4 CHASSIS FRONT WHEEL CONSTRUCTION 1 Spacer 2 Collar 3 Brake disc (R) 4 Bearing 5 Spacer 6 Front wheel 7 Brake disc (L) 8 Speedometer gearbox A Front axle B Front axle pinch bolt C Brake disc bolt " N .
  • Page 143 CHASSIS 5-5 Left Right " 39 N . m " 39 N . m (3.9 kgf-m) (3.9 kgf-m) " 23 N . m " 23 N . m (2.3 kgf-m) (2.3 kgf-m) " 100 N . m (10.0 kgf-m) " 2.3 N . m (2.3 kgf-m) Left Right...

  • Page 144: Removal

    5-6 CHASSIS REMOVAL • Remove the right and left brake caliper mounting bolts. • Loosen the front axle pinch bolts 1. • Loosen the front axle 2. • Raise the front wheel off the ground with a jack or wooden block. •...

  • Page 145: Inspection And Disassembly

    CHASSIS 5-7 INSPECTION AND DISASSEMBLY SPEEDOMETER GEARBOX DUST SEAL Inspect the lip of the dust seal for damage. TIRES ! 5-54 FRONT WHEEL Make sure that the wheel runout (axial and radial) does not ex- ceed the service limit when checked as shown. An excessive amount of runout is usually due to worn or loose wheel bearings and can be corrected by replacing the bearings.

  • Page 146: Reassembly And Remounting

    Reassemble and remount the front wheel in the reverse order of removal and disassembly. Pay attention to the following points: WHEEL BEARINGS • Apply SUZUKI SUPER GREASE “A” to the bearings before in- stallation. $ 99000-25010: SUZUKI SUPER GREASE “A”...
  • Page 147 CHASSIS 5-9 FRONT AXLE • Tighten the front axle 1 to the specified torque. • Tighten the front axle pinch bolts 2 to the specified torque. " " " Front axle: 100 N . m (10.0 kgf-m) " " Front axle pinch bolt: 23 N . m (2.3 kgf-m) NOTE: Before tightening the front axle and front axle pinch bolts, move the front fork up and down four or five times.

  • Page 148: Front Fork

    5-10 CHASSIS FRONT FORK CONSTRUCTION 1 O-ring 2 Spacer 3 Washer 4 Fork spring 5 Damper rod 6 Rebound spring 7 Inner tube 8 Inner tube slide metal 9 Dust seal 0 Oil seal stopper ring A Oil seal B Oil seal retainer C Outer tube slide metal D Oil lock piece E Outer tube...

  • Page 149: Removal And Disassembly

    CHASSIS 5-11 REMOVAL AND DISASSEMBLY • Remove the front wheel. (! 5-6) • Remove the front fender mounting bolt caps and front fender mounting bolts. • Remove the front fender. • Remove the front fork after loosening the front fork upper and lower clamp bolts.

  • Page 150: Inspection

    5-12 CHASSIS • Remove the damper rod bolt using a 6-mm hexagon wrench and the special tools. ' 09940-34520: “T” handle 09940-34531: Attachment “A” • Remove the damper rod 1 and rebound spring 2. • Remove the oil seal by slowly pulling out the inner tube. NOTE: Be careful not to damage the inner tube.

  • Page 151: Reassembly And Remounting

    CHASSIS 5-13 FORK SPRING Measure the fork spring free length. If it is shorter than the service limit, replace it with a new one. & & & & & Front fork spring free length Service Limit: 380 mm DAMPER ROD RING Inspect the damper rod ring for wear or damage.
  • Page 152 Use a new damper rod bolt gasket 2 to prevent oil leak- age. FORK OIL • Pour the specified fork oil into the inner tube. ) Fork oil type: Fork oil #10, SS-08 or equivalent fork oil 99000-99001-SS8: SUZUKI FORK OIL SS-08 99000-99044-10G: SUZUKI FORK OIL #10 & & &...
  • Page 153 CHASSIS 5-15 • Hold the front fork in a vertical position and adjust the fork oil level using the special tool. ' 09943-74111: Fork oil level gauge & & & Oil level: 85 mm & & NOTE: When adjusting the oil level, remove the fork spring and com- press the inner tube fully.

  • Page 154: Steering

    5-16 CHASSIS STEERING CONSTRUCTION 1 Handlebar clamp bolt cap 2 Handlebar clamp 3 Steering stem upper bracket 4 Headlight housing holders 5 Steering stem nut 6 Dust seal 7 Steering stem upper bearing 8 Steering stem lower bearing 9 Steering stem 0 Handlebars A Handlebar balancer A Steering stem head nut...
  • Page 155 CHASSIS 5-17 • Disconnect all the lead wire couplers in the headlight housing. • Remove the headlight housing. • Remove the headlight housing holders 1, horns and turn sig- nal lights. • Remove the speedometer cable 2. • Remove the speedometer. •...
  • Page 156 5-18 CHASSIS • Remove the brake hose joint mounting bolt 1. • Disconnect the front brake light switch lead wires 2. • Remove the front brake master cylinder 3 along with brake hose and calipers. • Remove the right handlebar balancer 4 and the right handle- bar switch box 5.
  • Page 157 CHASSIS 5-19 • Remove the handlebars by removing the handlebar clamp bolt caps, handlebar clamp bolts and handlebar clamps. • Remove the steering stem upper bracket by removing the steer- ing stem head nut 1. • Remove the steering stem nut using the special tool. ! 09940-14911: Steering stem nut wrench •...

  • Page 158: Inspection And Disassembly

    5-20 CHASSIS • Remove the steering stem upper bearing 1. • Remove the ignition switch 2 using a Torx wrench. ! 09930-11920: Torx bit 09930-11940: Bit holder INSPECTION AND DISASSEMBLY Inspect the removed parts for the following abnormalities. * Handlebars distortion * Race wear and brinelling * Bearing wear or damage * Abnormal bearing noise...

  • Page 159: Reassembly And Remounting

    • Press in the lower bearing using the special tool. ! 09941-74911: Steering bearing installer • Apply grease to the upper and lower bearings and the lip of the dust seal before remounting the steering stem. # 99000-25010: SUZUKI SUPER GREASE “A” • Install the bearings.
  • Page 160 5-22 CHASSIS STEERING STEM NUT • Put the upper bearing inner race onto the upper bearing. • Set the dust seal. • Tighten the steering stem nut to the specified torque using the special tool. ! 09940-14911: Steering stem nut wrench $ Stem nut: 45 N .
  • Page 161 CHASSIS 5-23 HANDLEBARS • Install the handlebars with the punched mark 1 aligned with the mating surfaces of the handlebar clamp as shown. • The gap A between the handlebar clamps should be even. $ Handlebar clamp bolt: 23 N . m (2.3 kgf-m) •...

  • Page 162: Steering Tension Adjustment

    5-24 CHASSIS STEERING TENSION ADJUSTMENT Check the steering tension as follows. • Support the motorcycle using a jack and raise the front wheel off the floor 20 – 30 mm. • Make sure that the cables and wire harness are properly routed. •...

  • Page 163: Rear Wheel

    CHASSIS 5-25 REAR WHEEL CONSTRUCTION 1 Rear axle 2 Brake disc 3 Brake caliper bracket 4 Collar 5 Dust seal (R) 6 Bearing (R) 7 Rear wheel 8 Spacer 9 Bearing (L) 0 Cushion A Retainer B Rear sprocket mounting drum C Rear sprocket D Bearing E Dust seal (L)
  • Page 164 5-26 CHASSIS Right Left $ 100 N . m (10.0 kgf-m) $ 26 N . m $ 50 N . m (2.6 kgf-m) (5.0 kgf-m) $ 23 N . m (2.3 kgf-m) Right Right Left Left Spacer Clearance Bearing installer...

  • Page 165: Removal

    CHASSIS 5-27 REMOVAL • Loosen the axle nut. • Support the motorcycle using a jack. • Remove the rear axle nut. • Remove the rear axle and disengage the drive chain from the rear sprocket. • Remove the rear brake caliper. •...

  • Page 166: Inspection And Disassembly

    5-28 CHASSIS INSPECTION AND DISASSEMBLY Play % 5-54 TIRE ................% Play REAR WHEEL ............. % % 5-7 (Use the front wheel specifications and procedure.) BEARINGS Inspect the play of the bearings by hand while they are in the rear wheel and rear sprocket mounting drum.

  • Page 167: Reassembly And Remounting

    Pay attention to the following points: WHEEL BEARING AND DUST SEAL • Apply grease to the bearings before installation. # 99000-25010: SUZUKI SUPER GREASE “A” • Install the wheel bearings using the special tool. ! 09941-34513: Bearing installer set "...
  • Page 168 NOTE: Apply grease to the bearing and dust seal lip before assembling the rear sprocket mounting drum. # 99000-25010: SUZUKI SUPER GREASE “A” BRAKE DISC • Apply THREAD LOCK SUPER “1360” to the brake disc bolts and tighten them to the specified torque.

  • Page 169: Rear Suspension

    CHASSIS 5-31 REAR SUSPENSION CONSTRUCTION 1 Cap 2 Rear shock absorber 3 Drive chain case 4 Rear torque link 5 Dust seal 6 Spacer 7 Bearing 8 Swingarm 9 Spacer 0 Chain buffer A Pivot shaft A Rear shock absorber upper mounting bolt B Rear shock absorber lower mounting nut...
  • Page 170 5-32 CHASSIS $ 23 N . m $ 23 N . m Frame (2.3 kgf-m) (2.3 kgf-m) Rear shock absorber $ 35 N . m (3.5 kgf-m) Swingarm $ 100 N . m (10.0 kgf-m) Pivot shaft...

  • Page 171: Removal

    CHASSIS 5-33 REMOVAL • Remove the rear wheel. (% 5-27) • Remove the rear shock absorber mounting bolt caps 1. • Remove the left and right rear shock absorbers by removing the upper and lower bolts. • Remove the drive chain case 2. •...

  • Page 172: Inspection And Disassembly

    5-34 CHASSIS INSPECTION AND DISASSEMBLY DUST SEALS AND SPACERS • Remove the dust seals, washers and spacers from the swingarm. • Inspect the spacers for any flaws or other damage. If any de- fects are found, replace the spacers with new ones. CHAIN BUFFER •...

  • Page 173: Reassembly And Remounting

    Install the needle bearings with the stamped mark facing out. • Apply grease to the spacers, dust seals and needle bearings. $ 99000-25010: SUZUKI SUPER GREASE “A” • Tighten the pivot shaft nut to the specified torque. % Pivot shaft nut: 100 N . m (10.0 kgf-m)

  • Page 174: Final Inspection And Adjustment

    5-36 CHASSIS • Tighten the brake hose union bolt to the specified torque. % Brake hose union bolt: 23 N . m (2.3 kgf-m) • Tighten the rear torque link nut. • Tighten the rear shock absorber upper mounting bolt 1 and rear shock absorber lower mounting nut 2 to the specified torque.

  • Page 175: Suspension Setting

    CHASSIS 5-37 SUSPENSION SETTING After installing the rear suspension, adjust the spring pre-load and compression damping force as follows. SPRING PRE-LOAD ADJUSTMENT Position “1” provides the softest spring pre-load. Position “5” provides the stiffest spring pre-load. (STD position: “2”) COMPRESSION DAMPING FORCE ADJUSTMENT Position “1”...

  • Page 176: Front Brake

    5-38 CHASSIS FRONT BRAKE CONSTRUCTION 1 Master cylinder reservoir cap 2 Diaphragm 3 Dust boot 4 Piston/cup set 5 Master cylinder clamp 6 Master cylinder 7 Brake hose #1 8 Brake hose joint 9 Brake hose #2 (R) 0 Brake hose #2 (L) A Brake pads B Brake pad mounting pin C Clip...

  • Page 177: Brake Pad Replacement

    CHASSIS 5-39 BRAKE PAD REPLACEMENT • Remove the brake pads by removing the clips 1, pad mounting pins 2 and spring 3. " * Do not operate the brake lever while dismounting the pads. * Replace the brake pads as a set, otherwise braking per- formance will be adversely affected.

  • Page 178: Brake Caliper Removal And Disassembly

    5-40 CHASSIS BRAKE CALIPER REMOVAL AND DISASSEMBLY • Disconnect the brake hose from the caliper by removing the union bolt and catch the brake fluid in a suitable receptacle. • Remove the brake caliper by removing the caliper mounting bolts. "...

  • Page 179: Brake Caliper Inspection

    CHASSIS 5-41 • With the opposite side of the pistons reassembled, perform the remainder of the pistons in the same manner of the previous page. BRAKE CALIPER INSPECTION BRAKE CALIPER PISTONS Inspect the brake caliper pistons for any scratches or other dam- age.

  • Page 180: Brake Disc Inspection

    5-42 CHASSIS • Tighten the brake caliper mounting bolts 1 and brake hose union bolt 2 to the specified torque. % Brake caliper mounting bolt 1: 39 N . m (3.9 kgf-m) Brake hose union bolt 2: 23 N . m (2.3 kgf-m) NOTE: Before remounting the brake caliper, push the brake caliper pis- tons all the way into the caliper.

  • Page 181: Master Cylinder Removal And Disassembly

    CHASSIS 5-43 MASTER CYLINDER REMOVAL AND DISASSEMBLY • Disconnect the front brake light switch lead wires 1. • 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 and disconnect the brake hose.

  • Page 182: Master Cylinder Inspection

    5-44 CHASSIS • Pull out the dust boot and remove the circlip 1. ! 09900-06108: Snap ring pliers • Remove the piston/secondary cup, primary cup and spring. 1 Circlip 2 Dust boot 3 Secondary cap 4 Piston 5 Primary cup 6 Spring MASTER CYLINDER INSPECTION MASTER CYLINDER...

  • Page 183: Master Cylinder Reassembly And Remounting

    CHASSIS 5-45 MASTER CYLINDER REASSEMBLY AND REMOUNTING Reassemble and remount the master cylinder in the reverse or- der of removal and disassembly. Pay attention to the following points: " * Wash the master cylinder components with new brake fluid before reassembly. * Do not wipe the brake fluid off after washing the com- ponents.
  • Page 184 5-46 CHASSIS • Tighten the brake hose union bolt to the specified torque. % Brake hose union bolt: 23 N . m (2.3 kgf-m) " Bleed air from the brake system after reassembling the & & & 2-16) & master cylinder. (&...

  • Page 185: Rear Brake

    CHASSIS 5-47 REAR BRAKE CONSTRUCTION 1 Brake caliper 2 Brake caliper piston 3 Piston seal N . m ITEM kgf-m 4 Dust seal 5 Inner shim 0.75 6 Brake pads 7 Outer shim 8 Spring 9 Brake pad mounting pin 0 Clip A O-ring B Brake pad cover...

  • Page 186: Brake Pad Replacement

    5-48 CHASSIS BRAKE PAD REPLACEMENT • Remove the brake pad cover. • Remove the clip 1. • Remove the brake pads along with the shims by removing the brake pad mounting pins 2 and springs 3. " * Do not operate the brake pedal during or after brake pad removal.

  • Page 187: Brake Caliper Removal And Disassembly

    CHASSIS 5-49 BRAKE CALIPER REMOVAL AND DISASSEMBLY • Remove the brake hose union bolt 1 and allow the brake fluid to drain into a suitable receptacle. " Never reuse the brake fluid left over from previous ser- vicing and which has been stored for long periods of time. Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces.

  • Page 188: Brake Caliper Inspection

    5-50 CHASSIS BRAKE CALIPER INSPECTION BRAKE CALIPER ............! 5-41 BRAKE CALIPER PISTONS ........! 5-41 BRAKE DISC ............... ! 5-42 " " " Brake disc thickness " " Service Limit (Rear): 4.5 mm Brake disc runout Service Limit (Rear): 0.3 mm BRAKE CALIPER REASSEMBLY AND REMOUNTING Reassemble and remount the brake caliper in the reverse order of...

  • Page 189: Master Cylinder Removal And Disassembly

    CHASSIS 5-51 MASTER CYLINDER REMOVAL AND DISASSEMBLY • Remove the seat. (!5-2) • Remove the document tray 1. • Remove the reservoir tank mounting bolt 2. • Remove the front footrest bracket mounting bolts 3. • Place a rag underneath the brake hose union bolt on the mas- ter cylinder to catch any spilt brake fluid.

  • Page 190: Master Cylinder Inspection

    5-52 CHASSIS • Remove the push rod, piston/primary cup and spring. MASTER CYLINDER INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or other dam- age. PISTON Inspect the piston surface for any scratches or other damage. RUBBER PARTS Inspect the primary/secondary cup and all of the rubber parts for damage.

  • Page 191: Clutch Master Cylinder

    CHASSIS 5-53 • Apply THREAD LOCK “ 1342’’ to the front footrest bracket mount- ing bolts 1 and tighten them to the specified torque. % Front footrest bracket mounting bolt: 35 N . m (3.5 kgf-m) ' 99000-32050: THREAD LOCK “ 1342’’ Bleed air from the brake system after reassembling the ! 2-16) master cylinder.

  • Page 192: Tire Removal

    5-54 CHASSIS TIRE AND WHEEL TIRE REMOVAL The most critical factor of a tubeless tire is the seal between the wheel rim and the tire bead. For this reason, it is recommended to use a tire changer that can satisfy this sealing requirement and can make the operation efficient as well as functional.

  • Page 193: Tire Installation

    CHASSIS 5-55 NOTE: When repairing a flat tire, follow the repair instructions and use only recommended repairing materials. VALVE INSPECTION Inspect the valve 1 after the tire is removed from the rim, and replace the valve with a new one if the seal rubber has any splits or scratches.
  • Page 194 5-56 CHASSIS • The tire is designed to have specified rotational direction. Never use oil, grease or gasoline on the tire bead in place of tire lubricant. • When installing the tire, the arrow 1 on the side wall should point the direction of wheel rotation.
  • Page 195 ELECTRICAL SYSTEM 6-1 ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ..............6- 2 LOCATION OF ELECTRICAL COMPONENTS ........6- 4 CHARGING SYSTEM ................. 6- 6 DESCRIPTION (GENERATOR WITH IC REGULATOR) ....6- 6 TROUBLESHOOTING ..............6- 7 INSPECTION ................... 6- 8 GENERATOR REMOVAL AND DISASSEMBLY ......

  • Page 196: Cautions In Servicing

    6-2 ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTORS • When disconnecting a connector, be sure to hold the termi- Click 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 197 ELECTRICAL SYSTEM 6-3 BATTERY • The MF battery used in this motorcycle does not require main- tenance (e.g., electrolyte level inspection, distilled water replen- ishing). • During normal charging, no hydrogen gas is produced. How- ever, if the battery is overcharged, hydrogen gas may be pro- duced.

  • Page 198: Location Of Electrical Components

    6-4 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS 1 Main fuse 2 Starter relay 3 Ignition coil 4 Front brake light switch 5 Handlebar switch (R) 6 Ignition switch 7 Ignitor 8 Rear brake light switch 9 Throttle position sensor 0 Signal generator A Oil pressure switch...
  • Page 199 ELECTRICAL SYSTEM 6-5 B Clutch lever position switch C Handlebar switch (L) D Fuel level gauge E Ignition coil F Battery G Horn H Starter motor I Generator J Neutral switch K Side-stand switch L Fuse box M Turn signal/side-stand relay...

  • Page 200: Charging System

    6-6 ELECTRICAL SYSTEM CHARGING SYSTEM DESCRIPTION (GENERATOR WITH IC REGULATOR) The generator features a solid-state regulator that is mounted inside the generator. All regulator components are enclosed into a solid mold, and this unit is attached to the brush holder frame. The regulator voltage setting cannot be adjusted.

  • Page 201: Troubleshooting

    ELECTRICAL SYSTEM 6-7 TROUBLESHOOTING Battery runs down quickly. Check accessories which use excessive Accessories • Remove accessories. are installed. amounts of electricity. No accessories Check the battery for current Current leaks. • Short circuit of the wire harness leaks. (! 6-8) •...

  • Page 202: Inspection

    6-8 ELECTRICAL SYSTEM INSPECTION BATTERY CURRENT LEAK INSPECTION • Turn the ignition switch to the “OFF” position. • Remove the seat and document tray 1. lead wire 2. • Disconnect the battery • Connect the multi circuit tester between the battery terminal and the battery lead wire as shown in the following illustra-...

  • Page 203: Generator Removal And Disassembly

    ELECTRICAL SYSTEM 6-9 GENERATOR REMOVAL AND DISASSEMBLY • Disconnect the battery - lead wire. • Remove the gearshift lever and engine sprocket cover. • Remove the two wire clamps. • Disconnect the starter motor lead wire 1. • Disconnect the generator lead wire 2 and coupler 3. •...
  • Page 204 6-10 ELECTRICAL SYSTEM • Remove the damper housing 1 using the bearing remover. # 09913-61510: Bearing remover • Remove the generator end cover. • Remove the brush holder 2 and IC regulator 3. • Remove the stator coil lead wire’s mounting screws. •...

  • Page 205: Generator Inspection

    ELECTRICAL SYSTEM 6-11 • Separate the generator housing 1 from the generator end hous- ing 2. • Remove the rotor 3 from the generator end housing 2 using a hand press 4 as shown. • Remove the bearing retainer 5. •...
  • Page 206 If any defects are found, replace the generator driven gear damp- ers as a set. NOTE: When installing the generator driven gear dampers, apply SUZUKI MOLY PASTE to the damper surface. ( 99000-25140: SUZUKI MOLY PASTE STATER COIL CONTINUITY CHECK Measure the continuity between the lead wires of the stator coil using a tester.
  • Page 207 ELECTRICAL SYSTEM 6-13 SLIP RINGS If the slip rings are dirty, polish them with #400 sandpaper and wipe them using a clean, dry cloth. Then, measure the slip ring O.D. using vernier calipers. If it is less than the service limit, replace the slip rings with new ones. # 09900-20102: Vernier calipers (200 mm) $ Slip ring O.D.

  • Page 208: Generator Reassembly And Remounting

    The removed oil seal should be replaced with a new one. • Apply grease to the lip of the oil seal. - 99000-25010: SUZUKI SUPER GREASE “A” • Apply a small quantity of THREAD LOCK “1342” to the bearing retainer screws and tighten them to the specified torque.
  • Page 209 NOTE: Apply Moly paste to the damper surface before installing. ( 99000-25140: SUZUKI MOLY PASTE • Tighten the generator housing nuts 1 to the specified torque. / Generator housing nut: 4.5 N . m (0.45 kgf-m) •...

  • Page 210: Generator Reassembly Information

    6-16 ELECTRICAL SYSTEM GENERATOR REASSEMBLY INFORMATION 1 Generator driven gear C Slip ring side bearing 2 Damper (4 pcs) D Bearing cover #1 3 Damper housing E Generator housing 4 Oil seal F Rectifier 5 O-ring G IC regulator N . m ITEM kgf-m 6 Spacer...

  • Page 211: Starter System And Side-Stand/Ignition Interlock System

    ELECTRICAL SYSTEM 6-17 STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM STARTER SYSTEM DESCRIPTION The starter system consists of the following components: the starter motor, starter relay, clutch lever position switch, turn signal/side-stand relay, side-stand switch, neutral switch, starter button, engine stop switch, igni- tion switch and battery.
  • Page 212 6-18 ELECTRICAL SYSTEM The circuit consists of the turn signal/side-stand relay, neutral indicator light and switches. The ignition coils will send voltage to the spark plugs dependant on what gear the transmission is in and whether the side- stand is either up or down. The neutral and side-stand switches work together in this system. The ignition coils work only in two situations as follows.

  • Page 213: Troubleshooting

    ELECTRICAL SYSTEM 6-19 TROUBLESHOOTING Starter motor will not run. The transmission is in neutral. Grasp the Check if the starter motor runs clutch lever. Turn on the ignition switch when its terminal is connected with the engine stop switch in the “RUN” Clicks to the battery terminal (Do...

  • Page 214: Starter Motor Removal And Disassembly

    6-20 ELECTRICAL SYSTEM STARTER MOTOR REMOVAL AND DISASSEMBLY • Remove the generator. (!6-9) • Disconnect the starter motor lead wire and remove the starter motor by removing the mounting bolts. • Disassemble the starter motor, as shown in the illustration. / 11 N .

  • Page 215: Starter Motor Reassembly

    Replace the O-rings with new ones to prevent oil leak- age and moisture. • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal. - 99000-25010: SUZUKI SUPER GREASE “A” • Fit the washer to the housing end correctly as shown.

  • Page 216: Starter Relay Inspection

    6-22 ELECTRICAL SYSTEM • Apply a small quantity of SUZUKI MOLY PASTE to the arma- ture shaft. ( 99000-25140: SUZUKI MOLY PASTE • Align the match marks on the starter motor case with the match marks on the housing end.

  • Page 217: Side-Stand/Ignition Interlock System Part Inspection

    ELECTRICAL SYSTEM 6-23 Apply 12 volts to terminals A and B, and check the continuity between the positive and negative terminals. If the starter relay clicks and continuity is found, the relay is OK. ! 09900-25008: Multi circuit tester set "...
  • Page 218 6-24 ELECTRICAL SYSTEM SIDE-STAND SWITCH The side-stand switch coupler is located under the fuel tank. • Remove the seat. (% 5-2) • Remove the fuel tank. (% 4-3) • Disconnect the side-stand switch lead wire coupler and mea- sure the voltage between Green and Black/White lead wires. ! 09900-25008: Multi circuit tester set ' Tester knob indication: Diode test (( NOTE:...
  • Page 219 ELECTRICAL SYSTEM 6-25 DIODE INSPECTION Using multi circuit tester, measure the voltage between the termi- nals in the following table. Unit: V ! 09900-25008:Multi circuit tester set ' Tester knob indication: Diode test (( NOTE: If the tester read under 1.4 V, replace the battery of multi circuit tester when do not connecting the tester probes.

  • Page 220: Ignition System (Digital Ignitor)

    6-26 ELECTRICAL SYSTEM IGNITION SYSTEM (DIGITAL IGNITOR) DESCRIPTION The fully transistorized ignition system consists of the following components: a signal generator (which is made up of the signal generator rotor and pickup coil), ignitor (including a 8-bit microcomputer and a 10 MHz ceramic vibrator), throttle position sensor, two ignition coils and four spark plugs.

  • Page 221: Troubleshooting

    ELECTRICAL SYSTEM 6-27 TROUBLESHOOTING * Check that the transmission is in neutral and the No spark or poor spark engine stop switch is in the “RUN” position. Grasp the clutch lever. Check that the main fuse is not blown and the battery is fully-charged before diagnosing. Check the ignition system couplers for Looseness •...

  • Page 222: Inspection

    6-28 ELECTRICAL SYSTEM INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the seat. (%5-2) • Remove the fuel tank. (% 4-3) • Disconnect the fuel pump lead wire coupler 1. • Remove all of the spark plug caps. • Connect four new spark plugs to each spark plug cap and ground them to the cylinder head.
  • Page 223 ELECTRICAL SYSTEM 6-29 Measure ignition coil (for #2 and #3 cylinders) primary peak volt- age in the same manner of the ignition coil (for #1 and #4 cylin- ders) measuring procedure. Ignition coil (For #2 and #3 cylinders): B/Y terminal – Ground Probe) Probe) B/Y: Black with Yellow tracer...
  • Page 224 6-30 ELECTRICAL SYSTEM SIGNAL GENERATOR PEAK VOLTAGE • Remove the seat. (% 5-2) • Remove the right frame cover. (% 5-3) NOTE: Be sure that all of the couplers are connected properly and the battery is fully-charged. • Disconnect the ignitor coupler 1 from the ignitor. •...
  • Page 225 ELECTRICAL SYSTEM 6-31 • Remove the seat. (% 5-2) • Remove the fuel tank. (%4-3) • Disconnect the signal generator coupler and connect the multi circuit tester with the peak volt adaptor. Blue ( Probe) – Yellow ( Probe) • Measure the signal generator peak voltage in the same man- ner as on the ignitor coupler.

  • Page 226: Combination Meter

    6-32 ELECTRICAL SYSTEM COMBINATION METER REMOVAL AND DISASSEMBLY • Remove the combination meter. (%5-16) • Disassemble the combination meter as follows. INSPECTION Measure the continuity between the lead wires in the diagram on the next page using a tester. If there is no continuity, replace the respective parts. NOTE: When performing this test, it is not necessary to remove the com- bination meter.
  • Page 227 ELECTRICAL SYSTEM 6-33 FUEL METER SPEEDMETER TACHOMETER TURN SIGNAL (R) TURN SIGNAL (L) HIGH BEAM NEUTRAL Y: HIGH BEAM G/Y: OIL O/G:IGNITION, NEUTRAL, OIL FUEL, FUEL METER B: TURN SIGNAL (L) B/R: TACHOMETER SIGNAL Lg: TURN SIGNAL (R) Y/B: FUEL METER W: FUEL METER B/W: TURN SIGNAL (R) (L), Gr: ILLUMINATION...
  • Page 228 6-34 ELECTRICAL SYSTEM FUEL METER INSPECTION To test the fuel meter, perform the following tests. Test 1 This test will determine if the fuel meter is operating. Harness To fuel level gauge • Remove the seat and fuel tank. (%5-2 and 4-3) •...
  • Page 229 ELECTRICAL SYSTEM 6-35 Float position Resistance 4 – 10 Ω F (Full) Approx. 51 Ω 90 – 100 Ω E (Empty) A 174.5 mm B 88.6 mm C 23.0 mm OIL PRESSURE INDICATOR INSPECTION • Remove the signal generator cover. (%3-11) •...

  • Page 230: Lamps

    6-36 ELECTRICAL SYSTEM LAMPS HEADLIGHT Headlight bulb: 12V 60/55W Position light bulb: 12V 5W NOTE: Adjust the headlight, both vertical and horizontal, after reassembling. BULB REPLACEMENT • Remove the headlight. (%5-16) • Disconnect the socket 1 and remove the rubber cap 2. •...

  • Page 231: Brake Light/Taillight

    ELECTRICAL SYSTEM 6-37 BRAKE LIGHT/TAILLIGHT Brake light/Taillight bulb: 12V 21/5W & 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. TURN SIGNAL LIGHTS Turn signal light bulb: 12V 21W &...

  • Page 232: Relays

    6-38 ELECTRICAL SYSTEM RELAYS STARTER RELAY The starter relay is located behind the right frame cover. (% 6-22) TURN SIGNAL/SIDE-STAND RELAY The turn signal relay is corporated with the side-stand relay and diode to form the one component part which is called the turn signal/side-stand relay.

  • Page 233: Switches

    ELECTRICAL SYSTEM 6-39 SWITCHES Measure each switch for continuity using a tester. If any abnormality is found, replace the respective switch assemblies with new ones. IGNITION SWITCH HORN BUTTON FRONT BRAKE LIGHT SWITCH LIGHTING SWITCH REAR BRAKE LIGHT SWITCH DIMMER SWITCH CLUTCH LEVER POSITION SWITCH TURN SIGNAL SWITCH OIL PRESSURE SWITCH...

  • Page 234: Battery

    6-40 ELECTRICAL SYSTEM BATTERY Filter Stopper Upper cover SPECIFICATIONS breather Type designation YTX12-BS Terminal Cathode Safety valve plates Capacity 12V 36 kC (10 Ah)/10HR Separator (fiberglass plate) Anode plates INITIAL CHARGING FILLING ELECTROLYTE • Remove the aluminum tape 1 which seals the battery filter holes 2.

  • Page 235: Servicing

    ELECTRICAL SYSTEM 6-41 NOTE: If air bubbles do not rise from any one of the filler ports, tap the bottom of the electrolyte container two or three times. Never remove the electrolyte container from the battery while there is still electrolyte in the container. •...

  • Page 236: Recharging Operation

    6-42 ELECTRICAL SYSTEM RECHARGING OPERATION • Measure the battery voltage using a tester. If the voltage read- ing is less than 12.0 V (DC), recharge the battery with a battery charger. & When recharging the battery, remove the battery from the motorcycle.
  • Page 237 SERVICING INFORMATION 7-1 SERVICING INFORMATION CONTENTS TROUBLESHOOTING ..............7- 2 ENGINE ..................7- 2 CARBURETOR ................7- 5 CHASSIS..................7- 6 BRAKES ..................7- 7 ELECTRICAL ................7- 8 BATTERY ..................7- 9 WIRING DIAGRAM ................7-10 WIRE HARNESS, CABLE AND HOSE ROUTING ......7-11 WIRE HARNESS ROUTING ............

  • Page 238: Troubleshooting

    7-2 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. Rebore or replace. 2. Worn piston ring. Replace. 3. Worn valve guide or improper valve seating. Reoair or replace.
  • Page 239 SERVICING INFORMATION 7-3 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 or rocker arm shaft. Replace. 4. Worn or burnt camshaft journal. Replace.
  • Page 240 7-4 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Transmission jumps 1. Worn gear. Replace. out of gear. 2. Worn or distorted gearshift fork. Replace. 3. Weakened gearshift stopper spring. Replace. 4. Worn gearshift pawl. Replace gearshift fork. Engine idles poorly. 1.

  • Page 241: Carburetor

    SERVICING INFORMATION 7-5 Complaint Symptom and possible causes Remedy Engine overheats. 1. Carbon build-up on piston crown. Clean. 2. Insufficient amount of engine oil. Check level and add. 3. Defective oil pump. Replace. 4. Clogged oil circuit. Clean. 5. Float chamber fuel level too low. Adjust float height.

  • Page 242: Chassis

    7-6 SERVICING INFORMATION CHASSIS Complaint Symptom and possible causes Remedy Steering is heavy. 1. Overtightened steering stem nut. Adjust. 2. Broken bearing/race in steering stem. Replace. 3. Distorted steering stem. Replace. 4. Low tire pressure. Regulate. Handlebar wobbles. 1. Loss of balance between right and left front forks. Adjust or replace.

  • Page 243: Brakes

    SERVICING INFORMATION 7-7 BRAKES Complaint Symptom and possible causes Remedy Brake power 1. Leakage of brake fluid. Repair or replace. insufficient. 2. Worn brake pad. Replace. 3. Oil on brake pad surface. Clean brake disc and brake pads. 4. Worn brake disc. Replace.

  • Page 244: Electrical

    7-8 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 signal generator. Replace. 4. Defective ignitor. Replace. Spark plug is wet or 1. Excessively rich air/fuel mixture. Adjust carburetor.

  • Page 245: Battery

    SERVICING INFORMATION 7-9 BATTERY (MF BATTERY) Complaint Symptom and possible causes Remedy Sulfation or spots on 1. Cracked battery case. Replace battery. surface of cell plates. 2. Battery has been left in a run-down condition for Replace battery. a long time. Battery runs down 1.

  • Page 246: Wiring Diagram

    7-10 SERVICING INFORMATION WIRING DIAGRAM...

  • Page 247: Wire Harness, Cable And Hose Routing

    SERVICING INFORMATION 7-11 WIRE HARNESS, CABLE AND HOSE ROUTING WIRE HARNESS ROUTING...
  • Page 248 7-12 SERVICING INFORMATION...
  • Page 249 SERVICING INFORMATION 7-13...

  • Page 250: Cable Routing

    7-14 SERVICING INFORMATION CABLE ROUTING Fasten the throttle cables and starter cable Wiring harness Throttle cable No.2 to the frame. Throttle cable No.1 Plastic clamp Clutch hose The starter cable must be passed over the throttle cables Starter cable and clutch hose. The starter cable must be passed in front of the clutch hose.

  • Page 251: Fuel Hose Routing

    SERVICING INFORMATION 7-15 FUEL HOSE ROUTING Backward Fuel pump Clamp Fuel valve Topward Downward...

  • Page 252: Front Brake Hose Routing

    7-16 SERVICING INFORMATION FRONT BRAKE HOSE ROUTING Master cylinder 30° Brake hose No.2 (RH) 21° Throttle cables 21° 14° The throttle cables must be passed in front of the Brake hose No.2 (LH) brake hose. Front 14° 5° 49° Clamp the brake hose firmly. 21°...

  • Page 253: Rear Brake Hose Routing

    SERVICING INFORMATION 7-17 REAR BRAKE HOSE ROUTING Clamp Clamp 10 – 11 mm Brake After touching the hose White mark brake hose union to the stopper, tighten the Brake hose union bolt to the speci- fied torque. 25° Hose guide Stopper Master cylinder Brake hose...

  • Page 254: Clutch Hose Routing

    7-18 SERVICING INFORMATION CLUTCH HOSE ROUTING Clutch hose Starter cable Clamp Starter cable Clamp Pass through the clutch hose out- side of the wiring harness and fas- ten the clutch hose along with the wiring harness by the clamps. Wiring harness Air cleaner Wire harness guide...

  • Page 255: Brake Pedal

    SERVICING INFORMATION 7-19 BRAKE PEDAL Front Front Front Align the punch mark on the shaft 40–50 mm with the slot on the brake pedal.

  • Page 256: Side-Stand Spring

    7-20 SERVICING INFORMATION SIDE-STAND SPRING Side-stand Spring #1 Spring #2 CENTER STAND SPRING Unit: mm Outer spring Inner spring...

  • Page 257: Fuel Level Gauge Wire Routing/Fuel Tank Protection Sheet

    SERVICING INFORMATION 7-21 FUEL LEVEL GAUGE WIRE ROUTING/FUEL TANK PROTECTION SHEET Fuel level gauge Fuel level gauge lead wire pro- tection sheet 40 mm Fuel tank 60 mm protection sheet 40 mm Clamp 50 mm 40 mm Fuel valve Clamp...

  • Page 258: Fuel Tank Water Drain Hose/Fuel Tank Air Breather Hose Routing

    7-22 SERVICING INFORMATION FUEL TANK WATER DRAIN HOSE/FUEL TANK AIR BREATHER HOSE ROUTING...

  • Page 259: Fuel Tank Under Cover

    SERVICING INFORMATION 7-23 FUEL TANK UNDER COVER Clamp Fuel tank under cover Clamp Frame center Frame Fuel tank under cover SPEEDOMETER CABLE ROUTING Speedometer cable Clamp Horn Pass through the speedometer cable behind of the brake hose. Cable guide Cable guide...

  • Page 260: Engine Mounting Bolt Installation

    7-24 SERVICING INFORMATION ENGINE MOUNTING BOLT INSTALLATION Washer Washer (Rear top) Spacer 27 mm #85 N . m (8.5 kgf-m) Bushing Bushing (Front top) #55 N . m (5.5 kgf-m) #5 N . m (5.5 kgf-m) Bushing (Center bottom) #55 N . m (5.5 kgf-m) Bushing #55 N .

  • Page 261: Seat Tail Cover Installation

    SERVICING INFORMATION 7-25 SEAT TAIL COVER INSTALLATION...

  • Page 262: Special Tools

    7-26 SERVICING INFORMATION 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 09900-20205 09900-20204 09900-20508 09900-20202 Micrometer 09900-20102 Micrometer Micrometer Cylinder gauge set (1/1000 mm, Vernier calipers (1/100 mm, (1/100 mm, (1/100 mm,...
  • Page 263 SERVICING INFORMATION 7-27 09914-25811 09913-60910 09913-61510 09914-24510 “T” type hexagon 09915-40610 Bearing remover Bearing remover T-handle wrench (6 mm) Oil filter wrench 09915-74510 09915-64510 Oil pressure gauge Compression gauge 09915-77330 09915-74540 Meter (for high Oil pressure gauge 09916-10911 09916-14510 09915-63210 pressure) adaptor Valve lapper set...
  • Page 264 7-28 SERVICING INFORMATION 09930-10121 09924-84510 09930-11920 09930-11940 09930-14530 Spark plug socket Bearing installer set Torx bit Bit holder Universal joint wrench set 09940-14911 09930-30102 09930-30720 Steering stem nut 09940-34531 09940-34520 Sliding shaft Rotor remover wrench Attachment “A” “T” handle 09941-34513 09941-54911 09941-74911 09940-52861...

  • Page 265: Tightening Torque

    SERVICING INFORMATION 7-29 TIGHTENING TORQUE ENGINE N . m kgf . m ITEM Cylinder head cover bolt (10 pcs) Cylinder head cover plug Cylinder head cover union bolt Cylinder head nut [M: 10] Cylinder head bolt [M: 6] Cylinder head plug Cylinder base nut Cylinder stud bolt Valve clearance adjuster locknut...

  • Page 266: Chassis

    7-30 SERVICING INFORMATION N . m kgf . m ITEM Starter motor terminal nut Signal generator stator mounting screw Starter relay terminal nut Spark plug Cam chain guide mounting bolt CHASSIS N . m kgf . m ITEM Steering stem head nut Front fork upper clamp bolt Front fork lower clamp bolt Front fork cap bolt...

  • Page 267: Tightening Torque Chart

    SERVICING INFORMATION 7-31 TIGHTENING TORQUE CHART For other bolts and nuts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt A A A A A (mm) N . m kgf .

  • Page 268: Service Data

    7-32 SERVICING INFORMATION SERVICE DATA VALVE + GUIDE Unit: mm ITEM STANDARD LIMIT Valve diam. 28.5 ——— ——— Valve clearance (when cold) ——— 0.10 – 0.15 ——— 0.18 – 0.23 ——— Valve guide to valve stem 0.020 – 0.047 clearance ———...
  • Page 269 SERVICING INFORMATION 7-33 ITEM STANDARD LIMIT Piston ring free end gap Approx. 10.0 Approx. 12.0 Piston ring end gap 0.20 – 0.35 0.35 – 0.50 Piston ring to groove clearance ——— 0.180 ——— 0.150 Piston ring groove width 1.01 – 1.03 ———...
  • Page 270 7-34 SERVICING INFORMATION TRANSMISSION + DRIVE CHAIN Unit: mm Except ratio ITEM STANDARD LIMIT 1.565 (72/46) ——— Primary reduction ratio 2.933 (44/15) ——— Final reduction ratio 2.384 (31/13) ——— Gear ratios 1.631 (31/19) ——— 1.250 (25/20) ——— 1.045 (23/22) ——— 0.913 (21/23) ———...
  • Page 271 SERVICING INFORMATION 7-35 ITEM SPECIFICATION NOTE Ignition coil primary peak voltage More than 140 V Slip ring O.D. Limit: 14.0 mm Generator Brush length Limit: 4.5 mm N.D. Approx. 364 W at 5 000 r/min. Generator Max. output Regulated voltage Above 13.6 –...
  • Page 272 7-36 SERVICING INFORMATION ITEM STANDARD LIMIT Wheel rim size ——— Front J17 × MT3.50 ——— Rear J17 × MT5.50 SUSPENSION Unit: mm ITEM STANDARD NOTE LIMIT Front fork stroke ——— Front fork spring free length 392.4 Front fork oil level ———...
  • Page 273 SERVICING INFORMATION 7-37...

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