Suzuki UG110 2021 Service Manual
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Suzuki UG110 2021 Service Manual

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Summary of Contents for Suzuki UG110 2021

  • Page 1 UG110 9 9 5 0 0 - 1 1 1 8 0 - 0 1 E...
  • Page 2 FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI UG110 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 fa-...
  • 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 al- low you to find the first page of the section easily.
  • Page 4 Data beside it indicates specified Apply or use brake fluid. torque. Apply oil. Use engine oil unless Measure in voltage range. otherwise specified. Apply SUZUKI SUPER GREASE “A”. Measure in resistance range. 99000-25010 Apply SUZUKI SILICONE GREASE. Measure in current range.

  • Page 5: Table Of Contents

    GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE ..............1- 2 GENERAL PRECAUTIONS ..............1- 2 SUZUKI UG110Y (2000-MODEL) ............1- 4 SERIAL NUMBER LOCATION ............... 1- 4 FUEL AND OIL RECOMMENDATIONS ..........1- 4 FUEL ....................1- 4 ENGINE OIL ..................1- 5 FINAL GEAR OIL ................

  • 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.

  • Page 8: Suzuki Ug110Y (2000-Model)

    1-4 GENERAL INFORMATION SUZUKI UG110Y (2000-MODEL) RIGHT SIDE LEFT SIDE * Difference between photographs and the actual motorcycles 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 frame.

  • Page 9: Engine Oil

    * Never reuse brake fluid left over from a last servicing or which has been stored for a long period of time. FRONT FORK OIL Use SUZUKI FORK OIL G10 (#10) or an equivalent fork oil. BREAK-IN PROCEDURES During manufacturing only the best possible materials are used and all machined parts are finished to a very high standard.

  • Page 10: Information Labels

    1-6 GENERAL INFORMATION INFORMATION LABELS Warning safety label Engine starting label Warning screen label Tire pressure label Fuel caution plate (For E-02) Loading capacity label Anti-tampering label ID plate 10 mm 10 mm...

  • Page 11: Specifications

    Corrected compression ratio ........6.8 : 1 Carburetor ..............MIKUNI VM18SH, single Air cleaner ..............Polyurethane foam element Starter system ............Electric and kick Lubrication system ..........SUZUKI “CCI” TRANSMISSION Clutch ............... Dry shoe, automatic, centrifugal type Gearshifting ............. Automatic, variable ratio Gear ratios ...............
  • Page 12 1-8 GENERAL INFORMATION CHASSIS Front suspension ............. Telescopic, coil spring, oil damped Rear suspension ............. Swingarm type, coil spring, oil damped Front fork stroke ............80 mm Rear wheel travel ............. 80 mm Steering angle ............45° (right and left) Caster ..............

  • Page 13: Country And Area Codes

    GENERAL INFORMATION 1-9 COUNTRY AND AREA CODES The following codes stand for the applicable country(-ies) and area(-s). CODE COUNTRY OR AREA E-02 E-04 France E-19...
  • 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 CYLINDER HEAD NUTS AND EXHAUST PIPE NUTS ....2- 4 CYLINDER HEAD AND CYLINDER..........

  • 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. Maintenance intervals are expressed in terms of kilometers and months, and are dependant on whichever comes first. 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. Rear brake lever holder Center stand pivot and spring hook Front brake lever holder Speedometer cable NOTE: * Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.

  • 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 mentioned in the Periodic Maintenance chart. CYLINDER HEAD NUTS AND EXHAUST PIPE NUTS Tighten initially at 1 000 km (1 month) and every 6 000 km (6 months) thereafter.

  • Page 18: Spark Plug

    PERIODIC MAINTENANCE 2-5 SPARK PLUG Replace every 6 000 km (6 months). • Remove the left and right side leg shields. (75-4) • Remove the lower leg shield. (75-5) • Disconnect the spark plug cap and remove the spark plug. DENSO Remarks If the standard spark plug is apt...

  • Page 19: Fuel Hose

    2-6 PERIODIC MAINTENANCE FUEL HOSE Inspect every 6 000 km (6 months). Replace every four years. • Remove the left and right side leg shields. (75-4) • Remove the lower leg shield. (75-5) Inspect the fuel hose for damage. If any damages are found, re- place the fuel hose with a new one.

  • Page 20: Carburetor

    PERIODIC MAINTENANCE 2-7 • Properly install the air cleaner element into the air cleaner case. * When installing the air cleaner element, have the large mesh side of the element face out. * Be sure to position the air cleaner element snugly and correctly, so that no incoming air will by-pass it.

  • Page 21: Oil Pump

    2-8 PERIODIC MAINTENANCE • Start the engine, turn the throttle stop screw 2 and set the engine idle speed as follows. 4 Engine idle speed: 1 800 ± 200 r/min OIL PUMP Inspect initially at 1 000 km (1 month) and every 6 000 km (6 months) thereafter.

  • Page 22: Brakes

    PERIODIC MAINTENANCE 2-9 BRAKES BRAKES: 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 hose every 4 years. Replace fluid every 2 years. FRONT BRAKE FLUID LEVEL •...
  • Page 23 2-10 PERIODIC MAINTENANCE AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylin- der, thus interferes with the full braking performance of the brake caliper.

  • Page 24: Tires

    PERIODIC MAINTENANCE 2-11 REAR BRAKE LEVER PLAY • Turn the adjusting nut 1 until the rear brake lever play is within specification. 4 Rear brake lever play A: 15 – 25 mm REAR BRAKE SHOE WEAR This motorcycle is equipped with the brake lining wear limit indi- cator 1 on the brake cam lever.

  • Page 25: Steering

    2-12 PERIODIC MAINTENANCE TIRE PRESSURE If the tire pressure is too high or too low, steering will be ad- versely affected and tire wear increased. Therefore, maintain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows. COLD INFLATION SOLO RIDING DUAL RIDING...

  • Page 26: Chassis Bolts And Nuts

    PERIODIC MAINTENANCE 2-13 CHASSIS BOLTS AND NUTS 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 2-14 for the locations of the following nuts and bolts on the motorcycle.) kgf .
  • Page 27 2-14 PERIODIC MAINTENANCE...

  • Page 28: Automatic Clutch Inspection

    PERIODIC MAINTENANCE 2-15 AUTOMATIC CLUTCH INSPECTION The UG110 is equipped with a centrifugal type automatic clutch and a variable ratio belt drive transmission. To insure proper performance and longevity of the clutch as- sembly it is essential that the clutch assembly engages smoothly and gradually.

  • Page 29: Clutch Lock-Up

    2-16 PERIODIC MAINTENANCE CLUTCH LOCK-UP Perform this inspection to determine if the clutch is engaging fully and not slipping. • Connect the multi circuit tester to the high-tension cord. • Start the engine. • Apply the rear brake as firm as possible. •...
  • Page 30 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- 7 ENGINE COMPONENTS INSPECTION AND SERVICE ......3-15 CYLINDER HEAD DISTORTION ............3-15 CYLINDER ..................3-15 PISTON .....................3-16 CRANKSHAFT AND CONROD ............3-18...

  • Page 31: 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 the page listed in each section for removal and reinstallation instructions. ENGINE LEFT SIDE PARTS REMOVAL INSTALLATION...

  • Page 32: Engine Removal And Installation

    ENGINE ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, wash the engine with a steam cleaner. • Remove the front leg shield cover. (75-4) • Remove the battery rubber band 1. • Disconnect the - battery lead wire 2. •...
  • Page 33 ENGINE • Disconnect the fuel hose 1, fuel valve vacuum hose 2 and carburetor heater lead wire 3 from the carburetor. • Remove the carburetor cap 4 with the throttle cable and throttle valve. • Remove the oil pump cover 5. •...
  • Page 34 ENGINE • Remove the air cleaner case. (74-12) • Remove the rear shock absorber lower mounting bolt. • Remove the left and right pillion rider footrests, 1 and 2. • Remove the engine mounting nut 3. • Remove the engine mounting shaft 4 and engine.

  • Page 35: Engine Installation

    ENGINE ENGINE INSTALLATION Install the engine in the reverse order of removal. • Install the crankcase bracket 1 to the frame. • Install the engine and engine mounting shaft. • Install the rear shock absorber lower mounting bolt. • Tighten the crankcase bracket nut 2 to the specified torque. "...

  • Page 36: Engine Disassembly

    ENGINE ENGINE DISASSEMBLY • Remove the exhaust pipe nuts. • Remove the exhaust pipe/muffler assembly. • Disconnect the spark plug cap 1. • Remove the spark plug 2 using the special tool. 2 09930-10120: Spark plug socket wrench set • Remove the ignition coil 3. •...
  • Page 37 ENGINE • Remove the oil pump gear 1. • Remove the oil hose guide 2. • Disconnect the oil hoses. • Remove the intake pipe by removing the two bolts and two twist- off bolts 3. • Remove the reed valve 4 and gaskets 5.
  • Page 38 ENGINE • Disconnect the fuel pump vacuum hose 1. • Remove the clutch cover 2. • Remove the cooling fan cover 3. • Remove the cylinder cover 4. • Remove the cooling fan 5 while holding the kick starter with a 32-mm offset wrench.
  • Page 39 3-10 ENGINE • Remove the generator rotor nut using the special tool. 2 09930-40113: Rotor holder • Remove the generator rotor using the special tool. 2 09920-13120: Crankcase separating tool • Remove the key 1. • Remove the stator coil 2 and pickup coil 3. •...
  • Page 40 ENGINE 3-11 • Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into the crankcase. Then, remove the piston pin circlip with long-nose pliers. • Remove the piston pin, piston and piston pin bearing. •...
  • Page 41 3-12 ENGINE • Remove the spacer 1 and movable drive face 2. • Remove the clutch housing nut using the special tool. 2 09930-40113: Rotor holder • Remove the clutch housing 3. • Remove the clutch shoe assembly 3 and drive belt 4. •...
  • Page 42 ENGINE 3-13 • Remove the rear wheel. • Remove the brake shoes 1. • Remove the brake cam lever 2, return spring 3, brake lining wear limit indicator 4, and brake camshaft 5. • Remove the spacer 6. • Remove the gear box cover. •...
  • Page 43 3-14 ENGINE • Remove the center stand springs, 1 and 2. • Remove the cotter pin 3 and center stand shaft 4. • Remove the center stand 5. • Remove the crankcase screws. • Separate the left and right crankcases using the special tool. 2 09920-13120: Crankcase separating tool •...

  • Page 44: Engine Components Inspection And Service

    ENGINE 3-15 ENGINE COMPONENTS INSPECTION AND SERVICE CYLINDER HEAD DISTORTION Decarbonize the combustion chamber. Check the gasket surface of the cylinder head for distortion. Use a straightedge and thickness gauge. Take clearance readings at several places. If readings exceed the service limit, replace or flatten the cylinder head.

  • Page 45: Piston

    3-16 ENGINE PISTON PISTON DIAMETER Measure the piston diameter using a micrometer at 20 mm from the skirt end. If the piston diameter is less than the service limit, replace the piston with a new one. 2 09900-20203: Micrometer (50 – 75 mm) 20 mm 4 Piston diameter Service Limit: 52.380 mm...
  • Page 46 ENGINE 3-17 PISTON PIN AND PIN BORE Measure the piston pin bore diameter using the dial calipers. If the diameter exceeds the service limit, replace the piston with a new one. 2 09900-20605: Dial calipers 4 Piston pin bore I.D. Service Limit: 14.030 mm Measure the piston pin outside diameter at three positions using the micrometer.

  • Page 47: Crankshaft And Conrod

    3-18 ENGINE CRANKSHAFT AND CONROD 1 Oil seal (R) 2 Bearing (R) 3 Crankshaft (R) 4 Crank pin 5 Washer 6 Crank pin bearing 7 Conrod 8 Crankshaft (L) 9 Spacer 0 Piston pin bearing A Shim B Bearing (L) C Oil seal (L) D Oil seal CRANKSHAFT RUNOUT...

  • Page 48: Reed Valve

    ENGINE 3-19 CONROD DEFLECTION 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 big end of the conrod.

  • Page 49: Clutch Shoe/Movable Driven Face

    3-20 ENGINE CLUTCH SHOE/MOVABLE DRIVEN FACE 1 Fixed driven face 2 Needle roller bearing 3 Circlip 4 Movable driven face 5 Bearing 6 Oil seal 7 Pin 8 Oil seal " 9 O-ring 0 Movable driven face spring guide A Spring N .
  • Page 50 ENGINE 3-21 • Remove the clutch shoe nut 1, clutch shoe assembly 2, and spring 3. • Use a thin-blade screwdriver to pry up the movable driven face spring guide. • Remove the pins 4, movable driven face 5, and fixed driven face 6.
  • Page 51 3-22 ENGINE • Remove the bearing using the special tool. 2 09941-50111: Bearing remover Replace the removed bearing with a new one. • Remove the oil seals 1 and O-rings 2. Replace the removed oil seals and O-rings with new ones. CLUTCH SHOES Inspect the clutch shoes for chips, cracks, uneven wear and burn- ing.
  • Page 52 ENGINE 3-23 DRIVEN FACE SPRING Measure the free length of the driven face spring. If the length is shorter than the service limit, replace the spring with a new one. 4 Driven face spring length Service Limit: 104.5 mm DRIVEN FACE PINS AND OIL SEALS Rotate the driven faces and make sure they turn smoothly.
  • Page 53 • Install the pins 1 at three places on the drive face hub. • Apply much SUZUKI SUPER GREASE “A” to the cam where the pins are placed and surface of the driven face as shown.

  • Page 54: Movable Drive

    ENGINE 3-25 MOVABLE DRIVE 1 Movable drive face 2 Roller 3 Movable drive plate 4 Damper 5 Movable drive face cover 6 Spacer 7 Drive belt 8 Fixed drive face 9 Starter gear 0 Fixed drive fan A Spacer B Kick starter C Concave washer D Kick starter nut DRIVE FACE...
  • Page 55 3-26 ENGINE DRIVE BELT Remove the drive belt and check for cracks, wear and separation and measure the drive belt width with vernier calipers. If any dam- ages are found or if the width of the drive belt is less than the service limit, replace the drive belt with a new one.

  • Page 56: Kick Starter

    ENGINE 3-27 KICK STARTER 1 Kick starter shaft 2 Kick starter spring 3 Spacer 4 Circlip 5 Kick starter lever 6 Kick starter drive gear DISASSEMBLY • Remove the oil separator 1. • Remove the kick starter lever. • Remove the circlip from the kick starter shaft.
  • Page 57 • Remove the cover 4. • Remove the element 5. REASSEMBLY • Apply SUZUKI SUPER GREASE “A” onto the inside of the kick starter shaft spacer. $ 99000-25010: SUZUKI SUPER GREASE “A” • Apply a light coat of SUZUKI SUPER GREASE “A” onto the end of the kick starter shaft.

  • Page 58: Gear Box Cover

    ENGINE 3-29 • Apply SUZUKI SUPER GREASE “A” onto the shaft and gear of the kick starter drive gear. $ 99000-25010: SUZUKI SUPER GREASE “A” • Install the kick starter drive gear 1. • Align the projection A with the groove of the clutch cover.

  • Page 59: Bearings

    3-30 ENGINE BEARINGS Wash the bearing with a cleaning solvent and lubricate it with motor oil before inspection. Rotate the inner race and check to see that it turns smoothly. If it does not turn quietly and smoothly, or if there are signs of any abnormalities, the bearing is defective and must be replaced with a new one.
  • Page 60 ENGINE 3-31 RIGHT DRIVESHAFT BEARING AND IDLE SHAFT BEARING • Remove the right driveshaft bearing 1 and idle shaft bearing 2 using the special tool. 2 09921-20220: Bearing remover set ( φ φ φ φ φ 12 mm) Replace the removed bearings with new ones. •...
  • Page 61 3-32 ENGINE • Install the left rear axle shaft bearing using the special tool. 2 09913-70210: Bearing installer set ( φ φ φ φ φ 40 mm) LEFT IDLE SHAFT BEARING • Remove the left idle shaft bearing using the special tool. 2 09921-20220: Bearing remover set ( φ...

  • Page 62: Oil Seals

    • Install the oil seals into the crankcases and gear box cover, as shown below. Replace the removed oil seals with new ones. • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seals. $ 99000-25010: SUZUKI SUPER GREASE “A” REAR AXLE SHAFT OIL SEAL •...
  • Page 63 3-34 ENGINE • Install the rear axle shaft oil seal into the gear box cover, slowly, using the special tool. 2 09913-70210: Bearing installer set ( φ φ φ φ φ 40 mm) DRIVE SHAFT OIL SEAL • Remove the drive shaft oil seal 2 from the left crankcase using the special tool.
  • Page 64 ENGINE 3-35 • Install the right crankshaft oil seal into the right crankcase, slowly, using the special tool. 2 09913-70210: Bearing installer set ( φ φ φ φ φ 25 mm) NOTE: * Align the oil seal with the edge A of the crankcase, as shown. * Install the left crankcase oil seal using the special tool after installing the crankshaft to the crankcase.

  • Page 65: Engine Mounting Bushings

    3-36 ENGINE ENGINE MOUNTING BUSHINGS Inspect engine mounting bushings 1 and rear shock absorber bushing 2 for damage. If any damage is found, replace the bushing with a new one. • Press out the each bushing in a vise using two steel tubes of the appropriate size, as shown.

  • Page 66: Engine Reassembly

    ENGINE 3-37 ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassembly. The following steps require special attention or precautionary mea- sures should be taken. NOTE: Apply engine oil to each running and sliding part before reas- sembling. CRANKSHAFT •...

  • Page 67: Crankcase

    ENGINE CRANKCASE • Install the shim 1 and two dowel pins 2. • Apply SUZUKI BOND “1215” to the mating surface of the right crankcase. ( 99000-31110: SUZUKI BOND “1215” • After installing the left crankcase onto the right crankcase, pull the left crankshaft with the special tools to smooth rotate crank- shaft.

  • Page 68: Center Stand

    ENGINE 3-39 • Apply SUZUKI SUPER GREASE “A” (approx. 10g) to the oil pump drive gear (on the crankshaft surface side). $ 99000-25010: SUZUKI SUPER GREASE “A” • Install the new left crankcase oil seal 1 using the special tool.

  • Page 69: Rear Axle Shaft And Transmission

    3-40 ENGINE REAR AXLE SHAFT AND TRANSMISSION 1 Gear box cover 2 O-ring 3 Rear axle shaft 4 Final driven gear 5 Circlip 6 Idle shaft/gear 7 Drive shaft • Install the idle shaft/gear 1, with the thrust washer 2, into the gear box.
  • Page 70 " Gear box cover bolt: 22 N . m (2.2 kgf . m) • Install rear axle shaft spacer 3 in the correct direction. • Apply a light coat of SUZUKI SUPER GREASE “A” onto the pivoting surface of the brake cam, and then install the brake cam into the crankcase.
  • Page 71 3-42 ENGINE • Align the tang 1 on the brake lining wear indicator plate 2 with the cutaway 3 on the brake cam. Then, slide the brake lining wear indicator plate 2 onto the brake cam. • Install the return spring and brake cam lever onto the brake cam.

  • Page 72: Drive Belt

    ENGINE 3-43 • Tighten the final gear oil drain bolt 1 to the specified torque. " Final gear oil drain bolt: 12 N . m (1.2 kgf . m) • Add final gear oil until it flows from the final gear oil level hole 4 Final gear oil quantity: 130 ml •...

  • Page 73: Piston

    3-44 ENGINE • Tighten the kick starter nut to the specified torque by holding the kick starter using a 32-mm offset wrench, as shown. " Kick starter nut: 50 N . m (5.0 kgf . m) • Turn the fixed drive face by hand, until the drive belt is properly seated and both the drive and driven faces rotate together smoothly and without slipping.

  • Page 74: Generator

    ENGINE 3-45 • Install the dowel pins 1 and new gasket 2. • Apply engine oil onto the piston and cylinder wall surfaces, and then carefully install the cylinder over the piston. • Install the new gasket 3. • Tighten the cylinder head nuts diagonally, as shown, and to the specified torque.

  • Page 75: Cooling Fan Cover

    • Install the clamps as shown. NOTE: Be sure to use the twist-off bolts 1 . OIL PUMP GEAR • Apply SUZUKI SUPER GREASE “A” onto the oil pump gear, and then install it. $ 99000-25010: SUZUKI SUPER GREASE “A”...

  • Page 76: Oil Pump

    ENGINE 3-47 OIL PUMP • Insert the projection 1 into the groove 2. EXHAUST PIPE/MUFFLER • Tighten the exhaust pipe nuts to the specified torque. " Exhaust pipe nut: 23 N . m (2.3 kgf . m) • Tighten the muffler mounting bolts to the specified torque. "...
  • Page 77 FUEL AND LUBRICATION SYSTEM FUEL AND LUBRICATION SYSTEM CONTENTS FUEL SYSTEM ..................4- 2 FUEL PUMP ..................4- 2 FUEL VALVE ..................4- 3 AIR CONTROL VALVE ..............4- 4 FUEL TANK ...................4- 5 REMOVAL..................4- 5 INSPECTION ..................4- 6 REMOUNTING .................4- 6 OIL TANK ....................4- 7 REMOVAL..................4- 7 REMOUNTING .................4- 7 FUEL VALVE ..................4- 8...

  • Page 78: Fuel System

    FUEL AND LUBRICATION SYSTEM FUEL SYSTEM The fuel pump is operated by a vacuum force which is supplied from the crankcase. 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 79: Fuel Valve

    FUEL AND LUBRICATION SYSTEM FUEL VALVE When the engine has started, negative pressure (vacuum) is generated at the intake port. The negative pressure causes the fuel valve diaphragm to compress its spring, opening the fuel passageway and allowing the fuel to flow to the fuel pump. When the engine has stopped, the spring pushes against the valve, closing the fuel passageway, and stop- ping the flow of fuel to the fuel pump.

  • Page 80: Air Control Valve

    FUEL AND LUBRICATION SYSTEM AIR CONTROL VALVE • The air control valve changes the valve opening area to adjust the air volume for slow system in accor- dance with temperature variation, thereby supplying the optimum air/fuel mixture for idling operation. In this system, air is taken in from the clean side of air cleaner and guided into the slow system through the air control valve.

  • Page 81: Fuel Tank

    FUEL AND LUBRICATION SYSTEM FUEL TANK REMOVAL Gasoline is highly flammable and explosive. Keep heat, sparks, and flames away from gasoline. • Remove the leg shield cover/rear leg shield. (75-9) • Disconnect the fuel level gauge coupler 1. • Remove the frame pipe 2. •...

  • Page 82: Inspection

    FUEL AND LUBRICATION SYSTEM INSPECTION FUEL FILTER If the fuel filter is dirty with sediment, fuel will not flow smoothly and loss in engine power may result. Clean the fuel filter with compressed air. Also check the fuel filter for cracks. REMOUNTING Remount the fuel tank in the reverse order of removal.

  • Page 83: Oil Tank

    FUEL AND LUBRICATION SYSTEM OIL TANK REMOVAL • Remove the frame covers. (75-7) • Disconnect the oil level gauge coupler 1. • Disconnect the oil hose 2. NOTE: Insert a suitable plug into the hole of the oil tank. • Remove the oil tank. INSPECTION OIL LEVEL INDICATOR SWITCH .....

  • Page 84: Fuel Valve

    FUEL AND LUBRICATION SYSTEM FUEL VALVE INSPECTION AND REMOVAL Gaosoline is highly flammable and explosive. Keep heat, sparks, and flames away from gasoline. • Remove the lower leg shield. (75-5) • Disconnect the fuel valve vacuum hose 1 from the carburetor. •...

  • Page 85: Fuel Pump

    FUEL AND LUBRICATION SYSTEM FUEL PUMP INSPECTION AND REMOVAL Gasoline is highly flammable and explosive. Keep heat, sparks, and flames away from gasoline. • Disconnect the fuel hose 1 from the carburetor and then put it into a receptacle. Check the fuel flow when cranking the engine for few seconds by pressing the starter button.

  • Page 86: Carburetor

    4-10 FUEL AND LUBRICATION SYSTEM CARBURETOR CONSTRUCTION 1 Top cap 2 Throttle valve spring 3 Jet needle 4 Throttle valve 5 Thermoelement 6 Air screw 7 Throttle stop screw 8 Pilot jet 9 Needle jet 0 Main jet A Needle valve B Float C O-ring D Float chamber...

  • Page 87: Specifications

    FUEL AND LUBRICATION SYSTEM 4-11 SPECIFICATIONS ITEM SPECIFICATIONS Carburetor type MIKUNI VM18SH Bore size 18 mm I.D. No. 16F1 Idle r/min. 1 800 ± 200 r/min Float height 9.5 ± 0.5 mm Main jet (M.J.) Jet needle (J.N.) 3DR8-3rd Needle jet (N.J.) Pilot jet (P .J.)

  • Page 88: Removal

    4-12 FUEL AND LUBRICATION SYSTEM REMOVAL • Remove the frame covers. (75-7) • Disconnect the oil hose 1, fuel valve vacuum hose 2 and fuel hose 3 from the carburetor. • Remove the carburetor top cap 4. • Disconnect the carburetor heater terminal lead wire 5. •...

  • Page 89: Disassembly

    FUEL AND LUBRICATION SYSTEM 4-13 • Remove the carburetor mounting bolt and nut. • Remove the carburetor. DISASSEMBLY • Remove the throttle cable 1 from the slit in the throttle valve 2, and then remove the throttle valve 2 along with the jet needle 3 and throttle valve spring 4.
  • Page 90 4-14 FUEL AND LUBRICATION SYSTEM • Remove the carburetor heater 1. • Remove the float chamber 2. • Remove the float pin 3, float 4 and needle valve 5. • Remove the main jet 6, needle jet 7 and pilot jet 8. Do not use wire to clean the passages and jets.

  • Page 91: Inspection And Adjustment

    FUEL AND LUBRICATION SYSTEM 4-15 INSPECTION AND ADJUSTMENT Check the following items for any damage or clogging. If any dam- ages are found, replace the damaged parts with new ones. * Main jet * Throttle valve * Pilot jet * Float * Needle jet * Needle valve * Air screw...
  • Page 92 4-16 FUEL AND LUBRICATION SYSTEM FUEL LEVEL ADJUSTMENT This inspection must be performed in an area well venti- lated, away from fire or sparks since gasoline, an explo- sive fluid, is used in this operation. • Remove the carburetor overflow hose. •...

  • Page 93: Reassembly

    FUEL AND LUBRICATION SYSTEM 4-17 REASSEMBLY Reassemble the carburetor in the reverse order of disassembly. Pay attention to the following points: • Adjust the air screw 1. (74-11) • Before installing the carburetor heater, apply a small quantity of THERMO-GREASE to the threads of the carburetor heater and tighten it to the specified torque.

  • Page 94: Air Control Valve

    4-18 FUEL AND LUBRICATION SYSTEM AIR CONTROL VALVE REMOVAL • Remove the carburetor. (74-12) • Remove the air control valve 1. INSPECTION To inspect the air control valve, perform the following inspections. • Blow the air inlet port of the air control valve as shown. If air does not flow out, replace the air control valve with a new one.

  • Page 95: Oil Pump

    • Disconnect the oil hose 1 from the oil tank. • Connect the suitable plug to the outlet of the oil tank. • Fill the CCI oil gauge with SUZUKI CCI SUPER OIL. Connect the oil gauge to the oil hose 1.

  • Page 96: Oil Strainer

    4-20 FUEL AND LUBRICATION SYSTEM OIL STRAINER • Remove the trunk. (75-6) • Remove the oil strainer 1. • Inspect the oil strainer for clogging. • If the oil strainer is clogged, replace it with a new one. • Install the oil strainer 1 in the correct direction as shown. NOTE: The arrow on the oil strainer indicates of oil flows.
  • Page 97 CHASSIS CHASSIS CONTENTS EXTERIOR PARTS ................5- 2 CONSTRUCTION ................5- 2 FASTENER REMOVAL AND REINSTALLATION ......5- 3 REMOVAL..................5- 4 REMOUNTING .................5- 9 FRONT WHEEL ..................5-10 CONSTRUCTION ................5-10 REMOVAL..................5-10 INSPECTION AND DISASSEMBLY ..........5-11 REASSEMBLY AND REMOUNTING ..........5-12 FRONT BRAKE ..................5-15 CONSTRUCTION ................5-15 BRAKE PADS REPLACEMENT............5-16 BRAKE FLUID REPLACEMENT............5-16 BRAKE CALIPER REMOVAL AND DISASSEMBLY .......5-17...

  • Page 98: Exterior Parts

    CHASSIS EXTERIOR PARTS CONSTRUCTION Front leg shield cover Front leg shield Leg shield cover Brace To frame Lower leg shield Fuel lid Right side leg shield Left side leg shield Maintenance lid Rear leg shield...

  • Page 99: Fastener Removal And Reinstallation

    CHASSIS Upper frame cover Right frame cover Left frame cover FASTENER REMOVAL AND REINSTALLATION FASTENER a REMOVAL • Depress the head of fastener core 1. • Pull out the fastener. INSTALLATION • Push the bottom A of fastener core as shown. •...

  • Page 100: Removal

    CHASSIS FASTENER b REMOVAL • Turn the head of fastener core 1 counterclockwise and pull it out. INSTALLATION • Push the bottom A of fastener core as shown. • Insert the fastener into the installation hole securely and then push the faster core. REMOVAL FRONT LEG SHIELD COVER •...
  • Page 101 CHASSIS LOWER LEG SHIELD • Remove the side leg shields. (75-4) • Remove the lower leg shield 1. : Hooked part FRONT LEG SHIELD • Remove the front leg shield cover and side leg shields. (75- • Disconnect the headlight coupler 1. •...
  • Page 102 CHASSIS SEAT • Open the seat using the key. • Remove the seat 1. TRUNK • Remove the rear carrier 1. • Remove the bolts and screws. • Remove the oil tank cap 2. • Disconnect the engine oil drain hose 3. •...
  • Page 103 CHASSIS FRAME COVERS • Remove the trunk. (75-6) • Remove the left and right side leg shields. (75-4) • Remove the lower leg shield. (75-5) • Remove the stand grip 1. • Disconnect the brake light/taillight lead wire coupler 2. •...
  • Page 104 CHASSIS • Separate the left frame cover, right frame cover and upper frame cover. : Hooked part REAR FENDER • Remove the frame covers. (75-7) • Remove the CDI unit 1. • Remove the rear fender 2.

  • Page 105: Remounting

    CHASSIS LEG SHIELD COVER/REAR LEG SHIELD • Remove the front leg shiled cover. (75-4) • Remove the torx bolt 1 using the special tool. 2 09930-11950: Torx wrench • Remove the ignition switch shutter 2. • Remove the side leg shields and lower leg shileds. (75-4 and -5) •...

  • Page 106: Front Wheel

    5-10 CHASSIS FRONT WHEEL CONSTRUCTION 1 Front axle 2 Spacer 3 Dust seal 4 Bearing 5 Spacer 6 Front wheel 7 Speedometer gearbox 8 Brake disc A Front axle nut B Brake disc bolt " N . m kgf . m ITEM REMOVAL •...

  • Page 107: Inspection And Disassembly

    CHASSIS 5-11 • Remove the brake disc. INSPECTION AND DISASSEMBLY SPEEDOMETER GEARBOX DUST SEAL Inspect the speedometer gearbox dust seal for damage. If any damage is found, replace the speedometer gearbox with a new one. WHEEL BEARINGS Play Inspect the play of the wheel bearings by hand while they are in Play the wheel.

  • Page 108: Reassembly And Remounting

    Reassemble and remount the front wheel in the reverse order of removal and disassembly. Pay attention to the following points: WHEEL BEARING • Apply SUZUKI SUPER GREASE “A” to the wheel bearings. $ 99000-25010: SUZUKI SUPER GREASE “A” • Install the wheel bearings using the special tool.
  • Page 109 " Brake disc mounting bolt: 23 N . m (2.3 kgf . m) SPEEDOMETER GEARBOX • Apply SUZUKI SUPER GREASE “A” to the teeth of the speed- ometer gear before installing the speedometer gearbox. $ 99000-25010: SUZUKI SUPER GREASE “A”...
  • Page 110 5-14 CHASSIS • Have the stopper 1 on the speedometer gearbox touch the lug 2 on the right front fork leg. FRONT AXLE • Tighten the front axle nut 1 to the specified torque. " Front axle nut: 42 N . m (4.2 kgf . m)

  • Page 111: Front Brake

    CHASSIS 5-15 FRONT BRAKE CONSTRUCTION 1 Brake hose 2 Master cylinder 3 Piston/secondary cup 4 Dust boot 5 Caliper holder 6 Pad mounting pin 7 Brake caliper 8 Brake caliper piston 9 Brake pad 0 Piston seal and dust seal A Brake master cylinder bolt B Brake hose union bolt C Brake caliper mounting bolt...

  • Page 112: Brake Pads Replacement

    5-16 CHASSIS BRAKE PADS REPLACEMENT • Remove the brake caliper mounting bolts 1. • Remove the clip 2 and brake pad mounting pin 3. • Remove the brake pads 4. Do not operate the front brake lever while removing the pads.

  • Page 113: Brake Caliper Removal And Disassembly

    CHASSIS 5-17 • Connect a clear hose 1 to the air bleeder valve 2 and insert the other end of the hose into a receptacle. • Loosen the air bleeder valve and pump the brake lever until the old brake fluid is completely out of the brake system. •...

  • Page 114: Brake Caliper Inspection

    5-18 CHASSIS • Place a rag over the brake caliper piston to prevent it from pop- ping out and then force out the piston with compressed air. Do not use high pressure air to prevent brake caliper piston damage. • Remove the dust seal 1 and piston seal 2. Do not reuse the dust seal and piston seal to prevent fluid leakage.
  • Page 115 • Install the piston seal and dust seal as shown. • Apply grease to the brake caliper holder. % 99000-25100: SUZUKI SILICONE GREASE • Tighten the brake caliper mounting bolts 1 and the brake hose union bolt 2 to the specified torque.

  • Page 116: Brake Disc Inspection

    5-20 CHASSIS BRAKE DISC INSPECTION • Remove the front wheel. (75-10) Check the brake disc for cracks or damage and measure the thick- ness using the micrometer. If the thickness is less than the ser- vice limit or if any damages are found, replace the brake disc with a new one.

  • Page 117: Master Cylinder Inspection

    CHASSIS 5-21 • Remove the brake lever 1 and brake light switch 2. • Remove the dust boot 3. • Remove the circlip 4 using the special tool. 2 09900-06108: Snap ring pliers • Remove the washer 5, piston/secondary cup 6 and return spring 7.

  • Page 118: Master Cylinder Reassembly And Remounting

    5-22 CHASSIS PISTON Inspect the piston surface for any scratches or other damage. If any damages are found, replace the piston with a new one. RUBBER PARTS Inspect the primary cup, secondary cup and dust seal for wear or damage. If any damages are found, replace the primary cup, sec- ondary cup, and dust seal with new ones.
  • Page 119 CHASSIS 5-23 • Tighten the master cylinder clamp bolts 1 to the specified torque. " Master cylinder clamp bolt 1: 10 N . m (1.0 kgf . m) NOTE: When remounting the master cylinder onto the handlebars, tighten the upper clamp bolt first. •...

  • Page 120: Front Fork

    5-24 CHASSIS FRONT FORK CONSTRUCTION 1 Cap 2 O-ring 3 Front fork spring 4 Damper rod ring 5 Damper rod 6 Spring 7 Inner tube 8 Dust seal 9 Oil seal stopper ring 0 Oil seal A Bushing B Outer tube C Gasket A Front fork cap bolt B Damper rod bolt...
  • Page 121 CHASSIS 5-25 • Remove the front fork. • Remove the rubber cap 1 and front fork cap bolt 2. • Remove the spring 3. • Invert the front fork and stroke it several times to drain out the fork oil. •...
  • Page 122 5-26 CHASSIS • Remove the damper rod bolt 1 by using the special tools. 2 09900-00410: Hexagon wrench set 09940-34520: “T”-handle • Remove the damper rod 2 and rebound spring 3 from the inner tube. • Separate the inner tube from the outer tube. •...

  • Page 123: Inspection

    CHASSIS 5-27 INSPECTION FORK SPRING Measure the fork spring free length. If the fork spring free length is shorter than the service limit, replace the fork spring with a new one. 4 Front fork spring free length Service Limit: 267 mm INNER AND OUTER TUBES Inspect the inner tube sliding surface and outer tube sliding sur- face for any scuffing or damage.

  • Page 124: Reassembly And Remounting

    • Install the oil seal 4 with the special tool. 2 09940-52861: Front fork oil seal installer set NOTE: Before installing the oil seal 4 , apply fork oil to the lip of oil seal. 3 99000-99044-10G: SUZUKI FORK OIL G10 (#10)
  • Page 125 NOTE: Before installing the dust seal 2 , apply fork oil to the lip of dust seal. 3 99000-99044-10G: SUZUKI FORK OIL G10 (#10) 1 Oil seal stopper ring 2 Dust seal 3 Oil seal • Pour the specified fork oil into the inner tube.
  • Page 126 5-30 CHASSIS • Apply grease to the O-ring 1. $ 99000-25010: SUZUKI SUPER GREASE “A” Use a new O-ring 1 to prevent oil leakage. • Install the front fork cap bolt to the inner tube. • Tighten the front fork cap bolt 2 to the specified torque.

  • Page 127: Handlebar Covers

    CHASSIS 5-31 HANDLEBAR COVERS CONSTRUCTION 1 Wind screen 2 Center handlebar cover 3 Front handlebar cover 4 Rear handlebar cover...

  • Page 128: Removal

    5-32 CHASSIS REMOVAL • Remove the screws. • Remove the front handlebar cover 1. : Hooked part • Remove the wind screen 2. • Remove the center handlebar cover 3. : Hooked part • Remove the handlebar right switch screws. •...

  • Page 129: Remounting

    Pay attention to the following points. • Install the handlebar right switch. NOTE: Apply SUZUKI SUPER GREASE “A” to the throttle grip and end of the throttle cable. $ 99000-25010: SUZUKI SUPER GREASE “A” • Insert the projection A into the hole of the handlebars.

  • Page 130: Steering Stem

    5-34 CHASSIS STEERING STEM CONSTRUCTION 1 Handlebars 2 Washer 3 Steering stem nut 4 Inner upper race 5 Inner lower race 6 Steel ball (upper) ..25 pcs 7 Steel ball (lower) ..30 pcs 8 Steering stem 9 Outer lower race A Handlebar clamp nut B Handlebar set bolt C Steering stem locknut...
  • Page 131 CHASSIS 5-35 • Remove the brake hose guide. • Disconnect the turn signal lead wire couplers. • Remove the handlebars. • Remove the steering stem locknut using the special tool. 2 09910-60611: Universal clamp wrench • Remove the washer 1 and steering stem nut 2. •...

  • Page 132: Inspection

    5-36 CHASSIS • Remove the upper and lower steel balls. Upper steel balls 25 pcs Lower steel balls 30 pcs • Remove the front fender No. 2 1. • Remove the speedometer cable guide 2. INSPECTION Inspect the removed parts for the following abnormalities. If any damages are found, replace the respective part with a new one.

  • Page 133: Reassembly And Remounting

    • Press in the lower inner race using the special tool. 2 09941-74910: Bearing installer • Apply grease to the upper and lower outer races. $ 99000-25010: SUZUKI SUPER GREASE “A” • Install the upper and lower steel balls. Upper steel balls...
  • Page 134 5-38 CHASSIS • When installing the washer, align the tongue 1 of the washer with the groove 2 of the steering stem shaft. • Tighten the steering stem locknut 3 to the specified torque using the special tool. " Steering stem locknut: 30 N . m (3.0 kgf . m) 2 09910-60611: Universal clamp wrench •...

  • Page 135: Construction

    CHASSIS 5-39 REAR WHEEL, BRAKE AND REAR SHOCK ABSORBER CONSTRUCTION 1 Rear wheel 2 Brake shoe 3 Brake cam 4 Return spring 5 Brake lining wear indicator plate 6 Brake cam lever 7 Rear shock absorber A Rear axle nut B Rear brake cam lever nut C Rear shock absorber mounting bolt "...

  • Page 136: Inspection

    5-40 CHASSIS • Remove the brake shoes 1. REAR SHOCK ABSORBER • Remove the frame covers. (75-7) • Remove the air cleaner box. (74-12) • Remove the rear shock absorber. INSPECTION BRAKE DRUM Inspect the brake drum and measure the brake drum I.D. to de- termine the extent of wear.

  • Page 137: Reassembly And Remounting

    Pay attention to the following points: • Apply SUZUKI SUPER GREASE “A” to the brake cam and pin, and then install the brake shoes. $ 99000-25010: SUZUKI SUPER GREASE “A”...

  • Page 138: Tire And Wheel

    5-42 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. Because of this, we recommended using a tire changer that can satisfy this sealing requirement and can make the operation efficient as well as functional.

  • Page 139: Installation

    CHASSIS 5-43 VALVE Inspect the valve 1 for damage. If the seal rubber is peeling or damaged, replace the valve with a new one. NOTE: If the external appearance of the valve shows no abnormal con- dition, removing the valve is not necessary. Inspect the valve core seal 2 for deformation or damage.
  • Page 140 5-44 CHASSIS TIRE • Apply a special tire lubricant to the tire bead. • When installing the tire, make sure the arrow 1 faces the di- rection of wheel rotation and align the balancing. Replace the removed valve with a new one. •...
  • Page 141 CHASSIS 5-45 • After the tire is properly seated to the wheel rim, inflate the tire to the recommended pressure. Correct the wheel balance if necessary. * Do not inflate the tire to more than 400 kPa (4.0 kgf/ ). The tire could burst with sufficient force to cause severe injury.
  • Page 142 ELECTRICAL SYSTEM 6-1 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- 2 BATTERY..................6- 3 CONNECTING THE BATTERY ............6- 3 WIRING PROCEDURE ..............

  • Page 143: Fuse

    6-2 ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTOR • When disconnecting a connector, be sure to hold the termi- nals; do not pull the lead wires. • When connecting a connector, push it in so it is firmly attached. • Inspect the connector for corrosion, contamination and any breakage in the cover.

  • Page 144: Battery

    ELECTRICAL SYSTEM 6-3 BATTERY • The MF battery used in this motorcycle does not require main- tenance (e.g., electrolyte level inspection, distilled water re- plenishing). • During normal charging, no hydrogen gas is produced. How- ever, if the battery is overcharged, hydrogen gas may be pro- duced.

  • Page 145: Location Of Electrical Components

    6-4 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS 1 Battery 2 Fuse 3 Turn signal relay 4 Horn 5 Oil level indicator switch 6 Carburetor thermo switch 7 CDI unit 8 Carburetor heater 9 Thermoelement 0 Fuel level gauge A Ignition switch B Starter relay C Ignition coil D Generator...

  • Page 146: Charging And Lighting System

    ELECTRICAL SYSTEM 6-5 CHARGING AND LIGHTING SYSTEM DESCRIPTION The charging system for this motorcycle uses a generator, as shown below. The charging and lighting coils are mounted on the generator stator and generate AC current as the generator rotor turns. The AC current, which is generated in the charging coil, flows to the regulator/rectifier where it is changed to the DC current.

  • Page 147: Troubleshooting

    6-6 ELECTRICAL SYSTEM TROUBLESHOOTING 6-7) 6-7) 6-8) 6-8 )

  • Page 148: Inspection

    ELECTRICAL SYSTEM 6-7 INSPECTION BATTERY CURRENT LEAK • Turn the ignition switch to the “OFF” position. • Remove the front leg shield cover. (!5-4) • Remove the battery rubber band 1. • Disconnect the - battery lead wire. • Measure the battery current leak between the - battery ter- minal and the - battery lead wire using the multi circuit tester.
  • Page 149 6-8 ELECTRICAL SYSTEM STATOR COIL RESISTANCE • Remove the frame covers. (!5-7) • Disconnect the stator coil lead wire coupler 1. Measure the resistance between the lead wires and ground us- ing the multi circuit tester. If the resistance is incorrect, replace the stator coil with a new one.

  • Page 150: Starter System

    ELECTRICAL SYSTEM 6-9 STARTER SYSTEM DESCRIPTION The starter system consists of the following components: the starter motor, starter relay, starter button, brake light switches (front and rear brakes), ignition switch, and battery. Pressing the starter button, while squeezing the front or rear brake lever, energizes the starter relay, causing the contact points to close, thus, completing the circuit from the starter motor to the battery.

  • Page 151: Troubleshooting

    6-10 ELECTRICAL SYSTEM TROUBLESHOOTING Turn on the ignition switch. Check if the starter motor runs when Listen for a click from the starter relay its terminal is connected to the battery terminal. (Do not use a thin when the starter button is pushed. Grasp the front or rear brake lever wire because a large amount of when pushing the starter button.

  • Page 152: Starter Motor Removal And Disassembly

    ELECTRICAL SYSTEM 6-11 STARTER MOTOR REMOVAL AND DISASSEMBLY • Disconnect the starter motor lead wire 1. • Remove the starter motor. • Disassemble the starter motor, as shown in the illustration. 1 Starter motor case 2 O-ring 3 Housing end (Inside) 4 O-ring 5 Brush spring 6 Armature...

  • Page 153: Starter Motor Reassembly

    Pay attention to the following points: " 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”...

  • Page 154: Starter Relay Inspection

    ELECTRICAL SYSTEM 6-13 • Apply a small quantity of SUZUKI MOLY PASTE to the arma- ture shaft. / 99000-25140: SUZUKI MOLY PASTE • Apply SUZUKI SUPER GREASE “A” to the O-ring. . 99000-25010: SUZUKI SUPER GREASE “A” STARTER RELAY INSPECTION •...

  • Page 155: Ignition System

    6-14 ELECTRICAL SYSTEM IGNITION SYSTEM DESCRIPTION In the capacitor discharged ignition system, the electrical energy generated by the generator charges the capacitor. This energy is released in a single surge at the specified ignition timing point and the current flows through the primary side of the ignition coil.

  • Page 156: Troubleshooting

    ELECTRICAL SYSTEM 6-15 TROUBLESHOOTING Improper lead wire connection Measure the battery voltage between input lead wires(O and B/W) at the CDI unit with the ignition switch in the "ON" position. Broken wire harness or improper connection of related circuit couplers 6-16) 2-5) Faulty CDI unit...

  • Page 157: Inspection

    6-16 ELECTRICAL SYSTEM INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the lower leg shield. (! 5-5) • Disconnect the spark plug cap. • Connect new spark plug to the spark plug cap and ground it. NOTE: Make sure that the spark plug cap and spark plug is connected properly and the battery is fully-charged.
  • Page 158 ELECTRICAL SYSTEM 6-17 IGNITION COIL RESISTANCE Measure the ignition coil resistance in both the primary and sec- ondary windings. If the windings are in sound condition, their resistance should be close to the specified values. & Ignition coil resistance Primary: 0.05 – 1.0 Ω (+ terminal – - terminal) Secondary: 12 –...
  • Page 159 6-18 ELECTRICAL SYSTEM • Remove the frame covers. (!5-7) • Disconnect the pickup coil lead wire coupler 1. • Connect the multi circuit tester with the peak volt adaptor. + Probe : Brown lead wire - Probe : White lead wire Measure the pickup coil peak voltage in the same manner as on the CDI unit coupler.

  • Page 160: Fuel Meter And Fuel Level Gauge

    ELECTRICAL SYSTEM 6-19 FUEL METER AND FUEL LEVEL GAUGE FUEL METER INSPECTION To test the fuel meter, perform the following tests. Test 1 This test will determine if the fuel meter is operating. • Remove the leg shield cover/rear leg shield. (!5-9) •...
  • Page 161 6-20 ELECTRICAL SYSTEM INSPECTION • Disconnect the lead wires coming out of the fuel level gauge. Measure the resistance at each fuel level gauge float position. If the resistance is incorrect, replace the fuel level gauge with a new one. •...

  • Page 162: Oil Level Indicator Switch

    ELECTRICAL SYSTEM 6-21 OIL LEVEL INDICATOR SWITCH INSPECTION Measure the continuity between the lead wires of the oil level indicator switch. If there is no continuity between the terminals when the float 1 is in the low-level position, replace the oil level indicator switch. # 09900-25008: Multi circuit tester set , Tester knob indication: Continuity test (-) THERMOELEMENT AND CARBURETOR HEATER...
  • Page 163 6-22 ELECTRICAL SYSTEM CARBURETOR HEATER • Disconnect the carburetor heater terminal lead wire 1. Measure the resistance between the terminals using the multi circuit tester. # 09900-25008: Multi circuit tester set ) Tester knob indication: Resistance (Ω Ω Ω Ω Ω ) &...

  • Page 164: Speedometer

    ELECTRICAL SYSTEM 6-23 SPEEDOMETER REMOVAL AND DISASSEMBLY • Remove the rear handlebar cover. (!5-32 and -33) • Remove the speedometer assembly. Disassemble the speedometer, as shown. INSPECTION Check the continuity between the lead wires using the multi cir- cuit tester. If there is no continuity, replace the respective parts. # 09900-25008: Multi circuit tester set , Tester knob indication: Continuity test (-)

  • Page 165: Headlight

    6-24 ELECTRICAL SYSTEM LAMPS HEADLIGHT BULB REPLACEMENT • Remove the front leg shield cover. (! 5-4) • Remove the rubber boot 1. • Unhook the headlight bulb socket holder spring 2 and remove the headlight bulb socket 3. • Turn the headlight bulb 4 counterclockwise and remove it. •...

  • Page 166: Brake Light/Taillight

    ELECTRICAL SYSTEM 6-25 LICENSE PLATE LIGHT BULB REPLACEMENT • Remove the license plate light lens 1. • Remove the license plate light bulb 2. " If you touch the bulb with your hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.

  • Page 167: Trunk Light

    6-26 ELECTRICAL SYSTEM TRUNK LIGHT BULB REPLACEMENT • Open the seat. • Remove the trunk light switch. • Turn the bulb socket 1 and remove the trunk light bulb 2. RELAYS STARTER RELAY The starter relay is located behind the leg shield cover. (!6- TURN SIGNAL RELAY The turn signal relay is located behind the front leg shield cover.

  • Page 168: Inspection

    ELECTRICAL SYSTEM 6-27 INSPECTION Measure each switch for continuity using a tester. If any abnormality is found, replace the respective switch assemblies with new ones. IGNITION SWITCH FRONT BRAKE LIGHT SWITCH Color Color Bl/W B/W Gr Position Position LOCK REAR BRAKE LIGHT SWITCH Color Position LIGHTING SWITCH...

  • Page 169: Battery

    6-28 ELECTRICAL SYSTEM BATTERY REMOVAL • Remove the front leg shield cover. (!5-4) • Remove the battery rubber band 1. • Remove the battery. NOTE: First, disconnect the - battery lead wire. REMOUNTING Remount the battery in the reverse order of removal.

  • Page 170: Specifications

    ELECTRICAL SYSTEM 6-29 SPECIFICATIONS Type designation FTX5L-BS Capacity 12 V, 14.4 kC (4 Ah)/10 HR INITIAL CHARGING FILLING ELECTROLYTE • Remove the aluminum tape 1 which seals the battery filler holes. • Remove the caps 2 from the electrolyte container. NOTE: * Do not remove or pierce the sealed areas 3 of the electrolyte container.

  • Page 171: Servicing

    6-30 ELECTRICAL SYSTEM 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 172: Recharging Operation

    ELECTRICAL SYSTEM 6-31 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 bat- tery charger. " When recharging the battery, remove the battery from the motorcycle.
  • Page 173 SERVICING INFORMATION SERVICING INFORMATION CONTENTS TROUBLESHOOTING ................7- 2 WIRING DIAGRAM ................7- 8 WIRE HARNESS, CABLE AND HOSE ROUTING .......7- 9 WIRE ROUTING ................7- 9 CABLE ROUTING ................7-10 FUEL HOSE ROUTING ..............7-12 ENGINE OIL DRAIN HOSE ROUTING ..........7-14 FRONT BRAKE HOSE ROUTING ...........7-15 CENTER STAND SET-UP ..............7-16 FUEL TANK CUSHION ADHERING .............7-16 SPECIAL TOOLS ..................7-17...

  • Page 174: Troubleshooting

    SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not Compression too low start, or is hard to 1. Worn cylinder. Rebore or replace. start. 2. Worn piston ring. Replace. 3. Stiff piston ring. Repair or replace. 4.
  • Page 175 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine idles poorly. 1. Worn cylinder. Replace. 2. Worn piston rings. Replace. 3. Stiff piston ring. Replace. 4. Gas leaks from crankshaft oil seal. Replace. 5. Excessive spark plug gap. Adjust or replace. 6.
  • Page 176 SERVICING INFORMATION CARBURETOR Complaint Symptom and possible causes Remedy Starting difficulty. 1. Clogged fuel pipe. Clean. 2. Air leaking from joint between intake pipe and Check intake pipe and carbu- carburetor. retor for tighteness, and re- place gasket. 3. Air leaking from carburetor joint or vacuum hose joint. Tighten or replace defective part.
  • Page 177 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Rear suspension too soft. 1. Weak rear shock abosorber spring. Replace. 2. Rear shock absorber leaks oil. Replace. Rear suspension too 1. Loose bolts on rear shock absorber. Tighten. noisy. 2. Worn engine mounting bushing. Replace.
  • Page 178 SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective Ignition coil or CDI unit. Replace. sparking. 2. Defective spark plug. Replace. 3. Defective starter coil or pickup coil. Replace. 4. Loose connection of lead wire. Connect or tighten.
  • Page 179 SERVICING INFORMATION BATTERY Complaint Symptom and possible causes Remedy Sulfation or sports on 1. Cracked battery case. Replace. surfaces of cell plates. 2. Battery has been left in a run-down condition for a long Replace. time. Battery runs down quickly. 1.

  • Page 180: Wiring Diagram

    SERVICING INFORMATION WIRING DIAGRAM WIRING DIAGRAM...

  • Page 181: Wire Harness, Cable And Hose Routing

    SERVICING INFORMATION WIRE, CABLE AND HOSE ROUTING WIRE ROUTING Pass the handlebar switch (R) lead wire over the bracket. Handlebar switch (L) Speedometer Front turn signal (L) Clamp Tape Trunk box light Wiring harness Ignition switch Clamp Throttle cable Brake hose Thermoelement Speedometer cable Engine ground...

  • Page 182: Cable Routing

    7-10 SERVICING INFORMATION CABLE ROUTING...
  • Page 183 SERVICING INFORMATION 7-11 Speedometer cable Cable guide Cable guide Speedometer cable Cable guide Speedometer gear box...

  • Page 184: Fuel Hose Routing

    7-12 SERVICING INFORMATION FUEL HOSE ROUTING...
  • Page 185 SERVICING INFORMATION 7-13...

  • Page 186: Engine Oil Drain Hose Routing

    7-14 SERVICING INFORMATION ENGINE OIL DRAIN HOSE ROUTING...

  • Page 187: Front Brake Hose Routing

    SERVICING INFORMATION 7-15 FRONT BRAKE HOSE ROUTING After touching the brake hose union to the stopper, tighten the union bolt to the specified torque. 14˚ Master cylinder Rear brake cable Insert the stopper into Wiring harness the hole of steering stem. Throttle cable Washer Speedometer...

  • Page 188: Center Stand Set-Up

    7-16 SERVICING INFORMATION CENTER STAND SET-UP Inner spring Inner spring Outer spring Outer spring Cushion Center stand Center stand FUEL TANK CUSHION ADHERING Cushion Cushion...

  • Page 189: Special Tools

    SERVICING INFORMATION 7-17 SPECIAL TOOLS 09900-00401 “L” type hexagon 09900-00410 09900-06107 09900-06108 09900-09003 wrench set Hexagon wrench set Snap ring pliers Snap ring pliers Impact driver set 09900-20101 09900-20203 09900-20205 09900-20508 09900-20605 Vernier calipers Micrometer Micrometer Cylinder gauge set Dial calipers (150 mm) (50 –...
  • Page 190 7-18 SERVICING INFORMATION 09930-11930 09930-11940 09930-11950 09930-30102 09930-40113 Torx bit Torx bit holder Torx wrench Sliding hammer Rotor holder 09940-52861 09941-34513 Front fork oil seal Steering inner race 09940-34520 09941-74910 09941-50111 installer set installer “T”-handle Bearing installer Bearing remover 09951-16080 09943-74111 Bearing installer Fork oil level gauge...

  • Page 191: Tightening Torque

    SERVICING INFORMATION 7-19 TIGHTENING TORQUE ENGINE kgf . m ITEM N·m Cylinder head nut Generator rotor nut Clutch housing nut Clutch shoe nut Gearbox cover bolt Kick starter nut Gear oil level bolt Gear oil drain bolt Crankcase bracket nut 10.2 Engine mounting nut Exhaust pipe nut...
  • Page 192 7-20 SERVICING INFORMATION TIGHTENING TORQUE CHART For other bolts and nuts not listed in the preceding page, refer to this chart: Conventional or “4” marked bolt “7” marked bolt Bolt Diameter A (mm) kgf . m kgf . m N·m N·m 0.15 0.23...

  • Page 193: Service Data

    SERVICING INFORMATION 7-21 SERVICE DATA CYLINDER + PISTON + PISTON RING Unit: mm ITEM STANDARD LIMIT Piston to cylinder clearance 0.035 – 0.045 0.120 Cylinder bore 52.500 – 52.515 52.595 Measure at 20 mm from the top surface. Piston diam. 52.460 –...
  • Page 194 7-22 SERVICING INFORMATION CARBURETOR ITEM SPECIFICATION Carburetor type MIKUNI VM18SH Bore size 18 mm I.D. No. 16F1 Idle r/min. 1 800 ± 200 r/min Float height 9.5 ± 0.5 mm Main jet (M.J.) Jet needle (J.N.) 3DR8-3rd Needle jet (N.J.) Pilot jet (P .J.) Air screw...

  • Page 195: Turn Signal Light

    Front fork stroke ——— Front fork spring free length 272.8 Front fork oil level ——— Front fork oil type SUZUKI FORK OIL G10 (#10) or ——— equivalent fork oil Front fork oil capacity (each leg) 81 ml ——— Rear wheel travel ———...

  • Page 196: Fuel Tank

    Fuel type higher. An unleaded gasoline is recommended. Fuel tank capacity 6.0 L Use SUZUKI CCI SUPER OIL. If they are not avail- Engine oil type able, use a good quality 2-stroke oil rated FC un- der JASO classification. Engine oil tank capacity 1.2 L...
  • Page 197 Prepared by Motorcycle Service Department November, 1999 Part No. 99500-11180-01E Printed in Japan...
  • Page 198 Printed in Japan...

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