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Table of Contents
RM250
OWNER'S SERVICE MANUAL
Part No. 99011-37F56-01A
May, 2006
EN
TK

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Table of Contents

   Summary of Contents for Suzuki RM250

  • Page 1 RM250 OWNER’S SERVICE MANUAL Part No. 99011-37F56-01A May, 2006...
  • Page 2 This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator. The manual contains important safety information and instructions which should be read carefully before operating the motorcycle.
  • Page 3 Please read this manual and follow its instructions This manual is presented as a means whereby you carefully. To emphasize special information, the can maintain your RM250 in top working condition symbol  and the words WARNING, CAUTION at all times. Your riding skill and the maintenance and NOTE have special meanings.
  • Page 4 You need to prepare for the unex- pected by wearing a helmet and other protective gear, and practicing safe riding techniques to minimize the damage to you and your machine. May all of your rides on your new Suzuki be winning rides!
  • Page 5: Serial Number Location

    SERIAL NUMBER LOCATION The frame number 1 is stamped on the steering head as shown in the photograph. The engine serial num- ber 2 is stamped on the right side of the crankcase assembly. Write down the serial numbers here for your future reference. Frame No.
  • Page 6 WARNINGS FOR SERVICING  WARNING  WARNING Never run the engine indoors or in a Fuel can catch on fire if you do not handle garage. Exhaust gas contains carbon mon- it properly. Gasoline vapors can catch fire oxide, a gas that is colorless and odorless easily.
  • Page 7: Replacement Parts

    NOTE: installing a circlip. Use of replacement parts which are not equivalent • Use special tools where specified. in quality to genuine SUZUKI parts can lead to per- • Use genuine SUZUKI parts and recommended formance problems and damage. oil.
  • Page 8 SYMBOL DEFINITION SYMBOL DEFINITION Torque control required. Use SUZUKI FORK OIL SS-05 or Data beside it indicates specified equivalent fork oil. torque. 99000-99001-SS5 Use SUZUKI REAR SUSPENSION OIL Apply oil. Use engine oil or transmission SS-25 or equivalent rear suspension oil.
  • Page 9 GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE TROUBLESHOOTING MACHINE TUNING ENGINE REMOVAL AND INSTALLATION CYLINDER, PISTON AND EXHAUST VALVE CLUTCH KICK STARTER GEARSHIFTING TRANSMISSION AND CRANKSHAFT FUEL SYSTEM COOLING SYSTEM ELECTRICAL SYSTEM FRONT AND REAR WHEELS FRONT AND REAR BRAKES FRONT FORK AND STEERING REAR SUSPENSION SERVICING INFORMATION...
  • Page 10: Table Of Contents

    GENERAL INFORMATION 1-1 GENERAL INFORMATION CONTENTS LOCATION OF PARTS ................1- 2 FUEL AND OIL RECOMMENDATION ............1- 3 OPERATING INSTRUCTIONS ..............1- 4 STARTING THE ENGINE ..............1- 4 STOPPING THE ENGINE ..............1- 5 TRANSMISSION ................... 1- 5 BREAK-IN (RUNNING-IN) ................
  • Page 11: Location Of Parts

    1-2 GENERAL INFORMATION LOCATION OF PARTS 1 Clutch lever 2 Engine stop switch 3 Clutch cable adjuster 4 Throttle grip 5 Front brake lever 6 Fuel tank cap 7 Starter knob 8 Gearshift lever 9 Fuel valve 0 Kick starter lever A Rear brake pedal...
  • Page 12: Fuel And Oil Recommendation

    GENERAL INFORMATION 1-3 FUEL AND OIL RECOMMENDATION This motorcycle is of the two-stroke design, which requires a premixture of gasoline and oil. Gasoline: Use only unleaded gasoline of at least 90 pump octane (R/2 + M/2 method)..For Canada Use only unleaded gasoline of at least 95 octane (Research Method).
  • Page 13: Operating Instructions

    1-4 GENERAL INFORMATION OPERATING INSTRUCTIONS STARTING THE ENGINE Inspect the transmission oil level, coolant level and air cleaner condition before starting the engine. When the engine is cold: 1) Turn the fuel valve lever to the “ON” position. 2) Shift the transmission into neutral. 3) Pull the bypass (starter) knob 1.
  • Page 14: Stopping The Engine

    GENERAL INFORMATION 1-5 STOPPING THE ENGINE 1) Shift the transmission into neutral. 2) Turn the fuel valve lever to the “OFF” position. 3) Push the engine stop switch 1 to stop the engine.  WARNING Leaving the fuel valve in the “ON” position may cause carburetor overflow.
  • Page 15 – MEMO –...
  • Page 16: Periodic Maintenance

    PERIODIC MAINTENANCE 2-1 PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE ................ 2- 3 PERIODIC MAINTENANCE CHART ............ 2- 3 INSPECTION BEFORE PRACTICE ............2- 5 INSPECTION BEFORE RACE (All items of inspection before practice above plus) ......2- 5 SPARK PLUG ....................2- 6 AIR CLEANER .....................
  • Page 17 PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS DRIVE CHAIN LUBRICATION ............. 2-17 SPROCKET INSPECTION ..............2-17 DRIVE CHAIN GUIDE, BUFFER, CONTROL ROLLER ......2-18 DRIVE CHAIN GUIDE ................2-18 DRIVE CHAIN GUIDE BUFFER ............2-18 DRIVE CHAIN CONTROL ROLLER ............ 2-18 BRAKES ...................... 2-18 BRAKE FLUID LEVEL .................
  • Page 18: Periodic Maintenance

    PERIODIC MAINTENANCE 2-3 PERIODIC MAINTENANCE PERIODIC MAINTENANCE CHART It is very important to inspect and maintain the machine regularly. Follow the guideline in the chart. The life of parts varies depending on the riding conditions. Perform more often than shown in the chart if you use the motorcycle under severe conditions.
  • Page 19 2-4 PERIODIC MAINTENANCE Interval Every Every Every races race 3 races 5 races Remarks Service Every Every Every hours Item 2 hours 6 hours 10 hours Tire — — Inspect every 20 min. up to initial 2 hours Spoke nipple —...
  • Page 20: Inspection Before Practice

    PERIODIC MAINTENANCE 2-5 INSPECTION BEFORE PRACTICE WHAT TO CHECK CHECK FOR Spark plug • Heat range, fouled electrode, tightness • Loose high-tension cord Air cleaner element Lubrication Transmission oil Oil level Coolant Coolant level Cooling system • Radiator hose damage •...
  • Page 21: Spark Plug

    2-6 PERIODIC MAINTENANCE SPARK PLUG Inspect the spark plug condition, electrode color, carbon depos- its, spark plug gap, and washer damage, after removing the spark plug. NOTE: Remove the dirt around the spark plug before removing the spark plug to prevent dirt from entering the combustion cham- ber.
  • Page 22: Air Cleaner

    PERIODIC MAINTENANCE 2-7 AIR CLEANER AIR CLEANER ELEMENT REMOVAL • Remove the seat. (5-4) • Remove the air cleaner box lid. • Remove screw 1. • Remove the element 2 from the element holder. WASHING • Fill a washing pan that is large enough to hold the element with non-flammable cleaning solvent A.
  • Page 23 2-8 PERIODIC MAINTENANCE • Install the air cleaner box lid properly as shown. NOTE: Running the engine without the air cleaner box lid can vary the carburetion. Do not run the engine without the air cleaner box lid. Cap to the front. Air cleaner box front wall NOTE:...
  • Page 24: Transmission Oil

    PERIODIC MAINTENANCE 2-9 TRANSMISSION OIL TRANSMISSION OIL LEVEL INSPECTION AND REPLENISHMENT  WARNING Transmission oil and exhaust pipe can be hot enough to burn you. Wait until the oil drain plug and exhaust pipe become cool enough to touch with bare hands before draining oil.
  • Page 25: Transmission Oil Change

    2-10 PERIODIC MAINTENANCE TRANSMISSION OIL CHANGE • Warm up the engine. • Place the motorcycle on the level ground and hold the motor- cycle vertically. • Remove filler cap and drain plug 1. Drain oil thoroughly. • Tighten the drain plug firmly. ...
  • Page 26: Engine Coolant

    PERIODIC MAINTENANCE 2-11 ENGINE COOLANT ENGINE COOLANT LEVEL CHECK  WARNING You can be injured by scalding fluid or steam if you open the radiator cap when the engine is hot. Do not open the radiator cap when the engine is hot. Wait until engine cools.
  • Page 27: Engine Coolant Replenishment

    2-12 PERIODIC MAINTENANCE ENGINE COOLANT REPLENISHMENT  WARNING Engine coolant is harmful if swallowed or if it comes in contact with your skin or eyes. Keep engine coolant away from children and pets. Call your doctor immediately if engine coolant is swal- lowed and induce vomiting.
  • Page 28: Clutch

    PERIODIC MAINTENANCE 2-13 CLUTCH Adjust the clutch cable play as follows: MAJOR ADJUSTMENT • Loosen the lock-nut 1. • Turn the adjuster 2 so that the clutch lever obtains 10 – 15 mm (0.4 – 0.6 in) play at the clutch lever end. •...
  • Page 29: Fuel Hose

    2-14 PERIODIC MAINTENANCE • Remove the throttle housing cover. • Apply oil to the throttle cable 3. (2-23) • Apply oil to the throttle cable spool 4. (2-23) FUEL HOSE Inspect the fuel hose for damage and fuel leakage. If any defects are found, the fuel hose must be replaced.
  • Page 30: Cylinder Head, Cylinder And Piston

    PERIODIC MAINTENANCE 2-15 CYLINDER HEAD, CYLINDER AND PISTON CYLINDER HEAD • Remove the cylinder head. (6-5) • Remove carbon deposits from combustion chamber surface. • Inspect for pinholes, cracks and other damage. CYLINDER • Remove the cylinder. (6-6) • Remove carbon deposits from the exhaust port and exhaust valve chamber.
  • Page 31: Exhaust Silencer

    • Replace the glasswool silencer with new one if necessary. NOTE: To seal between the frontal part and the aluminum case, apply SUZUKI BOND to the contact area of the frontal part.  99000-31140: SUZUKI BOND “1207B” DRIVE CHAIN AND SPROCKETS DRIVE CHAIN SLACK •...
  • Page 32: 20th Pitch Length

    • Clean the drive chain with non-flammable cleaning solvent. • Do not use gasoline to clean the drive chain. • Dry the drive chain. • Apply Suzuki Chain Lube or equivalent to the link plates and rollers. • Reassemble the drive chain.
  • Page 33: Drive Chain Guide, Buffer, Control Roller

    2-18 PERIODIC MAINTENANCE DRIVE CHAIN GUIDE, BUFFER, CONTROL ROLLER DRIVE CHAIN GUIDE Inspect the drive chain guide 1 for bends and damage. NOTE: The drive chain can hit a bent guide causing noise and drive chain wear. Inspect the chain guide defense 2 for wear. DRIVE CHAIN GUIDE BUFFER Inspect the drive chain guide buffer 1 for wear and cracks.
  • Page 34: Brake Pad

    PERIODIC MAINTENANCE 2-19  WARNING The use of any fluid except DOT 4 brake fluid from a sealed container can damage the brake system and lead to an accident. Use only DOT 4 brake fluid from a sealed container. Never use or mix different types of brake fluid. CAUTION Spilled brake fluid can damage painted surfaces and plastic parts.
  • Page 35: Brake Pedal Height Adjustment

    2-20 PERIODIC MAINTENANCE BRAKE PEDAL HEIGHT ADJUSTMENT Adjust the rear brake pedal height as follows: • Loosen the lock-nut 1. • Adjust the brake pedal height by turning the adjuster 2 to locate the pedal 0 – 10 mm (0 – 0.39 in) below from the top face of the footrest.
  • Page 36: Rear Suspension

    PERIODIC MAINTENANCE 2-21 REAR SUSPENSION • Move the rear suspension up and down several times and inspect for smooth movement. • Inspect for damage and oil leaks. • Inspect the bolts and nuts for tightness. • Inspect that the rear suspension has play or binds by moving the swingarm up and down, and right and left.
  • Page 37 2-22 PERIODIC MAINTENANCE CAUTION Improperly tightening of the spoke nipples can dam- age the wheel. Tighten the spoke nipples less than 1/2 turn at a time. Inspect the spoke tension and then retighten the spoke nipple. Tighten additionally the nipples after breaking-in runnning, until when initial looseness will eliminated.
  • Page 38: Lubrication

    A. Lightweight oil such as WD-40 or penetrating oil. B. Aerosol type Chain Lube. C. SUZUKI SUPER GREASE “A” or water-proof wheel bearing grease. Follow the schedule closely. The disassembly necessary to lubricate many components is in itself valuable preventative maintenance. It allows you to inspect for wear, fatigue, adjustment and fastener tightness and it...
  • Page 39 – MEMO –...
  • Page 40 TROUBLESHOOTING 3-1 TROUBLESHOOTING CONTENTS TROUBLESHOOTING ................. 3- 2 ENGINE ....................3- 2 CHASSIS ....................3- 5...
  • Page 41 3-2 TROUBLESHOOTING TROUBLESHOOTING ENGINE Complaint Possible Cause Remedy Engine does not start Fuel deterioration Replace or hard to start No fuel flow to the carburetor • Fuel valve clogged Clean • Fuel hose clogged Clean or replace • Fuel tank cap breather hose clogged Clean •...
  • Page 42 TROUBLESHOOTING 3-3 Complaint Possible Cause Remedy Engine runs poorly in Exhaust valve maladjustment Adjust low speed range Wide spark plug gap Adjust or replace Carburetor air screw maladjustment Adjust Incorrect carburetor fuel level Adjust Improper jet needle size Replace Incorrect ignition timing Adjust CDI unit malfunction Replace...
  • Page 43 3-4 TROUBLESHOOTING Complaint Possible Cause Remedy Overheating Low engine coolant level Replenish Engine coolant leak Repair Too lean air/fuel mixture Adjust Incorrect ignition timing Adjust Water pump malfunction Adjust or replace Cylinder head carbon deposits Clean Exhaust pipe carbon deposits Clean or replace Improper spark plug heat range Replace...
  • Page 44 Improper air bleeding Bleed air Dirty pads and disc Clean Brake fluid leak Repair Brake noise Brake pads worn Replace Brake disc worn Replace Dirty brake pads and disc Clean * An optional spring is available at your SUZUKI dealer.
  • Page 45 – MEMO –...
  • Page 46 MACHINE TUNING 4-1 MACHINE TUNING CONTENTS CARBURETOR TUNING ................4- 2 PRINCIPLES OF CARBURETOR TUNING .......... 4- 2 CARBURETOR TUNING IN PRACTICE ..........4- 6 FRONT FORK TUNING ................4- 9 COMPRESSION DAMPING FORCE ADJUSTMENT ......4- 9 REBOUND DAMPING FORCE ADJUSTMENT ........4- 9 OIL QUANTITY MINOR ADJUSTMENT ..........
  • Page 47: Carburetor Tuning

    Riders who are not familiar with the operation and jetting procedures of the KEIHIN carburetor should have their local authorized Suzuki dealer perform these alterations. Mechanically experienced riders can alter the carburetor settings based on the fol- lowing information and specifications.
  • Page 48 MACHINE TUNING 4-3 As shown below, each of the asterisk (*) marked parts is located between the air/fuel passage and has its own air/fuel mixture adjustable range in terms of the throttle valve opening. The chart indicates that the car- buretor can supply correct air/fuel mixture to the engine in any range because of the overlapping adjustable range of the each part.
  • Page 49 4-4 MACHINE TUNING Needle Clip Position Jet Needle Lean Needle O.D. of Needle clip Rich Clip The jet needle is linked to the throttle valve by Needle number means of the needle clip. Its lower part is tapered NEDH and it has five grooves cut in the upper part where O.D.
  • Page 50 MACHINE TUNING 4-5 Throttle stop screw When the throttle stop screw is turned clockwise, the throttle valve is forced upward allowing the engine to continue idling. Throttle valve opening After touching the throttle stop screw to the Standard throttle valve, turn in the stop screw five to six turns to raise the throttle valve.
  • Page 51: Carburetor Tuning In Practice

    4-6 MACHINE TUNING CARBURETOR TUNING IN PRACTICE In the previous section, basic principles of carburetor tuning have been discussed. Described in this section are the bases for carburetor tuning required when coping with variations in air (oxygen) concentration. Variation in Air (Oxygen) Concentration and Carburetor Conditions As the air, affected by the temperature, altitude and humidity, gets expanded or compressed, air (oxygen) concentration varies accordingly.
  • Page 52 MACHINE TUNING 4-7 Judging Air/Fuel Mixture Included Parts and Optional Parts For proper carburetor tuning, it is necessary to know how to judge the air/fuel mixture made in the Main jet carburetor; whether too rich, too lean or properly Air/fuel mixed.
  • Page 53 4-8 MACHINE TUNING 2 Adjustment of main system Jet needle With the throttle opened 3/4 to full, make main sys- Air/fuel SIZE P/NO. tem adjustment monitoring the air/fuel mixture con- mixture dition after completion of slow system settings. Lean NECL 13383-37FG0 * Make sure to adjust the main system before NEDL...
  • Page 54: Front Fork Tuning

    MACHINE TUNING 4-9 FRONT FORK TUNING The front fork compression and rebound damping force, and oil level are adjustable for rider’s preference, rider’s weight and course condition. NOTE: * Break-in new front forks before attempting adjustment. * Be sure to adjust both right and left front forks equally. * Inspect the following items before attempting adjustment.
  • Page 55: Oil Quantity Minor Adjustment

     Front fork oil quantity (With standard fork spring used) Standard: 350 ml (11.83/12.32 US/lmp oz) Oil quantity adjustable range: 305 – 400 ml (10.31/10.74 – 13.52/14.08 US/lmp oz)  99000-99001-SS5: SUZUKI FORK OIL SS-05 (or equivalent fork oil)
  • Page 56: Oil Change (only For Outer Tube Oil Chamber)

    MACHINE TUNING 4-11 OIL CHANGE (Only for outer tube oil chamber) • Remove the front forks. (16-3) • Thoroughly clean the fork before disassembly. CAUTION The fork oil quantity must be adjusted equally on both fork legs to provide equal performance. Scratches or other damage on the inner tube or on the oil seal lip will cause oil leak.
  • Page 57 4-12 MACHINE TUNING • Slide down the outer tube. • Pour the specified amount of fork oil into the outer tube.  99000-99001-SS5: SUZUKI FORK OIL SS-05 (or equivalent fork oil) NOTE: Be sure to adjust the fork oil quantity within the range below.
  • Page 58: Spring Change

    MACHINE TUNING 4-13 SPRING CHANGE • Remove the front forks. (16-3) • Thoroughly clean the fork before disassembly. CAUTION The fork oil quantity and spring rate must be adjusted equally on both fork legs to provide equal perfor- mance. Scratches or other damage the on inner tube or on the oil seal lip will cause oil leak.
  • Page 59 13.69/14.26 US/lmp oz) 305 – 400 ml 350 ml (10.31/10.74 – (11.83/12.32 US/lmp oz) 13.52/14.08 US/lmp oz) 300 – 395 ml 345 ml HARD (10.14/10.56 – (11.66/12.15 US/lmp oz) 13.35/13.91 US/lmp oz)  99000-99001-SS5: SUZUKI FORK OIL SS-05 (or equivalent fork oil)
  • Page 60: Front Fork Tuning Procedure

    MACHINE TUNING 4-15 FRONT FORK TUNING PROCEDURE Test ride the motorcycle and find out how the front suspension reacts on various types of surface. According to the symptom noticed, adjust the front fork to the best setting for rider and race track conditions. To adjust, attempt changing fork oil capacity and compression/rebound damping following the instructions below.
  • Page 61: Rear Suspension Tuning

    4-16 MACHINE TUNING REAR SUSPENSION TUNING The rear suspension compression and rebound damping force, and spring pre-load are adjustable for rider’s preference, rider’s weight and course condition. NOTE: * Break-in the rear suspension when riding with a new rear cushion unit. (1-5) * Inspect the following items before attempting adjustment.
  • Page 62: Spring Pre-load Adjustment

    MACHINE TUNING 4-17 SPRING PRE-LOAD ADJUSTMENT • Place a block under chassis tubes. • Remove the seat. (5-4) • Loosen the air cleaner clamp screw. • Remove the right frame cover. (5-2) • Remove the silencer and rear frame assembly. •...
  • Page 63: Rear Suspension Tuning Procedure

    4-18 MACHINE TUNING REAR SUSPENSION TUNING PROCEDURE • Select the rear suspension according to the rider’s weight and preference by referring to the table below. Spring Part No. Spring rate Set-length adjustable range 62211-37FH0 48 N/mm (4.8 kgf/mm) Soft 62211-37FJ0 51 N/mm (5.1 kgf/mm) 245 –...
  • Page 64 MACHINE TUNING 4-19 After the sag measurement has been set in 104 mm (4.09 in), test ride the motorcycle and adjust the sus- pension for the rider and track conditions referring to the guide below. SYMPTOM SECTION ADJUSTMENT PROCEDURE Feels too hard overall •...
  • Page 65: Suspension Balance

    4-20 MACHINE TUNING SUSPENSION BALANCE Balancing the front to rear suspension properly is the most critical adjustment for suspension performance. If the front forks are adjusted harder than the rear suspension, such as changing to heavier front fork oil, stiffer compression and rebound setting, air pressure build up in the forks and so on, the front forks will collapse less on bumps.
  • Page 66: Engine Removal And Installation

    ENGINE REMOVAL AND INSTALLATION 5-1 ENGINE REMOVAL AND INSTALLATION CONTENTS EXTERIOR PARTS ..................5- 2 CONSTRUCTION ..................5- 3 SEAT RAIL, DRIVE CHAIN CONTROL ROLLER ........ 5- 3 ENGINE DISMOUNTING ................5- 4 ENGINE MOUNTING ................... 5- 8 INSPECTION AFTER ENGINE MOUNTING ......... 5-10...
  • Page 67: Exterior Parts

    5-2 ENGINE REMOVAL AND INSTALLATION EXTERIOR PARTS 10 N·m (1.0 kgf-m, 7.0 lb-ft) 10 N . m 1.0 kgf-m 7.0 lb-ft 5 N·m (0.5 kgf-m, 3.5 lb-ft) 10 N . m 1.0 kgf-m 7.0 lb-ft 10 N . m 1.0 kgf-m 10 N .
  • Page 68: Construction

    ENGINE REMOVAL AND INSTALLATION 5-3 CONSTRUCTION SEAT RAIL, DRIVE CHAIN CONTROL ROLLER 23 N·m (2.3 kgf-m, 16.5 lb-ft) 43 N·m (4.3 kgf-m, 31.0 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft) 31 N·m (3.1 kgf-m, 22.5 lb-ft) 31 N·m (3.1 kgf-m, 22.5 lb-ft)
  • Page 69: Engine Dismounting

    5-4 ENGINE REMOVAL AND INSTALLATION ENGINE DISMOUNTING • Drain transmission oil. (2-10) • Drain engine coolant. (2-12) • Remove the seat 1. • Turn the fuel valve lever to the “OFF” position. • Disconnect the fuel hose. • Remove the fuel tank 2 with the radiator cover. •...
  • Page 70 ENGINE REMOVAL AND INSTALLATION 5-5 • Remove the exhaust pipe 3. • Remove the exhaust pipe gasket 4. • Disconnect the radiator hoses 5 and 6. • Disconnect the spark plug cap 7. • Disconnect the magneto lead wire coupler 8 and clamp. •...
  • Page 71 5-6 ENGINE REMOVAL AND INSTALLATION • Remove the cotter pins and brake pedal 0. • Remove the magneto cover. (13-10) • Disconnect the clutch cable. NOTE: Loosen the clutch cable adjuster when disconnecting. (2-13) • Extract the clutch cable A. •...
  • Page 72 ENGINE REMOVAL AND INSTALLATION 5-7 • Extract three quarters of the swingarm pivot shaft so as to keep the swingarm in position. NOTE: The swingarm will come off when the swingarm pivot shaft is completely removed. • Dismount the engine to the right side.
  • Page 73: Engine Mounting

    5-8 ENGINE REMOVAL AND INSTALLATION ENGINE MOUNTING Reassemble the removed parts in the reverse order of removal. Pay attention to the following points: • Mount the engine from the right side. • Tighten the engine mounting bolts/nuts to the specified torque. N·m kgf-m lb-ft...
  • Page 74 ENGINE REMOVAL AND INSTALLATION 5-9 • Install the spring 1 as shown. SECT AA • Apply grease to the brake pedal pivot bolt.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) Protector Protector • Tighten the brake pedal pivot bolt 2.
  • Page 75: Inspection After Engine Mounting

    5-10 ENGINE REMOVAL AND INSTALLATION INSPECTION AFTER ENGINE MOUNTING After mounting the engine, inspect the followings. • Transmission oil level (2-9) • Engine coolant level (2-11) • Throttle cable play (2-13) • Clutch cable play (2-13) • Drive chain slack (2-16) •...
  • Page 76: Cylinder, Piston And Exhaust Valve

    CYLINDER, PISTON AND EXHAUST VALVE 6-1 CYLINDER, PISTON AND EXHAUST VALVE CONTENTS CONSTRUCTION ..................6- 2 CYLINDER, PISTON ................6- 2 EXHAUST PIPE, SILENCER ..............6- 3 EXHAUST VALVE ................. 6- 4 REMOVAL ....................6- 5 CYLINDER HEAD ................. 6- 5 CYLINDER .....................
  • Page 77: Construction

    CYLINDER, PISTON AND EXHAUST VALVE CONSTRUCTION CYLINDER, PISTON 20 N . m (2.0 kgf-m, 14.5 lb-ft) 45 N . m (4.5 kgf-m, 32.5 lb-ft) 25 N . m (2.5 kgf-m, 18.0 lb-ft) 4.5 N . m (0.45 kgf-m, 3.0 lb-ft) 1216 38 N .
  • Page 78: Exhaust Pipe, Silencer

    CYLINDER, PISTON AND EXHAUST VALVE 6-3 EXHAUST PIPE, SILENCER 10 N . m (1.0 kgf-m, 7.0 lb-ft) 10 N . m (1.0 kgf-m, 7.0 lb-ft) 10 N . m (1.0 kgf-m, 7.0 lb-ft)
  • Page 79: Exhaust Valve

    CYLINDER, PISTON AND EXHAUST VALVE EXHAUST VALVE 4.5 N . m (0.45 kgf-m, 3.0 lb-ft) 4.5 N . m (0.45 kgf-m, 3.0 lb-ft) 4 N . m (0.4 kgf-m, 3.0 lb-ft) 10 N . m (1.0 kgf-m, 7.0 lb-ft) 4.5 N . m (0.45 kgf-m, 3.0 lb-ft)
  • Page 80: Removal

    CYLINDER, PISTON AND EXHAUST VALVE 6-5 REMOVAL CYLINDER HEAD • Drain engine coolant. (2-12) • Remove the seat and fuel tank. (5-4) • Disconnect the radiator hose 1. • Disconnect the spark plug cap 2 and remove the spark plug •...
  • Page 81: Piston And Piston Ring

    CYLINDER, PISTON AND EXHAUST VALVE • Remove the exhaust valve rod bolt 4. • Remove the radiator guards 5. (left & right) • Remove the radiator lower mounting bolts (left & right) and move the radiator forward. • Remove the reed valve. (11-11) •...
  • Page 82: Inspection

    CYLINDER, PISTON AND EXHAUST VALVE 6-7 NOTE: Use the special tool if necessary.  09910-34510: Piston pin puller • Remove the conrod small end bearing 4. INSPECTION CYLINDER HEAD • Remove carbon deposits from the cylinder head. • Inspect the cylinder head for cracks around the spark plug hole.
  • Page 83: Piston To Cylinder Clearance

    CYLINDER, PISTON AND EXHAUST VALVE • Inspect for cylinder distortion with the thickness gauge.  Cylinder distortion: Service limit: 0.05 mm (0.002 in)  09900-20803: Thickness gauge • Measure the cylinder bore for wear with the cylinder gauge at 20 mm (0.79 in) from the top surface. NOTE: The cylinder bore must be measured perpendicular to the crank- shaft axis direction.
  • Page 84 CYLINDER, PISTON AND EXHAUST VALVE 6-9 • Remove carbon deposits from piston ring and piston ring groove. • Measure the clearances with the thickness gauge.  Piston ring to groove clearance Standard: 0.02 – 0.06 mm (0.0008 – 0.0024 in) ...
  • Page 85: Installation

    6-10 CYLINDER, PISTON AND EXHAUST VALVE INSTALLATION PISTON AND PISTON RING Install the piston and piston ring in the reverse order of removal. Pay attention to the following points: • Apply engine oil to the piston rings and piston ring grooves. •...
  • Page 86: Cylinder

    • Install the caburetor. (11-7) • Install the exhaust pipe. (5-9) • Apply grease to the O-rings. • Install new O-rings 4 and 5.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) NOTE: Apply Bond to the stud bolt threads when assembling the removed stud bolts into the cylinder.
  • Page 87: Cylinder Head

    6-12 CYLINDER, PISTON AND EXHAUST VALVE CYLINDER HEAD • Tighten the cylinder head nuts to the specified torque accord- ing to the specified tightening order as shown.  Cylinder head nut: Initial:15 N·m (1.5 kgf-m, 11.0 lb-ft) Final: 25 N·m (2.5 kgf-m, 18.0 lb-ft) •...
  • Page 88: Exhaust Valve

    CYLINDER, PISTON AND EXHAUST VALVE 6-13 EXHAUST VALVE DISASSEMBLY • Remove the cylinder. (6-6) • Remove the cylinder breather hose 1 and exhaust valve breather hose 2. EXHAUST SIDE VALVE (RH) • Remove the exhaust side valve spacer 3. • Remove the exhaust side valve cam 4 and pin 5. •...
  • Page 89 6-14 CYLINDER, PISTON AND EXHAUST VALVE • Remove the exhaust valve shaft retainer 0. EXHAUST SIDE VALVE (LH) • Remove the side valve cap 1 and gasket. • Remove the spacer, exhaust valve cam and exhaust side valve in the same manner as the right side. •...
  • Page 90: Inspection

    CYLINDER, PISTON AND EXHAUST VALVE 6-15 • Remove the exhaust valve shaft arm bolts. • Remove the exhaust valve shaft 2. • Remove the following parts. 3 Exhaust valve arm 4 Spring 5 Right exhaust side valve rod 6 Left exhaust side valve rod •...
  • Page 91: Reassembly

    6-16 CYLINDER, PISTON AND EXHAUST VALVE REASSEMBLY Reassemble the exhaust valve in the reverse order of disassem- bly. Pay attention to the following points: • Apply engine oil to the exhaust side valve rods. • Install the exhaust side valve rods into the cylinder. NOTE: Yellow White...
  • Page 92 CYLINDER, PISTON AND EXHAUST VALVE 6-17 • Install a new gasket. • Install the return spring with its end engaged the groove of the exhaust valve shaft and the other side the spring cap. • Temporarily tighten the bolts B. •...
  • Page 93 6-18 CYLINDER, PISTON AND EXHAUST VALVE • Install the exhaust side valve cam as following. Right side : Yellow paint Left side : White paint Exhaust side valve cam Approx. 35˚ Exhaust side valve Install the exhaust side valve cam with In above position, the pin behind the aligning the emboss A with the pin of the exhaust side valve cam engages the...
  • Page 94: Exhaust Valve Governer And Actuator

    CYLINDER, PISTON AND EXHAUST VALVE 6-19 EXHAUST VALVE GOVERNER AND ACTUATOR DISASSEMBLY • Drain the transmission oil. (2-10) • Drain the engine coolant. (2-12) • Remove the exhaust pipe. (5-5) • Remove the exhaust side valve cover. (6-5) • Remove the right crankcase cover. (8-3) •...
  • Page 95: Inspection

    6-20 CYLINDER, PISTON AND EXHAUST VALVE • Disassemble the following parts from governer. 4 Retainer 0 Washer 5 Spring A Bearing 6 Retainer B Stater 7 Bearing C Balls 8 Washer D Governer 9 Spacer INSPECTION • Inspect the governer for wear and damage. •...
  • Page 96 CYLINDER, PISTON AND EXHAUST VALVE 6-21 • Install the governer with the actuator B engaged with the groove C of the governer. • Connect the exhaust valve rod to the exhaust valve shaft and tighten the exhaust valve rod bolt using the pin 1 as a stop- per.
  • Page 97 – MEMO –...
  • Page 98 CLUTCH 7-1 CLUTCH CONTENTS CONSTRUCTION ..................7- 2 REMOVAL ....................7- 3 CLUTCH PLATE ................... 7- 3 PRIMARY DRIVEN GEAR AND CLUTCH SLEEVE HUB ....7- 4 CLUTCH RELEASE CAMSHAFT ............7- 5 INSPECTION ....................7- 5 DRIVE PLATE ..................7- 5 DRIVEN PLATE ..................
  • Page 99: Construction

    7-2 CLUTCH CONSTRUCTION 11 N·m (1.1 kgf-m, 8.0 lb-ft) 5 N·m (0.5 kgf-m, 3.5 lb-ft) 90 N·m (9.0 kgf-m, 65.0 lb-ft)
  • Page 100: Removal

    CLUTCH 7-3 REMOVAL CLUTCH PLATE • Drain transmission oil. (2-10) • Remove the rear brake pedal. (5-6) • Remove the clutch cover 1. • Loosen and remove the bolts diagonally. • Remove the clutch springs. • Remove the pressure plate 2. •...
  • Page 101: Primary Driven Gear And Clutch Sleeve Hub

    7-4 CLUTCH PRIMARY DRIVEN GEAR AND CLUTCH SLEEVE HUB • Flatten the lock washer. • Hold the clutch sleeve hub with the special tool and remove the clutch sleeve hub nut.  09920-53740: Clutch sleeve hub holder • Remove the lock washer 1 and clutch sleeve hub 2. •...
  • Page 102: Clutch Release Camshaft

    CLUTCH 7-5 CLUTCH RELEASE CAMSHAFT • Remove the magneto cover, magneto rotor and stator. (13-10) • Loosen the clutch cable adjuster and unhook the clutch cable. (2-13, 5-6) • Remove the clutch release camshaft 1. INSPECTION DRIVE PLATE • Inspect the drive plates for wear, distortion and discoloration. •...
  • Page 103: Clutch Spring

    7-6 CLUTCH CLUTCH SPRING • Measure the clutch spring free length.  Clutch spring free length Service limit: 49.4 mm (1.94 in)  09900-20101: Vernier calipers NOTE: Replace six clutch springs together even if only one spring is beyond the service limit. CLUTCH PUSH ROD AND PUSH PIECE •...
  • Page 104: Oil Seal And Bearing

    CLUTCH 7-7 OIL SEAL AND BEARING • Inspect the oil seal for damage and oil leakage. • Inspect the bearings for abnormal noise, wear and damage. OIL SEAL REMOVAL AND INSTALLATION (10-9, -10) BEARING REMOVAL AND INSTALLATION (10-12, -13) INSTALLATION Install the clutch assembly in the reverse order of removal.
  • Page 105: Clutch Plate

    7-8 CLUTCH • Tighten the clutch sleeve hub nut with the special tool to the specified torque.  Clutch sleeve hub nut: 90 N·m (9.0 kgf-m, 65.0 lb-ft)  09920-53740: Clutch sleeve hub holder • Bend the lock washer to secure the nut. CLUTCH PLATE •...
  • Page 106: Clutch Cover

    CLUTCH COVER • Replace the O-ring with a new one. • Apply grease to the O-ring.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the clutch cover 1.  Clutch cover bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft) CLUTCH RELEASE CAMSHAFT •...
  • Page 107 – MEMO –...
  • Page 108: Kick Starter

    KICK STARTER 8-1 KICK STARTER CONTENTS CONSTRUCTION ..................8- 2 REMOVAL ....................8- 3 INSPECTION ....................8- 4 OIL SEAL ....................8- 4 KICK STARTER ..................8- 4 KICK STARTER IDLE GEAR ..............8- 4 REASSEMBLY .................... 8- 5 INSPECTION AFTER REASSEMBLY ..........8- 6...
  • Page 109: Construction

    8-2 KICK STARTER CONSTRUCTION 23 N·m (2.3 kgf-m, 16.5 lb-ft) 10 N·m (1.0 kgf-m, 7.0 lb-ft)
  • Page 110: Removal

    KICK STARTER 8-3 REMOVAL • Drain transmission oil. (2-10) • Drain the engine coolant. (2-12) • Remove the brake pedal. (5-6) • Disconnect the radiator hose. • Remove the kick starter lever. • Remove the crankcase cover. • Remove the clutch. (7-3, -4) •...
  • Page 111: Inspection

    8-4 KICK STARTER INSPECTION OIL SEAL • Inspect the oil seal for oil leakage and oil seal lip damage. • Remove the oil seal with the special tool.  09913-50121: Oil seal remover • Install the oil seal with the special tool. ...
  • Page 112: Reassembly

    KICK STARTER 8-5 REASSEMBLY Reassemble the kick starter assembly in the reverse order of disassembly. Pay attention to the following points: • Apply transmission oil to the kick starter shaft. • Install the return spring 1 into the kick starter shaft hole A. •...
  • Page 113: Inspection After Reassembly

    8-6 KICK STARTER • Install the clutch. (7-7, -8) • Fit a new gasket 6 and dowel pins. • Install the crankcase cover.  Crankcase cover bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft) • Install the kick starter lever.  Kick starter lever bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) •...
  • Page 114: Gearshifting

    GEARSHIFTING 9-1 GEARSHIFTING CONTENTS CONSTRUCTION ..................9- 2 REMOVAL ....................9- 3 INSPECTION ....................9- 5 REASSEMBLY .................... 9- 6...
  • Page 115: Construction

    9-2 GEARSHIFTING CONSTRUCTION 10 N·m (1.0 kgf-m, 7.0 lb-ft) 20 N·m (2.0 kgf-m, 14.5 lb-ft) 10 N·m (1.0 kgf-m, 7.0 lb-ft) 23.5 N·m (2.35 kgf-m, 17.0 lb-ft) 10 N·m (1.0 kgf-m, 7.0 lb-ft)
  • Page 116: Removal

    GEARSHIFTING 9-3 REMOVAL • Drain transmission oil. (2-10) • Drain engine coolant. (2-12) • Remove the drive chain clip and open the drive chain. (5-5) • Remove the gearshift lever 1. NOTE: Mark the gearshift shaft with slit position of the gearshift lever for right installation position.
  • Page 117 9-4 GEARSHIFTING • Remove the gearshift cam bolt 9 and stopper plate 0. • Remove the gearshift arm stopper bolt A and washer B. • Remove the gearshift cam stopper C. • Remove the spring D. • Remove the gearshift return spring E by removing the snap ring.
  • Page 118: Inspection

    GEARSHIFTING 9-5 INSPECTION • Inspect the gearshift shaft 1 for bends and damage. • Inspect the gearshift return spring 2 for damage. • Inspect the pawls 3, pins 4 and springs 5 for damage.
  • Page 119: Reassembly

    9-6 GEARSHIFTING REASSEMBLY • Temporarily install the spring 1, washer 2 and gearshift cam stopper 3. • Hook the spring 1 to the projection A. • Tighten the gearshift cam stopper bolt. • Align the pin groove B with the pin C when installing the stopper plate 4.
  • Page 120 GEARSHIFTING 9-7 • Fit the springs 7, pins 8 and pawls 9 to the gearshift cam driven gear 0. Wider side D of pawl should be positioned outside. • With the pawls held in pushed position, install the pawl lifter •...
  • Page 121 9-8 GEARSHIFTING • Align the center teeth on the gearshift shaft with the center teeth on the gearshift cam shifter. • Reassemble the clutch and crankcase cover. (7-8, 8-6) • Install the gearshift lever.  Gearshift lever bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) •...
  • Page 122: Transmission And Crankshaft

    TRANSMISSION AND CRANKSHAFT 10-1 TRANSMISSION AND CRANKSHAFT CONTENTS CONSTRUCTION ..................10- 2 CRANKSHAFT AND CRANKCASE ........... 10- 2 TRANSMISSION ................. 10- 3 ENGINE BOTTOM SIDE ................10- 4 PRIMARY DRIVE GEAR REMOVAL ..........10- 4 CRANKCASE SEPARATION ............. 10- 5 TRANSMISSION REMOVAL ..............
  • Page 123: Construction

    10-2 TRANSMISSION AND CRANKSHAFT CONSTRUCTION CRANKSHAFT AND CRANKCASE 70 N·m (7.0 kgf-m, 50.5 lb-ft) 21 N·m (2.1 kgf-m, 15.0 lb-ft) 5.5 N·m (0.55 kgf-m, 4.0 lb-ft)
  • Page 124: Transmission

    TRANSMISSION AND CRANKSHAFT 10-3 TRANSMISSION 10 N·m (1.0 kgf-m, 7.0 lb-ft) 10 N·m (1.0 kgf-m, 7.0 lb-ft) 10 N·m (1.0 kgf-m, 7.0 lb-ft)
  • Page 125: Engine Bottom Side

    10-4 TRANSMISSION AND CRANKSHAFT ENGINE BOTTOM SIDE • Dismount the engine. (5-4) NOTE: The following parts must be removed before disassembling the engine bottom side (crankcase). • Remove the engine sprocket 1. • Remove the gearshift lever. (9-3) • Remove the kick starter lever. (8-3) •...
  • Page 126: Crankcase Separation

    TRANSMISSION AND CRANKSHAFT 10-5 • Remove the washer 2 and primary drive gear 3. • Remove the magneto rotor, stator and key. (13-10) • Remove the clutch release camshaft. (7-5) CRANKCASE SEPARATION • Remove the engine sprocket spacer 1 and two O-rings 2. •...
  • Page 127: Transmission Removal

    10-6 TRANSMISSION AND CRANKSHAFT TRANSMISSION REMOVAL • Remove the dowel pins 1 and gasket 2. • Remove the gearshift fork shafts 3. • Remove the gearshift cam 4. • Remove the gearshift forks 5. • Remove the driveshaft assembly 6 and countershaft assem- bly 7.
  • Page 128 TRANSMISSION AND CRANKSHAFT 10-7 • Inspect the gearshift cam groove for abnormal wear and dam- age. • Inspect the gearshift forks and shafts for wear and damage. • Measure the gearshift fork thickness with a vernier calipers.  Gearshift fork thickness Standard: 4.6 –...
  • Page 129: Crankshaft Inspection

    10-8 TRANSMISSION AND CRANKSHAFT CRANKSHAFT INSPECTION • Measure the conrod small end inside diameter with the small bore gauge.  Conrod small end I.D. Service Limit: 23.040 mm (0.907 in)  09900-20605: Dial calipers (10 – 34 mm) • Measure the conrod deflection with the special tools. ...
  • Page 130: Oil Seal Inspection

    TRANSMISSION AND CRANKSHAFT 10-9 • Measure the crankshaft web to web width with a vernier cali- pers.  Crankshaft web to web width Standard: 59.9 – 60.1 mm (2.358 – 2.366 in)  09900-20101: Vernier calipers OIL SEAL INSPECTION • Inspect each oil seal lip for wear and damage. OIL SEAL REMOVAL •...
  • Page 131: Oil Seal Installation

    Oil seal 1:  25 Attachment Oil seal 2:  40 Attachment Oil seal 3:  37 Attachment Oil seal 4:  22 Attachment Oil seal 5:  42 Attachment  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) NOTE: Magneto Clutch...
  • Page 132: Bearing Inspection

    TRANSMISSION AND CRANKSHAFT 10-11 BEARING INSPECTION • Inspect the each bearings for play, discoloration, wear and seizure. • Move the inner race by finger and inspect for smooth move- ment.
  • Page 133: Bearing Removal

    10-12 TRANSMISSION AND CRANKSHAFT BEARING REMOVAL • Remove the each bearing retainers. • Remove the bearings with the special tools. Bearing 1, 2, 3, 4, 5, 6:  35 Attachment  09913-70210: Bearing remover/installer set • Remove the bearings 7, 8. ...
  • Page 134: Bearing Installation

    TRANSMISSION AND CRANKSHAFT 10-13 BEARING INSTALLATION • Press the each bearings with the special tools. Bearing 1, 5:  63 Attachment Bearing 2:  52 Attachment Bearing 3, 4:  42 Attachment Bearing 6:  55 Attachment Bearing 7:  40 Attachment Bearing 8: ...
  • Page 135: Transmission Reassembly

    Gearshift shafts Gearshift cam • Install the gearshift cam and gearshift forks. NOTE: The shape of the gearshift fork for countershaft is different from the others. (10-7) • Apply MOLY PASTE to the 5th drive gear.  99000-25140: SUZUKI MOLY PASTE...
  • Page 136: Crankcase Reassembly

    • Inspect the crankshaft, countershaft and driveshaft for smooth movement. • Apply grease to new O-rings 1. • Fit the O-rings 1 and spacer 2 to the driveshaft.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease)
  • Page 137: Primary Drive Gear Reassembly

    10-16 TRANSMISSION AND CRANKSHAFT PRIMARY DRIVE GEAR REASSEMBLY • Reassemble the clutch release camshaft. (7-9) • Reassemble the stator and magneto rotor. (13-11) • Install the primary drive gear and washer. NOTE: The washer is directional. Assemble the washer 1 as shown in the illustration.
  • Page 138: Fuel System

    FUEL SYSTEM 11-1 FUEL SYSTEM CONTENTS CARBURETOR ..................11- 2 CONSTRUCTION ................11- 2 REMOVAL AND DISASSEMBLY ............11- 3 CLEANING ..................11- 5 INSPECTION ..................11- 6 REASSEMBLY AND REMOUNTING ..........11- 7 CARBURETOR SOLENOID ..............11- 8 REMOVAL AND INSPECTION ............11- 8 REASSEMBLY ..................
  • Page 139: Carburetor

    11-2 FUEL SYSTEM CARBURETOR CONSTRUCTION...
  • Page 140: Removal And Disassembly

    FUEL SYSTEM 11-3 REMOVAL AND DISASSEMBLY • Open the clamp 1. • Disconnect the throttle position sensor coupler 2 and carbu- retor solenoid coupler 3. • Turn the fuel cock to OFF and disconnect the fuel hose 4. • Loosen the carburetor clamp screws and remove the carbure- tor.
  • Page 141 11-4 FUEL SYSTEM • Remove the cable holder 7. • Disassemble the throttle valve assembly as follows. Carburetor top cap 5 Cable holder 7 Collar spring 8 Collar 9 Clip and jet needle 0 Throttle valve A Throttle valve collar B Throttle valve spring C •...
  • Page 142: Cleaning

    FUEL SYSTEM 11-5 Carburetor solenoid K Throttle stop screw L and spring Starter knob M Air screw N, spring, washer and O-ring NOTE: Before removing the air screw N, Turn it clockwise until it lightly seats and record the number of turns. CLEANING ...
  • Page 143: Inspection

    11-6 FUEL SYSTEM INSPECTION • Inspect the following parts for damage. Jet needle Screws Throttle valve Springs Float • Inspect the following parts for clogging. Main jet Power jet Slow jet Starter jet Hoses Carburetor body NEEDLE VALVE • Inspect the needle valve tip for wear. Good Worn •...
  • Page 144: Reassembly And Remounting

    FUEL SYSTEM 11-7 REASSEMBLY AND REMOUNTING Reassembly and remounting is in the reverse order of removal and disassembly. Pay attention to the following points: • Fit the projection of the throttle valve collar into the groove of cable holder. • Set the throttle position sensor guide roller upon the throttle valve.
  • Page 145: Carburetor Solenoid

    11-8 FUEL SYSTEM CARBURETOR SOLENOID REMOVAL AND INSPECTION • Remove the carburetor solenoid 1. Make sure the coupler 2 is connected. • Connect the tachometer sensor. • Shift the transmission into neutral. • Start the engine. • Inspect if the solenoid valve switches according to the follow- ing engine RPM.
  • Page 146: Throttle Position Sensor

    FUEL SYSTEM 11-9 THROTTLE POSITION SENSOR INSPECTION THROTTLE POSITION SENSOR INPUT VOLTAGE • Disconnect the throttle position sensor coupler 1. • Shift the transmission into neutral. • Start the engine. B/Bl B/Br B/G • Measure the throttle position sensor input voltage with the multi-circuit tester.
  • Page 147: Removal

    11-10 FUEL SYSTEM REMOVAL • Remove the carburetor. (11-3) • Remove the throttle position sensor using the special tool.  09930-11960: Torx wrench, T20 CAUTION Do not loosen the bolt A.
  • Page 148: Reed Valve

    FUEL SYSTEM 11-11 REED VALVE CONSTRUCTION 10 N·m (1.0 kgf-m, 7.0 lb-ft) REMOVAL • Remove the carburetor. (11-3) • Remove the intake pipe 1. • Remove the reed valve 2, spacer 3 and gasket 4.
  • Page 149: Inspection

    11-12 FUEL SYSTEM INSPECTION • Inspect the reeds for damage. • Inspect the reed stoppers for damage. • Inspect the valve seat rubber for damage. • Inspect the reed valve clearance.  Reed valve clearance Service limit: 0.2 mm (0.008 in) ...
  • Page 150: Cooling System

    COOLING SYSTEM 12-1 COOLING SYSTEM CONTENTS CONSTRUCTION ..................12- 2 COOLING CIRCUIT ................... 12- 3 INSPECTION ..................12- 3 RADIATOR ....................12- 4 REMOVAL ................... 12- 4 INSPECTION ..................12- 4 INSTALLATION ................... 12- 4 WATER PUMP ................... 12- 5 REMOVAL ...................
  • Page 151: Construction

    12-2 COOLING SYSTEM CONSTRUCTION 5.5 N . m (0.55 kgf-m, 4.0 lb-ft) 10 N . m (1.0 kgf-m, 7.0 lb-ft)
  • Page 152: Cooling Circuit

    COOLING SYSTEM 12-3 COOLING CIRCUIT INSPECTION • Remove the radiator cap. • Connect the tester 1 to the filler.  WARNING Do not remove the radiator cap when the engine is hot. • Give a pressure of about 120 kPa (1.2 kgf/cm , 17 psi) and see if the system holds this pressure for 10 seconds.
  • Page 153: Radiator

    12-4 COOLING SYSTEM RADIATOR REMOVAL • Remove the seat and fuel tank. (5-4) • Drain engine coolant. (2-12) • Remove the radiator covers 1. (LH & RH) • Remove the hoses. • Remove the radiators. INSPECTION RADIATOR • Visually inspect the radiator for damage. •...
  • Page 154: Water Pump

    COOLING SYSTEM 12-5 WATER PUMP REMOVAL • Drain engine coolant. (2-12) • Drain transmission oil. (2-10) • Remove the kick starter lever. (8-3) • Remove the brake pedal. (5-6) • Disconnect the radiator hose 1. • Remove the water pump cover 2. •...
  • Page 155: Inspection

    12-6 COOLING SYSTEM INSPECTION IMPELLER AND GEAR SHAFT • Inspect the impeller and gear shaft for damage. WATER PUMP BEARING Play Inspect the inner race play of the water pump bearing while it is Play in the water pump housing. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation.
  • Page 156: Reassembly

    (or equivalent thread lock) • Press the oil seal with the suitable size socket wrench. • Apply grease to the oil seal lip.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install a new bearing with the special tool.
  • Page 157 12-8 COOLING SYSTEM Apply THREAD LOCK SUPER or equivalent thread lock to outside of the oil seal before installing it. Washer Water pump shaft Water pump driven gear Water pump case Bearing Oil seal Impeller Washer • Install the dowel pins 1 and a new gasket 2. CAUTION Use a new gasket to prevent engine coolant leakage.
  • Page 158: Electrical System

    ELECTRICAL SYSTEM 13-1 ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ............... 13- 2 CONNECTOR ..................13- 2 COUPLER ................... 13- 2 SEMI-CONDUCTOR EQUIPPED PART ..........13- 2 USING THE MULTI-CIRCUIT TESTER ..........13- 2 SWITCH ....................13- 2 LOCATION OF ELECTRICAL COMPONENTS ........13- 3 CONSTRUCTION ..................
  • Page 159: Cautions In Servicing

    13-2 ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTOR • When connecting a connector, be sure to push it in until a click is felt. Click • Inspect the connector for corrosion, contamination and break- age in its cover. COUPLER Click • With a lock type coupler, be sure to release the lock when dis- connecting, and push in fully to engage the lock when con- necting.
  • Page 160: Location Of Electrical Components

    ELECTRICAL SYSTEM 13-3 LOCATION OF ELECTRICAL COMPONENTS 1 Engine stop switch 3 CDI unit 2 Ignition coil 4 Magneto, pick-up coil...
  • Page 161: Construction

    13-4 ELECTRICAL SYSTEM CONSTRUCTION MAGNETO ROTOR AND STATOR 10 N·m (1.0 kgf-m, 7.0 lb-ft) 55 N·m (5.5 kgf-m, 40.0 lb-ft) 11 N·m (1.1 kgf-m, 8.0 lb-ft)
  • Page 162: Electrical Circuit

    ELECTRICAL SYSTEM 13-5 ELECTRICAL CIRCUIT Throttle position sensor Engine stop switch B/Br B/Br B/Bl B/Bl W/Bl Magneto W/Bl W/Bl Ignition coil CDI unit Y Y Y Spark plug Carburetor solenoid Bl/B Bl/B COLOR CODE Black B/R: Black with Red tracer Green B/W: Black with White tracer B/Y: Black with Yellow tracer...
  • Page 163 13-6 ELECTRICAL SYSTEM Step 3 1) Inspect the spark plug. (2-6) Is the spark plug OK? • Poor connection of the spark plug • Go to Step 4. Faulty spark plug Step 4 1) Measure the ignition coil resistanace. (13-8) Is the ignition coil resistanace OK? Go to Step 5.
  • Page 164: Inspection

    ELECTRICAL SYSTEM 13-7 INSPECTION IGNITION SYSTEM PEAK VOLTAGE • Remove the seat and fuel tank. (5-4) • Remove the spark plug. • Disconnect the magneto lead wire coupler 1. Measure the ignition system peak voltage in the following proce- dure: •...
  • Page 165: Ignition Coil

    13-8 ELECTRICAL SYSTEM • Connect the multi-circuit tester with the peak volt adaptor between Black/White lead wire and White/Blue lead wire. W/Bl • Measure the highest peak voltage by depressing the kick starter lever several times forcefully. Black/White – White/Blue 200 V and more NOTE: Be sure to connect the Red probe to the Black/White lead wire...
  • Page 166: Stator Coil

    ELECTRICAL SYSTEM 13-9 STATOR COIL • Remove the seat and fuel tank. (5-4) • Disconnect the magnet lead wire coupler 1. Measure the stator coils electrical resistance with the multi-cir- cuit tester. Reference data [at 20 °C (68 °F)] 24 – 40 Ω Exciter Black/Red –...
  • Page 167: Magneto Rotor And Stator

    13-10 ELECTRICAL SYSTEM MAGNETO ROTOR AND STATOR REMOVAL • Remove the seat. (5-4) • Remove the fuel tank. (5-4) • Disconnect the magneto lead wire coupler 1 and clamps. • Remove the magneto cover. • Remove the magneto rotor nut with the special tool. ...
  • Page 168: Installation

    ELECTRICAL SYSTEM 13-11 • Remove the stator. • Remove the key 2. INSTALLATION Install the stator and magneto rotor in the reverse order of removal. Pay attention to the following points: • Degrease the tapered portion of the crankshaft and magneto rotor.
  • Page 169 13-12 ELECTRICAL SYSTEM • Tighten the magneto rotor nut to the specified torque with the special tool.  Magneto rotor nut: 55 N·m (5.5 kgf-m, 40.0 lb-ft)  09930-40113: Rotor holder • Fit a new gasket. • Install the magneto cover. ...
  • Page 170: Front And Rear Wheels

    FRONT AND REAR WHEELS 14-1 FRONT AND REAR WHEELS CONTENTS FRONT WHEEL ..................14- 2 CONSTRUCTION ................14- 2 REMOVAL ................... 14- 3 INSPECTION ..................14- 3 BEARING REPLACEMENT ..............14- 4 DISC PLATE REPLACEMENT ............14- 5 INSTALLATION ................... 14- 5 REAR WHEEL ...................
  • Page 171: Front Wheel

    14-2 FRONT AND REAR WHEELS FRONT WHEEL CONSTRUCTION 35 N . m (3.5 kgf-m, 25.5 lb-ft) 10 N . m (1.0 kgf-m, 7.0 lb-ft)
  • Page 172: Removal

    • If any damage is found, replace the spacer together with the dust seal. NOTE: Apply grease to the spacer and dust seal when reassembling.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) AXLE SHAFT Support the axle shaft with V-blocks and measure the axle shaft runout.
  • Page 173: Bearing Replacement

    Right • Fit the dust seals and apply grease to their lips.  09924-84521: Bearing installer set  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) NOTE: * Install the left side (disc side) bearing first and then the right side bearing.
  • Page 174: Disc Plate Replacement

    FRONT AND REAR WHEELS 14-5 DISC PLATE REPLACEMENT • Remove the disc plate. • Apply THREAD LOCK SUPER to the bolts.  99000-32110: THREAD LOCK SUPER “1322” (or equivalent thread lock) • Install a new disc plate and tighten the bolts to the specified torque.
  • Page 175: Rear Wheel

    14-6 FRONT AND REAR WHEELS REAR WHEEL CONSTRUCTION 100 N . m (10.0 kgf-m, 72.5 lb-ft) 10 N . m 1.0 kgf-m 7.0 lb-ft 30 N . m (3.0 kgf-m, 21.5 lb-ft)
  • Page 176: Removal

    FRONT AND REAR WHEELS 14-7 REMOVAL • Place the motorcycle on a block to lift rear wheel off the ground. • Remove axle nut 1 and washer 2. • Loosen the chain adjuster lock-nuts 3 and chain adjuster bolts 4. •...
  • Page 177: Bearing Replacement

    • Reassemble the bearings and spacer with the special tool. • Fit the dust seals and apply grease to their lips.  09924-84521: Bearing installer set  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) NOTE: * Install the right side (disc side) bearing first and then the left side bearing.
  • Page 178: Rear Sprocket Replacement

    FRONT AND REAR WHEELS 14-9 REAR SPROCKET REPLACEMENT • Remove the rear sprocket. NOTE: Install the rear sprocket so the letters on the sprocket surface face outside. • Tighten the bolts/nuts to the specified torque.  Rear sprocket bolt/nut: 30 N·m (3.0 kgf-m, 21.5 lb-ft) INSTALLATION •...
  • Page 179 – MEMO –...
  • Page 180: Front And Rear Brakes

    FRONT AND REAR BRAKES 15-1 FRONT AND REAR BRAKES CONTENTS BRAKE PAD REPLACEMENT ..............15- 2 FRONT BRAKE PADS ................ 15- 2 REAR BRAKE PADS ................15- 2 BRAKE FLUID REPLACEMENT ............... 15- 4 BRAKE FLUID AIR BLEEDING ..............15- 5 BRAKE DISC INSPECTION ..............
  • Page 181: Brake Pad Replacement

    15-2 FRONT AND REAR BRAKES BRAKE PAD REPLACEMENT FRONT BRAKE PADS • Remove the plug 1. • Remove the pad mounting pin 2 behind the plug. • Remove the front brake pads. NOTE: Replace two pads as a set. • Fit new brake pads into the caliper and tighten the pad mount- ing pin to the specified torque.
  • Page 182 FRONT AND REAR BRAKES 15-3 • Apply SUZUKI SILICONE GREASE to the O-ring.  99000-25100: SUZUKI SILICONE GREASE • Fit new brake pads into the caliper and tighten the pad mount- ing pin to the specified torque.  Brake pad mounting pin: 18 N·m (1.8 kgf-m, 13.0 lb-ft)
  • Page 183: Brake Fluid Replacement

    15-4 FRONT AND REAR BRAKES BRAKE FLUID REPLACEMENT WARNING Brake fluid can be hazardous to humans and pets. Brake fluid is harmful if swallowed or if it comes in contact with skin or eyes. Keep brake fluid away from children or pets. Call doc- tor immediately if brake fluid is swallowed and induce vomiting.
  • Page 184: Brake Fluid Air Bleeding

    FRONT AND REAR BRAKES 15-5 BRAKE FLUID AIR BLEEDING • Connect a transparent tube to the air bleeder valve and set the other end into a receptacle. • Pour brake fluid up to the UPPER line.  Specification and classification: DOT 4 •...
  • Page 185: Brake Disc Inspection

    15-6 FRONT AND REAR BRAKES BRAKE DISC INSPECTION • Measure the front and rear brake disc thickness.  Brake disc thickness Service limit (Front): 2.5 mm (0.10 in) (Rear): 3.5 mm (0.14 in)  09900-20205: Micrometer (0 – 25 mm) •...
  • Page 186: Front Brake

    FRONT AND REAR BRAKES 15-7 FRONT BRAKE CONSTRUCTION 10 N·m (1.0 kgf-m, 7.0 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft) 26 N·m (2.6 kgf-m, 19.0 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft) 6 N·m (0.6 kgf-m, 4.4 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft) 23 N·m...
  • Page 187: Caliper

    15-8 FRONT AND REAR BRAKES CALIPER WARNING Brake fluid can be hazardous to humans and pets. Brake fluid is harmful or fatal if swallowed, and harm- ful if it comes in contact with your skin or eyes. Keep brake fluid away from children. Call your doctor immediately if brake fluid is swallowed and induce vomiting.
  • Page 188 FRONT AND REAR BRAKES 15-9 • Wrap the caliper with a rag to prevent brake fluid scatter and piston pop-out. • Apply low-pressure air into the caliper through the hole to remove the pistons. WARNING Fingers can get caught between piston and caliper body when removing the piston.
  • Page 189 • Replace the piston seals and dust seals with new ones. • Apply brake fluid to the piston seals, dust seals and pistons. • Apply SUZUKI SILICONE GREASE to the caliper axles. • Fit the caliper bracket and pad springs.
  • Page 190: Master Cylinder

    FRONT AND REAR BRAKES 15-11 MASTER CYLINDER WARNING Brake fluid can be hazardous to humans and pets. Brake fluid is harmful or fatal if swallowed, and harm- ful if it comes in contact with your skin or eyes. Keep brake fluid away from children. Call your doctor immediately if brake fluid is swallowed and induce vomiting.
  • Page 191 15-12 FRONT AND REAR BRAKES • Remove the dust boot 2. • Remove the snap ring 3 using the snap ring pliers. • Remove the washer 4 and piston/cup set 5.  09900-06106: Snap ring pliers INSPECTION • Inspect the cylinder for scuffing. •...
  • Page 192: Brake Lever

    • Apply grease to the brake lever adjuster return spring, pivot bolt and contact point between piston and brake lever.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Tighten the pivot bolt and pivot nut to the specified torque.
  • Page 193: Rear Brake

    15-14 FRONT AND REAR BRAKES REAR BRAKE CONSTRUCTION 29 N·m (2.9 kgf-m, 21.0 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft) 10 N·m (1.0 kgf-m, 7.0 lb-ft) 28 N·m 18 N·m 18 N·m (2.8 kgf-m, (1.8 kgf-m, 13.0 lb-ft) (1.8 kgf-m, 20.0 lb-ft)
  • Page 194: Caliper

    FRONT AND REAR BRAKES 15-15 CALIPER WARNING Brake fluid can be hazardous to humans and pets. Brake fluid is harmful or fatal if swallowed, and harm- ful if it comes in contact with your skin or eyes. Keep brake fluid away from children. Call your doctor immediately if brake fluid is swallowed and induce vomiting.
  • Page 195 15-16 FRONT AND REAR BRAKES • Remove the brake pads. (15-2) • Remove the caliper bracket from the caliper. • Remove the boots and springs. • Wrap the caliper with a rag to prevent brake fluid scatter and piston pop-out. •...
  • Page 196 • Replace the piston seal and dust seal with new ones. • Apply brake fluid to the piston seal, dust seal and piston. • Apply SUZUKI SILICONE GREASE to the caliper axles.  99000-25100: SUZUKI SILICONE GREASE • Fit the brake pads.
  • Page 197: Master Cylinder

    15-18 FRONT AND REAR BRAKES MASTER CYLINDER WARNING Brake fluid can be hazardous to humans and pets. Brake fluid is harmful or fatal if swallowed, and harm- ful if it comes in contact with your skin or eyes. Keep brake fluid away from children. Call your doctor immediately if brake fluid is swallowed and induce vomiting.
  • Page 198 FRONT AND REAR BRAKES 15-19 • Remove the reservoir cap and diaphragm. • Strip the dust seal boot 2 and unsnap the snap ring 3. • Remove the push rod assembly 4. • Remove the piston/cup set 5.  09900-06106: Snap ring pliers INSPECTION •...
  • Page 199: Brake Pedal

    INSTALLATION • Fit the return spring properly. (5-9) • Apply grease to the brake pedal pivot bolt.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Tighten the brake pedal pivot bolt to the specified torque.  Brake pedal pivot bolt: 29 N·m (2.9 kgf-m, 21.0 lb-ft) •...
  • Page 200: Front Fork And Steering

    FRONT FORK AND STEERING 16-1 FRONT FORK AND STEERING CONTENTS FRONT FORK .................... 16- 2 CONSTRUCTION ................16- 2 REMOVAL ................... 16- 3 DISASSEMBLY ................... 16- 4 INSPECTION ..................16- 8 REASSEMBLY ..................16-10 INSTALLATION ................... 16-16 HANDLEBAR CONTROLS ............... 16-17 CONSTRUCTION ................
  • Page 201: Front Fork

    16-2 FRONT FORK AND STEERING FRONT FORK CONSTRUCTION 30 N . m (3.0 kgf-m, 21.5 lb-ft) 35 N . m (3.5 kgf-m, 25.5 lb-ft) 18 N . m (1.8 kgf-m, 13.0 lb-ft) 22 N . m (2.2 kgf-m, 16.0 lb-ft) 70 N .
  • Page 202: Removal

    FRONT FORK AND STEERING 16-3 REMOVAL • Place a block under the chassis tubes. • Remove the front wheel. (14-3) • Remove the handlebars. (16-18) • Remove the fork protectors, brake hose guide and brake hose clamp. • Remove the front brake caliper. (15-8) •...
  • Page 203: Disassembly

    16-4 FRONT FORK AND STEERING DISASSEMBLY • Set rebound and compression damper settings to the mini- mum settings (softest) before disassembling. Record the set- ting before turning the adjuster. • Thoroughly clean the fork before disassembly. CAUTION Scratches or other damage on the inner tube or on the oil seal lip will cause oil leak.
  • Page 204 FRONT FORK AND STEERING 16-5 • Clamp the axle holder 2 with a vise. Protect the axle holder surface using a rag. • Loosen the center bolt 3 completely with a 21 mm socket wrench.  WARNING Clamping the axle holder too tight can damage it which will affect riding stability.
  • Page 205 16-6 FRONT FORK AND STEERING • With the outer tube compressed by hands, remove the special tool. CAUTION Removing the lock-nut 4 and pushing the inner rod thread into the damper rod will damage the inner rod oil seal. Do not remove the lock-nut 4 from the inner rod. •...
  • Page 206 FRONT FORK AND STEERING 16-7 INNER TUBE • Separate the inner tube out of the outer tube. • Remove the slide bushing from the inner tube. • Remove the following parts from the inner tube. Guide bushing 1 Seal retainer 2 Oil seal 3 Stopper ring 4 Dust seal 5...
  • Page 207: Inspection

    16-8 FRONT FORK AND STEERING • Remove the compression damper unit from the sub-tank. NOTE: Slowly compress the inner rod until it stops so that the compres- sion damper unit can be removed easily. • Drain the fork oil from the damper rod assembly by moving the inner rod several strokes.
  • Page 208 FRONT FORK AND STEERING 16-9 INNER TUBE AND OUTER TUBE • Inspect the inner tube for scratches. If it has scratches, replace it with a new one. • Inspect the outer tube for dent. If it is dented all the way to the inner side, replace it with a new one.
  • Page 209: Reassembly

    16-10 FRONT FORK AND STEERING SLIDE BUSHING AND GUIDE BUSHING Inspect the “teflon coating metals” (slide bushing and guide bushing) for wear or damage. If they are worn or damaged, replace them with new ones. Inspect the metal particles on the “teflon coating metals”. If they are not clean, clean them with a nylon brush and fork oil.
  • Page 210 • With the damper rod in fully extended position, pour the spec- ified amount of fork oil.  Fork oil quantity (Inside the damper rod): 193 ml (6.52/6.80 US/lmp oz)  99000-99001-SS5: SUZUKI FORK OIL SS-05 (or equivalent fork oil)
  • Page 211 16-12 FRONT FORK AND STEERING • Apply fork oil to the O-rings and bushing on the compression damper unit. • With the damper rod held immovable in fully extended posi- tion, gently install the compression damper unit to the sub- tank.
  • Page 212 FRONT FORK AND STEERING 16-13 • Force out the remaining oil (discharged oil) using compressed air completely. • With the damper rod in horizontal position, move the inner rod by hand to inspect it if operating smoothly. If the inner rod is not extend, repeat the “COMPRESSION DAMPER UNIT”...
  • Page 213 16-14 FRONT FORK AND STEERING • Clamp the axle holder with a vise. Protect the axle holder with a rag when using a vise.  WARNING Clamping the axle holder too tight can damage it which will affect riding stability. Do not clamp the axle holder too tight.
  • Page 214 • Pour the specified amount of fork oil into the outer tube.  Oil quantity (When standard fork spring is used): 350 ml (11.83/12.32 US/lmp oz)  99000-99001-SS5: SUZUKI FORK OIL SS-05 (or equivalent fork oil) • Raise the outer tube and temporarily tighten the fork cap bolt (sub-tank).
  • Page 215: Installation

    16-16 FRONT FORK AND STEERING INSTALLATION • Install the front fork with the line T aligned with the upper sur- face of the upper bracket. • Check that the air valve A is positioned at the front. • Tighten the fork lower clamp bolts to the specified torque. ...
  • Page 216: Handlebar Controls

    FRONT FORK AND STEERING 16-17 HANDLEBAR CONTROLS CONSTRUCTION Adhesive agent 25 N·m (2.5 kgf-m, 18.0 lb-ft) 6 N·m (0.6 kgf-m, 4.4 lb-ft) Adhesive agent 6 N·m (0.6 kgf-m, 4.4 lb-ft) REMOVAL • Place the motorcycle on a block to lift front wheel off the ground.
  • Page 217: Remounting

    16-18 FRONT FORK AND STEERING • Remove the front brake master cylinder. NOTE: Mark the paint mark to the matching surface of master cylinder holder and handlebars before removing. • Remove the throttle assembly mounting bolts. NOTE: Mark the paint mark to the matching surface of throttle holder and handlebars before removing.
  • Page 218 Clearance • Rout the cables and hose correctly. (18-13, -14, -17) • Apply grease to the throttle cable.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the throttle grip so the “ ” mark on it aligns with the Throttle spool hole throttle cable end hooked.
  • Page 219 16-20 FRONT FORK AND STEERING • Align the master cylinder holder mating surface with the paint mark E on the handlebars. • Align the clutch lever holder mating surface with the paint mark F on the handlebars.
  • Page 220: Steering

    FRONT FORK AND STEERING 16-21 STEERING CONSTRUCTION 25 N . m (2.5 kgf-m, 18.0 lb-ft) 100 N . m (10.0 kgf-m, 72.5 lb-ft) 23 N . m (2.3 kgf-m, 16.5 lb-ft) 23 N . m (2.3 kgf-m, 16.5 lb-ft)
  • Page 221: Removal

    16-22 FRONT FORK AND STEERING REMOVAL • Place a block under the chassis tubes. • Remove the front wheel. (14-3) • Remove the handlebars. (16-18) • Remove the fork protectors, brake hose guide and brake hose clamp. • Remove the front brake caliper. (15-8) •...
  • Page 222: Inspection

    FRONT FORK AND STEERING 16-23 • Remove the dust seal 4. • Remove the upper needle bearing 5. INSPECTION STEERING STEM • Inspect the needle bearings for wear. • Inspect the steering stem for distortion. BEARING OUTER RACES • Inspect the bearing outer races for wear. BEARING REPLACEMENT •...
  • Page 223: Installation

    Installation is in the reverse order of removal. Pay attention to the following points: • Apply grease to the bearings.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Tighten the steering stem nut using the special tools.  09940-14911: Steering nut wrench 09940-14960: Steering nut socket wrench ...
  • Page 224 FRONT FORK AND STEERING 16-25 • Tighten the steering stem head nut to the specified torque.  Steering stem head nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft) • Remount the handlebars. (16-19) INSPECTION AFTER INSTALLATION • Front fork (2-20) • Steering (2-20) •...
  • Page 225 – MEMO –...
  • Page 226 REAR SUSPENSION 17-1 REAR SUSPENSION CONTENTS REAR SHOCK ABSORBER ..............17- 2 CONSTRUCTION ................17- 2 REMOVAL ................... 17- 2 INSPECTION ..................17- 3 SPRING REPLACEMENT ..............17- 3 BEARING REPLACEMENT ..............17- 4 OIL REPLACEMENT ................17- 5 DISASSEMBLY AND INSPECTION ........... 17- 9 REASSEMBLY ..................
  • Page 227: Rear Shock Absorber

    17-2 REAR SUSPENSION REAR SHOCK ABSORBER CONSTRUCTION 55 N . m (5.5 kgf-m, 40.0 lb-ft) 55 N . m (5.5 kgf-m, 40.0 lb-ft) REMOVAL • Place a block under chassis tubes. • Remove the silencer and rear frame assembly. (4-17) •...
  • Page 228: Inspection

    REAR SUSPENSION 17-3 INSPECTION • Inspect the rear shock absorber for oil leakage. • Inspect the damper rod for bends and smooth movement. • Inspect the bump rubber for deterioration and damage. • Inspect the spacers and dust seals for damage. •...
  • Page 229: Bearing Replacement

    17-4 REAR SUSPENSION • Adjust the spring set length and tighten the lock-nut.  Standard spring set length: 4.1 mm (0.161 in) compressed from the free length Spring set length adjustable range: 245 – 263 mm (9.646 –10.354 in) a: Standard spring set length b: Spring free length ...
  • Page 230: Oil Replacement

    • Apply grease to the dust seals and spacers. • Install the spacers A and B. A for right side B for left side  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) OIL REPLACEMENT TOOLS AND EQUIPMENT • Following tools and equipment are required to perform oil replacement.
  • Page 231 • Push the valve core again to equalize the bladder to atmo- spheric pressure. • Pour the fresh specified rear suspension oil as shown while moving the rod. NOTE: Be sure to extend the rod after filling the oil. 99000-99001-S25: SUZUKI REAR SUSPENSION OIL SS-25 (or equivalent rear suspension oil)
  • Page 232 REAR SUSPENSION 17-7 • Tilt the shock absorber unit as shown and pour the fresh rear suspension oil fully into the reservoir tank. • Cover the compression adjuster hole with the root of thumb. • Tilt and shake the rear shock absorber unit to fill the reservoir tank with the oil.
  • Page 233 17-8 REAR SUSPENSION • Reinstall the compression adjuster assembly 1.  Compression adjuster assembly: 30 N·m (3.0 kgf-m, 21.5 lb-ft) • Fill the rear shock absorber unit with nitrogen gas to 981 kPa (9.8 kgf/cm , 139.5 psi). • Tighten the gas valve cap. •...
  • Page 234: Disassembly And Inspection

    REAR SUSPENSION 17-9 DISASSEMBLY AND INSPECTION • Clean and dry the rear shock absorber. • Remove the spring from the rear shock absorber. (17-3) • Turn the rebound damping force adjuster to the softest posi- tion. • Bleed out nitrogen gas. (17-6) •...
  • Page 235: Reassembly

    • Fit the stopper to the shock absorber body. • Fill the specified rear suspension oil in the rear shock absorber. (17-6) 99000-99001-S25: SUZUKI REAR SUSPENSION OIL SS-25 (or equivalent rear suspension oil)  Oil capacity: Approx. 380 ml (12.84/13.38 US/Imp oz) •...
  • Page 236: Installation

    REAR SUSPENSION 17-11 INSTALLATION Install the rear shock absorber in the reverse order of removal. Pay attention to the following points: • Tighten the rear shock absorber lower mounting bolt and nut to the specified torque. NOTE: If necessary, move the swingarm up or down to facilitate this mounting bolt/nut tightening.
  • Page 237: Swingarm

    17-12 REAR SUSPENSION SWINGARM CONSTRUCTION 70 N . m (7.0 kgf-m, 50.5 lb-ft) REMOVAL AND DISASSEMBLY • Place a block under chassis tubes. • Remove the rear wheel. (14-7) • Remove the chain guide. • Remove the rear brake hose guide. •...
  • Page 238 REAR SUSPENSION 17-13 • Remove the rear cushion lever bolt and nut. • Remove the brake pedal. (5-6) • Remove the swingarm pivot nut and shaft. • Remove the swingarm. • Remove the chain buffer. • Remove the following parts from the swingarm. Spacer 1 Dust seal 2 Washer 3...
  • Page 239: Inspection

    17-14 REAR SUSPENSION INSPECTION PIVOT SHAFT • Measure the pivot shaft runout with the dial gauge and V- blocks.  Swingarm pivot shaft runout Service Limit: 0.3 mm (0.01 in)  09900-20607: Dial gauge (1/100 mm) 09900-20701: Magnetic stand 09900-21304: V-block set (100 mm) CHAIN BUFFER AND CHAIN GUIDE •...
  • Page 240: Bearing Replacement

    • Remove the bearing using the special tool.  09921-20240: Bearing remover set • Apply grease to new bearings.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Press the bearing with the special tool.  09924-84521: Bearing installer set...
  • Page 241: Rear Suspension Linkage

    17-16 REAR SUSPENSION REAR SUSPENSION LINKAGE CONSTRUCTION 80 N . m (8.0 kgf-m, 58.0 lb-ft) 80 N . m (8.0 kgf-m, 80 N . m 58.0 lb-ft) (8.0 kgf-m, 58.0 lb-ft) REMOVAL AND DISASSEMBLY • Place a block under chassis tubes. •...
  • Page 242: Inspection

    REAR SUSPENSION 17-17 • Remove the cushion rod from the cushion lever. INSPECTION • Inspect the cushion rod and cushion lever for damage. • Inspect the dust seals and spacers for damage. • Insert the spacers into the bearings and inspect them for excessive play and smooth movement.
  • Page 243: Reassembly

    • Remove the needle roller bearing cage 1 with the special tool.  09921-20240: Bearing remover set • Apply grease to the bearings.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Press fit the bearing cage with the special tool.  09913-70210: Bearing installer set •...
  • Page 244 REAR SUSPENSION 17-19 • Tighten the cushion lever, cushion rod and swingarm nuts to the specified torque. Left Right 5 mm 4 mm 4 mm 4 mm  Tightening torque: A: 55 N·m (5.5 kgf-m, 40.0 lb-ft) B: 55 N·m (5.5 kgf-m, 40.0 lb-ft) C: 80 N·m (8.0 kgf-m, 58.0 lb-ft) D: 80 N·m (8.0 kgf-m, 58.0 lb-ft) E: 80 N·m (8.0 kgf-m, 58.0 lb-ft)
  • Page 245 17-20 REAR SUSPENSION Left Right CAUTION Improperly reassembled rear suspension linkage bolts can interfere with suspension move- ment and damage the rear suspension linkage. * Make sure that the rear shock absorber rebound damping adjuster on the bottom bracket of the rear shock absorber is located to the right side.
  • Page 246: Servicing Information

    SERVICING INFORMATION 18-1 SERVICING INFORMATION CONTENTS SERVICE DATA ..................18- 2 TIGHTENING TORQUE ................18- 8 SPECIAL TOOLS ..................18-10 WIRING DIAGRAM ..................18-12 WIRE, CABLE AND HOSE ROUTING ............18-13 WIRE HARNESS ROUTING ............... 18-13 CABLE ROUTING ................18-14 CARBURETOR HOSE AND WATER HOSE ROUTING ....
  • Page 247: Service Data

    18-2 SERVICING INFORMATION SERVICE DATA CYLINDER + PISTON + PISTON RING ITEM STD/SPEC. LIMIT Piston to cylinder clearance 0.045 – 0.055 mm 0.120 mm (0.0018 – 0.0022 in) (0.0047 in) Cylinder bore 66.400 – 66.415 mm Nicks or (2.6142 – 2.6148 in) scratches Measure 20 mm (0.79 in) from the top surface.
  • Page 248 SERVICING INFORMATION 18-3 RADIATOR + COOLANT ITEM STD/SPEC. LIMIT Radiator cap valve release 95 – 125 kPa — (0.95 – 1.25 kgf/cm , 14 – 18 psi) pressure Engine coolant type Use a anti-freeze & Summer coolant compatible with aluminum radiator, mixed with distilled water —...
  • Page 249 18-4 SERVICING INFORMATION ELECTRICAL ITEM STD/SPEC. NOTE Ignition timing BTDC 4.5° at 1 000 r/min Spark plug Type NGK: BR8EG 0.5 – 0.6 mm (0.020 – 0.024 in) Pick-up coil resistance 72 – 127 Ω at 20 °C (68 °F) R –...
  • Page 250 SERVICING INFORMATION 18-5 WHEEL ITEM STD/SPEC. LIMIT Wheel rim runout 2.0 mm Axial — (0.08 in) 2.0 mm Radial — (0.08 in) Wheel rim size Front 21 × 1.60 — Rear 19 × 2.15 — Wheel axle runout 0.25 mm Front —...
  • Page 251 Front fork spring rate 4.4 N/mm — (0.44 kgf/mm) Front fork oil type SUZUKI FORK OIL SS-05 or equivalent fork oil — Front fork oil capacity (each leg) OUTER: 350 ml (11.83/12.32 US/Imp oz) — INNER: 193 ml (6.52/6.80 US/Imp oz)
  • Page 252 SERVICING INFORMATION 18-7 FUEL + OIL ITEM STD/SPEC. NOTE Fuel type Use only unleaded gasoline of at least 90 pump For Canada octane (R/2 + M/2 method). Use only unleaded gasoline of at least 95 octane. For other coun- (Research method) tries Fuel tank capacity 8.0 L...
  • Page 253: Tightening Torque

    18-8 SERVICING INFORMATION TIGHTENING TORQUE ENGINE PART N·m kgf-m lb-ft Cylinder head nuts 18.0 Magneto rotor nut 40.0 Cylinder nuts 27.5 Clutch sleeve hub nut 65.0 Crankcase bolt Primary drive gear bolt 50.5 Gearshift cam bolt 23.5 2.35 17.0 Gearshift pawl lifter screw Exhaust valve shaft arm bolt Kick starter lever bolt 16.5...
  • Page 254 SERVICING INFORMATION 18-9 PART N·m kgf-m lb-ft Rear cushion rod nut 58.0 Spoke nipple Seat rail nut (upper) 16.5 Seat rail bolt (lower) 16.5 Brake lever pivot bolt Brake lever pivot nut TIGHTENING TORQUE CHART For other bolts and nuts not listed in the table, refer to this chart. Bolt Conventional or “4”...
  • Page 255: Special Tools

    18-10 SERVICING INFORMATION SPECIAL TOOLS 09900-20101 09900-20203 09900-20205 09900-06106 09900-06107 Vernier calipers Micrometer Micrometer Snap ring plier Snap ring plier (150 mm) (50 – 75 mm) (0 – 25 mm) 09900-20602 09900-20605 09900-20607 09900-20508 Dial gauge Dial caliper (1/100 Dial gauge 09900-20701 Cylinder gauge set (1/1 000 mm)
  • Page 256 SERVICING INFORMATION 18-11 09925-18011 09924-84510 09924-84521 Steering bearing 09930-11960 09930-30104 Bearing installer set Bearing installer set installer Torx wrench, T20 Sliding shfaft 09930-30113 09940-14960 Flywheel rotor 09930-40113 09940-14911 Steering nut socket 09940-34581 remover Rotor holder Steering nut wrench wrench Attachment F 09940-52861 09941-34513 09941-53630...
  • Page 257: Wiring Diagram

    18-12 SERVICING INFORMATION WIRING DIAGRAM IGNITION COIL CARBURETOR CDI UNIT ENGINE SOLENOID STOP SWITCH : Pickup THROTTLE coil POSITION SENSOR MAGNETO WIRE COLOR Black Green Orange Yellow B/Bl: Black with Blue tracer B/Br: Black with Brown tracer B/R: Black with Red tracer B/W: Black with White tracer B/Y:...
  • Page 258: Wire, Cable And Hose Routing

    SERVICING INFORMATION 18-13 WIRE, CABLE AND HOSE ROUTING WIRE HARNESS ROUTING FRONT...
  • Page 259: Cable Routing

    18-14 SERVICING INFORMATION CABLE ROUTING...
  • Page 260: Carburetor Hose And Water Hose Routing

    SERVICING INFORMATION 18-15 CARBURETOR HOSE AND WATER HOSE ROUTING...
  • Page 261: Brake Pedal Set-up

    18-16 SERVICING INFORMATION Avoid contact between the clamp and cables. 90˚ 90˚ BRAKE PEDAL SET-UP SECT AA Protector 10 mm (0.4 in)
  • Page 262: Front Brake Hose Routing

    SERVICING INFORMATION 18-17 FRONT BRAKE HOSE ROUTING Front brake master cylinder Washer Front brake hose Hose guide Set the brake hose end between the hose stopper, then tighten the brake hose union bolt to the specified torque. Front brake hose Clamp Clamp the upper difference portion in...
  • Page 263: Rear Brake Hose Routing

    18-18 SERVICING INFORMATION REAR BRAKE HOSE ROUTING...
  • Page 264: Handlebar Set-up

    SERVICING INFORMATION 18-19 HANDLEBAR SET-UP Quick adjuster Turn to tighten Turn to tighten the clutch cable tension. the clutch cable tension. When the movement is felt heavier, Turn to loosen Turn to loosen clean this and apply grease. the clutch cable tension. the clutch cable tension.
  • Page 265: Muffler Set-up

    18-20 SERVICING INFORMATION MUFFLER SET-UP...
  • Page 266: Specifications

    SERVICING INFORMATION 18-21 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ............2 170 mm (85.4 in) Overall width............830 mm (32.7 in) Overall height ............. 1 280 mm (50.4 in) Wheelbase ............1 465 mm (57.7 in) Ground clearance..........350 mm (13.8 in) Seat height ............
  • Page 267 18-22 SERVICING INFORMATION CHASSIS Front suspension ..........Telescopic, pneumatic/coil spring, oil damped Rear suspension ..........Link type Steering angle............45° (right & left) Caster ..............27° 30’ Trail ..............115 mm (4.53 in) Turning radius ............2.3 m (7.5 ft) Front brake............
  • Page 268: Spare Parts

    SERVICING INFORMATION 18-23 SPARE PARTS ITEM PART NAME PART NUMBER Q’TY PARTS SET, SPARE 19900-37F60 O-RING, CYLINDER HEAD NO. 1 11147-37F00 O-RING, CYLINDER HEAD NO. 2 11148-37F00 GASKET, CYLINDER COVER, NO. 1 11233-37F20 GASKET, CYLINDER COVER, NO. 2 11234-37F20 GASKET, CYLINDER COVER, NO. 3 11238-37F20 GASKET, CYLINDER 11241-37F20...
  • Page 269: Setting Data

    18-24 SERVICING INFORMATION SETTING DATA DATE RACE/COURSE TEMP./HUMIDITY WHETHER COURSE COUDITION MAIN JET JET NEEDLE SLOW JET AIR SCREW FLOAT LEVEL SPARK PLUG OIL LEVEL COMP. ADJ. POSITION RE-BOUND ADJ. POSITION SPRING SPRING SPRING SET LENGTH COMP. ADJ. POSITION LOW COMP.
  • Page 270 Failure to follow these safety precautions may increase your risk of injury: ! Wear a helmet, eye protection, and bright protective clothing. ! Don’t ride after consuming alcohol or other drugs. ! This owner’s service manual contains important safety information. Please read it carefully. Printed in Japan 300 TAKATSUKA, HAMAMATSU, JAPAN...

Comments to this Manuals

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  • Jamie Oct 04, 2019 09:55:
    Is their a 1996/1997 rm250 manual for all specificat​ions such as power valve adjustment​, the weight of the bike ect?
  • Steven Aug 28, 2018 04:16:
    Kind of figure out the spark on my 83 Suzuki RM 250
  • Jamie John Adams Aug 10, 2016 09:10:
    Thank you so much for making this Rm250 manual available to Brouse without downloadin​g.