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Suzuki RM-Z250 Owner's Manual

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RM-Z250
OWNER'S MANUAL AND
RACE PREPARATION MANUAL

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  Summary of Contents for Suzuki RM-Z250

  • Page 1 RM-Z250 OWNER’S MANUAL AND RACE PREPARATION MANUAL...
  • 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. VWARNING/VCAUTION/NOTICE/NOTE Please read this manual and follow its instructions carefully.
  • Page 3 This manual is presented as a means whereby you • Wear a helmet and goggles can maintain your RM-Z250 in top working condi- A helmet is the most important piece of gear to tion at all times. Your riding skill and the mainte- wear.
  • Page 4: Serial Number Location

    You need to prepare for the unex- pected by wearing a helmet and other protective Engine No. 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 WARNINGS FOR SERVICING  WARNING Fuel can catch on fire if you do not handle  WARNING it properly. Gasoline vapors can catch fire Never run the engine indoors or in a easily. garage. Exhaust gas contains carbon mon- Do not smoke when servicing the machine. oxide, a gas that is colorless and odorless Do not service the machine in an area and can cause death or severe injury.
  • Page 6 * Take care not to expand the end gap larger than required to slip the circlip over the shaft when installing a circlip. * Use special tools where specified. * Use genuine SUZUKI parts and recom- mended oil. * When more...
  • Page 7: Replacement Parts

    Use of replacement parts which are not equivalent enough pressure to damage the parts of in quality to genuine SUZUKI parts can lead to per- formance problems and damage. your motorcycle. It may cause rust, corro- sion and increase wear.
  • Page 8 F O R K oil unless otherwise specified. or equivalent. Apply molybdenum oil solution. Use REAR SUSPENSION OIL SS-25 (Mixture of engine oil and SUZUKI or equivalent. MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE “A” or equivalent.
  • Page 9: Abbreviations Used In This Manual

    ABBREVIATIONS USED IN THIS MANUAL : Alternating Current : Maximum : American Petroleum Institute : Minimum BTDC : Before Top Dead Center : Right Hand : Battery Positive Voltage : Society of Automotive Engineers CKP Sensor : Crankshaft Position Sensor (CKPS) TO Sensor : Tip-Over Sensor (TOS)
  • Page 11 GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE MACHINE TUNING DISASSEMBLY AND ASSEMBLY SERVICING INFORMATION...
  • Page 13: Table Of Contents

    GENERAL INFORMATION 1-1 GENERAL INFORMATION CONTENTS LOCATION OF PARTS ................. 1-2 ACCESSORY ....................1-3 SIDE STAND ................... 1-3 FUEL AND OIL RECOMMENDATION ............1-3 OPERATING INSTRUCTIONS ..............1-4 STARTING THE ENGINE ............... 1-4 STOPPING THE ENGINE ............... 1-6 TRANSMISSION ..................1-6 BREAK-IN (RUNNING-IN) ................
  • Page 14: Location Of Parts

    1-2 GENERAL INFORMATION LOCATION OF PARTS 1 Clutch lever 2 Hot starter lever 3 Engine stop switch 4 Front brake lever 5 Throttle grip 6 Fuel tank cap 7 Starter knob/Idle screw 8 Gearshift lever 9 Front suspension compression damping adjuster 0 Front suspension rebound damping adjuster A Kick starter lever...
  • Page 15: Accessory

    (R/2 + M/2 method) ..For USA and Canada Use only unleaded gasoline of at least 95 octane. (Research method) ....For other countries Engine oil: SUZUKI recommends the use of SUZUKI PERFOR- MANCE 4 MOTOR OIL or equivalent engine oil. Use of SG/SH/SJ/SL in API with JASO MA/MA1/MA2.
  • Page 16: Operating Instructions

    1-4 GENERAL INFORMATION OPERATING INSTRUCTIONS NOTICE Leaving the engine at idling speed after riding will cause engine overheat as this competition motorcycle does not have the radiator cooling fan and coolant reservoir. Riding the motorcycle under severe conditions such as muddy or sandy terrain with high ambient temperature can shorten time to be overheated.
  • Page 17 GENERAL INFORMATION 1-5 When the engine is already warm or restarts: 1) Pull the hot starter lever 1. 2) Kick down the kick starter lever slowly from the top position until engine compression resistance is felt, release the kick starter lever from this position and allow it to return to the top.
  • Page 18: Stopping The Engine

    1-6 GENERAL INFORMATION When the motorcycle is not used for long time: Due to deterioration of fuel remaining in the fuel line for long period, engine will be difficult to start until the deteriorated (stale) fuel is discharged from the fuel line. Repeated kick operation is required for flushing the fuel line with fresh fuel.
  • Page 19: Break-In (Running-In)

    GENERAL INFORMATION 1-7 BREAK-IN (RUNNING-IN) WHEN THE MOTORCYCLE IS NEW 1) Warm up the engine before starting off. 2) Ride for 60 minutes using less than 1/2 throttle opening. 3) Ride for 60 minutes using less than 3/4 throttle opening. NOTE: * The break-in (running-in) period is the period of greatest wear.
  • Page 21 PERIODIC MAINTENANCE 2-1 PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE ................2-3 INSPECTION BEFORE PRACTICE ............2-3 INSPECTION BEFORE RACE (All items of inspection before practice on previous page plus) ..2-4 PERIODIC MAINTENANCE CHART ............2-5 SPARK PLUG ....................2-7 AIR CLEANER ....................2-9 AIR CLEANER ELEMENT REMOVAL ...........
  • Page 22 2-2 PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS FUEL HOSE ....................2-26 VALVE CLEARANCE ................. 2-27 VALVE CLEARANCE ADJUSTMENT ..........2-28 CYLINDER HEAD, CYLINDER AND PISTON ........... 2-31 CYLINDER HEAD INSPECTION ............2-31 CYLINDER INSPECTION ..............2-31 PISTON AND PISTON RING REPLACEMENT ........2-31 DRIVE CHAIN AND SPROCKETS .............
  • Page 23: Periodic Maintenance

    PERIODIC MAINTENANCE 2-3 PERIODIC MAINTENANCE INSPECTION BEFORE PRACTICE WHAT TO CHECK CHECK FOR Spark plug • Heat range, fouled electrode, tightness • Loose high-tension cord Air cleaner element • Dust • Lubrication Engine oil Oil level Coolant Coolant level Cooling system •...
  • Page 24: Inspection Before Race

    2-4 PERIODIC MAINTENANCE INSPECTION BEFORE RACE (All items of inspection before practice on previous page plus) WHAT TO CHECK CHECK FOR Clutch Clutch disk plates wear and distortion Brake pads Wear Sprockets Wear Fuel tank Leakage Fuel hose • Damage •...
  • Page 25: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-5 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 26 2-6 PERIODIC MAINTENANCE Interval Every Every Every races race 3 races 6 races Remarks Every Every Every hours Service Item 2 hours 6 hours 12 hours Tire — — Inspect every 20 min. up to initial 2 hours Spoke nipple —...
  • Page 27: Spark Plug

    PERIODIC MAINTENANCE 2-7 SPARK PLUG • Remove the seat. (4-2) • Remove the radiator covers and fuel tank. (4-2) • Hold the cylinder head cover bolt immovable with the wrench. • Disconnect the lead wire coupler from the ignition coil/plug cap.
  • Page 28 2-8 PERIODIC MAINTENANCE • Measure the spark plug gap A with a wire gauge. • If it is not within the specification, replace the spark plug. NOTICE Changing the spark plug heat range improperly can damage the engine. To prevent the damage of iridium center electrode, use a wire gauge to check the gap.
  • Page 29: Air Cleaner

    PERIODIC MAINTENANCE 2-9 AIR CLEANER AIR CLEANER ELEMENT REMOVAL • Remove the seat. (4-2) • Remove the wing bolt 1. • Remove the element 2 from the element holder. WASHING • Fill a washing pan large enough to hold the element with a non-flammable cleaning solvent A.
  • Page 30: Installation

    2-10 PERIODIC MAINTENANCE INSTALLATION • Apply filter oil to the element base where it contacts the air cleaner box. • Fit the element 2 onto the element holder 1. NOTE: Fit the projection A of the element holder to the hole of the ele- ment 2.
  • Page 31: Engine Oil And Oil Filter

    PERIODIC MAINTENANCE 2-11 ENGINE OIL AND OIL FILTER  WARNING Improper engine oil treatment is hazardous. Read engine oil container instruction before replacing the engine oil. NOTICE Improper engine oil selection can cause clutch slip. Do not use engine oil which has friction decrease additives.
  • Page 32: Inspection Before Engine Oil Level Check

    2-12 PERIODIC MAINTENANCE INSPECTION BEFORE ENGINE OIL LEVEL CHECK • Before starting the engine, check that there is sufficient oil for operating the engine. NOTICE If the engine is started with insufficient or no oil, the engine components will possibly be damaged. Always keep the engine oil at the specified level.
  • Page 33: Engine Oil Level Inspection

    PERIODIC MAINTENANCE 2-13 ENGINE OIL LEVEL INSPECTION • During inspection, hold the motorcycle in an upright position on a level surface. NOTE: The oil level measurement may become inaccurate unless the motorcycle is held upright as the motorcycle inclination affects the oil level.
  • Page 34: Engine Oil Change

    2-14 PERIODIC MAINTENANCE ENGINE OIL CHANGE • During inspection, hold the motorcycle in an upright position on a level surface. • Warm up the engine. • Remove the filler cap, TDC plug 1, drain plug 2 and drain No.2 plug 3. Drain engine oil. •...
  • Page 35: Engine Oil Filter Change

    PERIODIC MAINTENANCE 2-15 ENGINE OIL FILTER CHANGE • Drain the engine oil as described in the engine oil replace- ment procedure. • Remove the oil filter cap 1 and spring 2 with oil filter 3. • Apply engine oil lightly to the gasket of new oil filter before installation.
  • Page 36: Oil Strainers

    2-16 PERIODIC MAINTENANCE OIL STRAINERS OIL STRAINER (No.1) REMOVAL • Hold the motorcycle upright. • Clean the engine to avoid engine trouble. • Drain engine oil. (2-14) • Remove the oil strainer cap. NOTE: Hold the motorcycle upright while replacing the oil strainer. •...
  • Page 37: Inspection

    PERIODIC MAINTENANCE 2-17 INSPECTION • Check the oil strainers for any damage or clogging. • If the oil strainer is clogging, clean the oil strainer with a com- pressed air. A Oil strainer No.1 B Oil strainer No.2 • Clean the oil nozzle by applying compressed air. OIL STRAINER (No.2) INSTALLATION •...
  • Page 38: Oil Strainer (No.1) Installation

    2-18 PERIODIC MAINTENANCE OIL STRAINER (No.1) INSTALLATION • Install the oil strainer and then tighten the oil strainer cap to the specified torque. NOTE: Replace the gasket washer with a new one.  Engine oil strainer cap: 21 N·m (2.1 kgf-m, 15.0 lbf-ft) •...
  • Page 39: Engine Coolant

    PERIODIC MAINTENANCE 2-19 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 40: Engine Coolant Replenishment

    2-20 PERIODIC MAINTENANCE ENGINE COOLANT REPLENISHMENT • Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50:50. NOTE: The radiator, cylinder and cylinder head are made of aluminum alloy. Using non-recommended engine coolant may corrode alu- minum alloy and may clog the coolant passageways.
  • Page 41: Clutch Cable

    PERIODIC MAINTENANCE 2-21 CLUTCH CABLE Adjust the clutch cable play as follows: MAJOR ADJUSTMENT • Loosen the lock-nut 1. • Turn adjuster 2 so the clutch lever clearance A measured at the lever holder obtains 2 – 3 mm (0.08 – 0.12 in) when squeezing the lever until pressure is felt.
  • Page 42: Throttle Cable

    2-22 PERIODIC MAINTENANCE THROTTLE CABLE  WARNING Inadequate throttle cable play can cause engine speed to rise suddenly when you turn the handlebars. This can lead to loss of rider control. Adjust the throttle cable play so that engine speed does not rise due to handlebars movement.
  • Page 43: Throttle Cable Oil Supply

    PERIODIC MAINTENANCE 2-23 THROTTLE CABLE OIL SUPPLY • Remove the throttle case 1. • Apply oil to the throttle cable. • Apply grease to the throttle cable spool.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
  • Page 44: Hot Starter

    2-24 PERIODIC MAINTENANCE HOT STARTER Adjust the hot starter cable play as follows: NOTE: Be careful not to damage the lever cover when installing. (5-18) • Loosen the lock-nut 1. • Turn adjuster 2 so the hot starter lever clearance A mea- sured at the lever holder obtains 2 –...
  • Page 45: Engine Idle Speed

    PERIODIC MAINTENANCE 2-25 ENGINE IDLE SPEED • Adjust the throttle cable play. (2-22) • Warm up the engine. NOTE: Make this adjustment when the engine is hot. • Insert the needle-pointed probe to the lead wire coupler (W/Bl). NOTE: Use the special tool (needle-pointed probe), to prevent the rub- ber of the water proof coupler from damage.
  • Page 46: Crankcase Breather Hose

    2-26 PERIODIC MAINTENANCE CRANKCASE BREATHER HOSE • Inspect the crankcase breather hose for damage, clogging and bend. If any defects are found, the breather hose must be replaced. FUEL HOSE • Inspect the fuel hose for damage and fuel leakage. If any defects are found, the fuel hose must be replaced.
  • Page 47: Valve Clearance

    PERIODIC MAINTENANCE 2-27 VALVE CLEARANCE • Remove the seat. (4-2) • Remove the radiator covers and fuel tank. (4-2) • Remove the ignition coil/plug cap and spark plug. (2-7) • Remove the cylinder head cover 2 and gasket 3 by remov- ing their bolts 1.
  • Page 48: Valve Clearance Adjustment

    2-28 PERIODIC MAINTENANCE VALVE CLEARANCE ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim with a thicker or thinner one. • Remove the intake or exhaust camshafts. (4-12) • Remove the tappet 1 and shim 2 by fingers or magnetic hand.
  • Page 49 PERIODIC MAINTENANCE 2-29 (INTAKE SIDE)
  • Page 50 2-30 PERIODIC MAINTENANCE (EXHAUST SIDE)
  • Page 51: Cylinder Head, Cylinder And Piston

    PERIODIC MAINTENANCE 2-31 CYLINDER HEAD, CYLINDER AND PISTON CYLINDER HEAD INSPECTION • Remove the cylinder head. (4-15) • Decarbonize the combustion chambers. • Inspect for pinholes, cracks and other damage. • If any defects are found, replace the cylinder head with a new one.
  • Page 52: Drive Chain And Sprockets

    2-32 PERIODIC MAINTENANCE DRIVE CHAIN AND SPROCKETS DRIVE CHAIN SLACK • Place the motorcycle on a block to lift the rear wheel off the ground. • Inspect the drive chain slack at the middle point between the drive chain buffer and rear sprocket. ...
  • Page 53: Drive Chain Adjustment

    PERIODIC MAINTENANCE 2-33 DRIVE CHAIN ADJUSTMENT • Loosen the axle nut 1. • Loosen the lock-nuts 2 and adjust the drive chain slack to the specification by turning the adjusters 3. Make sure that the right and left adjuster washers 4 are at the same position on scales 5.
  • Page 54: Drive Chain Lubrication

    Drive chain is damaged when cleaning it with gaso- line. 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. NOTE: Reassemble the drive chain clip so the slit end faces opposite the direction of rotation.
  • Page 55: Drive Chain Guide, Buffer And Tensioner Roller

    PERIODIC MAINTENANCE 2-35 DRIVE CHAIN GUIDE, BUFFER AND TENSIONER ROLLER DRIVE CHAIN GUIDE INSPECTION • 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. •...
  • Page 56: Brakes

    2-36 PERIODIC MAINTENANCE BRAKES BRAKE FLUID LEVEL • Inspect the brake fluid level in both front and rear reservoirs. If the brake fluid level is lower than LOWER mark A, replenish the reservoir with the specified brake fluid to the UPPER line. Inspect brake pad wear and brake fluid leakage if the brake fluid level decreases.
  • Page 57: Brake Pad

    PERIODIC MAINTENANCE 2-37 BRAKE PAD • Inspect the brake pads for wear. If the brake pads are worn, replace them with new ones. (4-64) A Wear limit NOTE: * Pump the brake lever and pedal several times to restore the brake pads after replacing the brake pads.
  • Page 58: Front Brake Lever Adjustment

    2-38 PERIODIC MAINTENANCE FRONT BRAKE LEVER ADJUSTMENT Adjust the brake lever position as follows: • Loosen the lock-nut 1. • Turn in or out adjuster 2 to obtain the proper brake lever position. • The standard adjuster length A is from 11 – 15 mm (0.4 – 0.6 in).
  • Page 59: Front Fork

    PERIODIC MAINTENANCE 2-39 FRONT FORK • Move the front fork up and down several times and inspect for smooth movement. • Inspect for damage and oil leaks. • Inspect the bolts and nuts for tightness. • If any defects are found, replace the front fork with a new one. •...
  • Page 60: Wheels And Tires

    2-40 PERIODIC MAINTENANCE WHEELS AND TIRES WHEEL RIM AND TIRES INSPECTION • Inspect the wheel and tires for damage. • Inspect the wheel bearing for rattles. (4-55) • Inspect the wheel rim runout. (4-55) • If necessary, replace the defective parts with a new one. SPOKE NIPPLE AND RIM LOCK INSPECTION •...
  • Page 61: Steering

    PERIODIC MAINTENANCE 2-41 STEERING • Inspect the steering by moving the front forks up and down, and back and forward. If the steering has play or binds, inspect steering stem head nut tightness and steering bear- ings. (4-92, -93) FRAME •...
  • Page 62: Lubrication

    Grease the bearing and seals. according to conditions The following materials are necessary: A. Lightweight oil such as WD-40 or penetrating oil B. Aerosol type Chain Lube C. SUZUKI SUPER GREASE “A” (or equivalent grease) or Water-proof wheel bearing grease...
  • Page 63 PERIODIC MAINTENANCE 2-43 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 allows you to clean out the grit which otherwise cannot be gotten out.
  • Page 65 MACHINE TUNING 3-1 MACHINE TUNING CONTENTS SELECTION OF ECM TUNING MAP ............3-2 SHORT WIRE CONNECTING PROCEDURE ........3-3 FRONT FORK TUNING ................. 3-4 COMPRESSION DAMPING FORCE ADJUSTMENT ......3-4 REBOUND DAMPING FORCE ADJUSTMENT ........3-4 OIL QUANTITY MINOR ADJUSTMENT ..........3-5 OIL CHANGE (Only for outer tube oil chamber) .........
  • Page 66: Selection Of Ecm Tuning Map

    3-2 MACHINE TUNING SELECTION OF ECM TUNING MAP In the ECM of this model, there are three different maps pro- vided, a standard map and two modified maps (injection map for slightly leaner mixture and that for slightly richer mixture). Select the appropriate short wire among those that come sup- plied with the motorcycle and connect it to the mode select cou- pler.
  • Page 67: Short Wire Connecting Procedure

    MACHINE TUNING 3-3 SHORT WIRE CONNECTING PROCEDURE • Disconnect the mode select coupler 2 from the bracket 1. • Disconnect the mode select coupler cap 3. • Connect the short wire 4 to the mode select coupler 2. • Reinstall the mode select coupler. •...
  • Page 68: Front Fork Tuning

    3-4 MACHINE TUNING FRONT FORK TUNING The front fork compression and rebound damping force, and oil capacity 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 69: Oil Quantity Minor Adjustment

    MACHINE TUNING 3-5 OIL QUANTITY MINOR ADJUSTMENT ADDING THE FORK OIL • Remove the air bleeder valve 1. • Add the fork oil with a injector from the air bleed hole. REDUCING THE FORK OIL • Remove the front forks. (4-72) •...
  • Page 70: Oil Change (Only For Outer Tube Oil Chamber)

    3-6 MACHINE TUNING OIL CHANGE (Only for outer tube oil chamber) • Remove the front forks. (4-72) • Thoroughly clean the fork before disassembly. NOTICE Scratches or other damage on the inner tube or on the oil seal lip will cause oil leak. Use a mild detergent or car wash soap and sponge out dirt with plenty of water.
  • Page 71 MACHINE TUNING 3-7 Identification Oil quantity Parts No. Spring rate (Slit mark Oil quantity adjustable range on the spring end) 319 – 408 ml 45°: I 388 ml 4.5 N/mm (10.78/11.23 – Soft 51171-28H10 120°: II (13.11/13.66 (0.45 kgf/mm) 13.79/14.37 (See Fig.1 below) US/Imp oz) US/Imp oz)
  • Page 72: Spring Change

    3-8 MACHINE TUNING SPRING CHANGE • Remove the front forks. (4-72) • Thoroughly clean the fork before disassembly. NOTICE Scratches or other damage on the inner tube or on the oil seal lip will cause oil leakage. Use a mild detergent or car wash soap and sponge out dirt with plenty of water.
  • Page 73 MACHINE TUNING 3-9 • Replace the spring. Identification SPRING/No. SPRING RATE (Slit mark on the spring end) 4.5 N/mm Soft 51171-28H10 (3-7) (0.45 kgf/mm) 4.7 N/mm 51171-28H00 (3-7) (0.47 kgf/mm) 4.9 N/mm Hard 51171-28H20 (3-7) (0.49 kgf/mm) • Tighten the lock nut 2. NOTE: Thread length a should be approx.
  • Page 74 3-10 MACHINE TUNING • Check or adjust the clearance between the lock-nut 2 and center bolt 5 to provide more than 1 mm (0.04 in) and more. (4-86) • Tighten the lock-nut/center bolt to the specified torque.  Lock-nut/center bolt: 22 N·m (2.2 kgf-m, 16.0 lbf-ft) •...
  • Page 75: Front Fork Tuning Procedure

    MACHINE TUNING 3-11 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 and rebound damping force following the instructions below.
  • Page 76: Rear Suspension Tuning

    3-12 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. (1-7) * Inspect the following items before attempting adjustment.
  • Page 77: Rebound Damping Force Adjustment

    MACHINE TUNING 3-13 REBOUND DAMPING FORCE ADJUSTMENT NOTE: To set the adjuster, you must gently turn the adjust screw clock- wise until it stops, then back it out the recommended number of turns. Do not force the adjust screw past the stopped position, or you may damage the adjuster.
  • Page 78: Rear Suspension Tuning Procedure

    3-14 MACHINE TUNING REAR SUSPENSION TUNING PROCEDURE • Remove the rear shock absorber. (4-98) • Remove the rear shock absorber spring. (4-100) • Adjust the rear suspension according to the rider’s weight and preference by referring to the table below. Spring Part No.
  • Page 79 MACHINE TUNING 3-15 After the sag measurement has been set 105 mm (4.13 in), test ride the motorcycle and adjust the suspen- sion for the rider and track conditions referring to the guide below. SYMPTOM SECTION ADJUSTMENT PROCEDURE Feels too hard •...
  • Page 80: Suspension Balance

    3-16 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 81: Disassembly And Assembly

    DISASSEMBLY AND ASSEMBLY 4-1 DISASSEMBLY AND ASSEMBLY CONTENTS ENGINE REMOVAL AND INSTALLATION ..........4-2 REMOVAL ....................4-2 INSTALLATION ..................4-7 CYLINDER HEAD, CYLINDER AND PISTON ..........4-12 ENGINE TOP SIDE DISASSEMBLY ............ 4-12 ENGINE TOP SIDE ASSEMBLY ............4-19 CAM CHAIN, CAM CHAIN TENSIONER AND CAM CHAIN No.1 GUIDE ..............
  • Page 82: Engine Removal And Installation

    4-2 DISASSEMBLY AND ASSEMBLY ENGINE REMOVAL AND INSTALLATION REMOVAL • Drain engine oil. (2-14) • Drain engine coolant. (4-49) • Remove the seat 1. • Remove the radiator covers 2, left and right. • Remove the right frame cover 3. •...
  • Page 83 DISASSEMBLY AND ASSEMBLY 4-3 NOTICE Dirt and dust in the fuel supply line can damage the motorcycle. * Put the plug and cap to the fuel hose and fuel pump when the fuel pump connector is disconnected. * Be sure to keep the parts clean when disconnecting and connecting the connector.
  • Page 84 4-4 DISASSEMBLY AND ASSEMBLY • Remove the front protectors E by removing their bolts D. • Remove the radiator louvers F, left and right. • Remove the radiator mounting bolts G, left and right. • Loosen the radiator hose clamps H. •...
  • Page 85 DISASSEMBLY AND ASSEMBLY 4-5 • Remove the clutch cable bracket bolt Q and disconnect the clutch cable R. NOTE: Loosen the clutch cable adjuster when disconnecting. • Remove the throttle body S. (4-45) • Remove the ignition coil/plug cap T. (2-7) •...
  • Page 86 4-6 DISASSEMBLY AND ASSEMBLY • Remove the gearshift lever ]. NOTE: Mark A the gearshift shaft head at which the gearshift lever slit set for correct reinstallation. • Remove the engine sprocket cover ^ and front chain guide plate a. •...
  • Page 87: Installation

    DISASSEMBLY AND ASSEMBLY 4-7 INSTALLATION Install the engine in the reverse order of removal. Pay attention to the following points: • Fit the swingarm in its position and hold it with the swingarm pivot shaft. • Mount the engine on the frame. •...
  • Page 88 • Install the return spring 7, brake pedal 8 and master cylinder rod pin 9. • Apply grease to the brake pedal pivot bolt 0.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Tighten the brake pedal pivot bolt 0 to the specified torque.
  • Page 89 DISASSEMBLY AND ASSEMBLY 4-9 • Install the clip A, washer B and cotter pin C. NOTE: Replace the cotter pin C with a new one. • Install the kick starter lever D in the correct position. (4-44) • Tighten the kick starter lever bolt E to the specified torque. ...
  • Page 90 4-10 DISASSEMBLY AND ASSEMBLY • Install the muffler joint connector K and exhaust pipe gasket NOTE: Replace the connector K and gasket L with new ones to pre- vent exhaust gas leakage. NOTE: When installing a new connector K, clean the exhaust pipe and joint of the muffler.
  • Page 91 DISASSEMBLY AND ASSEMBLY 4-11 • Temporarily tighten the muffler connector clamp bolt P. NOTE: When installing the connector clamp, fit the convex part I of the connector clamp onto the concave part of muffler. • Check the clearance between exhausted pipe and radiator hose.
  • Page 92: Cylinder Head, Cylinder And Piston

    4-12 DISASSEMBLY AND ASSEMBLY CYLINDER HEAD, CYLINDER AND PISTON ENGINE TOP SIDE DISASSEMBLY CYLINDER HEAD COVER REMOVAL • Remove the seat. (4-2) • Remove the radiator covers and fuel tank. (4-2) • Remove the ignition coil/plug cap and spark plug. (2-7) •...
  • Page 93 DISASSEMBLY AND ASSEMBLY 4-13 • Place a wrench over the crankshaft and turn it counter clock- wise to align the TDC mark A with the center of the groove B of the timing inspection hole. NOTE: * The piston must be at TDC on the compression stroke. * Make sure that the cylinder is at TDC on compression stroke and also the timing mark C on the camshafts are aligned with the mating surface of the cylinder head.
  • Page 94 4-14 DISASSEMBLY AND ASSEMBLY • Remove the cam chain tension adjuster cap bolt 5, gasket 6, bar 7 and spring 8. • Remove the cam chain tension adjuster 0 by removing their bolts 9. • Remove the camshaft journal holder A. NOTE: Be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench in the descending order of numbers.
  • Page 95 DISASSEMBLY AND ASSEMBLY 4-15 CYLINDER HEAD REMOVAL • Remove the camshafts. (4-12) • Remove the spark plug. (2-7) • Remove the throttle body. (4-45) • Drain engine coolant. (4-49) • Loosen the muffler connector clamp bolt 1. • Remove the nuts 2. •...
  • Page 96 4-16 DISASSEMBLY AND ASSEMBLY • Remove the cylinder head base nuts C. • Loosen the cylinder base bolt D. • Remove the cylinder head bolts E. NOTE: When loosening the cylinder head bolts E, loosen each bolt lit- tle by little diagonally. •...
  • Page 97 DISASSEMBLY AND ASSEMBLY 4-17 CYLINDER REMOVAL • Remove the cylinder head. (4-15) • Remove the cylinder 2 by removing the cylinder base bolt 1. NOTE: Do not drop the cam chain 3 into the crankcase. NOTE: If the cylinder does not come off easily, lightly tap it using a plas- tic hammer.
  • Page 98 4-18 DISASSEMBLY AND ASSEMBLY PISTON AND PISTON RING REMOVAL • Remove the cylinder. (4-17) • Place a clean rag over the cylinder base to prevent the piston pin circlip 1 from dropping into the crankcase. • Remove the piston pin circlip 1. •...
  • Page 99: Engine Top Side Assembly

    DISASSEMBLY AND ASSEMBLY 4-19 ENGINE TOP SIDE ASSEMBLY PISTON AND PISTON RING INSTALLATION Install the piston and piston ring in the reverse order of removal. Pay attention to the following points: PISTON RING • Install the piston rings in the order of oil ring and 1st ring. •...
  • Page 100 4-20 DISASSEMBLY AND ASSEMBLY PISTON • Install the piston 1 with the punch mark A facing towards the exhaust side. • Before installing the piston pin 2, apply MOLYBDENUM OIL SOLUTION onto its surface.  MOLYBDENUM OIL SOLUTION • Place a clean rag over the cylinder base to prevent the piston pin circlip 3 from dropping into crankcase.
  • Page 101: Cam Chain, Cam Chain Tensioner And Cam Chain No.1 Guide

    DISASSEMBLY AND ASSEMBLY 4-21 CAM CHAIN, CAM CHAIN TENSIONER AND CAM CHAIN No.1 GUIDE REMOVAL • Remove the cylinder head. (4-15) • Remove the magneto cover and magnet rotor. (4-51, -52) • Remove the cam chain No.1 guide 1. • Remove the cam chain guide retainer 3 by removing its bolt •...
  • Page 102 4-22 DISASSEMBLY AND ASSEMBLY INSTALLATION Install the cam chain and cam chain tensioner in the reverse order of removal. Pay attention to the following points: • Install the cam chain tensioner 1, spacer 2 and cam chain tensioner bolt 3. •...
  • Page 103 • Thoroughly wipe off oil from the fitting surface of the crank- case. • Apply SUZUKI BOND “1215” to the crankcase as shown.  99000-31110: SUZUKI BOND “1215” or equivalent • Install the dowel pins 1 into the crankcase and then install the cylinder gasket 2.
  • Page 104 4-24 DISASSEMBLY AND ASSEMBLY Cylinder Head • Install the dowel pins 1 into the cylinder and then install the cylinder head gasket 2 onto the cylinder. NOTE: Replace the cylinder head gasket 2 with a new one. • Place the cylinder head 3 on the cylinder. NOTE: Do not drop the cam chain 4 into the crankcase.
  • Page 105 DISASSEMBLY AND ASSEMBLY 4-25 • With the cylinder head snugly seated on the cylinder, secure it by tightening the cylinder head bolts 5 in diagonal stages. • Tighten the cylinder head bolts 5 to the specified torque.  Cylinder head bolt: Initial 25 N·m (2.5 kgf-m, 18.0 lbf-ft) Final 51 N·m (5.1 kgf-m, 37.0 lbf-ft) •...
  • Page 106 4-26 DISASSEMBLY AND ASSEMBLY CAMSHAFT (AUTOMATIC DECOMP.) AND CAM CHAIN TENSION ADJUSTER INSTALLATION Install the camshaft and cam chain tension in the reverse order of removal. Pay attention to the following points: Camshaft (Automatic Decomp.) • Place a wrench over the crankshaft and turn it counter-clock- wise to align the TDC mark A with the center of the groove B of the timing inspection hole.
  • Page 107 DISASSEMBLY AND ASSEMBLY 4-27 • Pull the exhaust side of the cam chain taut to install the camshaft sprocket (exhaust side). • Turn the exhaust camshaft so that the timing mark C is aligned with the gasket surface of the cylinder head.
  • Page 108 • Apply grease to the new O-ring 5 and install it to the cam- shaft journal holder 6. NOTE: Replace the O-ring 5 with a new one.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the camshaft journal holder 6. • Have the camshaft journal holder evenly by tightening the camshaft journal holder bolts lightly, in the ascending order of numbers.
  • Page 109 • Retract the push rod by pushing the stopper 1. • Apply grease to the O-ring 2. NOTE: Replace the O-ring 2 with a new one.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the cam chain tension adjuster 3 as shown. A Upward •...
  • Page 110 • Inspect the valve clearance. (2-27) • Apply grease to the O-rings 9. NOTE: Replace the O-rings 9 with new ones.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Tighten the TDC plug 0 and crankshaft hole plug A to the specified torque.
  • Page 111 * Replace the cylinder head cover gasket 1 with a new one. • Apply bond to the end caps of the cylinder head cover gasket as shown.  99000-31140: SUZUKI BOND “1207B” or equivalent • Install the cylinder head cover No.2 gasket 4. NOTE: Replace the cylinder head cover No.2 gasket 4 with a new one.
  • Page 112: Clutch

    4-32 DISASSEMBLY AND ASSEMBLY CLUTCH CLUTCH PLATE REMOVAL • Drain engine oil. (2-14) • Remove the brake pedal. (4-71) • Remove the clutch cover 1 and its gasket 2. • Remove the clutch spring set bolts 3 and clutch springs. NOTE: Loosen the clutch spring set bolts 3 little by little and diagonally.
  • Page 113 DISASSEMBLY AND ASSEMBLY 4-33 • Remove the clutch drive plates 9 and driven plates 0. NOTE: Mark the paint mark a to the clutch driven No. 2 plate. A Clutch driven No. 2 plate B Clutch driven No. 1 plate C Direction of outside •...
  • Page 114 4-34 DISASSEMBLY AND ASSEMBLY INSPECTION Drive Plate • Measure the drive plate thickness.  Drive plate thickness Service Limit: 2.42 mm (0.095 in)  09900-20101: Vernier calipers • Inspect the drive plates for wear, distortion and discoloration. • If the drive plate thickness is found to have reached the limit, replace it with a new one.
  • Page 115 DISASSEMBLY AND ASSEMBLY 4-35 Push Rod • Inspect the push rod for wear and damage. • If any defects are found, replace the push rod with a new one. Release Bearing • Inspect the clutch release bearing 1 for any abnormality, par- ticularly cracks, to decide whether it can be reused or should be replaced.
  • Page 116 4-36 DISASSEMBLY AND ASSEMBLY • Apply engine oil to the drive plates 3 and driven plates 4. • Install the clutch drive plates and driven plates one by one into the clutch sleeve hub in the prescribed order as show in illustration.
  • Page 117 DISASSEMBLY AND ASSEMBLY 4-37 • Install the clutch springs and clutch spring set bolts 9. • Tighten the clutch spring set bolts 9 to the specified torque. NOTE: Tighten the clutch spring set bolts 9 diagonally.  Clutch spring set bolt: 10 N·m (1.0 kgf-m, 7.0 lbf-ft) •...
  • Page 118: Primary Driven Gear And Clutch Sleeve Hub

    4-38 DISASSEMBLY AND ASSEMBLY PRIMARY DRIVEN GEAR AND CLUTCH SLEEVE HUB REMOVAL • Remove the clutch cover. (4-32) • Remove the pressure plate and clutch plates. (4-32, -33) • Flatten the lock washer 1. • Hold the clutch sleeve hub 3 with the special tool and loosen the clutch sleeve hub nut 2.
  • Page 119 DISASSEMBLY AND ASSEMBLY 4-39 INSPECTION • Inspect the clutch sleeve hub and primary driven gear for wear and cracks. • If any defects are found, replace the sleeve hub or driven gear with a new one. • Inspect the needle bearing and spacer for damage and wear. •...
  • Page 120 4-40 DISASSEMBLY AND ASSEMBLY • Fit the clutch sleeve hub 5, new lock washer 6 and clutch sleeve hub nut 7. NOTE: Replace the lock washer 6 with a new one. • Tighten the clutch sleeve hub nut 7 with the special tool to the specified torque.
  • Page 121 DISASSEMBLY AND ASSEMBLY 4-41 • Reassemble the clutch plates and pressure plate. (4-35 to -37) • Install the gasket 8 and clutch cover 9. NOTE: Replace the gasket with a new one. • Tighten the clutch cover bolts (A, B) diagonally to the speci- fied torque.
  • Page 122: Clutch Release Camshaft

    4-42 DISASSEMBLY AND ASSEMBLY CLUTCH RELEASE CAMSHAFT REMOVAL • Remove the clutch cover and its gasket. (4-32) • Remove the pressure plate and push rod. (4-32) • Remove the retainer 2 by removing its bolt 1. • Disconnect the clutch cable 3. •...
  • Page 123 Install the clutch release camshaft 1 in the reverse order of removal. Pay attention to the following points: • Apply SUZUKI MOLY PASTE to the clutch release camshaft.  99000-25140: SUZUKI MOLY PASTE or equivalent • Apply grease to the oil seal lip.
  • Page 124: Kick Starter

    4-44 DISASSEMBLY AND ASSEMBLY KICK STARTER REMOVAL • Remove the kick starter lever 1 by removing its bolt 2. INSTALLATION • Install the kick starter lever 1 onto the kick starter shaft. NOTE: When installing the kick starter lever 1, align the wide spline teeth A and B.
  • Page 125: Throttle Body

    DISASSEMBLY AND ASSEMBLY 4-45 THROTTLE BODY REMOVAL • Remove the seat and radiator covers. (4-2) • Remove the fuel tank. (4-2) NOTE: Be sure to follow the NOTICE in fuel tank section when remov- ing the fuel tank. • Disconnect the TP sensor coupler 1 and condenser coupler •...
  • Page 126 4-46 DISASSEMBLY AND ASSEMBLY • Remove the throttle cable cover 9 by removing their bolts 8. • Loosen the lock-nuts 0. • Disconnect the throttle cables from their pulley. • Remove the throttle body assembly. NOTICE Snapping down the throttle valve with the throttle cable released can damage the throttle valve and throttle body.
  • Page 127: Installation

    DISASSEMBLY AND ASSEMBLY 4-47 INSTALLATION Install the throttle body assembly in the reverse order of removal. Pay attention to the following points: • Connect the throttle pulling cable 1 and throttle returning cable 2 to the pulley. • Turn in each throttle cable adjuster fully and locate each outer cable so that the clearance a is 0 –...
  • Page 128: Tp Sensor Adjustment

    4-48 DISASSEMBLY AND ASSEMBLY TP SENSOR ADJUSTMENT 1. Connect a 12 volt battery to the service coupler 1 using the battery lead wire 2. 36890-28H00: Battery lead wire (option) 2. Loosen the screw 3 with the special tool. 3. Turn the TP sensor 4. 4.
  • Page 129: Engine Coolant

    DISASSEMBLY AND ASSEMBLY 4-49 ENGINE COOLANT REPLACEMENT  WARNING Engine coolant may be harmful if swallowed or if it comes in contact with the skin or eyes. If engine cool- ant gets into the eyes or contacts the skin, flush the eyes or wash the skin thoroughly, with plenty of water.
  • Page 130 4-50 DISASSEMBLY AND ASSEMBLY • Tighten the air bleeder bolt 3 to the specified torque.  Radiator air bleeder bolt: 6 N·m (0.6 kgf-m, 4.5 lbf-ft) • Add engine coolant up to the radiator inlet. • Tighten the radiator cap securely. •...
  • Page 131: Electrical System

    DISASSEMBLY AND ASSEMBLY 4-51 ELECTRICAL SYSTEM MAGNETO ROTOR REMOVAL • Drain engine oil. (2-14) • Disconnect the magneto lead wire coupler 1. • Remove the clamp 2. • Remove the gearshift lever. • Remove the magneto cover 4 by removing their bolts 3. •...
  • Page 132 4-52 DISASSEMBLY AND ASSEMBLY • Remove the magneto rotor 8 with the special tool.  09930-34951: Rotor remover • Remove the magneto rotor key 9. INSTALLATION • Remove any grease from the tapered portion A of the mag- neto rotor and crankshaft B. •...
  • Page 133 DISASSEMBLY AND ASSEMBLY 4-53 • Install the dowel pins 3 and gasket 4. NOTE: Replace the gasket 4 with a new one. • Install the magneto cover 5. • Tighten the magneto cover bolts (A,B,C) to the specified torque. NOTE: * The bolts A are 5 mm longer than the others.
  • Page 134: Front And Rear Wheels

    4-54 DISASSEMBLY AND ASSEMBLY FRONT AND REAR WHEELS FRONT WHEEL REMOVAL • Remove the front axle nut 1. • Loosen the left axle holder bolts 2. • Place the motorcycle on a block to lift front wheel off the ground. •...
  • Page 135 DISASSEMBLY AND ASSEMBLY 4-55 Axle Shaft • Support the axle shaft with the V blocks and measure the axle shaft runout. • If the runout exceeds the limit, replace the axle shaft with a new one.  Axle runout Service Limit: 0.25 mm (0.010 in) ...
  • Page 136 4-56 DISASSEMBLY AND ASSEMBLY DISK PLATE REPLACEMENT • Remove the disk plate 2 by removing their bolts 1. • Apply THREAD LOCK SUPER to the disk plate bolts 1.  99000-32110: THREAD LOCK SUPER “1322” or equivalent • Tighten the disk plate bolts 1 to the specified torque. ...
  • Page 137: Rear Wheel

    DISASSEMBLY AND ASSEMBLY 4-57 REAR WHEEL REMOVAL • Loosen the rear axle nut 1. • Place the motorcycle on a block to lift the rear wheel off the ground. • Remove rear axle nut 1 and washer 2. • Remove the rear axle shaft 3 and chain adjuster washers 4. •...
  • Page 138 4-58 DISASSEMBLY AND ASSEMBLY INSPECTION Wheel Spacer • Remove the wheel spacers from the rear wheel. • Inspect the rear wheel spacers 1 and dust seals 2 for wear and cracks. • If any defects are found, replace the spacer 1 together with the dust seal 2.
  • Page 139 DISASSEMBLY AND ASSEMBLY 4-59 DISK PLATE REPLACEMENT • Remove the disk plate 2 by removing their bolts 1. • Apply THREAD LOCK SUPER to the disk plate bolts 1.  99000-32110: THREAD LOCK SUPER “1322” or equivalent • Tighten the disk plate bolts 1 to the specified torque. ...
  • Page 140 4-60 DISASSEMBLY AND ASSEMBLY INSTALLATION • Install the rear wheel, chain adjuster washers 1 and axle shaft. • Adjust the drive chain slack. (2-33) A FWD B Left C Right • Tighten the rear axle nut 2 to the specified torque. ...
  • Page 141: Front And Rear Brakes

    DISASSEMBLY AND ASSEMBLY 4-61 FRONT AND REAR BRAKES BRAKE FLUID AIR BLEEDING  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.
  • Page 142 4-62 DISASSEMBLY AND ASSEMBLY • Pour brake fluid up to the UPPER line A.  Specification and classification: DOT 4 • Connect a transparent tube to the bleeder valve and set the other end into a receptacle. • Pump the brake lever/pedal until air bubbles stop coming out from the reservoir.
  • Page 143: Brake Fluid Replacement

    DISASSEMBLY AND ASSEMBLY 4-63 BRAKE FLUID REPLACEMENT • Remove the reservoir cap. (4-61) • Suck up the brake fluid as much as possible. • Drain the old brake fluid as much as possible. • Fill the reservoir with new brake fluid. •...
  • Page 144: Brake Pads Replacement

    NOTE: Replace the two pads as a set. • Fit the new brake pads into the caliper. • Apply SUZUKI SILICONE GREASE to the O-ring.  99000-25100: SUZUKI SILICONE GREASE or equivalent • Tighten the brake pad mounting pin 1 to the specified torque.
  • Page 145: Caliper

    DISASSEMBLY AND ASSEMBLY 4-65 CALIPER  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 sealed container. Never use or mix different types of brake fluid.
  • Page 146 4-66 DISASSEMBLY AND ASSEMBLY FRONT CALIPER REMOVAL AND DISASSEMBLY • Place a rag under the brake hose union bolt 1 to catch spilled brake fluid. • Disconnect the brake hose 2 by removing the union bolt 1. • Remove the caliper mounting bolts 3. •...
  • Page 147 25 N·m (2.5 kgf-m, 18.0 lbf-ft) • Apply brake fluid to the new dust seals and pistons. • Apply SUZUKI SILICONE GREASE to the new piston seals. • Fit the piston seals, dust seals and pistons.  Specification and classification: DOT 4 ...
  • Page 148 4-68 DISASSEMBLY AND ASSEMBLY • Tighten the caliper mounting bolts 2 to the specified torque.  Front brake caliper mounting bolt: 26 N·m (2.6 kgf-m, 19.0 lbf-ft) • Tighten the brake pad mounting pin 3 to the specified torque.  Brake pad mounting pin: 18 N·m (1.8 kgf-m, 13.0 lbf-ft) •...
  • Page 149 DISASSEMBLY AND ASSEMBLY 4-69 • Remove the brake pad. (4-64) • Remove the spring 7. • Remove the caliper bracket 8 from the caliper 9. • Remove the boots 0 and A. • Remove the spring B. • Remove the rear brake caliper axle bolt (bracket) C. •...
  • Page 150 Pay attention to the following points: • Apply brake fluid to the new dust seal and piston. • Apply SUZUKI SILICONE GREASE to the new piston seal. • Fit the piston seal, dust seal and piston.  Specification and classification: DOT 4 ...
  • Page 151: Brake Pedal

    • Remove the brake pedal pivot bolt 5 and return spring 6. INSTALLATION • Apply grease to the oil seals and brake pedal pivot bolt.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the return spring 1 properly. (5-19) •...
  • Page 152: Front Fork And Steering

    4-72 DISASSEMBLY AND ASSEMBLY FRONT FORK AND STEERING FRONT FORK REMOVAL • Place the motorcycle on a block to lift front wheel off the ground. • Remove the front wheel. (4-54) • Remove the front number plate 2 by removing its bolt 1. •...
  • Page 153 DISASSEMBLY AND ASSEMBLY 4-73 • Hold the fork body and loosen the front fork lower clamp bolts • Remove the front fork. DISASSEMBLY • Set rebound and compression damper settings to the mini- mum settings (softest) before disassembling. Record the set- ting before turning the adjuster.
  • Page 154 4-74 DISASSEMBLY AND ASSEMBLY • Place a drain pan under the front fork and drain fork oil. NOTE: Face the oil hole A on the sub-tank downward. • Raise the outer tube and temporarily install the fork cap bolt 1 (sub-tank) to the outer tube. •...
  • Page 155 DISASSEMBLY AND ASSEMBLY 4-75 • Hold the lock-nut 5 with a wrench and remove the center bolt • Remove the push rod 6. • With the outer tube compressed by hands, remove the special tool. NOTICE If the lock nut 5 is removed, the inner rod can slip into the damper rod and damper rod threaded can damage the oil seal.
  • Page 156 4-76 DISASSEMBLY AND ASSEMBLY • Loosen the fork cap bolt 1 (sub-tank) and remove the sub-tank 7 along with the damper rod assembly 8. • Remove the fork spring 9. NOTE: Do not attempt to disassemble the damper rod assembly 8. The damper rod assembly 8 is available only as an assembly.
  • Page 157 DISASSEMBLY AND ASSEMBLY 4-77 INNER TUBE • Separate the inner tube 1 out of the outer tube 2. • Remove the slide bushing 3 from the inner tube 1. • Remove the following parts from the inner tube 1. • Guide bushing 4 •...
  • Page 158 4-78 DISASSEMBLY AND ASSEMBLY DAMPER ROD ASSEMBLY AND COMPRESSION DAMPER UNIT • Clamp the bottom (flat part) of the sub-tank with a vise. NOTE: Do not clamp the sub-tank too tight. • Loosen the compression damper unit 1. • Remove the compression damper unit 1 from the sub-tank NOTE: Slowly compress the inner rod 3 until it stops so that the com- pression damper unit can be removed easily.
  • Page 159 DISASSEMBLY AND ASSEMBLY 4-79 INSPECTION Center Bolt • Inspect the adjuster rod of the center bolt for damage. If it is damaged, replace it with a new one. Compression Damper Unit • Inspect the compression damper unit for damage. If it is dam- aged, replace it with a new one.
  • Page 160 4-80 DISASSEMBLY AND ASSEMBLY Damper Rod Assembly • Inspect the damper rod assembly for scratches or bending. If it has scratches or is bent, replace it with a new one. Fork Spring • Measure the free length of front fork spring. •...
  • Page 161 DISASSEMBLY AND ASSEMBLY 4-81 REASSEMBLY NOTE: * Clean all fork parts before reassembling. * Replace the O-rings, oil seal and dust seal with new ones. * Apply specified front fork oil when installing the O-rings, slide bushing, guide bushing, damper unit and sliding parts. Inner Tube •...
  • Page 162 4-82 DISASSEMBLY AND ASSEMBLY • Install a new oil seal 3 with the special tool until the stopper ring groove of the outer tube can be seen.  09940-52861: Front fork oil seal installer set • Attach the stopper ring securely to the stopper ring groove of the outer tube.
  • Page 163 DISASSEMBLY AND ASSEMBLY 4-83 • 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 (6.5/6.8 US/lmp oz)  FORK OIL SS-19 or equivalent •...
  • Page 164 4-84 DISASSEMBLY AND ASSEMBLY • Tighten the lock-nut 7 by hand completely. • With the damper rod held in vertical position, compress the damper rod fully to discharge an excess of oil. NOTE: Protect the inner rod end with a rag when compressing the damper rod.
  • Page 165 DISASSEMBLY AND ASSEMBLY 4-85 • Tighten the lock nut 7. NOTE: Thread length b should be approx. 10 mm (0.39 in). b Approx. 10 mm (0.39 in) • Completely wipe off the fork oil from the spring and damper rod assembly. •...
  • Page 166 4-86 DISASSEMBLY AND ASSEMBLY • Insert the push rod A into the inner rod. • Replace the O-ring with a new one. • Apply fork oil to the O-ring. shaped projection A of center bolt B into the • Insert the push rod B.
  • Page 167 DISASSEMBLY AND ASSEMBLY 4-87 • Loosen and remove the fork cap bolt 9 (sub-tank) from the outer tube with the special tool and slowly slide down the outer tube.  09941-53630: Front fork cap socket wrench (50 mm) • Pour the specified amount of fork oil into the outer tube. ...
  • Page 168 4-88 DISASSEMBLY AND ASSEMBLY • Tighten the fork cap bolt 2 (sub-tank) to the specified torque with the special tool.  09941-53630 : Front fork cap socket wrench (50 mm)  Fork cap bolt: 34 N·m (3.4 kgf-m, 24.5 lbf-ft) •...
  • Page 169: Steering

    DISASSEMBLY AND ASSEMBLY 4-89 STEERING REMOVAL Handlebars • Place the motorcycle on a block to lift front wheel off the ground. • Remove the front number plate and handlebar pad. (4-72) • Remove the clamps 1. • Remove the engine stop switch 3 by removing its screw 2. •...
  • Page 170 4-90 DISASSEMBLY AND ASSEMBLY • Slightly loosen the handlebar holder set nuts 9. • Remove the handlebars A by removing the handlebar clamp bolts 0. NOTE: Mark the paint mark D to the matching surface of handlebar holder and handlebars before removing. Steering Stem •...
  • Page 171 DISASSEMBLY AND ASSEMBLY 4-91 • Remove the steering stem head nut 6 and washer 7. • Remove the steering stem upper bracket 8. • Remove the handlebar holder set bolts and nuts 9. • Remove the handlebar holders, damper bushings and spac- ers.
  • Page 172 4-92 DISASSEMBLY AND ASSEMBLY • Remove the washer B, upper dust seal C and upper bearing INSPECTION • Inspect the removed parts for the following abnormalities. • Distortion of the steering stem • Bearing wear or damage • Abnormal bearing noise •...
  • Page 173 Install the steering in the reverse order of steering removal. Pay attention to the following points: Steering Stem • Apply grease to the bearings.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Fit the steering stem lower bracket, upper bearing, upper dust seal and washer.
  • Page 174 4-94 DISASSEMBLY AND ASSEMBLY • Fit the steering stem upper bracket 2 and washer 3 • Temporarily tighten the steering stem head nut 4. NOTE: Pay attention to the direction of the washer 3. • Temporarily install the front forks to the steering stem, and tighten the lower clamp bolts.
  • Page 175 • Tighten the handlebar holder set nuts A to the specified torque.  Handlebar holder set nut: 44 N·m (4.4 kgf-m, 32.0 lbf-ft) • Apply grease to the throttle cable and their hole.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
  • Page 176 4-96 DISASSEMBLY AND ASSEMBLY • Align the matching mark D on the handlebars with the throttle holder matching surface. • Tighten the screws B securely. NOTE: Make sure that the cut-line E of collar C to lower side. • Align the matching mark F on the handlebars with the master cylinder matching surface.
  • Page 177 DISASSEMBLY AND ASSEMBLY 4-97 ” mark on the left grip with the matching mark B • Align the “ on the left handlebar end. • Align the matching mark C on the handlebars with the match- ing surface clutch lever holder. •...
  • Page 178: Rear Suspension

    4-98 DISASSEMBLY AND ASSEMBLY REAR SUSPENSION REAR SHOCK ABSORBER REMOVAL • Place the motorcycle on a block to lift rear wheel off the ground. • Remove the seat and right frame cover. (4-2) • Loosen the air cleaner clamp screw 1. •...
  • Page 179 DISASSEMBLY AND ASSEMBLY 4-99 • Remove the rear shock absorber upper mounting bolt and nut • Remove the rear shock absorber lower mounting bolt and nut NOTE: If necessary, move the swingarm up or down to facilitate this mounting bolt/nut removal. •...
  • Page 180 4-100 DISASSEMBLY AND ASSEMBLY SPRING REPLACEMENT • Loosen the lock-nut 1 with the special tool and turn it fully to the end of the thread. • Turn the adjuster 2 as well as the lock-nut 1.  09910-60611: Universal clamp wrench •...
  • Page 181 DISASSEMBLY AND ASSEMBLY 4-101 • Adjust the spring set length and tighten the lock-nut.  Standard spring set length: 4.2 mm (0.17 in) compressed from the free length Spring set length adjustable range: 245 – 263 mm (9.64 – 10.35 in) [at spring free length 265 mm (10.43 in)] a: Hardest spring setting b: Softest spring setting...
  • Page 182: Swingarm

    4-102 DISASSEMBLY AND ASSEMBLY SWINGARM REMOVAL • Place the motorcycle on a block to lift rear wheel off the ground. • Remove the rear wheel. (4-57) • Remove the chain guide bolts and nuts 1. • Remove the chain guide plate 2 and chain guide 3. •...
  • Page 183 DISASSEMBLY AND ASSEMBLY 4-103 • Down the rear brake pedal A and remove the pivot shaft B. • Remove the swingarm. • Remove the chain buffer D by removing its screws C. • Remove the plates F by removing its screws E. •...
  • Page 184: Installation

    7 Spacer 4 Thrust bearing 8 Washer • Apply grease to the dust seals, bearings and oil seals.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Apply a small quantity of THREAD LOCK SUPER to the plate mounting screws 9.
  • Page 185: Rear Suspension Linkage

    DISASSEMBLY AND ASSEMBLY 4-105 REAR SUSPENSION LINKAGE REMOVAL • Place a block under the chassis tubes. • Remove the rear cushion rod bolts and nuts 1. • Remove the cushion lever bolt and nut 2. • Remove the shock absorber lower bolt and nut 3. •...
  • Page 186: Installation

    Pay attention to the following points: • Install the washers 1. • Position the dust seals 2 so that the manufacturer’s code indicated side of the seals face outside. • Apply grease to the dust seals 2.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
  • Page 187 DISASSEMBLY AND ASSEMBLY 4-107 • Tighten the cushion lever, cushion rod and swingarm nuts to the specified torque. Left Right 3: Rear suspension linkage bolt  Tightening torque: A: 50 N·m (5.0 kgf-m, 36.0 lbf-ft) D: 80 N·m (8.0 kgf-m, 58.0 lbf-ft) a: 6.25 mm (0.25 in) B: 50 N·m (5.0 kgf-m, 36.0 lbf-ft) E: 80 N·m (8.0 kgf-m, 58.0 lbf-ft)
  • Page 188 4-108 DISASSEMBLY AND ASSEMBLY Left Right 4: Stamped mark d: 4.0 mm (0.16 in)  Tightening torque: F: 70 N·m (7.0 kgf-m, 50.5 lbf-ft) NOTICE 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 189: Servicing Information

    SERVICING INFORMATION 5-1 SERVICING INFORMATION CONTENTS TIGHTENING TORQUE ................5-2 ENGINE ....................5-2 FI SYSTEM AND INTAKE AIR SYSTEM ..........5-3 COOLING SYSTEM ................5-3 CHASSIS ....................5-4 SPECIAL TOOLS ..................5-7 WIRING DIAGRAM ..................5-9 CABLE ROUTING ..................5-10 FUEL HOSE ROUTING ................
  • Page 190: Tightening Torque

    5-2 SERVICING INFORMATION TIGHTENING TORQUE ENGINE N·m kgf-m lbf-ft ITEM Cylinder head cover bolt 10.0 Spark plug (Initial) 18.0 Cylinder head bolt (Final) 37.0 Cylinder head base nut Cylinder base bolt Camshaft journal holder bolt Primary drive gear nut 65.0 Magneto rotor nut 58.0 Clutch sleeve hub nut...
  • Page 191: Fi System And Intake Air System

    SERVICING INFORMATION 5-3 N·m kgf-m lbf-ft ITEM Engine mounting nut (front) 47.5 Engine mounting bracket nut (upper) 29.0 Engine mounting bracket nut (front) 29.0 Engine sprocket cover bolt Kick starter lever bolt 21.0 Kick starter lever screw Intake pipe bolt Exhaust pipe nut 13.0 Muffler connector clamp bolt...
  • Page 192: Chassis

    5-4 SERVICING INFORMATION CHASSIS N·m kgf-m lbf-ft ITEM Handlebar clamp bolt 18.0 Handlebar holder set nut 32.0 Front fork upper clamp bolt (right and left) 16.5 Front fork lower clamp bolt (right and left) 16.5 Steering stem head nut 10.0 72.5 Front fork cap bolt 24.5...
  • Page 193 SERVICING INFORMATION 5-5 N·m kgf-m lbf-ft ITEM Seat rail bolt and nut (upper and lower) 16.5 Footrest bolt 25.5 Cable adjuster lock-nut (throttle, clutch and hot starter) 0.22 1.60 Clutch cable bracket bolt Radiator cover upper bolt Radiator cover bolt...
  • Page 194 5-6 SERVICING INFORMATION Each fastener should be tightened to the torque specified in “TIGHTENING LIST”. If no description or speci- fication is provided, refer to the following tightening torque chart for the applicable torque for each fastener. Thread diameter (Nominal diameter) A [mm] Strength Unit A equivalent of 4T strength fastener...
  • Page 195: Special Tools

    SERVICING INFORMATION 5-7 SPECIAL TOOLS 09900-06107 09900-20101 Snap ring remover Vernier calipers 09900-20607 09900-20701 09900-20803 (Open type) (150 mm) Dial gauge Dial gauge chuck Thickness gauge 09900-25008 09900-25009 09900-21304 Multi circuit tester Needle-pointed 09900-26006 09910-20115 V blocks probe set Engine tachometer Piston holder 09910-60611 09920-53740...
  • Page 196 5-8 SERVICING INFORMATION 09940-34581 09940-14911 09940-14960 Front fork assem- 09930-34951 09930-44560 Steering stem nut Steering stem nut bling attachment Rotor remover Rotor holder socket wrench socket wrench 09941-53630 09940-52861 Front fork cap Front fork oil seal socket wrench installer set (50 mm)
  • Page 197: Wiring Diagram

    SERVICING INFORMATION 5-9 WIRING DIAGRAM...
  • Page 198: Cable Routing

    5-10 SERVICING INFORMATION CABLE ROUTING Throttle cable (Pulling cable) Radiator overflow hose Throttle cable (Returning cable) Cable guide Hot starter cable 2 – 3 mm (0.08 – 0.12 in) Clutch cable 14 – 16 mm (0.55 – 0.63 in) Bind the engine stop switch lead wire and clutch cable (White taping position) with the clamp. Bind the hot starter cable and wiring harness with the clamp.
  • Page 199 SERVICING INFORMATION 5-11 Throttle cable (Pulling cable) Wiring harness Throttle cable (Returning cable) 2 – 3 mm (0.08 – 0.12 in) Hot starter cable 0 – 1.5 mm (0 – 0.06 in) Radiator overflow hose Pass the throttle cables over the radiator and radiator overflow hose. Pass the hot starter cable between the radiator and frame.
  • Page 200: Fuel Hose Routing

    5-12 SERVICING INFORMATION FUEL HOSE ROUTING Fuel hose Fuel tank Throttle body TP sensor Air cleaner Condenser IAT sensor ECT sensor Intake pipe clamp Breather hose Air cleaner outlet pipe clamp Air cleaner box Fuel pump Upward Gray button Yellow button Do not slack the breather hose at this position.
  • Page 201: Radiator Hose Routing

    SERVICING INFORMATION 5-13 RADIATOR HOSE ROUTING Radiator LH Radiator RH Radiator overflow hose 15 ± 10° Bind the radiator overflow hose. Face the white mark to the backward. Face the yellow mark to the backward. Pass the radiator overflow hose between engine mounting lower bracket. Face the blue mark to the backward.
  • Page 202: Crankcase And Cover Installation

    5-14 SERVICING INFORMATION CRANKCASE AND COVER INSTALLATION...
  • Page 203 SERVICING INFORMATION 5-15 Right crankcase cover bolt Magneto cover bolt L: 30 mm (1.2 in) L: 35 mm (1.4 in) Right crankcase cover bolt Magneto cover bolt L: 25 mm (1.0 in) L: 30 mm (1.2 in) Clutch cover bolt Crankcase bolt L: 60 mm (2.4 in) L: 40 mm (1.6 in)
  • Page 204: Exhaust Pipe And Muffler Installation

    5-16 SERVICING INFORMATION EXHAUST PIPE AND MUFFLER INSTALLATION Muffler mounting bolt Muffler connector clamp bolt Exhaust pipe cover bolt  ITEM N·m kgf-m lbf-ft 16.5 13.0...
  • Page 205: Clutch Cable Adjuster

    SERVICING INFORMATION 5-17 CLUTCH CABLE ADJUSTER Clutch cable adjuster Turn to tighten the clutch cable tension. Turn to loosen the clutch cable tension. When the movement is felt heavier, clean this and apply grease. Do not apply grease to the rubber covers. Fit the cover positively. Adjustable range.
  • Page 206: Hot Starter Lever Installation

    5-18 SERVICING INFORMATION HOT STARTER LEVER INSTALLATION Pass the hot starter cable into the lever cover. Connect the hot starter cable to the master cylinder holder and hot starter lever. Pass the hot starter lever into the lever cover. Tighten the lower bolt first temporarily to provide clearance on the upper side and then tighten both the bolts to the specified torque.
  • Page 207: Rear Brake Pedal Set-Up

    SERVICING INFORMATION 5-19 REAR BRAKE PEDAL SET-UP Rear master cylinder Return spring Brake pedal 0 – 10 mm (0 – 0.4 in)
  • Page 208: Front Brake Hose Routing

    5-20 SERVICING INFORMATION FRONT BRAKE HOSE ROUTING Front brake hose Front fork protector Front brake master cylinder Clamp Stopper Front brake caliper Hose guide Set the brake hose end between the hose stopper, then tighten the brake hose union bolt. Clamp the upper difference portion in brake hose diameter.
  • Page 209: Rear Brake Hose Routing

    SERVICING INFORMATION 5-21 REAR BRAKE HOSE ROUTING A – A Rear brake hose Rear brake caliper Rear brake master cylinder Hose guide Set the brake hose end between the hose stopper, then tighten the brake hose union bolt. Outside...
  • Page 210: Handlebar Set-Up

    5-22 SERVICING INFORMATION HANDLEBAR SET-UP Throttle cable (Pulling cable) 190 mm (7.48 in) Throttle cable (Returning cable) 2 – 3 mm (0.08 – 0.12 in) Marking 121 mm (4.76 in) Forward 175 mm (6.89 in) 145 mm (5.71 in) 14 – 16 mm (0.55 – 0.63 in) Align the matching surface of master cylinder with marking.
  • Page 211: Rear Wheel Spokes Installation

    SERVICING INFORMATION 5-23 REAR WHEEL SPOKES INSTALLATION Spoke (Inner) L: 206.5 mm (8.13 in) Spoke (Outer) L: 204.5 mm (8.05 in)
  • Page 212: Specifications

    5-24 SERVICING INFORMATION SPECIFICATIONS DIMENSIONS AND CURB MASS Overall length ............2 170 mm (85.4 in) Overall width ............830 mm (32.7 in) Overall height ............1 270 mm (50.0 in) Wheelbase ............1 475 mm (58.1 in) Ground clearance ..........345 mm (13.6 in) Seat height............
  • Page 213: Chassis

    SERVICING INFORMATION 5-25 CHASSIS Front suspension..........Upside-down telescopic fork Rear suspension ..........Swingarm type Front suspension stroke ........310 mm (12.2 in) Rear wheel travel ..........310 mm (12.2 in) Caster..............30° 20’ Trail..............140 mm (5.5 in) Steering angle ............. 45° (right & left) Front brake ............
  • Page 214: Spare Parts List

    5-26 SERVICING INFORMATION SPARE PARTS LIST ITEM PART NAME PART NUMBER Q’TY PARTS SET, SPARE 19900-49H00 GASKET, MAGNETO COVER 11483-49H00 GASKET, CLUTCH COVER OUTER 11484-10H00 GASKET, EXHAUST PIPE 14181-49H00 CONNECTOR, MUF JT 14771-29F00 FILTER COMP, ENGINE OIL 16510-35G00 O-RING, WATER PUMP CASE 17431-10H00 LEVER, BRAKE 57310-37F00...
  • Page 215: Optional Parts

    SERVICING INFORMATION 5-27 OPTIONAL PARTS PART No. NUMBER OF TEETH COMMENTS 64511-29F00 112 L 64511-37E00 114 L REAR SPROCKET 64511-36E00 114 L 64511-40261 116 L FI INDICATOR LIGHT ASSY 36380-28H00 — BATTERY LEAD WIRE 36890-28H00 — FRONT BRAKE DISK COVER 59231-36E30 —...
  • Page 216: Setting Data

    5-28 SERVICING INFORMATION SETTING DATA DATE RACE/COURSE TEMP./HUMIDITY WEATHER COURSE COUDITION SPARK PLUG OIL CAPACITY COMP. ADJ. POSITION RE-BOUND ADJ. POSITION SPRING SPRING SPRING SET LENGTH COMP. ADJ. POSITION LOW COMP. ADJ. POSITION HIGH RE-BOUND ADJ. POSITION FINAL REDUCTION RATIO MAKER/SIZE PRESSURE MAKER/SIZE...
  • Page 219 WARNING 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 competition vehicle is designed and manufactured for use in closed course competition only - do not use on public streets, roads, or highways.