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Suzuki RM-Z250 Owner's Service Manual

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  • 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. WARNING/CAUTION/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 gear, and practicing safe riding techniques to Engine No. 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 ! 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 6: 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 7: Table Of Contents

    GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE TROUBLESHOOTING MACHINE TUNING ENGINE REMOVAL AND INSTALLATION CYLINDER HEAD, CYLINDER AND PISTON CLUTCH KICK STARTER GEARSHIFTING TRANSMISSION AND CRANKSHAFT LUBRICATION SYSTEM FUEL SYSTEM COOLING SYSTEM ELECTRICAL SYSTEM FRONT AND REAR WHEELS FRONT AND REAR BRAKES FRONT FORK AND STEERING REAR SUSPENSION SERVICING INFORMATION...
  • Page 8 Apply THREAD LOCK SUPER “1360”. Data beside it indicates specified 99000-32130 torque. Apply oil. Use engine oil or transmission Use SUZUKI FORK OIL SS-05 or oil unless otherwise specified. equivalent fork oil. 99000-99001-SS5 Apply molybdenum oil solution. Use SUZUKI REAR SUSPENSION OIL (Mixture of engine oil and SUZUKI SS-25 or equivalent rear suspension oil.
  • Page 9 GENERAL INFORMATION 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- 5 TRANSMISSION ...................
  • Page 10: Location Of Parts

    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 Carburetor starter knob 8 Gearshift lever 9 Front suspension compression damp- ing adjuster 0 Front suspension rebound damping adjuster A Kick starter lever...
  • Page 11: Accessory

    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 SF/SG or SH/SJ in API with JASO MA. The rec- ommended viscosity is SAE 10W-40.
  • Page 12: Operating Instructions

    GENERAL INFORMATION OPERATING INSTRUCTIONS CAUTION 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 13: Stopping The Engine

    GENERAL INFORMATION When the engine is already warm or restarts: 1) Pull the hot starter lever 1. 2) Kickstart the engine, leaving the throttle closed without using the starter knob. 3) Return the hot starter lever back immediately after the engine starts.
  • Page 14: Break-In (Running-In)

    GENERAL INFORMATION BREAK-IN (RUNNING-IN) WHEN THE MOTORCYCLE IS NEW CLOSED CLOSED 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. FULL NOTE: OPEN...
  • Page 15: Exterior Parts

    GENERAL INFORMATION EXTERIOR PARTS 6 N . m (0.6 kgf . m, 4.5 lb-ft) 4.4 mm (0.17 in) 4.4 mm (0.17 in) 6 mm (0.24 in) 15 mm 16 mm 9 mm 16 mm 10 mm 11 mm (0.59 in) (0.63 in) (0.35 in) (0.63 in)
  • Page 16 PERIODIC MAINTENANCE 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 ....................
  • Page 17 PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS MUFFLER SILENCER ................. 2-27 SILENCER INSPECTION AND REPLACEMENT ........ 2-27 DRIVE CHAIN AND SPROCKETS ............. 2-28 DRIVE CHAIN SLACK ................2-28 CRANKCASE DRIVESHAFT OIL SEAL ..........2-28 DRIVE CHAIN ADJUSTMENT .............. 2-28 20TH PITCH LENGTH ................2-28 DRIVE CHAIN LUBRICATION .............
  • Page 18: Periodic Maintenance

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE INSPECTION BEFORE PRACTICE WHAT TO CHECK CHECK FOR Spark plug Heat range, fouled electrode, tightness Air cleaner element • Dust • Lubrication Engine oil Oil level Coolant Coolant level Cooling system • Radiator hose damage • Engine coolant leak Clutch •...
  • Page 19: Inspection Before Race

    PERIODIC MAINTENANCE INSPECTION BEFORE RACE (All items of inspection before practice on previous page plus) WHAT TO CHECK CHECK FOR Clutch Clutch disc plates wear and distortion Brake pads Wear Sprockets Wear Cleanliness Fuel tank Leakage Fuel hose • Damage •...
  • Page 20: Periodic Maintenance Chart

    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 21: Periodic Maintenance

    PERIODIC MAINTENANCE Interval Every Every Every races race 3 races 6 races Remarks Service Every Every Every hours Item 2 hours 6 hours 12 hours Tire — — Inspect every 20 min. up to initial 2 hours Spoke nipple — —...
  • Page 22: Spark Plug

    PERIODIC MAINTENANCE SPARK PLUG • Remove the seat. (!5-2) • Remove the radiator covers and fuel tank. (!5-2) • Disconnect the lead wire coupler from the ignition coil/plug cap. CAUTION Disconnect the lead wire coupler before removing the ignition coil/plug cap to avoid lead wire coupler dam- age.
  • Page 23: Periodic Maintenance

    PERIODIC MAINTENANCE • Check the spark plug gap A with a thickness gauge. " 09900-20803: Thickness gauge # Spark plug gap: 0.9 – 1.0 mm (0.035 – 0.039 in) # Standard Spark plug CR8EIA-10 CAUTION Changing the spark plug heat range improperly can damage the engine.
  • Page 24: Air Cleaner

    PERIODIC MAINTENANCE AIR CLEANER AIR CLEANER ELEMENT REMOVAL • Remove the left frame cover. • Remove the wing nut 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 25: Engine Oil And Oil Filter

    PERIODIC MAINTENANCE 2-10 NOTE: Follow the instructions below to keep the air cleaner element dry when cleaning the motorcycle. • Cover the element with vinyl bag. • Install the left frame cover. • Cover the inlet hole on the frame cover in order to prevent water from coming into the air cleaner box.
  • Page 26: Inspection Before Engine Oil Level Check

    2-11 PERIODIC MAINTENANCE INSPECTION BEFORE ENGINE OIL LEVEL CHECK • Before starting the engine, check that there is sufficient oil for operating the engine. CAUTION If the engine is started with insufficient or no oil, the engine components will possibly be damaged. NOTE: The oil level measurement may become inaccurate unless the motorcycle is held upright as the motorcycle inclination affects...
  • Page 27: Engine Oil Change

    PERIODIC MAINTENANCE 2-12 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 oil thoroughly. •...
  • Page 28: Engine Oil Filter Change

    2-13 PERIODIC MAINTENANCE 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 29: Oil Strainers

    PERIODIC MAINTENANCE 2-14 OIL STRAINERS OIL STRAINER (Feed pump side) REMOVAL • Drain engine oil. (!2-12) • Remove the engine oil strainer cap. CAUTION Do not lie the motorcycle to prevent dirty engine oil into the oil circuit when removing the oil strainer (Feed pump side).
  • Page 30: Engine Coolant

    2-15 PERIODIC MAINTENANCE 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 31: Engine Coolant Replenishment

    PERIODIC MAINTENANCE 2-16 ENGINE COOLANT REPLENISHMENT • Use an anti-freeze and Summer engine coolant which is com- patible with aluminum radiator, mixed with distilled water at the ratio of 50:50. NOTE: The radiator, cylinder and cylinder head are made of aluminum alloy.
  • Page 32: Clutch Cable

    2-17 PERIODIC MAINTENANCE 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 33: Throttle Cable

    THROTTLE CABLE LUBRICATION • 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 grease)
  • Page 34: Hot Starter

    2-19 PERIODIC MAINTENANCE HOT STARTER Adjust the hot starter cable play as follows: NOTE: Be careful not to damage the lever cover when installing. (!19-21) • Loosen the lock-nut 1. • Turn adjuster 2 so the hot starter lever clearance A mea- sured at the lever holder obtains 2 –...
  • Page 35: Engine Idle Speed

    PERIODIC MAINTENANCE 2-20 ENGINE IDLE SPEED • Adjust the throttle cable play. (!2-18) • Warm up the engine. • Connect the multi-circuit tester to the primary lead wire (W/Bl). " 09900-25008: Multi-circuit tester set • Start the engine, turn the throttle stop screw 1 and set the engine idle speed as follows.
  • Page 36: Fuel Hose

    2-21 PERIODIC MAINTENANCE FUEL HOSE • Inspect the fuel hose for damage and fuel leakage. If any defects are found, the fuel hose must be replaced. • Replace the fuel hose every four years. FUEL FILTER % WARNING Gasoline is highly flammable and explosive. Keep heat, sparks and flames away from gasoline.
  • Page 37: Valve Clearance

    PERIODIC MAINTENANCE 2-22 VALVE CLEARANCE • Remove the seat. (!5-2) • Remove the radiator covers and fuel tank. (!5-2) • Disconnect the ignition coil/plug cap coupler. (!2-7) • Remove the ignition coil/plug cap and spark plug. (!2-7) • Remove the cylinder head cover and its gasket. The valve clearance specification is different for both intake and exhaust valves.
  • Page 38: Valve Clearance Adjustment

    2-23 PERIODIC MAINTENANCE VALVE CLEARANCE ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim. • Remove the intake or exhaust camshafts. (!6-4) • Remove the tappet 1 and shim 2 by fingers or magnetic hand.
  • Page 39: Periodic Maintenance

    PERIODIC MAINTENANCE 2-24 (INTAKE SIDE)
  • Page 40: Periodic Maintenance

    2-25 PERIODIC MAINTENANCE (EXHAUST SIDE)
  • Page 41: Cylinder Head, Cylinder And Piston

    PERIODIC MAINTENANCE 2-26 CYLINDER HEAD, CYLINDER AND PISTON CYLINDER HEAD INSPECTION • Remove the cylinder head. (!6-4) • 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 42: Muffler Silencer

    • If necessary, replace the muffler silencer 4 with a new one. • Insert the muffler silencer 4 into the muffler body. • Apply the SUZUKI BOND to the circumference of the rear muffler body 2. ( 99000-31140: SUZUKI BOND “1207B”...
  • Page 43: Drive Chain And Sprockets

    PERIODIC MAINTENANCE 2-28 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. 35 –...
  • Page 44: Drive Chain Lubrication

    • Clean the drive chain with non-flammable cleaning solvent. CAUTION 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:...
  • Page 45: Drive Chain Guide, Buffer And Chain Roller

    PERIODIC MAINTENANCE 2-30 DRIVE CHAIN GUIDE, BUFFER AND CHAIN 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 46: Brakes

    2-31 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. (!16-3) Inspect brake pad wear and brake fluid leakage if the brake fluid level decreases.
  • Page 47: Brake Pad

    PERIODIC MAINTENANCE 2-32 BRAKE PAD Wear limit • Inspect the brake pads for wear. If the brake pads are worn, replace them with new ones. (!16-5) NOTE: * Pump the brake lever and pedal several times to restore the Wear limit brake pads after replacing the brake pads.
  • Page 48: Front Fork

    2-33 PERIODIC MAINTENANCE 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 49: Spoke Nipple And Rim Lock Inspection

    PERIODIC MAINTENANCE 2-34 SPOKE NIPPLE AND RIM LOCK INSPECTION • Inspect the spokes for tension by squeezing the spoke nip- ples. • Retighten the spoke nipples with a spoke nipple wrench so as all spokes have same tension. $ Spoke nipple: 6 N·m (0.6 kgf-m, 4.5 lb-ft) CAUTION Improperly tightening the spoke nipples can damage the wheel.
  • Page 50: Lubrication

    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 Follow the schedule closely. The disassembly necessary to lubricate many components is in itself valuable preventative maintenance.
  • Page 51: Compression Pressure Check

    PERIODIC MAINTENANCE 2-36 COMPRESSION PRESSURE CHECK The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to replace the cylinder is often based on the results of a compression test. COMPRESSION PRESSURE SPECIFICATION (Automatic decomp. actuated) Standard 400 –...
  • Page 52: Oil Pressure Check

    2-37 PERIODIC MAINTENANCE OIL PRESSURE CHECK Check the oil pressure periodically. This will give a good indication of the condition of the moving parts. # Oil pressure: 20 kPa (0.2 kgf/cm², 2.8 psi) at 6 000 r/min, oil temp. at 50 °C (122 °F) Low or high oil pressure can indicate any of the following conditions: LOW OIL PRESSURE * Clogged oil filter...
  • Page 53: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING CONTENTS ENGINE ......................3- 2 CARBURETOR .................... 3- 6 RADIATOR (COOLING SYSTEM) .............. 3- 6 CHASSIS ..................... 3- 7 BRAKES ...................... 3- 8 ELECTRICAL ....................3- 9...
  • Page 54: Engine

    TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. • Valve clearance out of adjustment Adjust • Worn valve guides or poor seating of valves Repair or replace • Mistiming valves Adjust •...
  • Page 55 TROUBLESHOOTING Complaint Symptom and possible causes Remedy Noisy engine Excessive valve chatter • Too large valve clearance Adjust • Weakened or broken valve springs Replace • Worn tappet or cam surface Replace • Worn and burnt camshaft journal Replace Noise seems to come from piston •...
  • Page 56 TROUBLESHOOTING Complaint Symptom and possible causes Remedy Engine lacks power. Defective engine internal parts • Loss of valve clearance Adjust • Weakened valve springs Replace • Valve timing out of adjustment Adjust • Worn piston ring or cylinder Replace • Poor seating of valves Repair •...
  • Page 57 TROUBLESHOOTING Complaint Symptom and possible causes Remedy Slipping clutch • Weakened clutch springs Replace • Worn or distorted pressure plate Replace • Worn or distorted clutch plates Replace • Insufficient clutch cable play Adjust Dragging clutch • Some clutch spring weakened while others are not Replace •...
  • Page 58: Carburetor

    TROUBLESHOOTING CARBURETOR Complaint Symptom and possible causes Remedy Starting difficulty. • Improperly working starter knob — • Improperly working hot starter lever — • Clogged starter jet passage Clean • Maladjusted pilot screw Adjust • Maladjusted throttle stop screw Adjust •...
  • Page 59: Chassis

    TROUBLESHOOTING CHASSIS Complaint Symptom and possible causes Remedy Heavy steering • Overtightened steering stem nut Adjust • Broken bearing in steering stem Replace • Distorted steering stem Replace • Not enough pressure in tires Adjust Wobbly handlebars • Loss of balance between right and left front forks Adjust •...
  • Page 60: Brakes

    TROUBLESHOOTING BRAKES Complaint Symptom and possible causes Remedy Insufficient brake • Leakage of brake fluid from hydraulic system Repair or replace power • Worn pads Replace • Oil adhesion of engaging surface of pads Clean disc and pads • Worn disc Replace •...
  • Page 61: Electrical

    TROUBLESHOOTING ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor • Defective ignition coil/plug cap Replace sparking • Defective spark plug Replace • Defective CDI unit Replace • Defective magneto Replace • Open-circuited wiring connections Check and repair Spark plug soon •...
  • Page 62: Machine Tuning

    MACHINE TUNING MACHINE TUNING CONTENTS CARBURETOR TUNING ................4- 2 PRINCIPLES OF CARBURETOR TUNING ......... 4- 2 SLOW SYSTEM ..................4- 3 MAIN SYSTEM ..................4- 5 INTERMEDIATE SYSTEM ..............4- 5 CARBURETOR TUNING IN PRACTICE ..........4- 7 FRONT FORK TUNING ................4-10 COMPRESSION DAMPING FORCE ADJUSTMENT ......
  • Page 63: 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 following information and specifications.
  • Page 64: Slow System

    MACHINE TUNING 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 65 MACHINE TUNING PILOT SCREW (P.S.) The pilot screw controls volume of the air/fuel mixture in slow range. Pilot screw specifications indicate the number of turns back from the lightly seated position. Air/fuel mixture Pilot screw turn back Lean 1 and 1/4 turns back 1 and 1/2 turns back 1 and 3/4 turns back 2 turns back...
  • Page 66: Main System

    MACHINE TUNING MAIN SYSTEM MAIN JET (M.J.) The main jet, like the slow jet, meters fuel flow. Each jet size is indicated by a number. Larger number means a larger bore diameter and fitting a larger number main jet enriches the air/fuel mixture.
  • Page 67 MACHINE TUNING Jet needle clip position To adjust the air/fuel mixture with the jet needle, change position Lean of the needle clip which is set in the 4th groove. The lower groove the clip is moved to, the higher the jet needle rises and the larger the clearance with the main nozzle becomes, resulting Rich in a richer air/fuel mixture ratio.
  • Page 68: Carburetor Tuning In Practice

    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 69 MACHINE TUNING JUDGING AIR/FUEL MIXTURE INCLUDED PARTS AND OPTIONAL PARTS For proper carburetor tuning, it is necessary to Main jet know how to judge the air/fuel mixture made in the Air/fuel carburetor; whether too rich, too lean or properly SIZE P/NO.
  • Page 70 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 NLDV 13383-10H90 * Make sure to adjust the main system before NLCV 13383-10H80...
  • Page 71: Front Fork Tuning

    MACHINE TUNING 4-10 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 72: Oil Quantity Minor Adjustment

    Operating the motorcycle with the fork oil quantity unevenly adjusted can cause handling instability. Never mix different types of fork oil. Different oils may cause chemical reaction and deteriorate. # 99000-99001-SS5: SUZUKI FORK OIL SS-05 (or equivalent fork oil)
  • Page 73: Oil Change (Only For Outer Tube Oil Chamber)

    MACHINE TUNING 4-12 OIL CHANGE (Only for outer tube oil chamber) • Remove the front forks. (!17-4) • 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 74 4-13 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) Identification Oil quantity Part No. Spring rate (Slit mark...
  • Page 75: Spring Change

    MACHINE TUNING 4-14 SPRING CHANGE • Remove the front forks. (!17-4) • 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 leakage.
  • Page 76 320 – 414 ml 370 ml (10.82/11.27 – 51171-10H10 (12.51/13.03 13.99/14.58 US/Imp oz) US/Imp oz) 315 – 409 ml 365 ml (10.65/11.09 – Hard 51171-10H30 (12.34/12.85 13.82/14.40 US/Imp oz) US/Imp oz) # 99000-99001-SS5: SUZUKI FORK OIL SS-05 (or equivalent fork oil)
  • Page 77: Front Fork Tuning Procedure

    MACHINE TUNING 4-16 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 78: Rear Suspension Tuning

    4-17 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. (!1-6) * Inspect the following items before attempting adjustment.
  • Page 79: Rebound Damping Force Adjustment

    MACHINE TUNING 4-18 REBOUND DAMPING FORCE ADJUSTMENT NOTE: To set the adjuster, you must gently turn the adjust screw clock- Soft Hard 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 80: Rear Suspension Tuning Procedure

    4-19 MACHINE TUNING REAR SUSPENSION TUNING PROCEDURE • Adjust the rear suspension according to the rider’s weight and preference by referring to the table below. Spring Part No. Spring rate Marking paint Set-length adjustable range 50 N/mm 62211-10H20 White (5.0 kgf/mm) Soft 52 N/mm 62211-10H10...
  • Page 81 MACHINE TUNING 4-20 After the sag measurement has been set 100 mm (3.94 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 overall •...
  • Page 82: Suspension Balance

    4-21 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 83: Engine Removal And Installation

    ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL AND INSTALLATION CONTENTS ENGINE REMOVAL AND INSTALLATION ..........5- 2 REMOVAL ..................... 5- 2 INSTALLATION ..................5- 6...
  • Page 84: Engine Removal And Installation

    ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL AND INSTALLATION REMOVAL • Drain engine oil. (!2-12) • Drain engine coolant. (!13-3) • Remove the seat 1. • Remove the radiator covers 2, left and right. • Remove the right frame cover 3. •...
  • Page 85 ENGINE REMOVAL AND INSTALLATION • Remove the muffler 5. • Remove the exhaust pipe 6 and exhaust pipe gasket 7. • Remove the front protector. • Remove the radiator mounting bolts, left and right. • Disconnect the radiator hoses, 8 and 9. •...
  • Page 86 ENGINE REMOVAL AND INSTALLATION • Disconnect the magneto lead wire coupler A and clamp. • Remove the cable bracket bolt B and disconnect the clutch cable. NOTE: Mark the clutch cable at which the bracket slit set for correct reinstallation. •...
  • Page 87 ENGINE REMOVAL AND INSTALLATION • Remove the drive chain clip M and release the drive chain. • Remove the snap ring N and engine sprocket O. # 09900-06107: Snap ring pliers • Remove the engine mounting upper brackets P, left and right.
  • Page 88 ENGINE REMOVAL AND INSTALLATION 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 89 $ Engine sprocket cover bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft) • Install the gearshift lever in the correct position. • Apply grease to the brake pedal pivot bolt. % 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the brake pedal and brake pedal spring. (!19-29) $ Brake pedal pivot bolt: 29 N·m (2.9 kgf-m, 21.0 lb-ft)
  • Page 90 ENGINE REMOVAL AND INSTALLATION • Install the muffler joint connector A and exhaust pipe gasket CAUTION Replace the connector A and gasket B with new ones to prevent exhaust gas leakage. NOTE: When installing a new connector, clean the exhaust pipe and joint of the muffler.
  • Page 91 CYLINDER HEAD, CYLINDER AND PISTON CYLINDER HEAD, CYLINDER AND PISTON CONTENTS CONSTRUCTION ..................6- 2 CYLINDER HEAD, CYLINDER AND PISTON ........6- 2 ENGINE TOP SIDE ..................6- 3 CYLINDER HEAD COVER REMOVAL ..........6- 3 CAMSHAFTS (AUTOMATIC DECOMP.) AND CAM CHAIN TENSION ADJUSTER REMOVAL .................
  • Page 92: Construction

    CYLINDER HEAD, CYLINDER AND PISTON CONSTRUCTION CYLINDER HEAD, CYLINDER AND PISTON 14 N . m (1.4 kgf-m, 10.0 lb-ft) 50 N . m (5.0 kgf-m, 36.0 lb-ft) 10 N . m 11 N . m (1.0 kgf-m, 7.0 lb-ft) (1.1 kgf-m, 8.0 lb-ft) 4.5 N .
  • Page 93: Engine Top Side

    CYLINDER HEAD, CYLINDER AND PISTON ENGINE TOP SIDE CYLINDER HEAD COVER REMOVAL • Remove the seat. (!5-2) • Remove the radiator covers and fuel tank. (!5-2) • Disconnect the ignition coil/plug cap and remove the spark plug. (!2-7) • Remove the cylinder head cover 1 and its gasket. CAMSHAFTS (AUTOMATIC DECOMP.) AND CAM CHAIN TENSION ADJUSTER REMOVAL •...
  • Page 94: Cylinder Head Removal

    CYLINDER HEAD, CYLINDER AND PISTON • Remove the cam chain tension adjuster cap bolt 3, washer, bar and spring. • Remove the cam chain tension adjuster 4. • Remove the camshaft journal holders 5. NOTE: Loosen the camshaft journal holder bolts diagonally. •...
  • Page 95: Cylinder Removal

    CYLINDER HEAD, CYLINDER AND PISTON • Remove the cylinder head base nuts 3. • Loosen the cylinder base bolt 4. • Remove the cylinder head bolts and washers. NOTE: When loosening the cylinder head bolts, loosen each bolt little by little diagonally. •...
  • Page 96: Piston And Piston Ring Removal

    CYLINDER HEAD, CYLINDER AND PISTON PISTON AND PISTON RING REMOVAL • Remove the cylinder. (!6-5) • 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 97: Engine Top Components Inspection And Service

    CYLINDER HEAD, CYLINDER AND PISTON ENGINE TOP COMPONENTS INSPECTION AND SERVICE AUTOMATIC DECOMP. INSPECTION • Check the decomp. cam moves smoothly and shaft 1 rotates together. • If any abnormal condition are found, replace the camshaft assembly. CAMSHAFT INSPECTION CAUTION The camshaft assembly can not be disassembled.
  • Page 98 CYLINDER HEAD, CYLINDER AND PISTON CAM WEAR • Measure the cam height H using the micrometer. • Replace a camshaft if the cams are worn to the service limit. " Cam height H: Service Limit IN.: 34.56 mm (1.361 in) EX.: 34.08 mm (1.342 in) # 09900-20202: Micrometer (25 –...
  • Page 99: Cam Chain Tension Adjuster Inspection

    CYLINDER HEAD, CYLINDER AND PISTON • If the camshaft journal oil clearance measured exceeds the limit, measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal. • Replace the camshaft or the cylinder head depending upon which one exceeds the specification.
  • Page 100: Cam Chain No.1 Guide, Cam Chain No.2 Guide And Cam Chain Tensioner Inspection

    6-10 CYLINDER HEAD, CYLINDER AND PISTON CAM CHAIN No.1 GUIDE, CAM CHAIN No.2 GUIDE AND CAM CHAIN TENSIONER INSPECTION • Inspect the contacting surface of the cam chain guides and cam chain tensioner. • If it is worn or damaged, replace it with a new one. CYLINDER HEAD AND VALVE INSPECTION VALVE DISASSEMBLY •...
  • Page 101 CYLINDER HEAD, CYLINDER AND PISTON 6-11 (Exhaust side) • Install the sleeve protector b between the valve spring and cylinder head. • Using the special tools, compress the valve spring and remove the two cotter halves 3 from the valve stem. CAUTION To prevent damage of the tappet sliding surface with the special tool, use the sleeve protector b.
  • Page 102 6-12 CYLINDER HEAD, CYLINDER AND PISTON CYLINDER HEAD DISTORTION • Decarbonize the combustion chamber. • Check the gasket surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading at several places indicated. • If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder head.
  • Page 103 CYLINDER HEAD, CYLINDER AND PISTON 6-13 VALVE STEM DEFLECTION • Lift the valve about 10 mm (0.39 in) from the valve seat. • Measure the valve stem deflection in two directions, perpen- dicular to each other, by positioning the dial gauge as shown. •...
  • Page 104 6-14 CYLINDER HEAD, CYLINDER AND PISTON • Cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 – 150 °C (212 – 302 °F) with a hot plate. CAUTION Do not use a burner to heat the valve guide hole to prevent cylinder head distortion.
  • Page 105 CYLINDER HEAD, CYLINDER AND PISTON 6-15 • If the seat width W measured exceeds the standard value or seat width is not uniform, refuse the seat using the seat cutter. " Valve seat width W: Standard: 0.9 – 1.1 mm (0.035 – 0.043 in) VALVE SEAT SERVICING ˚...
  • Page 106 6-16 CYLINDER HEAD, CYLINDER AND PISTON • Clean and assemble the head and valve components. Fill the intake and exhaust ports with gasoline to check for leaks. • If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from sealing.
  • Page 107 CYLINDER HEAD, CYLINDER AND PISTON 6-17 • Install the valve spring with the small-pitch portion A facing cylinder head. A Small-pitch portion B Large-pitch portion C UPWARD D Paint (IN. – Pink) (EX. – Gray) • Put on the valve spring retainer 2, and using the valve lifter and sleeve protector (a or b), press down the spring, fit the valve cotter halves to the stem end, and release the lifter to allow the valve cotter 3 to wedge in between retainer and...
  • Page 108: Intake Pipe Removal

    6-18 CYLINDER HEAD, CYLINDER AND PISTON INTAKE PIPE REMOVAL • Remove the intake pipe 1. INTAKE PIPE INSTALLATION • Install the intake pipe. NOTE: Fit the recess A of the intake pipe into the projection B of the cylinder head.
  • Page 109: Cylinder Inspection

    CYLINDER HEAD, CYLINDER AND PISTON 6-19 CYLINDER INSPECTION CYLINDER DISTORTION • Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance read- ing at several places indicated. • If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder.
  • Page 110: Piston And Piston Ring Inspection

    6-20 CYLINDER HEAD, CYLINDER AND PISTON PISTON AND PISTON RING INSPECTION PISTON DIAMETER • Using a micrometer, measure the piston outside diameter at 6.0 mm (0.24 in) A from the piston skirt end. • If the measurement is less than the limit, replace the piston. "...
  • Page 111: Piston Ring Groove Width

    CYLINDER HEAD, CYLINDER AND PISTON 6-21 PISTON RING-TO-GROOVE CLEARANCE • Decarbonize the piston ring and piston ring groove. • Measure the side clearances of the 1st piston ring using the thickness gauge. • If any of the clearances exceed the limit, replace both the pis- ton and piston ring.
  • Page 112: Crankshaft And Conrod Inspection

    6-22 CYLINDER HEAD, CYLINDER AND PISTON CRANKSHAFT AND CONROD INSPECTION For inspection other than the following, refer to page 10-7, -8. CONROD SMALL END I.D. • Using a small bore gauge, measure the inside diameter of the conrod small end. •...
  • Page 113: Cam Chain, Cam Chain Tensioner And Cam Chain Guide Installation

    CYLINDER HEAD, CYLINDER AND PISTON 6-23 CAM CHAIN, CAM CHAIN TENSIONER AND CAM CHAIN GUIDE 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. $ Cam chain tensioner bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) •...
  • Page 114: Piston And Piston Ring Installation

    6-24 CYLINDER HEAD, CYLINDER AND PISTON 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 115 CYLINDER HEAD, CYLINDER AND PISTON 6-25 PISTON • Install the piston with the punch mark 1 facing towards the exhaust side. • Before installing the piston pin, apply MOLYBDENUM OIL SOLUTION onto its surface. % MOLYBDENUM OIL SOLUTION • Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into crankcase.
  • Page 116: Cylinder And Cylinder Head Installation

    CYLINDER • Thoroughly wipe off oil from the fitting surface of the crank- case. • Apply SUZUKI BOND to the crankcase as shown. ' 99000-31110: SUZUKI BOND “1215” (or equivalent bond) • Install the dowel pins into the crankcase and then install the cylinder gasket 1.
  • Page 117 CYLINDER HEAD, CYLINDER AND PISTON 6-27 CYLINDER HEAD • Install the dowel pins into the cylinder and then install the cyl- inder head gasket 1 onto the cylinder. CAUTION Use a new gasket to prevent gas leakage. • Place the cylinder head 2 on the cylinder. CAUTION Do not drop the cam chain into the crankcase.
  • Page 118: Camshaft (Automatic Decomp.) And Cam Chain Tension Adjuster Installation

    6-28 CYLINDER HEAD, CYLINDER AND PISTON 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 counterclock- wise to align the TDC mark A with the center of the grooves B of the timing inspection hole.
  • Page 119 CYLINDER HEAD, CYLINDER AND PISTON 6-29 • 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 120 • Retract the push rod by pushing the stopper 1. • Apply grease to the O-ring 2. CAUTION Use a new O-ring 2 prevent oil leakage. ( 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the cam chain tension adjuster 3 as shown. Upward •...
  • Page 121 • Apply grease to the O-rings. CAUTION Use the new O-rings to prevent oil leakage. ( 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Tighten each plug to the specified torque. $ TDC plug: 14 N·m (1.4 kgf-m, 10.0 lb-ft)
  • Page 122: Clutch

    • Install the gasket to the cylinder head cover. CAUTION Use a new gasket to prevent oil leakage. • Apply SUZUKI BOND to the end caps of the cylinder head cover gasket as shown. ) 99000-31140: SUZUKI BOND “1207B” • Place the cylinder head cover on the cylinder head.
  • Page 123 CLUTCH CLUTCH CONTENTS CONSTRUCTION ..................7- 2 CLUTCH ....................7- 2 CLUTCH PLATE ................... 7- 3 REMOVAL ....................7- 3 INSPECTION ..................7- 5 INSTALLATION ..................7- 6 PRIMARY DRIVEN GEAR AND CLUTCH SLEEVE HUB ......7- 8 REMOVAL ....................7- 8 INSPECTION ..................
  • Page 124: Construction

    CLUTCH CONSTRUCTION CLUTCH 10 N . m (1.0 kgf-m, 7.0 lb-ft) 90 N . m (9.0 kgf-m, 65.0 lb-ft) A Clutch driven No.1 plate (Silver) B Clutch driven No.2 plate (Gray)
  • Page 125: Clutch Plate

    CLUTCH CLUTCH PLATE REMOVAL • Drain engine oil. (!2-12) • Remove the brake pedal. (!16-18) • Remove the clutch cover 1 and its gasket. • Remove the clutch spring set bolts and clutch springs. NOTE: Loosen the clutch spring set bolts little by little and diagonally. •...
  • Page 126 CLUTCH • Remove the clutch drive plates 6 and driven plates 7. NOTE: Mark the paint mark to the clutch driven No. 2 plate. Mark the paint mark. A Clutch driven No. 2 plate B Clutch driven No. 1 plate C Direction of outside •...
  • Page 127: Inspection

    CLUTCH INSPECTION DRIVE PLATE • Measure the drive plate thickness. " Drive plate thickness Service Limit: 2.42 mm (0.095 in) # 09900-20101: Vernier calipers (150 mm) • 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 128: Installation

    CLUTCH 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 for any abnormality, partic- ularly cracks, to decide whether it can be reused or should be replaced.
  • Page 129 CLUTCH Direction of outside Driven No. 1 plate A Silver Driven No. 2 plate B Gray • Install the push rod and push piece. • Apply engine oil to the release bearing 5. NOTE: The covered side C of the bearing should face outside. Outside •...
  • Page 130: Primary Driven Gear And Clutch Sleeve Hub

    CLUTCH PRIMARY DRIVEN GEAR AND CLUTCH SLEEVE HUB REMOVAL • Remove the clutch cover. (!7-3) • Remove the pressure plate and clutch plates. (!7-3, -4) • Flatten the lock washer 1. • Hold the clutch sleeve hub 2 with the special tool and loosen the nut 3.
  • Page 131: Inspection

    CLUTCH INSPECTION • Inspect the clutch sleeve hub and primary driven gear for wear and cracks. • If necessary, replace the sleeve hub or driven gear. • Inspect the needle bearing and spacer for damage and wear. • If any defects are found, replace the bearing or spacer. INSTALLATION Install the primary driven gear and clutch sleeve hub in the reverse order of removal.
  • Page 132 7-10 CLUTCH • Fit the clutch sleeve hub 5 and lock washer 6. CAUTION Replace the lock washer 6 with a new one. • Tighten the clutch sleeve hub nut with the special tool to the specified torque. # 09920-53740: Clutch sleeve hub holder 09920-31020: Extension handle $ Clutch sleeve hub nut: 90 N·m (9.0 kgf-m, 65.0 lb-ft) •...
  • Page 133: Clutch Release Camshaft

    CLUTCH 7-11 CLUTCH RELEASE CAMSHAFT REMOVAL • Remove the cam chain tension adjuster. (!6-4) CAUTION Do not turn the crankshaft after removing the cam chain tension adjuster. • Disconnect the clutch cable 1 and remove the retainer 2. • Pull the clutch release camshaft 3 out of crankcase. INSPECTION CLUTCH RELEASE CAMSHAFT •...
  • Page 134: Installation

    7-12 CLUTCH INSTALLATION • Apply SUZUKI MOLY PASTE to the clutch release camshaft. % 99000-25140: SUZUKI MOLY PASTE • Apply engine oil to the oil seal lip. • Install the clutch release camshaft 1. • Connect the clutch cable 2 and install the retainer 3.
  • Page 135: Kick Starter

    KICK STARTER KICK STARTER CONTENTS CONSTRUCTION ..................8- 2 KICK STARTER ..................8- 2 KICK STARTER ................... 8- 3 REMOVAL ..................... 8- 3 INSPECTION ..................8- 4 INSTALLATION ..................8- 5...
  • Page 136: Construction

    KICK STARTER CONSTRUCTION KICK STARTER 10 N·m (1.0 kgf-m, 7.0 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft) 10 N·m (1.0 kgf-m, 7.0 lb-ft)
  • Page 137: Removal

    KICK STARTER KICK STARTER REMOVAL • Drain engine oil. (!2-12) • Drain engine coolant. (!13-3) • Remove the brake pedal. (!16-18) • Disconnect the radiator hose 1. • Remove the kick starter lever 2. • Remove the right crankcase cover 3, dowel pins and gasket. •...
  • Page 138: Inspection

    KICK STARTER • Remove the kick starter guide F. INSPECTION • Inspect the oil seal lip for wear and damage. • If any defects are found, replace the oil seal with a new one. • Inspect the kick starter drive gear teeth for damage. •...
  • Page 139: Installation

    KICK STARTER INSTALLATION Install the kick starter in the reverse order of removal. Pay atten- tion to the following points: • Install the kick starter guide 1. # Kick starter guide bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Install the kick starter drive gear 2, washers and snap ring 3 to the kick starter shaft.
  • Page 140 KICK STARTER • Install the spring 7 to the kick starter shaft. • Install the kick starter shaft assembly to the crankcase. NOTE: Securely engage the stopper portion E of the kick starter with the stopper guide F. • Install the end of return spring to the crankcase. •...
  • Page 141 KICK STARTER • Install the kick starter lever onto the kick starter shaft. NOTE: When installing the kick starter lever, align the wide spline teeth G and H. • Tighten the kick starter lever bolt to the specified torque. # Kick starter lever bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) •...
  • Page 142: Gearshifting

    GEARSHIFTING GEARSHIFTING CONTENTS CONSTRUCTION ..................9- 2 GEARSHIFT LINKAGE ................ 9- 2 GEARSHIFT LINKAGE ................9- 3 REMOVAL .................... 9- 3 INSPECTION ..................9- 5 INSTALLATION ..................9- 5...
  • Page 143: Construction

    GEARSHIFTING CONSTRUCTION GEARSHIFT LINKAGE 23 N . m (2.3 kgf-m, 16.5 lb-ft) 24 N . m (2.4 kgf-m, 17.5 lb-ft) 10 N . m (1.0 kgf-m, 7.0 lb-ft)
  • Page 144: Gearshift Linkage

    GEARSHIFTING GEARSHIFT LINKAGE REMOVAL • Drain engine oil. (!2-12) • Drain engine coolant. (!13-3) • Remove the gearshift lever 1. NOTE: Mark the gearshift shaft head at which the gearshift lever slit set for correct reinstallation. • Remove the right crankcase cover and clutch component parts.
  • Page 145 GEARSHIFTING • Remove the gearshift pawls 8, pins 9 and springs 0. • Remove the gearshift cam driven gear pin A and gearshift cam stopper plate B. • Remove the gearshift cam stopper C, spring D and washer • Remove the gearshift arm stopper F and washer G.
  • Page 146: Inspection

    GEARSHIFTING INSPECTION • Inspect the gearshift shaft 1 for bends and damage. • Inspect the return spring 2 for damage. • If necessary, replace the defective parts with a new one. • Inspect the pawls 3, pins 4 and springs 5 for damage. •...
  • Page 147 GEARSHIFTING • Align the pin groove A with the pin B when installing the stopper plate 5. • Apply a small quantity of THREAD LOCK to the gearshift cam driven pin 6 and tighten it to the specified torque. % 99000-32050: THREAD LOCK “1342” $ Gearshift cam driven pin: 24 N·m (2.4 kgf-m, 17.5 lb-ft) •...
  • Page 148 GEARSHIFTING • Apply THREAD LOCK SUPER to the pawl lifter screws and tighten them. # 99000-32030: THREAD LOCK SUPER “1303” • Install the gearshift return spring C, snap ring D and washer E to the gearshift shaft B properly. CAUTION Replace the snap ring D with a new one.
  • Page 149 TRANSMISSION AND CRANKSHAFT 10-1 TRANSMISSION AND CRANKSHAFT CONTENTS CONSTRUCTION ..................10- 2 TRANSMISSION AND CRANKSHAFT ..........10- 2 ENGINE BOTTOM SIDE ................10- 3 PRIMARY DRIVE GEAR REMOVAL ..........10- 3 CRANKCASE SEPARATION ............. 10- 4 TRANSMISSION REMOVAL .............. 10- 4 CRANKSHAFT REMOVAL ..............
  • Page 150: Construction

    10-2 TRANSMISSION AND CRANKSHAFT CONSTRUCTION TRANSMISSION AND CRANKSHAFT 90 N . m (9.0 kgf-m, 65.0 lb-ft)
  • Page 151: Engine Bottom Side

    TRANSMISSION AND CRANKSHAFT 10-3 ENGINE BOTTOM SIDE • Remove the engine assembly. (!5-2 to -5) NOTE: The following parts must be removed before disassembling the engine bottom side (crankcase). • Disconnect the crankcase breather hose 1. • Remove the cylinder head, cylinder and piston. (!6-3 to -6) •...
  • Page 152: Crankcase Separation

    10-4 TRANSMISSION AND CRANKSHAFT CRANKCASE SEPARATION • Remove the engine sprocket spacer 1 and two O-rings 2. • Remove the oil strainer cap 3 and oil strainer (Feed pump side). (!2-14) • Separate the crankcase with the special tool. " 09920-13120: Crankcase separating tool NOTE: * Set the crankcase separating tool to the clutch side of the crankcase.
  • Page 153: Crankshaft Removal

    TRANSMISSION AND CRANKSHAFT 10-5 • Remove the gearshift fork shafts 4. • Remove the gearshift cam 5. • Remove the gearshift forks 6. • Remove the countershaft assembly 7 and driveshaft assem- bly 8. CRANKSHAFT REMOVAL • Remove the crankshaft with the special tool. CAUTION Be careful not to damage the thread part of the crank- shaft.
  • Page 154: Transmission Inspection

    10-6 TRANSMISSION AND CRANKSHAFT TRANSMISSION INSPECTION • Inspect the gear teeth, dogs, and gearshift grooves for abnor- mal wear and damage. • Inspect the bushings and splines for abnormal wear and dis- coloration. • If necessary, replace defective parts with a new one. •...
  • Page 155: Conrod Inspection

    TRANSMISSION AND CRANKSHAFT 10-7 • Measure the gearshift fork to groove clearance with a thick- ness gauge. • If the clearance checked is noted to exceed the limit, replace the fork or dog. # Gearshift fork to groove clearance Service Limit: 0.50 mm (0.020 in) "...
  • Page 156: Crankshaft Inspection

    10-8 TRANSMISSION AND CRANKSHAFT CRANKSHAFT INSPECTION • Measure the crankshaft runout with V-blocks and dial gauge. NOTE: Place the crankshaft onto the V-blocks so that it becomes hori- zontally. # Crankshaft runout Service Limit: 0.08 mm (0.003 in) " 09900-20607: Dial gauge (1/100, 10 mm) 09900-20701: Magnetic stand 09900-21304: V-block (100 mm) •...
  • Page 157: Oil Seal Removal And Installation

    Oil seal 2: $ 22 Attachment Oil seal 3: $ 17 Attachment • Apply grease to each oil seal lip. % 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) NOTE: Be sure to check the direction of the crankshaft bearing oil seal 4 before installing them.
  • Page 158: Bearing Removal And Installation

    10-10 TRANSMISSION AND CRANKSHAFT BEARING REMOVAL AND INSTALLATION • Remove the oil seals. (!10-9) • Remove the bearing retainers. REMOVAL CAUTION The removed bearing should be discard. • Remove the bearings (1, 3, 5, 6, 7) with the special tool. "...
  • Page 159 TRANSMISSION AND CRANKSHAFT 10-11 • Remove the bearing 4 with the special tools. " 09923-74511: Bearing puller 09930-30104: Sliding shaft • Remove the bearings (9, 0) with the special tools. " 09921-20200: Bearing remover 09930-30104: Sliding shaft...
  • Page 160 10-12 TRANSMISSION AND CRANKSHAFT INSTALLATION • Press the new bearings with the special tool. " 09913-70210: Bearing installer set Bearing 1: $ 52 Attachment Bearing 2, 8: $ 40 Attachment Bearing 3, 6: $ 62 Attachment Bearing 4: $ 32 Attachment Bearing 5: $ 47 Attachment Bearing 7: $ 42 Attachment Bearing 9: $ 15 Attachment...
  • Page 161: Reed Valve Installation

    TRANSMISSION AND CRANKSHAFT 10-13 REED VALVE INSTALLATION • Install the reed valve 1 and reed valve guide 2 direction as shown. ' Reed valve guide bolt: 4.5 N·m (0.45 kgf-m, 3.0 lb-ft) 1 Reed valve 2 Reed valve guide A Crankcase CRANKSHAFT INSTALLATION •...
  • Page 162: Transmission Installation

    10-14 TRANSMISSION AND CRANKSHAFT TRANSMISSION INSTALLATION CAUTION The removed snap ring should be replaced with a new Thrust one. Install the snap ring in the groove and locate its end as shown in the illustration. Sharp edge • Apply engine oil to the following parts: driveshaft, countershaft, transmission gears, bearings.
  • Page 163 TRANSMISSION AND CRANKSHAFT 10-15 • Install the gearshift forks 3, 4 and 5. 3 For 5th driven gear 4 For sliding dog 5 For 3rd/4th drive gear • Install the gearshift cam 6 and gearshift shafts 7. NOTE: Turn the gearshift cam to the neutral position and confirm that the driveshaft and countershaft turn without resistance.
  • Page 164: Crankcase Installation

    2. (!2-14) • Inspect the crankshaft, countershaft and driveshaft for smooth movement. • Apply grease to oil seal lip and O-rings 3. % 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) CAUTION Replace the O-rings 3 with new ones. • Fit the O-rings 3 and spacer 4 to the driveshaft.
  • Page 165: Primary Drive Gear Installation

    • Install the gearshift linkage. (!9-5 to -7) • Install the oil pump and oil pump idle gear. (!11-6, -7) • Apply grease to the oil seal lip. % 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the primary drive gear 1 and washer 2.
  • Page 166: Lubrication System

    11-1 LUBRICATION SYSTEM LUBRICATION SYSTEM CONTENTS ENGINE LUBRICATION SYSTEM ............11- 2 ENGINE LUBRICATION SYSTEM CHART ........11- 2 ENGINE OIL LEVEL INSPECTION ............ 11- 3 ENGINE OIL CHANGE ............... 11- 3 ENGINE OIL FILTER CHANGE ............11- 3 OIL PRESSURE CHECK ..............11- 3 OIL STRAINERS REMOVAL ..............
  • Page 167: Engine Lubrication System

    LUBRICATION SYSTEM 11-2 ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM CHART...
  • Page 168: Engine Oil Level Inspection

    11-3 LUBRICATION SYSTEM ENGINE OIL LEVEL INSPECTION (!2-11) ENGINE OIL CHANGE (!2-12) ENGINE OIL FILTER CHANGE (!2-13) OIL PRESSURE CHECK (!2-37) OIL STRAINERS REMOVAL (!2-14, 10-4) OIL STRAINERS INSPECTION (!2-14) OIL STRAINERS INSTALLATION (!2-14, 10-15) OIL SEAL REMOVAL • Remove the right crankcase cover. (!8-3) •...
  • Page 169: Oil Seal Installation

    " 09913-70210: Bearing installer set Oil seal: # 22 Attachment 09900-06108: Snap ring pliers • Apply grease to the oil seal lip. $ 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) OIL PUMP REMOVAL • Drain engine oil. (!2-12) • Drain engine coolant. (!13-3) •...
  • Page 170: Oil Pump Inspection

    11-5 LUBRICATION SYSTEM • Remove the following parts from the oil pump. 6 Oil pump No.2 outer rotor A Oil pump No.1 inner rotor 7 Oil pump No.2 inner rotor B Pin 8 Pin C Oil pump cover 9 Oil pump plate D Oil pump driven gear shaft 0 Oil pump No.1 outer rotor •...
  • Page 171: Oil Pump Installation

    LUBRICATION SYSTEM 11-6 OIL PUMP INSTALLATION Install the oil pump in the reverse order of removal. Pay attention to the following points: • Install the oil pump cover 2 and pin 3 to the oil pump driven gear shaft 1. •...
  • Page 172 11-7 LUBRICATION SYSTEM • Install the oil pump No.2 outer rotor 8. CAUTION Face the punch mark E on outer rotor 8 to the crank- case. • Apply engine oil to the outer rotor and inner rotor. • Install the oil pump and tighten the oil pump mounting bolts to the specified torque.
  • Page 173: Fuel System

    FUEL SYSTEM 12-1 FUEL SYSTEM CONTENTS FUEL TANK AND FUEL VALVE ............... 12- 2 CONSTRUCTION ................12- 2 REMOVAL ................... 12- 2 CLEANING AND INSPECTION ............12- 3 INSTALLATION ................... 12- 3 CARBURETOR ..................12- 4 CONSTRUCTION ................12- 4 REMOVAL ...................
  • Page 174: Fuel Tank And Fuel Valve

    12-2 FUEL SYSTEM FUEL TANK AND FUEL VALVE CONSTRUCTION 5 N . m (0.5 kgf-m, 3.5 lb-ft) 5 N . m (0.5 kgf-m, 3.5 lb-ft) 6 N . m (0.6 kgf . m, 4.5 lb-ft) REMOVAL " WARNING Gasoline is highly flammable and explosive. Keep heat, spark and flame away.
  • Page 175: Cleaning And Inspection

    FUEL SYSTEM 12-3 CLEANING AND INSPECTION If the fuel strainer is dirty with sediment, fuel will not flow smoothly and loss in engine power may result. Clean the fuel strainer with compressed air. INSTALLATION Install the fuel tank and fuel valve in the reverse order of removal.
  • Page 176: Carburetor

    12-4 FUEL SYSTEM CARBURETOR CONSTRUCTION 1 Clip 2 Jet needle (J.N.) 3 Throttle valve Throttle position sensor 5 Slow air jet (S.A.J) 6 Starter jet 7 Pilot screw 8 Slow jet (S.J.) 9 Main jet (M.J.) 0 Float valve A Float B Leak jet C Throttle stop screw...
  • Page 177: Removal

    FUEL SYSTEM 12-5 REMOVAL " WARNING Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Turn the fuel valve OFF. • Place a container beneath the drain hose, drain fuel from the float chamber by loosening the drain screw 1. •...
  • Page 178: Disassembly

    12-6 FUEL SYSTEM DISASSEMBLY • Remove the hot starter valve 1 and spring from the hot starter cable. • Remove the drain hose and air vent hoses. NOTE: Do not remove the throttle position sensor 2 unless it is neces- sary to replace it.
  • Page 179 FUEL SYSTEM 12-7 • Disassemble the throttle valve assembly. 6 Throttle valve A Spring 7 Bearing B Needle set screw 8 Jet needle C Floating valve 9 Clip D Seal 0 Collar • Remove the throttle shaft E with the link arm F, plastic washer G, steel washer H and spring I.
  • Page 180 12-8 FUEL SYSTEM • Remove the drain plug O and float chamber P from the car- buretor body. • Remove the leak jet Q. • Remove the gasket R and O-ring S. • Remove the plate from the float chamber. •...
  • Page 181 FUEL SYSTEM 12-9 • Remove the float pin W. • Remove the float X with the float valve Y. • Remove the following parts. Z Main jet [ Main nozzle \ Buffer plate ] Slow jet ^ Starter jet • Remove the slow air jet a.
  • Page 182: Cleaning

    12-10 FUEL SYSTEM CLEANING " WARNING Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and storage. • Clean all jets with a spray-type carburetor cleaner and dry them using compressed air.
  • Page 183 FUEL SYSTEM 12-11 FUEL LEVEL • Remove the drain hose and then install a proper cap 1 to the carburetor drain. • Remove the drain screw and than connect the special tool. $ 09913-14541: Fuel level gauge set • Hold the carburetor in the proper angle with a stand. Lateral direction: Horizontal Carburetor set position...
  • Page 184: Reassembly

    12-12 FUEL SYSTEM FLOAT HEIGHT • Tilt the carburetor until the float arm B just touches the float valve rod. • Measure the float height A. % Standard float height: 8 mm (0.31 in) $ 09900-20101: Vernier calipers (150 mm) •...
  • Page 185 Replace the O-rings with new ones. • Apply thin coat of the grease to the O-ring. CAUTION Replace the O-ring with a new one. ' 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the pilot screw 0. NOTE: Turn in the pilot screw 0 until it lightly seats, then back it out the counted number of turns.
  • Page 186 12-14 FUEL SYSTEM • Apply SUZUKI SILICONE GREASE to the throttle shaft. ( 99000-25100: SUZUKI SILICONE GREASE • Hook the return spring onto the stopper of the throttle pulley. • Insert the throttle shaft and install the steel washer A, plastic washer B and link arm C.
  • Page 187 FUEL SYSTEM 12-15 CAUTION Replace the gasket with a new one. • Reassemble the hot start valve E to the hot start cable end. ACCELERATION PUMP TIMING If turn the stop screw of the acceleration pump, adjust the accel- eration pump timing after assemble the carburetor. •...
  • Page 188: Installation

    12-16 FUEL SYSTEM INSTALLATION Install the carburetor in the reverse order of removal. Pay atten- tion to the following points: • Fit the projection on the carburetor body in the depression of the intake pipe. • Position the carburetor clamps correctly. (!19-23) •...
  • Page 189: Throttle Position Sensor

    FUEL SYSTEM 12-17 THROTTLE POSITION SENSOR INSPECTION THROTTLE POSITION SENSOR INPUT VOLTAGE • Disconnect the throttle position sensor coupler 1. • Shift the transmission into neutral. B/Bl • Start the engine. • Measure the throttle position sensor input voltage using the multi circuit tester.
  • Page 190: Removal

    12-18 FUEL SYSTEM REMOVAL • Remove the carburetor. (!12-5) • Remove the throttle position sensor using the special tool. $ 09930-11950: Torx wrench (T25) INSTALLATION • Apply a thin coat of engine oil to the O-ring. • With the throttle valve fully closed, install the throttle position sensor.
  • Page 191 COOLING SYSTEM 13-1 COOLING SYSTEM CONTENTS CONSTRUCTION ..................13- 2 ENGINE COOLANT ................... 13- 3 REPLACEMENT .................. 13- 3 COOLING CIRCUIT ................... 13- 4 INSPECTION ..................13- 4 RADIATOR ....................13- 5 REMOVAL ................... 13- 5 INSPECTION ..................13- 5 INSTALLATION ...................
  • Page 192: Construction

    13-2 COOLING SYSTEM CONSTRUCTION 11 N . m (1.1 kgf-m, 8.0 lb-ft) 11 N . m (1.1 kgf-m, 8.0 lb-ft) 6 N . m (0.6 kgf-m, 4.5 lb-ft)
  • Page 193: Engine Coolant

    COOLING SYSTEM 13-3 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 194: Cooling Circuit

    13-4 COOLING SYSTEM COOLING CIRCUIT INSPECTION • Remove the radiator cap. $ 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 195: Radiator

    COOLING SYSTEM 13-5 RADIATOR REMOVAL $ 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. If engine coolant is swallowed, induce vomiting and call a physician immediately.
  • Page 196: Water Pump

    13-6 COOLING SYSTEM WATER PUMP REMOVAL $ 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 197: Inspection

    COOLING SYSTEM 13-7 CRANKCASE COVER • Remove the brake pedal. ("16-18) • Remove the kick starter lever. ("8-3) • Remove the right crankcase cover 1, dowel pins and gasket. IMPELLER AND GEAR SHAFT • Hold the water pump shaft 1 with a wrench and remove the impeller 2.
  • Page 198: Installation

    (or equivalent thread lock) • Press the oil seal with the suitable size socket wrench. • Apply a small quantity of grease to the oil seal lips. & 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) IMPELLER AND WATER PUMP SHAFT •...
  • Page 199 COOLING SYSTEM 13-9 • Fit the right crankcase cover. • Tighten the right crankcase cover bolts to the specified torque. ! Right crankcase cover bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft) • Install the brake pedal. ("16-18) • Install the kick starter lever. ("8-7) WATER PUMP CASE •...
  • Page 200: Electrical System

    14-1 ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ............... 14- 2 CONNECTOR ..................14- 2 COUPLER ................... 14- 2 SEMI-CONDUCTOR EQUIPPED PART ..........14- 2 USING THE MULTI-CIRCUIT TESTER ..........14- 2 SWITCH ....................14- 2 LOCATION OF ELECTRICAL COMPONENTS ........14- 3 CONSTRUCTION ..................
  • Page 201: Cautions In Servicing

    ELECTRICAL SYSTEM 14-2 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 • 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 202: Location Of Electrical Components

    14-3 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS 1 Engine stop switch 4 CDI unit 2 Ignition coil/plug cap 5 Pick-up coil 3 Throttle position sensor 6 Magneto...
  • Page 203: Construction

    ELECTRICAL SYSTEM 14-4 CONSTRUCTION ELECTRICAL SYSTEM 4.5 N . m (0.45 kgf-m, 3.25 lb-ft) 80 N . m (8.0 kgf-m, 58.0 lb-ft) 10 N . m (1.0 kgf-m, 7.0 lb-ft) ELECTRICAL CIRCUIT Throttle position sensor Engine stop switch B/Br B/Br B/Br B/Bl B/Bl...
  • Page 204: Troubleshooting

    14-5 ELECTRICAL SYSTEM TROUBLESHOOTING No spark or poor spark Step 1 1) Check the ignition system couplers for poor connections. Is there connection in the ignition system couplers? Go to Step 2. Poor connection of couplers Step 2 1) Measure the ignition coil primary peak voltage. ("14-8) Is the peak voltage OK? Go to Step 3.
  • Page 205 ELECTRICAL SYSTEM 14-6 Step 7 1) Measure the exciter coil and charge coil peak voltages. ("14-7) Are the peak voltages OK? Go to Step 9. Go to Step 8. Step 8 1) Check the stator. Is the stator OK? Go to Step 9. Faulty stator Step 9 1) Measure the engine stop switch resistance.
  • Page 206: Ignition System

    14-7 ELECTRICAL SYSTEM IGNITION SYSTEM IGNITION SYSTEM PEAK VOLTAGE INSPECTION • Disconnect the magneto lead wire coupler 1. • Connect the multi-circuit tester with peak volt adaptor as shown. • Measure the highest peak voltage by depressing the kick starter lever several times forcefully. # Stator coil peak voltage + Black/Red –...
  • Page 207: Ignition System Coil Inspection

    ELECTRICAL SYSTEM 14-8 IGNITION SYSTEM COIL INSPECTION • Disconnect the magneto lead wire coupler 1. • Measure the exciter, charge and pick-up coils resistance. # Stator coil resistance 24 – 42 Ω Exciter Black/Red – Red/White 1.6 – 3.2 Ω Charge Yellow –...
  • Page 208: Ignition Coil/Plug Cap Inspection

    14-9 ELECTRICAL SYSTEM • Insert the needle pointed probe A to the lead wire coupler. NOTE: Use the special tool (needle pointed probe), to prevent the rub- ber of the water proof coupler from damage. • Measure the ignition coil primary peak voltage by depressing the kick starter lever several times forcefully.
  • Page 209: Engine Stop Switch Inspection

    ELECTRICAL SYSTEM 14-10 ENGINE STOP SWITCH INSPECTION • Remove the seat, radiator covers and fuel tank. ("5-2) • Disconnect the engine stop switch lead wire coupler 1. • Measure the engine stop switch resistance between Black/ Yellow lead wire and Black/White lead wire. # Engine stop switch resistance Black/Yellow –...
  • Page 210: Magneto Rotor

    14-11 ELECTRICAL SYSTEM MAGNETO ROTOR REMOVAL • Drain engine oil. ("2-12) • Disconnect the magneto lead wire coupler 1 and clamp. • Move the left radiator by removing the mounting bolts. ("13-5) • Remove the gearshift lever. ("9-3) • Remove the magneto cover 2. •...
  • Page 211: Installation

    ELECTRICAL SYSTEM 14-12 • Remove the magneto rotor with the special tool. ! 09930-35020: Rotor remover • Remove the magneto rotor key 5. INSTALLATION • Remove any grease from the tapered portion A of the mag- neto rotor and crankshaft B. •...
  • Page 212: Stator

    14-13 ELECTRICAL SYSTEM • Install the magneto cover 3. NOTE: Fit the bracket to the bolt C. ( Magneto cover bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft) • Install the gearshift lever. ("9-7) • Pour engine oil. ("2-12) STATOR REMOVAL •...
  • Page 213: Front And Rear Wheels

    FRONT AND REAR WHEELS 15-1 FRONT AND REAR WHEELS CONTENTS CONSTRUCTION ..................15- 2 FRONT WHEEL ..................15- 3 REMOVAL ................... 15- 3 INSPECTION ..................15- 3 DUST SEAL AND BEARING REPLACEMENT ........15- 4 DISC PLATE REPLACEMENT ............15- 5 INSTALLATION ...................
  • Page 214: Construction

    15-2 FRONT AND REAR WHEELS CONSTRUCTION 90 N . m (9.0 kgf-m, 65.0 lb-ft) 26 N . m (2.6 kgf-m, 19.0 lb-ft) 30 N . m (3.0 kgf-m, 21.5 lb-ft) 11 N . m (1.1 kgf-m, 8.0 lb-ft) 35 N . m (3.5 kgf-m, 25.5 lb-ft)
  • Page 215: Front Wheel

    FRONT AND REAR WHEELS 15-3 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. • Loosen the right axle holder bolts 3. •...
  • Page 216: Dust Seal And Bearing Replacement

    15-4 FRONT AND REAR WHEELS WHEEL RIM • Measure the wheel rim runout with the dial gauge. • If the runout exceeds the limit, replace the bearings or wheel. ! Service Limit: 2.0 mm (0.08 in) ... axial and radial "...
  • Page 217: Disc Plate Replacement

    When installing the dust seal, place the manufacturer’s code indicated side of the dust seal outside. " 09913-70210: Bearing installer set Bearing: # 40 Attachment $ 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) DISC PLATE REPLACEMENT • Remove the disc plate.
  • Page 218: Installation

    15-6 FRONT AND REAR WHEELS INSTALLATION • Hold the front axle shaft with the special tool and tighten the front axle nut temporarily. " 09940-34581: Attachment (F) • Remove the block from under the chassis tube and move the front forks up and down several times. •...
  • Page 219: Rear Wheel

    FRONT AND REAR WHEELS 15-7 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 220: Inspection

    15-8 FRONT AND REAR WHEELS 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 together with the dust seal.
  • Page 221 FRONT AND REAR WHEELS 15-9 • Remove the bearings with the special tool. " 09921-20240: Bearing remover set (Remover 25 mm) CAUTION The removed bearings must be replaced with new ones. • Remove the spacer. • Install new bearings with the special tool, using the suitable spacer A match for the outside dimension of bearings.
  • Page 222: Disc Plate Replacement

    When installing the dust seal, place the manufacturer’s code indicated side of the dust seal outside. " 09913-70210: Bearing installer set Oil seal: # 42 Attachment $ 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) DISC PLATE REPLACEMENT • Remove the disc plate.
  • Page 223: Installation

    FRONT AND REAR WHEELS 15-11 INSTALLATION Left Right • Install the rear wheel, chain adjuster washers and axle shaft. • Adjust the drive chain slack. ('2-28) Chain adjuster washer • Tighten the rear axle nut to the specified torque. & Rear axle nut: 90 N·m (9.0 kgf-m, 65.0 lb-ft) REAR WHEEL SPOKES REPLACEMENT ('19-31)
  • Page 224: Front And Rear Brakes

    16-1 FRONT AND REAR BRAKES FRONT AND REAR BRAKES CONTENTS CONSTRUCTION ..................16- 2 BRAKE FLUID AIR BLEEDING ..............16- 3 BRAKE FLUID REPLACEMENT .............. 16- 4 BRAKE PADS REPLACEMENT ............... 16- 5 FRONT BRAKE PADS ............... 16- 5 REAR BRAKE PADS ................. 16- 5 BRAKE DISC INSPECTION ..............
  • Page 225: Construction

    FRONT AND REAR BRAKES 16-2 CONSTRUCTION 12 N . m 10 N . m 1.2 kgf . m 1.0 kgf . m 8.5 lb-ft 7.0 lb-ft 23 N·m 23 N·m (2.3 kgf-m, (2.3 kgf-m, 16.5 lb-ft) 16.5 lb-ft) 10 N·m (1.0 kgf-m, 7.0 lb-ft) 23 N·m (2.3 kgf-m,...
  • Page 226: Brake Fluid Air Bleeding

    16-3 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 227: Brake Fluid Replacement

    FRONT AND REAR BRAKES 16-4 • Pump the brake lever/pedal until air bubbles stop coming out from the reservoir. • Hold the brake lever/pedal in the squeezed position. • Open the bleeder valve and tighten the bleeder valve. • Release the brake lever/pedal. •...
  • Page 228: Brake Pads Replacement

    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 • Tighten the brake pad mounting pin to the specified torque.
  • Page 229: Brake Disc Inspection

    FRONT AND REAR BRAKES 16-6 BRAKE DISC INSPECTION • Inspect the brake discs for damage or cracks. • Measure the front and rear brake disc thickness. • Replace the disc if the thickness is less than the service limit or if damage is found. &...
  • Page 230: Front Caliper Removal And Disassembly

    16-7 FRONT AND REAR BRAKES FRONT CALIPER REMOVAL AND DISASSEMBLY • Place a rag under the brake hose union bolt to catch spilled brake fluid. • Disconnect the brake hose by removing the union bolt. • Remove the caliper mounting bolts 1. •...
  • Page 231: Caliper Inspection

    ! Specification and classification: DOT 4 • Install the springs and boots. • Apply SUZUKI SILICONE GREASE to the caliper axles. % 99000-25100: SUZUKI SILICONE GREASE • Install the caliper bracket.
  • Page 232: Rear Caliper Removal And Disassembly

    16-9 FRONT AND REAR BRAKES • Tighten the caliper mounting bolts 1 to the specified torque. # Brake caliper mounting bolt: 26 N·m (2.6 kgf-m, 19.0 lb-ft) • Tighten the brake pad mounting pin 2 to the specified torque. # Brake pad mounting pin: 18 N·m (1.8 kgf-m, 13.0 lb-ft) •...
  • Page 233: Rear Caliper Reassembly And Installation

    FRONT AND REAR BRAKES 16-10 • Remove the caliper bracket 4 from the caliper. • Remove the boots 5 and 6. • Remove the spring 7. • Wrap the caliper with a rag to prevent brake fluid scatter and piston pop-out. •...
  • Page 234 16-11 FRONT AND REAR BRAKES • Install the springs and boots. • Apply SUZUKI SILICONE GREASE to the caliper axles. % 99000-25100: SUZUKI SILICONE GREASE • Install the caliper bracket. • Install the brake pads. • Apply SUZUKI SILICONE GREASE to the O-ring.
  • Page 235: Master Cylinder

    FRONT AND REAR BRAKES 16-12 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 236: Master Cylinder Inspection

    16-13 FRONT AND REAR BRAKES • Remove the dust boot 5 and snap ring 6. ' 09900-06108: Snap ring pliers • Remove the washer 7 and piston/cup set 8. MASTER CYLINDER INSPECTION • Inspect the cylinder bore and piston for scuffing, wear and damage.
  • Page 237: Front Master Cylinder Reassembly And Installation

    FRONT AND REAR BRAKES 16-14 FRONT MASTER CYLINDER REASSEMBLY AND INSTALLATION Reassemble and install the master cylinder in the reverse order of removal and disassembly. Pay attention to the following points: • Install the brake lever. ($16-17) NOTE: When remounting the master cylinder onto the handlebar, align the master cylinder holder’s mating surface A with the matching mark B on the handlebar and tighten the lower bolt 1 first.
  • Page 238: Rear Master Cylinder Removal And Disassembly

    16-15 FRONT AND REAR BRAKES REAR MASTER CYLINDER REMOVAL AND DISASSEMBLY • Drain brake fluid. ($16-4) • Remove the cotter pin and then master cylinder rod pin 1 and washer. • Remove the master cylinder 2 by removing the bolts. •...
  • Page 239: Master Cylinder Inspection

    • Apply grease to the contact point between piston and push rod. ( 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Set the brake hose end between the hose stoppers, then tighten the brake hose union bolt 1 to the specified torque.
  • Page 240: 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 brake lever pivot bolt and lock-nut to the specified torque.
  • Page 241: 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 grease) • Install the return spring 1 properly. ($19-29) •...
  • Page 242: Front Fork And Steering

    17-1 FRONT FORK AND STEERING FRONT FORK AND STEERING CONTENTS CONSTRUCTION ..................17- 2 FRONT FORK, STEERING ..............17- 2 HANDLEBAR CONTROLS ..............17- 3 REMOVAL ..................17- 4 DISASSEMBLY .................. 17- 5 INSPECTION ..................17- 9 REASSEMBLY ................... 17-11 INSTALLATION ..................
  • Page 243: Construction

    FRONT FORK AND STEERING 17-2 CONSTRUCTION FRONT FORK, STEERING 25 N . m (2.5 kgf-m, 18.0 lb-ft) 100 N . m (10.0 kgf-m, 72.5 lb-ft) 30 N . m (3.0 kgf-m, 21.5 lb-ft) 23 N . m (2.3 kgf-m, 16.5 lb-ft) 45 N .
  • Page 244: Handlebar Controls

    17-3 FRONT FORK AND STEERING HANDLEBAR CONTROLS 25 N·m (2.5 kgf-m, 18.0 lb-ft) Apply handle grip bond. Apply handle grip bond. 6 N·m (0.6 kgf-m, 4.5 lb-ft) 6 N·m (0.6 kgf-m, 4.5 lb-ft)
  • Page 245: Removal

    FRONT FORK AND STEERING 17-4 REMOVAL • Place the motorcycle on a block to lift front wheel off the ground. • Remove the front wheel. (!15-3) • Remove the front number plate 1. • Remove the protector 2. • Remove the handlebars. NOTE: Mark the paint mark A to the matching surface of handlebar holder and handlebars before removing.
  • Page 246: Disassembly

    17-5 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 leakage.
  • Page 247 FRONT FORK AND STEERING 17-6 • Clamp the axle holder 2 with a vise. Protect the axle holder with a rag when using a vise. • 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 248 17-7 FRONT FORK AND STEERING • With the outer tube compressed by hands, remove the special tool. CAUTION Do not remove the lock-nut 4. If removed, the inner rod may slip into the damper rod, possibly causing the threaded section to damage the oil seal. •...
  • Page 249 FRONT FORK AND STEERING 17-8 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 Seal retainer 5 Oil seal 6...
  • Page 250: Inspection

    17-9 FRONT FORK AND STEERING • Drain the fork oil from the damper rod assembly by moving the inner rod several strokes. 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 •...
  • Page 251 FRONT FORK AND STEERING 17-10 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 252: Reassembly

    17-11 FRONT FORK AND STEERING REASSEMBLY CAUTION 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.
  • Page 253 $ 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) • Replace the O-ring 4 with a new one. • Apply fork oil to the O-ring 4.
  • Page 254 17-13 FRONT FORK AND STEERING • Clamp the bottom (flat part) of the sub-tank with a vise. CAUTION Do not clamp the sub-tank too tight. • Tighten the compression damper unit 5 to the specified torque. & Compression damper unit: 30 N·m (3.0 kgf-m, 21.5 lb-ft) •...
  • Page 255 FRONT FORK AND STEERING 17-14 • 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” procedures (Pour the specified amount fork oil and discharge an excess of oil).
  • Page 256 17-15 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 257 • Pour the specified amount of fork oil into the outer tube. $ Oil quantity (When standard fork spring is used): 370 ml (12.51/13.03 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 258: Installation

    17-17 FRONT FORK AND STEERING INSTALLATION • Install the front fork with the upper surface T of the outer tube 2.0 mm (0.079 in) positioned 2.0 mm (0.079 in) from the upper surface of the upper bracket. • Check that the air valve A is positioned at the front. 2.0 mm (0.079 in) •...
  • Page 259: Steering

    FRONT FORK AND STEERING 17-18 STEERING REMOVAL HANDLEBARS • Place the motorcycle on a block to lift front wheel off the ground. • Remove the front number plate and protector. (!17-4) • Remove the clamps. • Remove the engine stop switch 1. •...
  • Page 260 17-19 FRONT FORK AND STEERING • Remove the handlebars by removing the handlebar clamp bolts. NOTE: Mark the paint mark to the matching surface of handlebar holder and handlebars before removing. STEERING STEM • Remove the front wheel 1. (!15-3) •...
  • Page 261: Inspection

    FRONT FORK AND STEERING 17-20 • Remove the handlebar holders, damper bushings and spac- ers. • Remove the steering stem nut with the special tools. NOTE: Hold the steering stem lower bracket to prevent it from falling. " 09940-14911: Steering nut socket wrench 09940-14960: Steering nut wrench socket •...
  • Page 262: Bearing Replacement

    17-21 FRONT FORK AND STEERING BEARING REPLACEMENT • Remove the lower bearing. • Fit the lower bearing with the special tool. " 09925-18011: Steering bearing installer NOTE: Replace the outer race and bearing as a set. • Remove the upper outer race with the special tools. "...
  • Page 263: Installation

    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 grease) • Fit the steering stem lower bracket, upper bearing and upper dust seal.
  • Page 264 17-23 FRONT FORK AND STEERING • Temporarily install the front forks to the steering stem, and tighten the lower clamp bolts. • 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) •...
  • Page 265 & Handlebar holder set nut: 44 N·m (4.4 kgf-m, 32.0 lb-ft) • Apply grease to the throttle cable and their hole. ( 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Align the matching mark D on the handlebars with the throttle holder matching surface.
  • Page 266 17-25 FRONT FORK AND STEERING HANDLEBARS • Apply handle grip bond to the left handlebar end and inside of the left grip. Apply handle grip bond. Apply handle grip bond. ” mark on the left grip with the matching mark A •...
  • Page 267 FRONT FORK AND STEERING 17-26 • Align the matching mark B on the handlebars with the clutch lever holder matching surface. • Tighten the upper bolt first temporarily to provide clearance on the lower side and then tighten both the bolts. •...
  • Page 268 18-1 REAR SUSPENSION REAR SUSPENSION CONTENTS CONSTRUCTION ..................18- 2 REAR SUSPENSION ................. 18- 2 REAR SHOCK ABSORBER ..............18- 3 REMOVAL ..................18- 3 SPRING REPLACEMENT ..............18- 4 INSPECTION ..................18- 5 BEARING REPLACEMENT ............... 18- 6 OIL REPLACEMENT ................18- 7 DISASSEMBLY AND INSPECTION ..........
  • Page 269: Construction

    REAR SUSPENSION 18-2 CONSTRUCTION REAR SUSPENSION 80 N . m (8.0 kgf-m, 58.0 lb-ft) 60 N . m (6.0 kgf-m, 43.5 lb-ft) 80 N . m 8.0 kgf . m 58.0 lb-ft 60 N . m 80 N . m 6.0 kgf .
  • Page 270: Rear Shock Absorber

    18-3 REAR SUSPENSION REAR SHOCK ABSORBER REMOVAL • Place a block under chassis tube. • Remove the seat. (!5-2) • Loosen the air cleaner clamp screw. • Remove the right frame cover. (!5-2) • Remove the muffler 1 and seat rail assembly 2. •...
  • Page 271: Spring Replacement

    REAR SUSPENSION 18-4 • 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. • Remove the rear shock absorber. SPRING REPLACEMENT • Loosen the lock-nut 1 with the special tool and turn it fully to the end of the thread.
  • Page 272: Inspection

    18-5 REAR SUSPENSION • Adjust the spring set length and tighten the lock-nut. # Standard spring set length: 5.7 mm (0.22 in) compressed from the free length Spring set length adjustable range: 247 – 263 mm (9.72 – 10.35 in) [at spring free length 265 mm (10.43 in)] a: Hardest spring setting b: Softest spring setting...
  • Page 273: Bearing Replacement

    • Apply grease to the needle roller bearings and install them. • Apply grease to the dust seals and spacers. • Install the spacers B and C. B For right side C For left side % 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease)
  • Page 274: Oil Replacement

    18-7 REAR SUSPENSION OIL REPLACEMENT TOOLS AND EQUIPMENT • Following tools and equipment are required to perform oil replacement. 1 Screwdriver or small punch 7 Rags 2 Vise* 8 Nitrogen tank 3 Drain Pan 9 Filler Hose and Nozzle 4 Oil can 0 Regulator Assembly 5 Beaker A Owner’s Service Manual...
  • Page 275 Be sure to extend the rod after filling the oil. • Tilt the shock absorber unit as shown and pour the fresh rear suspension oil fully into the reservoir. 99000-99001-S25: SUZUKI REAR SUSPENSION OIL SS-25 (or equivalent rear suspension oil) # Oil capacity: 395 ml (13.35/13.91 US/Imp oz) •...
  • Page 276 18-9 REAR SUSPENSION • Replace the O-rings on the compression adjuster assembly with new ones. • Apply the rear suspension oil to the O-rings. • Reinstall the compression adjuster assembly 1. " 09941-53660: RCU socket wrench $ Compression adjuster assembly: 30 N·m (3.0 kgf-m, 21.5 lb-ft) •...
  • Page 277: Disassembly And Inspection

    REAR SUSPENSION 18-10 DISASSEMBLY AND INSPECTION • Clean and dry the rear shock absorber. • Remove the spring from the rear shock absorber. (!18-4) • Turn the rebound damping force adjuster to the softest posi- tion. • Press the valve with a screwdriver to bleed out nitrogen gas. (!18-7) •...
  • Page 278: Reassembly

    • Fit the stopper to the shock absorber body. • Fill the specified rear suspension oil in the rear shock absorber. (!18-8) 99000-99001-S25: SUZUKI REAR SUSPENSION OIL SS-25 (or equivalent rear suspension oil) # Oil capacity: 395 ml (13.35/13.91 US/Imp oz) •...
  • Page 279: Installation

    REAR SUSPENSION 18-12 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 280: Swingarm

    18-13 REAR SUSPENSION SWINGARM REMOVAL • Place the motorcycle on a block to lift rear wheel off the ground. • Remove the rear wheel. (!15-7) • Remove the chain guide. • Remove the rear master cylinder mounting bolts and brake hose guide bolt.
  • Page 281 REAR SUSPENSION 18-14 • Down the rear brake pedal and remove the pivot shaft. • Remove the swingarm. • Remove the chain buffer. • Remove the plates. • Remove the following parts from the swingarm. Spacer 1 Oil seal 2 Washer 3 Thrust bearing 4 Dust seal 5...
  • Page 282: Inspection

    18-15 REAR SUSPENSION INSPECTION PIVOT SHAFT • Measure the pivot shaft runout with the dial gauge and V-blocks. • If any the runout exceeds the limit, replace the pivot shaft with a new one. # Swingarm pivot shaft runout Service Limit: 0.3 mm (0.01 in) "...
  • Page 283: Bearing Replacement

    • Remove the bearings with the special tool. " 09921-20240: Bearing remover set (Remover 20 mm) • Press the new bearings with the special tool. (!18-23) " 09924-84521: Bearing installer • Apply grease to the bearings. % 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease)
  • Page 284: Installation

    7 Spacer 4 Thrust bearing • Apply grease to the dust seals, bearings and oil seals. % 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Apply THREAD LOCK SUPER to the plate mounting screws. ' 99000-32110: THREAD LOCK SUPER “1322”...
  • Page 285: Rear Suspension Linkage

    REAR SUSPENSION 18-18 REAR SUSPENSION LINKAGE REMOVAL • Place a block under the chassis tubes. • Remove the lower drive chain control roller 1. • Remove the rear cushion rod bolt and nut. • Remove the cushion lever bolt and nut. •...
  • Page 286: Inspection

    18-19 REAR SUSPENSION INSPECTION • Inspect the cushion rod and cushion lever for damage. • Inspect the dust seals, oil seals and spacers for damage. • If necessary, replace the defective parts with a new one. • Insert the spacers into the bearings and inspect them for excessive play and smooth movement.
  • Page 287: Bearing Replacement

    (3: right side) * Position the needle roller bearing cages by referring to the illustration of page 18-22. • Apply grease to the needle roller bearings and install them. % 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease)
  • Page 288: Installation

    Pay attention to the following points: • Position the dust seals 1 so that the manufacturer’s code indicated side of the seals face outside. (2: inside) • Apply grease to the dust seals. % 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease)
  • Page 289 REAR SUSPENSION 18-22 • Tighten the cushion lever, cushion rod and swingarm nuts to the specified torque. Left Right 4 mm (0.16 in) 4 mm (0.16 in) 4 mm (0.16 in) 4 mm (0.16 in) $ Tightening torque: A: 60 N·m (6.0 kgf-m, 43.5 lb-ft) B: 60 N·m (6.0 kgf-m, 43.5 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)
  • Page 290 18-23 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 291: Servicing Information

    SERVICING INFORMATION 19-1 SERVICING INFORMATION CONTENTS SERVICE DATA ..................19- 2 TIGHTENING TORQUE ................19-10 SPECIAL TOOLS ..................19-14 WIRING DIAGRAM ..................19-17 CABLE ROUTING ..................19-18 WIRING HARNESS ROUTING ..............19-20 FUEL HOSE ROUTING ................19-21 HOT STARTER LEVER INSTALLATION ..........19-21 FUEL TANK CUSHION INSTALLATION ..........
  • Page 292: Service Data

    19-2 SERVICING INFORMATION SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.22) — (0.98) Valve clearance (when cold) 0.09 – 0.16 — (0.004 – 0.006) 0.17 – 0.24 — (0.006 – 0.009) Valve guide to valve stem 0.010 –...
  • Page 293 SERVICING INFORMATION 19-3 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 34.86 – 34.91 34.56 (1.372 – 1.374) (1.361) 34.38 – 34.43 34.08 (1.354 – 1.356) (1.342) Camshaft journal oil clearance 0.023 – 0.066 0.150 IN. & EX. (0.0013 –...
  • Page 294: Oil Pump

    19-4 SERVICING INFORMATION CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end I.D. 16.010 – 16.018 16.040 (0.6303 – 0.6306) (0.6315) Conrod deflection — (0.12) Conrod big end side clearance 0.20 – 0.65 (0.008 – 0.026) (0.04) Conrod big end width 17.75 –...
  • Page 295 SERVICING INFORMATION 19-5 TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3.210 (61/19) — Final reduction ratio 4.000 (48/12) — Gear ratios 2.153 (28/13) — 1.764 (30/17) — 1.470 (25/17) — 1.238 (26/21) —...
  • Page 296 19-6 SERVICING INFORMATION ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Ignition timing 18° B.T.D.C. at 2 100 r/min. Spark plug Type NGK: CR8EIA-10 0.9 – 1.0 (0.035 – 0.039) Spark performance Over 8 (0.3) at 1 atm. 72 – 127 Ω Pick-up coil resistance R –...
  • Page 297 SERVICING INFORMATION 19-7 ITEM STANDARD LIMIT Brake caliper cylinder bore 27.000 – 27.050 Front — (1.0630 – 1.0650) 25.400 – 25.450 Rear — (1.0000 – 1.0020) Brake caliper piston diam. 26.900 – 26.950 Front — (1.0591 – 1.0610) 25.335 – 25.368 Rear —...
  • Page 298 19-8 SERVICING INFORMATION SUSPENSION Unit: mm (in) ITEM STANDARD LIMIT NOTE Front fork stroke — (12.2) Front fork inner tube — O.D. (18.5) Front fork spring free 494 ± 2.5 487 (19.17) length (19.45 ± 0.10) Front fork damping Rebound MAX –...
  • Page 299 (1.1/0.9 US/Imp qt) Air cleaner element oil type MOTUL AIR FILTER OIL or equivalent filter oil Front fork oil type SUZUKI FORK OIL SS-05 or an equivalent fork oil Front fork oil capacity 370 ml Outer tube oil (each leg) (12.51/13.03 US/Imp oz)
  • Page 300: Tightening Torque

    19-10 SERVICING INFORMATION TIGHTENING TORQUE ENGINE PART N·m kgf-m lb-ft Cylinder head cover bolt 10.0 Spark plug Cylinder head bolt (Initial) 18.0 (Final) 36.0 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 301 SERVICING INFORMATION 19-11 PART N·m kgf-m lb-ft Engine mounting nut (upper) 32.5 Engine mounting nut (lower) 40.0 Engine mounting nut (front) 43.5 Engine mounting bracket nut (upper) 29.0 Engine mounting bracket nut (front) 29.0 Engine sprocket cover bolt Kick starter lever bolt 16.5 Kick starter lever screw Fuel valve mounting bolt...
  • Page 302 19-12 SERVICING INFORMATION CHASSIS PART N·m kgf-m lb-ft 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 25.5...
  • Page 303 SERVICING INFORMATION 19-13 For other bolts and nuts not listed in the table, refer to this chart. Conventional or “4” marked bolt “7” marked or crown headed bolt Bolt Diameter (mm) N·m kgf-m lb-ft N·m kgf-m lb-ft 0.15 0.23 0.45 0.55 16.5 21.0...
  • Page 304: Special Tools

    19-14 SERVICING INFORMATION SPECIAL TOOLS 09900-20101 09900-20202 09900-20204 09900-06107 09900-06108 Vernier calipers Micrometer Micrometer Snap ring pliers Snap ring pliers (150 mm) (25 – 50 mm) (75 – 100 mm) 09900-20205 09900-20602 09900-20607 Micrometer 09900-20530 Dial gauge Dial gauge 09900-20701 (0 –...
  • Page 305 SERVICING INFORMATION 19-15 09913-50121 09913-70210 09915-64512 09915-74511 09916-10911 Oil seal remover Bearing installer set Compression gauge Oil pressure gauge Valve lapper set 09916-33210 09916-14510 09916-14522 09916-14530 09916-34542 Valve guide reamer Valve lifter Attachment Attachment Reamer handle (4.5 mm) 09916-44920 09916-33320 09916-43211 Valve guide installer Valve guide reamer...
  • Page 306 19-16 SERVICING INFORMATION 09930-10121 Spark plug wrench 09930-11950 09930-30104 09930-35020 09930-44560 Torx wrench (T25) Slide shaft Rotor remover Rotor holder 09940-14911 09940-14960 09940-52861 Steering nut socket Steering nut wrench 09940-34581 09940-40211 Front fork oil seal wrench socket Attachment (F) Adapter installer set 09941-34513 09941-53630...
  • Page 307: Wiring Diagram

    SERVICING INFORMATION 19-17 WIRING DIAGRAM IGNITION COIL CDI UNIT ENGINE STOP SWITCH Ground : Pickup THROTTLE coil POSITION SENSOR MAGNETO WIRE COLOR Black Blue Green Yellow B/Bl: Black with Blue tracer B/Br: Black with Brown tracer B/G: Black with Green tracer B/R: Black with Red tracer B/W:...
  • Page 308: Cable Routing

    19-18 SERVICING INFORMATION CABLE ROUTING...
  • Page 309 SERVICING INFORMATION 19-19...
  • Page 310: Wiring Harness Routing

    19-20 SERVICING INFORMATION WIRING HARNESS ROUTING Number plate clamp Engine stop switch lead wire Engine stop switch lead wire Handlebars Be careful not to slack the Throttle position sensor coupler. 20 – 30 mm 20 – 30 mm (0.8 – 1.2 in) (0.8 –...
  • Page 311: Fuel Hose Routing

    SERVICING INFORMATION 19-21 FUEL HOSE ROUTING 5 N . m (0.5 kgf-m, 3.5 lb-ft) Pass the fuel hose above the hot starter cable and starter knob. Set the expanded diameter side (white paint) of fuel hose to carburetor. The ends of the clamp should face forward.
  • Page 312: Fuel Tank Cushion Installation

    19-22 SERVICING INFORMATION FUEL TANK CUSHION INSTALLATION Clean an adhesive surface before adhering the cushion.
  • Page 313: Radiator Hose And Carburetor Hose Routing

    SERVICING INFORMATION 19-23 RADIATOR HOSE AND CARBURETOR HOSE ROUTING Pass the breather hose upper the intake pipe. Fit the projection of the carburetor to the depression of intake pipe. 20 – 30˚ Pass the several hoses inside of guide. Pass the several hoses behind of swingarm bridge.
  • Page 314: Radiator Hose Routing

    19-24 SERVICING INFORMATION RADIATOR HOSE ROUTING : The clamp screw head should face..Hose clamp screw tightening torque: 2.3 N·m (0.23 kgf-m, 1.65 lb-ft) Left side. Right side. Face the white mark Face the white mark to the backward. to the backward. Right side.
  • Page 315: Crankcase And Cover Installation

    SERVICING INFORMATION 19-25 CRANKCASE AND COVER INSTALLATION 11 N . m (1.1 kgf-m, 8.0 lb-ft) 6 N . m (0.6 kgf-m, 4.5 lb-ft) 11 N . m (1.1 kgf-m, 8.0 lb-ft) 6 N . m (0.6 kgf-m, 4.5 lb-ft) 90˚ 11 N .
  • Page 316: Magneto Installation

    19-26 SERVICING INFORMATION MAGNETO INSTALLATION 80 N . m (8.0 kgf-m, 58.0 lb-ft) 4.5 N . m (0.45 kgf-m, 3.25 lb-ft) Pass the lead wire between stator mount boss and mount rib. Do not pinch the lead wire between stator and magneto cover. 10 N .
  • Page 317: Front Brake Hose Routing

    SERVICING INFORMATION 19-27 FRONT BRAKE HOSE ROUTING Front brake hose Front brake master cylinder Front brake hose Hose guide Stopper Set the brake hose end between the hose stopper, then tighten the brake hose union bolt to the specified torque. Front fork protector Front brake hose Clamp...
  • Page 318: Rear Brake Hose Routing

    19-28 SERVICING INFORMATION REAR BRAKE HOSE ROUTING...
  • Page 319: Rear Brake Pedal Set-Up

    SERVICING INFORMATION 19-29 REAR BRAKE PEDAL SET-UP SECT A A 0 – 10 mm (0.0 – 0.4 in) FRONT NUMBER PLATE INSTALLATION Number plate band Number plate band Handlebars Engine stop switch lead wire Clutch cable VIEW A...
  • Page 320: Handlebars Set-Up

    19-30 SERVICING INFORMATION HANDLEBARS SET-UP Set the boot of throttle cable to throttle case firmly. Throttle cable (Return side) Throttle cable (Pull side) Make the cut-line of collar to lower side. Upper Apply adhesive to Upper inner of grip and Marking on drawing position.
  • Page 321: Clutch Cable Adjuster

    SERVICING INFORMATION 19-31 CLUTCH CABLE ADJUSTER Quick adjuster Turn to tighten Tur urn to tighten n to tighten the clutch cable tension. the clutch cab the clutch cable tension. le tension. Turn to loosen Tur urn to loosen n to loosen the clutch cable tension.
  • Page 322: Exhaust Pipe And Muffler Installation

    19-32 SERVICING INFORMATION EXHAUST PIPE AND MUFFLER INSTALLATION 23 N . m (2.3 kgf-m, 16.5 lb-ft) 21 N . m 2.1 kgf-m, 15.0 lb-ft 23 N . m 11 N . m (2.3 kgf-m, 16.5 lb-ft) (1.1 kgf-m, 8.0 lb-ft) RIM LOCK INSTALLATION ROTATIONAL DIRECTION Rim lock for 1.85 RIM...
  • Page 323: Front Fender Installation

    SERVICING INFORMATION 19-33 FRONT FENDER INSTALLATION REAR FENDER INSTALLATION...
  • Page 324: Frame Cover Installation

    19-34 SERVICING INFORMATION FRAME COVER INSTALLATION FRAME COVER CUSHION INSTALLATION Double-faced tape NOTE: Clean the adhesive surface before adhering the cushion rubber.
  • Page 325: Specifications

    SERVICING INFORMATION 19-35 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ............2 165 mm (85.2 in) Overall width............830 mm (32.7 in) Overall height ............. 1 260 mm (49.6 in) Wheelbase ............1 465 mm (57.7 in) Ground clearance..........350 mm (13.8 in) Seat height ............
  • Page 326 19-36 SERVICING INFORMATION 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 ..............27.17° Trail ..............115 mm (4.5 in) Steering angle............45° (right & left) Front brake............
  • Page 327: Spare Parts List

    SERVICING INFORMATION 19-37 SPARE PARTS LIST ITEM PART NAME PART NUMBER Q’TY PARTS SET, SPARE 19900-10H00 GASKET, MAGNETO COVER 11483-10H00 GASKET, CLUTCH COVER OUTER 11484-10H00 GASKET, EXHAUST PIPE 14181-10H00 CONNECTOR, MUF JT 14771-10H00 FILTER COMP, ENGINE OIL 16510-35G00 O-RING, WATER POMP CASE 17431-10H00 LEVER, BRAKE 57310-37F00...
  • Page 328: Setting Data

    19-38 SERVICING INFORMATION SETTING DATA DATE RACE/COURSE TEMP./HUMIDITY WEATHER 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.