Suzuki UF50 Service Manual
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Suzuki UF50 Service Manual

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Summary of Contents for Suzuki UF50

  • Page 1 UF50 9 9 5 0 0 - 1 0 4 9 1 - 0 1 E...
  • Page 2 GROUP INDEX FOREWORD This manual contains an introductory description on the SUZUKI UF50/UF50Z and procedures for its in- GENERAL INFORMATION spection, service, and overhaul of its main components. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to famil- PERIODIC MAINTENANCE iarize yourself with the motorcycle and its maintenance.
  • Page 3 HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily.
  • Page 4 Indicates service data. Measure in voltage range. Apply oil. Use engine oil unless other- Measure in resistance range. wise specified. Apply SUZUKI SUPER GREASE “A”. Measure in current range. 99000-25010 Apply SUZUKI MOLY PASTE. Measure in diode test range. 99000-25140 Apply THREAD LOCK “1342”.

  • Page 5: Table Of Contents

    GENERAL INFORMATION GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE................1- 2 GENERAL PRECAUTIONS ................1- 2 SUZUKI UF50Y/UF50ZY (2000-MODEL) ............1- 4 SERIAL NUMBER LOCATION ............... 1- 4 FUEL AND OIL RECOMMENDATIONS ............1- 4 FUEL ......................1- 4 ENGINE OIL ....................1- 4 FINAL GEAR OIL ..................

  • Page 6: Warning/Caution/Note

    GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. Indicates a potential hazard that could result in death or injury.
  • Page 7 GENERAL INFORMATION If parts replacement is necessary, replace the parts with SUZUKI Genuine Parts or their equiva- lent. When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order.

  • Page 8: Suzuki Uf50Y/Uf50Zy (2000-Model)

    Research Method. 3 Fuel tank cap ENGINE OIL Use SUZUKI CCI SUPER OIL or an equivalent premium quality 2-stroke synthetic engine oil. Use only oils which are rated FC under the JASO classification. 4 Engine oil tank cap...

  • Page 9: Final Gear Oil

    GENERAL INFORMATION FINAL GEAR OIL Use a good quality SAE 10W-40 multigrade motor oil. BRAKE FLUID Specification and classification: DOT 4 This motorcycle uses a glycol-based brake fluid. Do not use or mix other types of brake fluid such as silicone-based and petroleum-based fluids for refilling the system, otherwise seri- ous damage will result to the brake system.

  • Page 10: Information Labels

    GENERAL INFORMATION INFORMATION LABELS Loading cap label General warning label Tire information label Engine starting label Battery caution label...

  • Page 11: Specifications

    Corrected compression ratio ......7.2:1 Carburetor ............KEIHIN PWS14 Air cleaner ............Polyurethane foam element Starter system ..........Electric and kick Lubrication system ........... SUZUKI “CCI” TRANSMISSION Clutch ............... Dry shoe, automatic, centrifugal type Gearshifting ............. Automatic, variable ratio Gear ratios ............Variable reduction ratio... (2.975 – 1.033) Final reduction ratio .........
  • Page 12 GENERAL INFORMATION CHASSIS Front suspension ..........Inverted telescopic, coil spring Rear suspension ..........Swingarm type, coil spring, oil damped Steering angle ..........45° (right & left) Caster .............. 25°30’ Trail ..............82 mm Turning radius ..........1.9 m Front brake ............Disc brake Rear brake ............
  • Page 13 PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE ............2- 2 PERIODIC MAINTENANCE CHART ............2- 2 MAINTENANCE AND TUNE-UP PROCEDURE ..........2- 3 BATTERY..................... 2- 3 AIR CLEANER .................... 2- 4 CYLINDER HEAD AND CYLINDER ............2- 5 SPARK PLUG ....................2- 5 CARBURETOR ...................

  • Page 14: Periodic Maintenance Schedule

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometers and months, and are dependent on whichever comes first. NOTE: More frequent servicing may be performed on motorcycles that are used under severe conditions.

  • Page 15: Maintenance And Tune-Up Procedure

    PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURE This section describes the servicing procedures for each item mentioned in the periodic maintenance chart on the previous page. BATTERY Inspect every 3 000 km (6 months). UPPER LEVEL LOWER LEVEL Remove the battery holder cover. ( 6-30) First, disconnect the - battery lead wire, and then discon- nect the + battery lead wire.

  • Page 16: Air Cleaner

    PERIODIC MAINTENANCE AIR CLEANER Clean every 3 000 km (6 months). If the air cleaner is clogged with dust, intake resistance will be increased, with a resultant decrease in engine output and an increase in fuel consumption. Check and clean the air cleaner elements in the following manner.

  • Page 17: Cylinder Head And Cylinder

    PERIODIC MAINTENANCE CYLINDER HEAD AND CYLINDER Remove carbon every 3 000 km (6 months). 3-13) SPARK PLUG Clean every 3 000 km (6 months). Replace every 6 000 km (12 months). Remove the left side leg shield. ( 5-3) Disconnect the spark plug cap and remove the spark plug. DENSO Standard BPR7HS...
  • Page 18 PERIODIC MAINTENANCE SPARK PLUG GAP Measure the spark plug gap using a thickness gauge. If the spark plug gap is out of specification, adjust the gap. Spark plug gap Standard: 0.6 – 0.7 mm 09900-20804: Thickness gauge 0.6 – 0.7 mm ELECTRODES Check the condition of the electrodes.

  • Page 19: Carburetor

    PERIODIC MAINTENANCE CARBURETOR Inspect Initially at 1 000 km (2 months) and every 3 000 km (6 months) thereafter. ENGINE IDLE SPEED Adjust the throttle cable play. Remove the left side leg shield. ( 5-3) Warm up the engine. NOTE: Make this adjustment when the engine is hot.

  • Page 20: Final Gear Oil

    PERIODIC MAINTENANCE FINAL GEAR OIL Inspect initially at 1 000 km (2 months) and every 6 000 km (12 months) thereafter. Remove the final gear oil level bolt 1 and inspect the oil level. If the oil level is below the brim of the final gear oil level hole, add oil until it runs out from the level hole.

  • Page 21: Brake Hose

    PERIODIC MAINTENANCE BRAKE HOSE Inspect every 3 000 km (6 months). Replace every four years. Check the brake hose for leakage, cracks, wear, and damages. If any damages are found, replace the brake hose with a new one. BRAKE FLUID Inspect every 3 000 km (6 months).
  • Page 22 2-10 PERIODIC MAINTENANCE AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cyl- inder, thus interferes with the full braking performance of the brake caliper.

  • Page 23: Steering

    PERIODIC MAINTENANCE 2-11 STEERING Inspect Initially at 1 000 km (2 months) and every 3 000 km (6 months) thereafter. The steering should be adjusted properly for smooth turning of the handlebar and safe operation. Overtight steering prevents smooth turning of the handlebar and too loose steering will cause poor stability.

  • Page 24: Tires

    2-12 PERIODIC MAINTENANCE TIRES Inspect initially at 1 000 km (2 months) and every 3 000 km (6 months) thereafter. TIRE TREAD CONDITION Operating the motorcycle with excessively worn tires will de- crease riding stability and consequently invite a dangerous situ- ation.

  • Page 25: Cylinder Head Nuts And Exhaust Pipe Nut And Bolt

    PERIODIC MAINTENANCE 2-13 CYLINDER HEAD NUTS AND EXHAUST PIPE NUT AND BOLT Tighten initially at 1 000 km (2 months) and every 3 000 km (6 months) thereafter. Cylinder head nuts, when they are not tightened to the specified torque, may result in leakage of the compressed mixture and reduce output.
  • Page 26 2-14 PERIODIC MAINTENANCE...

  • Page 27: General Lubrication

    PERIODIC MAINTENANCE 2-15 GENERAL LUBRICATION Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. 1 Rear brake lever holder 3 Front brake lever holder 2 Center stand pivot and spring hook 4 Speedometer cable NOTE: Before lubricating each part, remove any rust and wipe off any grease, oil, dirt, or grime.

  • Page 28: Automatic Clutch Inspection

    2-16 PERIODIC MAINTENANCE AUTOMATIC CLUTCH INSPECTION The UF50/UF50Z is equipped with a centrifugal type automatic clutch and a variable ratio belt drive transmission. To insure proper performance and longevity of the clutch as- sembly it is essential that the clutch assembly engages smoothly and gradually.

  • Page 29: Clutch Lock-Up

    PERIODIC MAINTENANCE 2-17 CLUTCH LOCK-UP Perform this inspection to determine if the clutch is engaging fully and not slipping. Remove the trunk. ( 5-4) Connect the multi circuit tester to the high-tension cord. Start the engine. Apply the rear brake as firm as possible. Fully open the throttle for a brief period and note the maxi- mum engine speed sustained during the test cycle.
  • Page 30 ENGINE ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE..................3- 2 ENGINE REMOVAL AND REMOUNTING ............3- 3 ENGINE REMOVAL ..................3- 3 ENGINE REMOUNTING ................3- 5 ENGINE DISASSEMBLY................. 3- 6 ENGINE COMPONENTS INSPECTION AND SERVICE ....... 3-13 CYLINDER HEAD DISTORTION ..............

  • Page 31: Engine Components Removable With The Engine In Place

    ENGINE ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to the page listed in each section for removal reinstallation instructions. ENGINE LEFT SIDE PARTS REMOVAL INSTALLATION...

  • Page 32: Engine Removal And Remounting

    ENGINE ENGINE REMOVAL AND REMOUNTING ENGINE REMOVAL Before taking the engine out of the frame, wash the engine with a steam cleaner. Engine removal is sequentially explained in the following steps. Remove the side leg shields and frame covers. ( 5-3 to 5-5) Disconnect the - battery lead wire.
  • Page 33 ENGINE Remove the rear brake cable holders 1 and adjusting nut 2. Disconnect the air cleaner intake boot. Remove the rear shock absorber lower mounting bolt. Remove the engine mounting nut, shaft, and engine.

  • Page 34: Engine Remounting

    ENGINE ENGINE REMOUNTING Remount the engine in the reverse order of removal. Pay atten- tion to the following points: Install the crankcase bracket 1 to the frame and insert the crankcase bracket mounting shaft. Push down on the rear part of the crankcase bracket and have the damper 2 touch the stopper 3.

  • Page 35: Engine Disassembly

    ENGINE ENGINE DISASSEMBLY Remove the air cleaner. Remove the exhaust pipe/muffler assembly. Disconnect the oil hoses and remove the oil pump.
  • Page 36 ENGINE Remove the oil pump gear 1, intake pipe and carburetor. A: Twist-off bolt Remove the reed valve and gaskets. Remove the cylinder/cylinder head cover 2 and cooling fan cover 3. Remove the cooling fan. Remove the cooling fan case.
  • Page 37 ENGINE Remove the rear fender. Loosen the cylinder head nuts diagonally, as shown, and then remove them. Remove the cylinder head and gasket. Remove the cylinder and gasket. Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into the crankcase.
  • Page 38 ENGINE Remove the kick starter lever 1, clutch cover 2, gaskets, and dowel pins. Hold the generator rotor using the special tool and then re- move the kick starter nut. 09930-40113: Rotor holder Remove the kick starter 3, fixed drive face 4, movable drive face 5, spacers, and washers.
  • Page 39 3-10 ENGINE Remove the starter pinion gear cap 1, starter pinion gear assembly 2, and dowel pins. Drain the final gear oil. Hold the generator rotor using the special tool and then re- move the generator rotor nut. 09930-40113: Rotor holder Remove the generator rotor using the special tool.
  • Page 40 ENGINE 3-11 Remove the rear wheel. Remove the brake shoes. Remove the brake cam lever 1, return spring 2, brake lining wear limit indicator 3, and brake camshaft 4. Remove the gearbox cover. Remove the final driven gear with the rear axle shaft 5, idle shaft/gear 6, and dowel pins 7.
  • Page 41 3-12 ENGINE Remove the driveshaft using the special tool. 09920-13120: Crankcase separating tool Remove the center stand spring 1. Remove the cotter pin 2 and center stand shaft 3. Remove the center stand 4. Remove the crankcase bolts. Separate the left and right crankcases using the special tool. 09920-13120: Crankcase separating tool Remove the gaskets and dowel pins.

  • Page 42: Engine Components Inspection And Service

    ENGINE 3-13 ENGINE COMPONENTS INSPECTION AND SERVICE CYLINDER HEAD DISTORTION Decarbonize the combustion chamber. Check the gasket surface of the cylinder head for distortion. Use a straightedge and thickness gauge. Take clearance readings at several places. If readings exceed the service limit, replace or flatten the cylinder head.

  • Page 43: Piston

    3-14 ENGINE PISTON PISTON DIAMETER Measure the piston diameter using a micrometer at 15 mm from the skirt end. If the piston diameter is less than the service limit, replace the piston with a new one. 09900-20202: Micrometer (25 – 50 mm) Piston diameter Service Limit: 40.885 mm PISTON-TO-CYLINDER CLEARANCE...
  • Page 44 ENGINE 3-15 PISTON PIN AND PIN BORE Measure the piston pin bore inside diameter using the dial cali- pers and the piston pin outside diameter using the micrometer. If either is out of specification or the difference between the mea- surements is more than their limits, replace the piston and pis- ton pin with new ones.

  • Page 45: Crankshaft And Conrod

    3-16 ENGINE CRANKSHAFT AND CONROD 1 Oil seal (R) 2 Bearing (R) 3 Crankshaft (R) 4 Crank pin 5 Crank pin bearing 6 Conrod 7 Crankshaft (L) 8 Spacer 9 Piston pin bearing 0 Bearing (L) A Oil seal (L) B Oil seal CRANKSHAFT RUNOUT Support the crankshaft using V-blocks as shown.

  • Page 46: Reed Valve

    ENGINE 3-17 CONROD DEFLECTION Wear on the big end of the conrod can be estimated by checking the movement of the small end of the rod. This method can also check the extent of wear on the parts of the big end of the conrod. 09900-20701: Magnetic stand 09900-20606: Dial gauge (1/100 mm) 09900-21304: V-block set (100 mm)

  • Page 47: Clutch Shoe/Movable Driven Face

    3-18 ENGINE CLUTCH SHOE/MOVABLE DRIVEN FACE 1 Fixed driven face 0 Oil seal 2 Bearing A Spring 3 Circlip B Clutch shoe assembly 4 Needle roller bearing C Clutch housing 5 Movable driven face D Washer 6 Oil seal ITEM N·m kgf-m A Clutch shoe nut...
  • Page 48 ENGINE 3-19 Remove the clutch shoe assembly 1 and driven face spring 2. Use a thin-blade screwdriver to pry up the movable driven face spring guide. Remove the pins 3, movable driven face 4, and fixed driven face 5. Remove the bearing using the special tools. 09923-73210: Bearing remover 09930-30102: Sliding hammer Replace the removed bearing with a new one.
  • Page 49 3-20 ENGINE Remove the bearing using the special tool. 09941-50111: Bearing remover Replace the removed bearing with a new one. Remove the oil seals 1 and O-rings 2. Replace the removed oil seals and O-rings with new ones. CLUTCH SHOE Inspect the clutch shoe for chips, cracks, uneven wear and burn- ing.
  • Page 50 ENGINE 3-21 DRIVEN FACE SPRING Measure the free length of the driven face spring. If the length is shorter than the service limit, replace the spring with a new one. Driven face spring length Service Limit: 104.5 mm DRIVEN FACE PINS AND OIL SEALS Rotate the driven faces and make sure that they turn smoothly.
  • Page 51 Install the needle roller bearing using the special tool. 09924-84521: Bearing installer NOTE: Face the stamped side of the needle roller bearing out. Apply SUZUKI SUPER GREASE “A” between the sliding sur- face of the fixed driven face and movable driven face. 99000-25010: SUZUKI SUPER GREASE “A” NOTE: When installing the movable face to the fixed face, make sure that the oil seal is positioned properly.

  • Page 52: Movable Drive Face

    ENGINE 3-23 MOVABLE DRIVE FACE 1 Movable drive face 2 Roller 3 Movable drive plate 4 Damper 5 Movable drive face cover 6 Spacer 7 Spacer 8 Drive belt 9 Fixed drive face 0 Washer A Kick starter B Concave washer A Kick starter nut ITEM N·m...
  • Page 53 3-24 ENGINE ROLLER AND SLIDING SURFACE Inspect each roller and its sliding surface for wear or damage. If any damages are found, replace the rollers as a set. DRIVE BELT Remove the drive belt and check for cracks, wear and separa- tion and measure the drive belt width with vernier calipers.

  • Page 54: Kick Starter

    9 Kick starter drive gear DISASSEMBLY Remove the kick starter driven gear 1, kick starter shaft spring 2, and kick starter shaft 3. REASSEMBLY Apply SUZUKI SUPER GREASE “A” onto the inside of the kick starter shaft spacer. 99000-25010: SUZUKI SUPER GREASE “A”...

  • Page 55: Bearings

    3-26 ENGINE Apply a light coat of SUZUKI SUPER GREASE “A” onto the end of the kick starter shaft. 99000-25010: SUZUKI SUPER GREASE “A” Install the kick starter spring and hook its end 1 onto the clutch cover boss 2.
  • Page 56 ENGINE 3-27 Install the rear axle shaft bearing using the special tool. 09913-70210: Bearing installer set RIGHT DRIVESHAFT BEARING AND IDLE SHAFT BEARING Remove the right driveshaft bearing and idle shaft bearing using the special tools. 09921-20210: Bearing remover 09930-30102: Sliding hammer Replace the removed bearings with new ones.

  • Page 57: Oil Seals

    3-28 ENGINE RIGHT CRANKSHAFT BEARING Remove the right crankshaft bearings using the special tools. 09923-73210: Bearing remover 09930-30102: Sliding hammer Replace the removed bearing with a new one. Install the right crankshaft bearing using the special tool. 09913-70210: Bearing installer set LEFT CRANKSHAFT BEARING Remove the left crankshaft bearing using the special tools.
  • Page 58 Install the oil seals into the crankcase and gearbox cover, as shown below. Replace the removed oil seals with new ones. Apply SUZUKI SUPER GREASE “A” to the lip of the oil seals. 99000-25010: SUZUKI SUPER GREASE “A” Be sure to apply THREAD LOCK “1342” to the outer surfaces of the right and left crankshaft oil seals to prevent them from moving.
  • Page 59 3-30 ENGINE Install the drive shaft oil seal into the left crankcase, slowly, using the special tool. 09913-70210: Bearing installer set CRANKSHAFT OIL SEALS Remove the crankshaft oil seals from the left and right crank- case, using the special tool. 09913-50121: Oil seal remover Replace the removed oil seals with new ones.

  • Page 60: Engine Mounting Bushings

    ENGINE 3-31 ENGINE MOUNTING BUSHINGS Inspect each engine mounting bushings 1 and 2 for damage. If any damage is found, replace the engine mounting bushing with a new one. Press out the engine mounting bushings in a vise using two steel tubes of the appropriate size, as shown.

  • Page 61: Engine Reassembly

    3-32 ENGINE ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassembly. The following steps require special attention or precautionary mea- sures should be taken. NOTE: Apply engine oil to each running and sliding part before reas- sembling. CRANKSHAFT Mount the crankshaft into the right crankcase by pulling its right end into the crankcase using the special tools.
  • Page 62 09941-74910: Bearing installer 28.5 mm Apply SUZUKI SUPER GREASE “A” (approximately 10 g) to the oil pump drive gear (on the crankshaft surface side). 99000-25010: SUZUKI SUPER GREASE “A” Install the left crankshaft outer oil seal using the special tool.

  • Page 63: Rear Axle Shaft And Transmission

    3-34 ENGINE REAR AXLE SHAFT AND TRANSMISSION 1 Crankcase 2 Gearbox cover 3 Rear axle shaft/final driven gear 4 Idle shaft/gear 5 Washer 6 Washer 7 Drive shaft Install the idle shaft/gear 1, with the thrust washer 2, into the gearbox. Install the rear axle shaft/final driven gear 3.
  • Page 64 Install the driveshaft 1 and dowel pins 2. Install the gearbox cover. Tighten the bolts, a little at a time, diagonally. Apply a light coat of SUZUKI SUPER GREASE “A” onto the pivoting surface of the brake cam, and then install the brake cam into the crankcase.

  • Page 65: Generator

    3-36 ENGINE Align the tang 1 on the brake lining wear indicator plate 2 with the cutaway 3 on the brake cam. Then, slide the brake lining wear indicator plate onto the brake cam. Install the return spring and brake cam lever onto the brake cam and tighten the brake cam lever nut to the specified torque.

  • Page 66: Starter Pinion And Starter Gear

    Tighten the final gear oil level bolt to the specified torque. Oil level bolt: 12 N·m (1.2 kgf-m) Apply SUZUKI SUPER GREASE “A” onto the starter pinion shaft and install the starter pinion gear assembly 3. 99000-25010: SUZUKI SUPER GREASE “A”...

  • Page 67: Drive Belt

    3-38 ENGINE DRIVE BELT Insert the drive belt, as low as possible, between the clutch shoe/movable driven face while pulling out the driven face to provide the maximum drive belt clearance. The drive belt contact surface of the driven face should be thoroughly cleaned.

  • Page 68: Piston

    ENGINE 3-39 Install the dowel pins 1 and new gaskets 2. Install the clutch cover 3 and kick starter lever 4. PISTON Install the piston rings onto the piston. 1st: Keystone ring 2nd: Rectangular ring and expander ring NOTE: The piston rings should be installed with the mark facing up. Position the piston ring gaps, as shown.

  • Page 69: Cylinder

    Tighten the cylinder head nuts diagonally, as shown, and to the specified torque. Cylinder head nut: 10 N·m (1.0 kgf-m) OIL PUMP GEAR Apply SUZUKI SUPER GREASE “A” onto the oil pump gear, and then install it. 99000-25010: SUZUKI SUPER GREASE “A” INTAKE PIPE Install the intake pipe and tighten the bolts securely.

  • Page 70: Fuel And Lubrication System

    FUEL AND LUBRICATION SYSTEM FUEL AND LUBRICATION SYSTEM CONTENTS FUEL VALVE ....................4- 2 FUEL TANK AND OIL TANK ................4- 3 REMOVAL ....................4- 3 REMOUNTING .................... 4- 4 FUEL TANK CUSHIONS ................4- 5 CARBURETOR ....................4- 6 CONSTRUCTION ..................

  • Page 71: Fuel Valve

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

  • Page 72: Fuel Tank And Oil Tank

    FUEL AND LUBRICATION SYSTEM FUEL TANK AND OIL TANK REMOVAL Gasoline is highly flammable and explosive. Keep heat, sparks, and flames away from gasoline. Remove the frame cover. ( 5-4 and 5-5) Disconnect the turn signal light lead wires 1 and license plate light coupler 2.

  • Page 73: Remounting

    FUEL AND LUBRICATION SYSTEM Remove the fuel tank cap 1 and fuel tank 2. NOTE: After removing the fuel tank, reinstall the fuel tank cap. Disconnect the oil hose 3, oil level indicator switch coupler 4, and remove the oil tank 5. REMOUNTING Remount the fuel tank and oil tank in the reverse order of re- moval.

  • Page 74: Fuel Tank Cushions

    FUEL AND LUBRICATION SYSTEM FUEL TANK CUSHIONS Cushion 80 mm 20 mm VIEW A 15 mm Cushion VIEW B...

  • Page 75: Carburetor

    FUEL AND LUBRICATION SYSTEM CARBURETOR CONSTRUCTION 1 Top cap 2 Throttle valve spring 3 Jet needle 4 Throttle valve 5 Thermoelement 6 Carburetor body 7 Pilot air screw 8 Throttle stop screw 9 Needle valve 0 Float pin A Float B Needle jet C Needle jet holder D Slow jet...

  • Page 76: Specifications

    FUEL AND LUBRICATION SYSTEM SPECIFICATIONS ITEM SPECIFICATION Carburetor type KEIHIN PWS14 Bore size 14 mm I.D. No. 30F0 Idle r/min 1 900 ± 200 r/min Float height 5.1 ± 0.5 mm Main jet (M.J.) # 65 Jet needle (J.N.) N5GJ-2nd Slow jet (S.J.) # 42...

  • Page 77: Removal

    FUEL AND LUBRICATION SYSTEM REMOVAL Remove the trunk. ( 5-4) Remove the clamps, disconnect the thermoelement coupler 1 and carburetor heater lead wire 2. Disconnect the vacuum hose 3 and fuel hose 4. Loosen the carburetor clamp screw and remove the carbure- tor mounting bolts.
  • Page 78 FUEL AND LUBRICATION SYSTEM Separate the jet needle 1 and throttle valve 2. Remove the each carburetor hoses. Remove the float chamber 3. Remove the float 4 and needle valve 5 by removing the float pin 6. When removing the float pin, be careful not to damage the carburetor body and float.
  • Page 79 4-10 FUEL AND LUBRICATION SYSTEM Remove the thermoelement cover 1 and remove the ther- moelement 2. Do not disassemble the thermoelement. It is not ser- viceable. Remove the carburetor heater.

  • Page 80: Cleaning

    FUEL AND LUBRICATION SYSTEM 4-11 CLEANING Some carburetor cleaning chemicals, especially dip- type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions for proper use, handling and storage. Clean all jets with a spray-type carburetor cleaner and dry them using compressed air.

  • Page 81: Reassembly

    4-12 FUEL AND LUBRICATION SYSTEM FLOAT HEIGHT ADJUSTMENT To check the float height, turn the carburetor upside down. Mea- sure the float height A while the float arm is just contacting the needle valve using vernier calipers. Bend the tongue as neces- sary to bring the float height A to the specified value.

  • Page 82: Oil Pump

    Remove the trunk. ( 5-4) Fill the CCI oil gauge with SUZUKI CCI SUPER OIL. Connect the oil gauge to the suction side of the oil pump. Run the engine at 3 000 r/min. Keep the engine speed at 3 000 r/min and allow the pump to draw for five minutes.
  • Page 83 CHASSIS CHASSIS CONTENTS EXTERIOR PARTS ...................... 5- 2 CONSTRUCTION ....................5- 2 REMOVAL ....................... 5- 3 REMOUNTING ......................5- 5 FRONT WHEEL ......................5- 6 CONSTRUCTION ....................5- 6 REMOVAL ....................... 5- 6 INSPECTION AND DISASSEMBLY ............... 5- 7 REASSEMBLY AND REMOUNTING ..............5- 8 FRONT BRAKE ......................

  • Page 84: Exterior Parts

    CHASSIS EXTERIOR PARTS CONSTRUCTION...

  • Page 85: Removal

    CHASSIS REMOVAL LEG SHIELD Remove the battery. ( 6-30) Remove the side leg shields 1. Remove the frame cover. Remove the footboard 2. Remove the cover 3. Remove the front leg shield mounting screws. Disconnect the headlight lead wires 4 and remove the front leg shield 5.
  • Page 86 CHASSIS Remove the lower leg shield 1. Remove the ignition switch cap 2. Remove the leg shield 3. SEAT Remove the seat 1. FRAME COVER Remove the seat. Remove the side leg shield. ( 5-3) Remove the trunk 1 and fuel tank cap 2.

  • Page 87: Remounting

    CHASSIS Remove the upper fuel tank cover 1. After removing the upper fuel tank cover, reinstall the fuel tank cap. Remove the passenger grab handle 2. Remove the frame cover mounting screw. Disconnect the seat lock cable 3, brake light/taillight lead wires 4, and remove the frame cover 5.

  • Page 88: Front Wheel

    CHASSIS FRONT WHEEL CONSTRUCTION 1 Front axle 2 Spacer 3 Brake disc 4 Bearing 5 Front wheel 6 Spacer 7 Speedometer gearbox A Front axle nut B Brake disc bolt ITEM N·m kgf-m REMOVAL Disconnect the speedometer cable 1. Remove the front axle nut 2. Raise the front wheel off the ground by raising the motorcycle with a jack or wooden block.

  • Page 89: Inspection And Disassembly

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

  • Page 90: Reassembly And Remounting

    Reassemble and remount the front wheel in the reverse order of removal and disassembly. Pay attention to the following points: WHEEL BEARINGS Apply SUZUKI SUPER GREASE “A” to the wheel bearings. 99000-25010: SUZUKI SUPER GREASE “A” Install the wheel bearings using the special tool.
  • Page 91 99000-32130: THREAD LOCK SUPER “1360” Brake disc mounting bolt: 23 N·m (2.3 kgf-m) SPEEDOMETER GEARBOX Apply SUZUKI SUPER GREASE “A” to the teeth of the speed- ometer gear before installing the speedometer gearbox. 99000-25010: SUZUKI SUPER GREASE “A” Align the grooves 1 on the speedometer gearbox with the lugs 2 on the wheel hub.

  • Page 92: Front Brake

    5-10 CHASSIS FRONT BRAKE CONSTRUCTION 1 Cap 2 Diaphragm 3 Master cylinder 4 Piston set 5 Push rod 6 Dust boot 7 Brake hose 8 Caliper 9 Piston 0 Piston and dust seal A Shim B Pad set C Pad mounting pin D O-ring A Master cylinder mounting bolt B Brake hose union bolt...

  • Page 93: Brake Pads Replacement

    CHASSIS 5-11 BRAKE PADS REPLACEMENT Remove the brake caliper mounting bolts 1. Remove the brake pad mounting pins 2 and brake pads. Do not operate the brake lever during or after brake pad removal. Measure the thickness A of the brake pads. If the brake pad thickness is below the service limit, replace the brake pads with new ones.

  • Page 94: Brake Fluid Replacement

    5-12 CHASSIS BRAKE FLUID REPLACEMENT Place the motorcycle on a level surface and keep the handle- bar straight. Remove the master cylinder reservoir cap and diaphragm. Suck up the old brake fluid as much as possible. Fill the reservoir with fresh brake fluid. Specification and classification: DOT 4 Connect a clear hose to the air bleeder valve and insert the other end of the hose into a receptacle.

  • Page 95: Brake Caliper Inspection

    CHASSIS 5-13 Remove the brake pads. ( 5-11) Remove the brake caliper housing bolts. Separate the brake caliper. Remove the O-ring. Do not reuse the O-ring to prevent fluid leakage. Place a rag over the brake caliper pistons to prevent them from popping out, and then force out the piston using com- pressed air.

  • Page 96: Brake Caliper Reassembly And Remounting

    5-14 CHASSIS BRAKE CALIPER REASSEMBLY AND REMOUNTING Reassemble and remount the brake caliper in the reverse order of removal and disassembly. Pay attention to the following points: Wash the caliper bores and brake caliper pistons with the specified brake fluid. Thoroughly wash the dust seal grooves and piston seal grooves.

  • Page 97: Brake Disc Inspection

    CHASSIS 5-15 BRAKE DISC INSPECTION Remove the front wheel. ( 5-6) Check the brake disc for cracks or damage and measure the thickness using the micrometer. If the thickness is less than the service limit or if any damages are found, replace the brake disc with a new one.

  • Page 98: Master Cylinder Inspection

    5-16 CHASSIS Remove the brake lever and brake light switch. Remove the dust boot and push rod. Remove the circlip. Remove the piston/secondary cup 1 and return spring 2. Remove the master cylinder reservoir cap 3 and diaphragm 4. Drain the brake fluid. MASTER CYLINDER INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or other dam-...

  • Page 99: Master Cylinder Reassembly And Remounting

    CHASSIS 5-17 PISTON Inspect the piston surface for any scratches or other damage. If any damages are found, replace the piston with a new one. RUBBER PARTS Inspect the primary cup, secondary cup and dust seal for wear or damage. If any damages are found, replace the piston/sec- ondary cup, and dust seal with new ones.

  • Page 100: Front Suspension

    5-18 CHASSIS FRONT SUSPENSION CONSTRUCTION 1 Damper 2 Upper spring 3 Inner tube 4 Lower spring 5 Upper circlip 6 Bushing 7 Lower circlip 8 Dust seal 9 Brake caliper bracket A Brake caliper bracket mounting bolt ITEM N·m kgf-m REMOVAL AND DISASSEMBLY Remove the front wheel.
  • Page 101 CHASSIS 5-19 Remove the lower circlip 1. Replace the removed lower circlip with a new one. Remove the lower bushing 2. NOTE: When removing the lower bushing 2 , pull the inner tube 3 down. Remove the upper circlip 4, lower spring 5, and inner tube 6. Replace the removed upper circlip with a new one.

  • Page 102: Inspection

    Pay attention to the following points: DAMPER AND SPRING Apply SUZUKI SUPER GREASE “A” (15 g) to the damper and springs. 99000-25010: SUZUKI SUPER GREASE “A” When installing the upper spring 1 and damper 2, face the smaller diameter end of the upper spring and the hollow end of the damper towards the wheel.
  • Page 103 CHASSIS 5-21 UPPER CIRCLIP Install the circlip 1 into the groove 2. Replace the upper circlip with a new one. The rounded side on the circlip must face upward. After installing the upper circlip, make sure that it is properly seated in the groove. BUSHING Install the lower bushing 3 using the special tool.

  • Page 104: Handlebar Covers And Speedometer Assembly

    5-22 CHASSIS HANDLEBAR COVERS AND SPEEDOMETER ASSEMBLY CONSTRUCTION 1 Front handlebar cover 2 Rear handlebar cover...

  • Page 105: Removal

    CHASSIS 5-23 REMOVAL Remove the rear view mirrors 1. Remove the front handlebar cover 2. Disconnect the front turn signal light lead wires. Disconnect the speedometer cable 3 and speedometer cou- plers 4. Remove the speedometer assembly 5. Disconnect the handlebar switch couplers.

  • Page 106: Remounting

    5-24 CHASSIS Remove the rear handlebar cover 1. 94P50730 REMOUNTING Remount the handlebar covers and the speedometer assembly in the reverse order of removal.

  • Page 107: Steering Stem

    CHASSIS 5-25 STEERING STEM CONSTRUCTION 1 Handlebar 2 Washer 3 Steering stem nut 4 Inner upper race 5 Inner lower race 6 Steel ball 7 Outer lower race 8 Steering stem A Handlebar clamp nut B Handlebar set bolt C Steering stem locknut ITEM N·m kgf-m...
  • Page 108 5-26 CHASSIS Remove the throttle cable 1 and throttle grip 2. Remove the brake hose 3 and speedometer cable 4. Remove the rear brake cable 5. Disconnect the rear brake light switch lead wires 6. Remove the handlebar. Remove the steering stem locknut using the special tool. 09910-60611: Universal clamp wrench...

  • Page 109: Inspection

    CHASSIS 5-27 Remove the washer 1 and steering stem nut 2. Remove the steering stem. NOTE: Hold the steering stem bracket to prevent it from falling. Remove the upper and lower steel balls. Steel balls Upper : 25 pcs Lower : 30 pcs INSPECTION Inspect the removed parts for the following abnormalities.

  • Page 110: Reassembly And Remounting

    Press in the upper and lower races using the special tool. 09941-34513: Steering inner race installer STEEL BALLS Apply SUZUKI SUPER GREASE “A” to the steering races when installing the upper and lower steel balls. 99000-25010: SUZUKI SUPER GREASE “A”...
  • Page 111 CHASSIS 5-29 Finger tighten the handlebar set bolt 1 and handlebar clamp nut 2, and then tighten them to the specified torque. Handlebar set bolt: 25 N·m (2.5 kgf-m) Handlebar clamp nut: 50 N·m (5.0 kgf-m) NOTE: Hold the front fork legs, move them back and forth and make sure that the steering is not loose.

  • Page 112: Rear Wheel, Rear Brake, And Rear Shock Absorber

    5-30 CHASSIS REAR WHEEL, REAR BRAKE, AND REAR SHOCK ABSORBER CONSTRUCTION 1 Rear wheel 2 Brake shoe 3 Brake cam 4 Return spring 5 Brake lining wear indicator plate 6 Brake cam lever 7 Rear shock absorber ITEM N·m kgf-m 12.0 A Rear axle nut B Rear brake cam lever nut...

  • Page 113: Inspection

    CHASSIS 5-31 REAR SHOCK ABSORBER Remove the frame cover. ( 5-4 and 5-5) Remove the rear shock absorber. INSPECTION BRAKE DRUM Inspect the brake drum and measure the brake drum I.D. to de- termine the extent of wear. If the measurement exceeds the ser- vice limit, replace the brake drum with a new one.

  • Page 114: Reassembly And Remounting

    Reassemble and remount the rear wheel, rear brake, and rear shock absorber in the reverse order of removal and disassem- bly. Pay attention to the following points: Apply SUZUKI SUPER GREASE “A” to the brake cam and pin, and then install the brake shoes. 99000-25010: SUZUKI SUPER GREASE “A”...

  • Page 115: Tires And Wheels

    CHASSIS 5-33 TIRES AND WHEELS TIRE REMOVAL The most critical factor of a tubeless tire is the seal between the wheel rim and the tire bead. Because of this, we recommended using a tire changer that can satisfy this sealing requirement and can make the operation efficient as well as functional.

  • Page 116: Installation

    5-34 CHASSIS VALVE Inspect the valve 1 for damage. If the seal rubber is peeling or damaged, replace the valve with a new one. NOTE: If the external appearance of the valve shows no abnormal con- dition, removing the valve is not necessary. Inspect the valve core seal 2 for deformation or damage.
  • Page 117 CHASSIS 5-35 TIRE Apply a special tire lubricant to the tire bead. When installing the tire, make sure the arrow 1 faces the direction of wheel rotation and align the balancing. Replace the removed valve with a new one. The tire is designed to have specified rotational direction. Never apply oil, grease, or gasoline to the tire bead.
  • Page 118 5-36 CHASSIS After the tire is properly seated to the wheel rim, inflate the tire to the recommended pressure. Correct the wheel balance if necessary. Do not inflate the tire to more than 400 kPa (4.0 kgf/ ). The tire could burst with sufficient force to cause severe injury.

  • Page 119: Electrical System

    ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ........................... 6- 2 CONNECTOR ............................6- 2 COUPLER ..............................6- 2 CLAMPS ..............................6- 2 FUSE ................................ 6- 2 SEMICONDUCTOR EQUIPPED PARTS ....................6- 2 CONNECTING THE BATTERY ....................... 6- 3 WIRING PROCEDURE ..........................6- 3 USING THE MULTI CIRCUIT TESTER ....................

  • Page 120: Fuse

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

  • Page 121: Connecting The Battery

    ELECTRICAL SYSTEM CONNECTING THE BATTERY When disconnecting terminals from the battery for disassem- bly or servicing, be sure to disconnect the - battery lead wire, first. When connecting the battery lead wires, be sure to connect the + battery lead wire, first. If the terminal is corroded, remove the battery, pour warm water over it and clean it with a wire brush.

  • Page 122: Location Of Electrical Components

    ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS 1 Fuel level indicator switch 2 Thermoswitch 3 Oil level indicator switch 4 CDI unit 5 Right handlebar switch 6 Horn 7 Turn signal relay 8 Resistor 9 Regulator/rectifier 0 Generator A Starter motor...
  • Page 123 ELECTRICAL SYSTEM B Left handlebar switch C Ignition switch D Thermoelement E Carburetor heater F Battery G Fuse H Starter relay I Ignition coil...

  • Page 124: Charging And Lighting System

    ELECTRICAL SYSTEM CHARGING AND LIGHTING SYSTEM DESCRIPTION The charging system for this motorcycle uses a generator, as shown below. The charging and lighting coils are mounted on the generator stator and generate AC current as the generator rotor turns. The AC current, which is generated in the charging coil, is converted by the regulator/rectifier into DC current.

  • Page 125: Troubleshooting

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

  • Page 126: Inspection

    ELECTRICAL SYSTEM INSPECTION BATTERY CURRENT LEAKAGE Turn the ignition switch to the “OFF” position. Remove the battery holder cover. ( 6-30) Disconnect the - battery lead wire. Measure the battery current between the - battery terminal and the - battery lead wire using the multi circuit tester. If the read- ing exceeds the specified value, leakage is evident.
  • Page 127 ELECTRICAL SYSTEM STATOR COIL RESISTANCE Remove the trunk. ( 5-4) Disconnect the generator coupler 1. Measure the resistance between the lead wires using the multi circuit tester. If the resistance is not within the specified value, replace the stator coil with a new one. 09900-25008: Multi circuit tester set Tester knob indication: Resistance (Ω...

  • Page 128: Starter System

    6-10 ELECTRICAL SYSTEM STARTER SYSTEM DESCRIPTION The starter system consists of the following components: the starter motor, starter relay, starter button, brake light switches (front and rear brakes), ignition switch, and battery. Pressing the starter button, while squeezing the front or rear brake lever, energizes the starter relay, causing the contact points to close, thus, completing the circuit from the starter motor to the battery.

  • Page 129: Starter Motor Removal And Disassembly

    ELECTRICAL SYSTEM 6-11 Measure the starter relay voltage at the starter relay connectors (between W and Y/G No voltage • Faulty ignition switch when the starter button is pushed. • Faulty starter button • Faulty brake light switches (front and rear brakes) •...

  • Page 130: Starter Motor Inspection

    6-12 ELECTRICAL SYSTEM Disassemble the starter motor, as shown. STARTER MOTOR INSPECTION CARBON BRUSHES Inspect the carbon brushes for abnormal wear, cracks, or smooth- ness in the brush holder. If any damages are found, replace the brush assembly with a new one. COMMUTATOR Inspect the commutator for discoloration, abnormal wear, or un- dercut A.

  • Page 131: Starter Motor Reassembly

    STARTER MOTOR REASSEMBLY Reassemble the starter motor in the reverse order of disassem- bly. Pay attention to the following point: Apply a small quantity of SUZUKI MOLY PASTE to the arma- ture shaft. 99000-25140: SUZUKI MOLY PASTE STARTER RELAY INSPECTION Remove the battery holder cover.

  • Page 132: Ignition System

    6-14 ELECTRICAL SYSTEM IGNITION SYSTEM DESCRIPTION In the capacitor discharged ignition system, the battery’s electrical energy charges the capacitor. This en- ergy is released in a single surge at the specified ignition timing point and the current flows through the primary side of the ignition coil.
  • Page 133 ELECTRICAL SYSTEM 6-15 Measure the ignition coil primary peak voltage. 6-16) Inspect the spark plug. NOTE: The ignition coil peak voltage Correct 2-5 and 2-6) inspection method is applicable only with the multi circuit tester and the peak volt adaptor. Correct Incorrect Correct...

  • Page 134: Inspection

    6-16 ELECTRICAL SYSTEM INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE Remove the left side leg shield. ( 5-3) Remove the spark plug cap and spark plug. Connect a new spark plug to the spark plug cap and ground it to the crankcase. NOTE: Make sure that the spark plug cap and spark plug are connected properly.
  • Page 135 ELECTRICAL SYSTEM 6-17 IGNITION COIL RESISTANCE Remove the footboard. ( 5-3) Disconnect the ignition coil coupler 1. Measure the ignition coil resistance in both the primary and sec- ondary windings using the multi circuit tester. If the resistance in both the primary and secondary windings is close to the speci- fied values, the windings are in sound condition.
  • Page 136 6-18 ELECTRICAL SYSTEM Remove the trunk. ( 5-4) Disconnect the generator coupler 1. Connect the multi circuit tester with the peak volt adaptor as follows. Brown (- Probe) – White (+ Probe) Measure the pickup coil peak voltage in the same manner as on the CDI unit coupler.

  • Page 137: Fuel Level Indicator Switch

    ELECTRICAL SYSTEM 6-19 FUEL LEVEL INDICATOR SWITCH Fuel level indicator light Ignition switch Fuse Battery Fuel level indicator switch INSPECTION Remove the trunk. ( 5-4) Turn the ignition switch to the “ON” position, and disconnect the fuel level indicator coupler 1 going into the fuel level indi- cator switch, connect the lead wires from the main wiring har- ness with a jumper lead and check whether the fuel level indi- cator light comes on.

  • Page 138: Oil Level Indicator Switch

    6-20 ELECTRICAL SYSTEM Connect a 12 V battery to the fuel level indicator switch and ground it through a 2 W bulb. The bulb should light up after several seconds if the switch is in good condition. Test bulb When the switch is immersed in water under the above condi- 12 V 2 W tion, the bulb should go out.

  • Page 139: Thermoelement, Carburetor Heater, And Thermoswitch

    ELECTRICAL SYSTEM 6-21 THERMOELEMENT, CARBURETOR HEATER, AND THERMOSWITCH Resistor Thermo- Regulator/ Thermo- Carburetor element rectifier switch heater Generator INSPECTION THERMOELEMENT Remove the trunk. ( 5-4) Disconnect the thermoelement coupler 1 and remove the thermoelement 2. Connect the thermoelement lead wires to a 12 V battery. Wait five minutes and feel the thermoelement to see if it has reached approximately 36°C.
  • Page 140 6-22 ELECTRICAL SYSTEM CARBURETOR HEATER Remove the trunk. ( 5-4) Disconnect the carburetor heater lead wire and remove the carburetor heater 1. Measure the resistance between the terminals using the multi circuit tester. If the resistance is not within the specified value, replace the carburetor heater with a new one.

  • Page 141: Speedometer

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

  • Page 142: Lamps

    6-24 ELECTRICAL SYSTEM LAMPS HEADLIGHT Headlight bulb: 12 V 35/35 W HEADLIGHT BULB REPLACEMENT Remove the front leg shield. ( 5-3) Remove the headlight bulb. If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy wa- ter to prevent premature bulb failure.

  • Page 143: Front And Rear Turn Signal Light

    ELECTRICAL SYSTEM 6-25 FRONT AND REAR TURN SIGNAL LIGHT Turn signal light: 12 V 10 W FRONT AND REAR TURN SIGNAL LIGHT BULB REPLACEMENT Remove the front turn signal light lens 1 and rear turn signal light lens 2. Remove the front turn signal light bulb 3 and rear turn signal light bulb 4.

  • Page 144: Brake Light/Taillight

    6-26 ELECTRICAL SYSTEM BRAKE LIGHT/TAILLIGHT Brake light/taillight: 12 V 21/5 W BRAKE LIGHT/TAILLIGHT BULB REPLACEMENT Remove the brake light/taillight lens. Remove the brake light/taillight bulb. If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy wa- ter to prevent premature bulb failure.

  • Page 145: License Plate Light

    ELECTRICAL SYSTEM 6-27 LICENSE PLATE LIGHT License plate light: 12 V 5 W LICENSE PLATE LIGHT BULB REPLACEMENT Remove the license plate light case mounting screw. Remove the license plate light case. Remove the license plate light bulb. If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy wa- ter to prevent premature bulb failure.

  • Page 146: Relays

    6-28 ELECTRICAL SYSTEM RELAYS STARTER RELAY The starter relay is located behind the battery holder cover. 6-30) TURN SIGNAL RELAY The turn signal relay is located behind the front leg shield. 5-3) If the turn signal light does not light, inspect the bulb or repair the circuit connection.

  • Page 147: Switches

    ELECTRICAL SYSTEM 6-29 SWITCHES Measure each switch for continuity using the multi circuit tester. If there is no continuity, replace the respec- tive switch with a new one. IGNITION SWITCH HORN BUTTON Color Color Bl/W Position Position ON ( PUSH C ( •...

  • Page 148: Battery

    6-30 ELECTRICAL SYSTEM BATTERY REMOVAL Remove the battery holder cover 1. Remove the battery. NOTE: Disconnect the - battery lead wire, first. REMOUNTING Remount the battery in the reverse order of removal.

  • Page 149: Specifications

    ELECTRICAL SYSTEM 6-31 SPECIFICATIONS Type designation CB4L-B, FB4L-B Capacity 12 V, 14.4 kC (4 Ah)/10 HR Standard electrolyte 1.280 at 20°C (Specific gravity) When installing the battery onto the motorcycle, connect the breather tube to the battery vent. INITIAL CHARGING FILLING ELECTROLYTE Remove the short sealed tube.

  • Page 150: Servicing

    6-32 ELECTRICAL SYSTEM SERVICING Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, clean the battery terminals with sandpa- per.

  • Page 151: Service Life

    ELECTRICAL SYSTEM 6-33 SERVICE LIFE Lead oxide is on the plates of the battery and will gradually come off of the plates during the life of the battery. When the bottom of the battery case becomes full of this sediment, replace the bat- tery.

  • Page 152: Servicing Information

    SERVICING INFORMATION SERVICING INFORMATION CONTENTS TROUBLESHOOTING ..................7- 2 ENGINE ......................7- 2 CARBURETOR .................... 7- 4 CHASSIS ...................... 7- 5 BRAKES ....................... 7- 6 ELECTRICAL ....................7- 7 BATTERY ...................... 7- 8 WIRING DIAGRAM ................... 7- 9 WIRE HARNESS, CABLE, AND HOSE ROUTING ......... 7-10 WIRE HARNESS ..................

  • Page 153: Troubleshooting

    SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. 1. Worn cylinder. Replace. 2. Worn piston ring. Repair or replace. 3. Gas leaks from the joint in crankcase, cylinder or cylin- Repair or replace.
  • Page 154 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine idles poorly. 1. Worn cylinder. Replace. 2. Worn piston rings. Replace. 3. Stiff piston ring. Replace. 4. Gas leaks from crankshaft oil seal. Replace. 5. Excessive spark plug gap. Adjust or replace. 6.

  • Page 155: Carburetor

    SERVICING INFORMATION CARBURETOR Complaint Symptom and possible causes Remedy Starting difficulty. 1. Defective thermoelement. Replace. 2. Air leaking from the joint between intake pipe and car- Check intake pipe and car- buretor. buretor for tightness, and re- place gasket. 3. Air leaking from carburetor joint or vacuum hose joint. Tighten or replace the defec- tive part.

  • Page 156: Chassis

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

  • Page 157: Brakes

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

  • Page 158: Electrical

    SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy Replace. No sparking or poor 1. Defective ignition coil. Replace. sparking. 2. Defective spark plug. Replace. 3. Defective stator coil or pickup coil. Replace. 4. Defective CDI unit. Connect or tighten. 5.

  • Page 159: Battery

    SERVICING INFORMATION BATTERY Complaint Symptom and possible causes Remedy Sulfation, acidic white 1. Insufficient electrolyte. Add distilled water, if the bat- powdery substance tery has not been damaged or spots on surfaces and sulfation has not ad- of cell plates. vanced too far, then re- charge.

  • Page 160: Wiring Diagram

    SERVICING INFORMATION WIRING DIAGRAM...

  • Page 161: Wire Harness, Cable, And Hose Routing

    7-10 SERVICING INFORMATION WIRE HARNESS, CABLE, AND HOSE ROUTING WIRE HARNESS 1 Set the wires under the bracket seat striker and the tube frame.
  • Page 162 SERVICING INFORMATION 7-11...

  • Page 163: Cable Routing

    7-12 SERVICING INFORMATION CABLE ROUTING...
  • Page 164 SERVICING INFORMATION 7-13...

  • Page 165: Fuel System Hose Routing

    7-14 SERVICING INFORMATION FUEL SYSTEM HOSE ROUTING...

  • Page 166: Battery Breather Hose Routing

    SERVICING INFORMATION 7-15 BATTERY BREATHER HOSE ROUTING Forward Cushion Battery Forward Slit position Breather hose NOTE: The slit on the breather hose must face battery side.

  • Page 167: Front Brake Hose Routing

    7-16 SERVICING INFORMATION FRONT BRAKE HOSE ROUTING...

  • Page 168: Special Tools

    SERVICING INFORMATION 7-17 SPECIAL TOOLS 09900-00401 09900-20101 Hexagon wrench 09900-06107 09900-06108 09900-09003 Vernier calipers Snap ring pliers Snap ring pliers Impact driver set (150 mm) 09900-20202 09900-20205 09900-20508 09900-20606 Micrometer Micrometer Cylinder bore 09900-20605 Dial gauge (25 – 50 mm) (0 –...
  • Page 169 7-18 SERVICING INFORMATION 09921-20220 09924-84521 Bearing remover 09923-73210 09923-74510 09930-30102 Bearing installer Bearing remover Bearing remover Sliding hammer 09930-40131 09940-52860 09941-34513 09930-40113 Rotor holder Front fork oil seal Steering inner race 09941-50111 Rotor holder attachment installer installer Bearing remover 09943-88211 09941-74910 Bearing remover/ Bearing installer...

  • Page 170: Tightening Torque

    SERVICING INFORMATION 7-19 TIGHTENING TORQUE ENGINE ITEM N·m kgf-m Cylinder head nut Spark plug Exhaust pipe mounting nut and bolt Engine mounting bracket nut Engine mounting nut Clutch housing nut Kick starter nut Generator rotor nut Clutch shoe nut Kick starter lever bolt Final gear oil drain bolt 0.55 Final gear oil level bolt...

  • Page 171: Tightening Torque Chart

    7-20 SERVICING INFORMATION TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt A (mm) N·m kgf-m N·m kgf-m 0.15 0.23 0.45 0.55 13.5 10.5...
  • Page 172 SERVICING INFORMATION 7-21 SERVICE DATA CYLINDER + PISTON + PISTON RING Unit: mm ITEM STANDARD LIMIT 0.06 – 0.07 0.120 Piston to cylinder clearance Cylinder bore 41.005 – 41.020 41.075 Measure at 20 mm from the top surface Piston diameter 40.940 –...
  • Page 173 7-22 SERVICING INFORMATION TRANSMISSION Unit: mm Except ratio ITEM STANDARD LIMIT Reduction ratio Variable 2.975 – 1.033 — 13.812 (51/15 × 65/16) Final reduction ratio — Drive belt width 18.4 17.4 Driven face spring free length 104.5 CARBURETOR ITEM SPECIFICATION Carburetor type KEIHIN PWS14 Bore size...

  • Page 174: Turn Signal Light

    SERVICING INFORMATION 7-23 ELECTRICAL Unit: mm ITEM SPECIFICATION NOTE Spark plug NGK: BPR7HS Type DENSO: W22FPR 0.6 – 0.7 Spark performance Over 8 at 1 atm. 0.2 – 1.5 Ω Ignition coil resistance Primary W/Bl – B/W Secondary 10 – 20 kΩ Plug cap-B/W Ignition coil primary peak voltage +: Ground...
  • Page 175 7-24 SERVICING INFORMATION BRAKE + WHEEL Unit: mm ITEM STANDARD/SPECIFICATION LIMIT Brake lever play Rear 15 – 25 — Brake drum I.D. Rear — 120.7 Brake disc thickness Front 4.0 ± 0.2 Brake disc runout Front — 0.30 Master cylinder bore Front 11.000 –...

  • Page 176: Fuel Tank

    Use only gasoline that is graded 91 octane or higher. Unleaded gasoline is recommended. Fuel tank capacity 6.0 L Engine oil type Use SUZUKI CCI SUPER OIL. If not available, use a good quality 2-stroke oil rated FC under JASO classification. Engine oil tank capacity 1.2 L...

  • Page 177: Uf50K1 And Uf50Zk1 ('01-Model)

    UF50K1 AND UF50ZK1 (’01-MODEL) UF50K1 AND UF50ZK1 (’01-MODEL) CONTENTS SPECIFICATIONS .................... 8- 2 SERVICE DATA ....................8- 4 WIRE HARNESS ROUTING ................8- 7...

  • Page 178: Dimensions And Dry Mass

    Corrected compression ratio ......7.2:1 Carburetor ............KEIHIN PWS14 Air cleaner ............Polyurethane foam element Starter system ..........Electric and kick Lubrication system ........... SUZUKI “CCI” TRANSMISSION Clutch ............... Dry shoe, automatic, centrifugal type Gearshifting ............. Automatic, variable ratio Gear ratios ............Variable reduction ratio... (2.975 – 1.033) Final reduction ratio .........
  • Page 179 UF50K1 AND UF50ZK1 (’01-MODEL) CHASSIS Front suspension ..........Inverted telescopic, coil spring Rear suspension ..........Swingarm type, coil spring, oil damped Steering angle..........45° (right & left) Caster .............. 25°30’ Trail ..............82 mm Turning radius ..........1.9 m Front brake ............Disc brake Rear brake ............

  • Page 180: Service Data

    UF50K1 AND UF50ZK1 (’01-MODEL) SERVICE DATA CYLINDER + PISTON + PISTON RING Unit: mm ITEM STANDARD LIMIT Piston to cylinder 0.06 – 0.07 0.120 clearance Cylinder bore 41.005 – 41.020 41.075 Measure at 20 mm from the top surface Piston diam. 40.940 –...
  • Page 181 UF50K1 AND UF50ZK1 (’01-MODEL) CARBURETOR ITEM SPECIFICATION Carburetor type KEIHIN PWS14 Bore size 14 mm I.D. No. 30F0 Idle r/min. 1 900 ± 200 r/min. Float height 5.1 ± 0.5 mm Main jet (M.J.) Jet needle (J.N.) N5GJ-2nd Slow jet (S.J.) Air screw (A.S.)

  • Page 182: Brake Disc

    Fuel type higher. An unleaded gasoline is recommended. Fuel tank capacity 6.0 L Use SUZUKI CCI SUPER OIL. If they are not Engine oil type available, use a good quality 2-stroke oil rated FC under JASO classification. Engine oil tank capacity 1.2 L...
  • Page 183 UF50K1 AND UF50ZK1 (’01-MODEL) WIRE HARNESS ROUTING 1 Set the wires under the bracket seat striker and the tube frame. Brake light/taillight W (White) lead wire Clamp Brake light/taillight coupler Gr (Gray) lead wire B/W (Black with White tracer) lead wire VIEW License plate light Rear turn signal light...
  • Page 184 Prepared by Motorcycle Service Department 2nd Ed. March, 2001 1st Ed. April, 2000 Part No. 99500-10491-01E Printed in Japan...
  • Page 185 Printed in Japan Y K1...

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