Suzuki AY50 Manuals

Manuals and User Guides for Suzuki AY50. We have 1 Suzuki AY50 manual available for free PDF download: Service Manual

Suzuki AY50 Service Manual (269 pages)

Brand: Suzuki | Category: Scooter | Size: 59.61 MB

Foreword
2
Group Index
2
Component Parts and Work to be Done
3
How to Use this Manual
3
To Locate What You Are Looking for
3
Symbol
4
Contents
5
General Information
5
General Precautions
6
Warning/Caution/Note
6
Fuel, Oil and Engine Coolant Recommendations
8
Serial Number Location
8
Suzuki AY50V/50WV ('97-Model) View
8
Anti-Freeze and Distilled Water
9
Break-In Procedures
9
Coolant Mixture Ratio
9
Information Labels
10
Specifications AY50
11
Specifications AY50W
12
Country or Area
13
Periodic Maintenance
14
Periodic Maintenance Chart
15
Periodic Maintenance Schedule
15
Lubrication Points
16
Battery
17
Maintenance and Tune-Up Procedures
17
Air Cleaner
18
Cylinder Head and Cylinder
19
Spark Plug
19
Fuel Line
20
Throttle Cable Play
20
Cooling System (for AY50W)
21
Engine Coolant Change
21
Engine Coolant Level Check
21
Final Gear Oil
22
Front Brake Fluid Level
23
Front Brake Pads
23
Air Bleeding the Brake Fluid Circuit
24
Brake Shoe Wear
25
Front Fork
25
Rear Brake Lever Play
25
Steering
25
Rear Suspension
26
Tire Tread Condition
26
Chassis Bolts and Nuts
27
Cylinder Head Nuts and Exhaust Pipe Bolt and Nut
27
Automatic Clutch Inspection
29
Clutch "Lock-Up" Inspection
29
Initial Engagement Inspection
29
Engine
30
Engine Center
31
Engine Components Removable with the Engine in Place
31
Engine Left Side
31
Engine Right Side
31
Engine Removal
32
Engine Reinstallation
34
Engine Disassembly
35
Engine Components Inspection and Service
43
Rear Axle Shaft Bearing
43
Right Driveshaft Bearing and Idle Shaft Bearing
43
Left Driveshaft Bearing
44
Right Crankshaft Bearing
44
Left Crankshaft Bearing
45
Oil Seals
45
Crankshaft Oil Seals
46
Drive Shaft Oil Seal
46
Rear Axle Shaft Oil Seal
46
Engine Mounting Bushings
47
Clutch Shoe/Movable Driven Face
49
Disassembly
49
Clutch Shoes
51
Driven Face Spring
51
Driven Face Pins and Oil Seals
52
Reassembly
52
Movable Drive Face
53
Roller and Sliding Surface
53
Cylinder Head
54
Drive Belt
54
Carbon Removal
55
Piston Diameter
55
Piston-Cylinder Clearance
55
Piston Pin Bore
56
Piston Pin O.D.
56
Piston Rings
56
Condition of the Big End Bearing
57
Conrod Small End I.D.
57
Crankshaft Runout
57
Reed Valve
58
Crankshaft
59
Engine Reassembly
59
Crankcase
60
Rear Axle Shaft and Transmission
61
Starter Pinion and Starter Gear
64
Movable Drive
65
Kick Starter
67
Piston
68
Magneto
69
Oil Pump Driven Gear
69
Fuel and Lubrication System
70
Fuel Valve
71
Fuel Tank and Oil Tank
72
Fuel Tank and Oil Tank Cushions
73
Remounting
73
Carburetor
74
Needle Valve Inspection
77
Float Height Adjustment
78
Reassembly and Remouting
78
Air Bleeding
79
Checking Oil Pump
79
Oil Pump
79
Cooling System (AY50W)
80
Cooling System
81
Description
81
Engine Coolant
82
Radiator and Engine Coolant Reservoir
83
Radiator Removal
83
Engine Coolant Reservoir Removal
84
Installation
84
Radiator Hoses Inspection
84
Radiator Inspection
84
Engine Coolant Temperature
85
Inspection
85
Removal and Disassembly
86
Water Pump
86
Chassis
90
Leg Shield and Frame Covers
91
Leg Shield Removal
92
Frame Cover Removal
93
Leg Shield and Frame Cover Remounting
93
Front Wheel
94
Inspection and Disassembly
95
Speedometer Gearbox Dust Seal
95
Wheel Bearings
95
Front Axle
96
Reassembly and Remounting
96
Wheel
96
Brake Disc
97
Speedometer Gearbox
97
Front Brake
98
Brake Fluid Replacement
99
Brake Pads Replacement
99
Brake Caliper Removal and Disassembly
100
Brake Caliper Inspection
101
Brake Caliper Reassembly and Remounting
102
Brake Disc Inspection
103
Master Cylinder Removal and Disassembly
103
Master Cylinder Inspection
104
Master Cylinder Reassembly and Remounting
105
Front Suspension
106
Bushings
108
Damper and Spring
108
Fork Spring
108
Bushing
109
Circlip
109
Stopper Ring
109
Handlebar Covers/Speedometer Cover
110
Steering Stem
112
Steel Ball
115
Steering Stem Nut
115
Rear Wheel and Brake
117
Brake Drum
118
Rear Shock Absorber
118
Brake Shoe
119
Tire and Wheel
120
Tire Removal
120
Valve Inspection
122
Tire Installation
123
Valve Installation
123
Electrical System
125
Cautions in Servicing
126
Connector
126
Coupler
126
Semi-Conductor Equipped Part
126
Connecting the Battery
127
Using the Pocket Tester
128
Location of Electrical Components
129
Charging and Lighting System
130
Charging Output Check
131
Regulator/Rectifier
132
Stator Coil
132
Starter System
133
Armature Coil
135
Carbon Brush
135
Commutator
135
Starter Motor Inspection
135
Starter Relay Inspection
136
Ignition System
137
CDI/Ignition Coil Inspection
138
Checking with the Suzuki Pocket Tester
138
Pick-Up Coil
139
Speedometer
139
Fuel Level Gauge Inspection
140
Fuel Meter Inspection
140
Oil Level Indicator Switch
141
Thermoelement and Carburetor Heater
141
Carburetor Heater Inspection (P-02 Only)
142
Carburetor Thermo-Switch Inspection (P-02 Only)
142
Wire Color
143
Battery (for P-53)
144
Filling Electrolyte
144
Initial Charging
144
Recharging Operation
145
Servicing
145
Service Life
146
Battery (for the Others)
147
Servicing Information
150
Troubleshooting
151
Radiator (AY50W)
152
Brakes
154
Electrical
155
Battery (for Conventional Battery for P-53)
156
Battery (MF Battery)
157
For P-02
158
Wiring Diagram AY50
158
For the Others
159
Wiring Diagram AY0W
160
Wire Routing
162
Wire, Cable and Hose Routing
162
Cable Routing
164
Fuel Hose Routing
165
Battery Breather Hose (for P-53)
167
Oil Hose Routing
167
Front Brake Hose Routing
168
Center Stand Set-Up
169
Special Tools
170
Tightening Torque
172
Tightening Torque Chart
173
Cylinder + Piston + Piston Ring
174
Service Data
174
Clutch
175
Conrod + Crankshaft
175
Radiator + Engine Coolant Temp. Switch AY50W
175
Carburetor AY50
176
Transmission
176
Carburetor AY50W
177
Brake + Wheel
178
Wattage
178
Suspension
179
Tire Pressure P-26, 34, 53
179
Fuel + Oil + Coolant
180
AY50W/WW/WRW ('98-Model)
181
Specifications AY50WW
183
Specifications AY50WRW
184
Radiator + Engine Coolant Temp. Switch AY50W and AY50WR
186
Carburetor AY50W and AY50WR
188
AY50X/WX/WRX ('99-Model)
192
AY50Y/WY/WRY ('00-Model)
192
Specifications AY50X/Y
193
Specifications AY50WX/WY
194
Specifications AY50WRX/WRY
195
Service Data AY50X/Y
196
Fuel + Oil
199
Tire Pressure P-26, 34
199
Specifications AY50WX/WRX/WY/WRY
200
Radiator + Engine Coolant Temp. Switch + Engine Coolant
201
Rear Wheel (for AY50WX/WRX/WY/WRY)
205
Rear Brake
206
Caliper
209
Brake Disc Inspection and Replacement
211
Brake Disc Removal
211
Rear Brake Hose Routing
213
Table of Contents
214
AY50K1/WRK1 (’01-Model)
214
AY50K2/WRK2 (’02-Model)
214
Specifications AY50K1
215
Specifications AY50WRK1
216
Service Data AY50K1
217
Ay50K1
219
- Service Data AY50WRK1
  221
- Thermostat + Radiator + Engine Coolant Temp. Switch + Engine Coolant
  222
Thermostat (for AY50WRK1)
226
Engine Coolant Temp. Switch (for AY50WRK1)
227
CDI/Ignition Coil
229
Regulator/Rectifier
229
- Wiring Diagram AY50K
  230
- For P-39
  231
- Wiring Diagram AY50WRK1
  233
- For P-18
  234
- AY50K3/SK3/WK3/WSK3 (’03-Model)
  236
- Specifications AY50 and AY50S
  237
- Specifications AY50W and AY50WS
  239
- Service Data AY50 and AY50S
  241
- Headlight
  243
- High Beam Indicator Light
  243
- Oil Level Indicator Light
  243
- Speedometer Light
  243
- Trunk Light
  243
- Turn Signal Indicator Light
  243
- Turn Signal Light
  243
- Fuel Tank
  244
  - Tire Pressure AY50S & AY50
    244
  - Service Data AY50W and AY50WS
    245
- Battery
  247
- Fuse
  247
- Headlight
  247
- High Beam Indicator Light
  247
- Oil Level Indicator Light
  247
- Speedometer Light
  247
- Turn Signal Indicator Light
  247
- Turn Signal Light
  247
  - Tire Pressure AY50WS & AY50W
    248
  - Wiring Diagram AY50 and AY50S
    250
  - Wiring Diagram AY50W and AY50WS
    252
  - AY50K4/WK4 (’04-Model)
    255
- Capacities
  257
- Coolant Temperature Check Light
  257
- Engine Oil Tank
  257
- Final Gear Oil, Oil Change
  257
- Trunk Light
  257
- Service Data AY50
  258
- Service Data AY50W
  262

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Suzuki AY50 Service Manual (269 pages)

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