FOREWORD This manual contains an introductory descrip- tion on SUZUKI XF650 and procedures for its in- spection/service and overhaul ofits main compo: nents. Other information considered as generally known is not included. Read GENERAL INFORMATION section to famil- iarize yourself with outline of the vehicle aad MAINTENANCE and other sections to use as a guide for proper inspection and service. This manual will help you know the vehicle better 80 that you can assure your customers of your optimum and quick service. basis of the latest specification atthe time | of publication. | If modification has been made since then, difference may exist between the content | of this manual and the actual vehicle. * (llustrations in this manual are used to show the basic principles of operation and work procedures. They may net representthe actual vehicle | exactly in detail. | * This manual is intended for those who have enough knowledge and skills for | servicing SUZUKI vehicles. Without such | knowledge and skills, you should not at- | tempt servicing by relying on this manual) only. Instead, please contact your nearby au- | thorized SUZUKI motorcycle dealer. * This manual has been prepared on the | \ SUZUKI MOTOR CORPORATION Overseas Service Department © COPYRIGHT SUZUKI MOTOR CORPORATION 1896, | ELECTRICAL SYSTEM | | SERVICING INFORMATION a XF6SOW/UW/X/UX (98, ‘99-MODELS) XF650Y (2000-MODEL) Ee | xrasons (01-MODEL)HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. Asthetitle of these sections are listed on the previous page as GROUP INDEX, select the section where what you are looking for belong. 3, Holding the manual as shown at the right will allow you to find the first page of the section easily. 4.On the first page of each section, its contents are listed. Find the item and page you need. COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit, its exploded view is pro service information such as the tightening torque, lubricating points and locking agent points. Example: Front wheel 80008 Sk 3 SS QD Oring @Housing end (inside) @ Washer set @ Orting pest @ Starter motor case @ Armature @ Washer set @ Brush holder ® Brush spring Housing end (Outside) 1d with work instruction and other | | | | |SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing and meaning associated with them respectively. SYMBOL DEFINITION DEFINITION © Torque control required. Data beside it indicates specified torque. ‘Apply THREAD LOCK SUPER "7303". (99000-32030) Apply oil. Use engine oil unless otherwise speci Use fork oil. (99000-99044-10G) Apply SUZUKI SUPER GREASE nA", (99000-25010) Apply or use brake fluid. ‘Apply SUZUKI SILICONE GREASE. (98000-25100) ‘Measure in voltage range. ‘Apply SUZUKI MOLY PASTE. (99000-25140) Measure in resistance range. Apply SUZUKI BOND “1215” (99000-31110) G6 8 a} Measure in current range. ‘Apply THREAD LOCK 1342” 19000-32050) Use special tool. Baahagdas Apply THREAD LOCK SUPER, "1360". (9000-32130)GENERAL INFORMATION [ WARNING/CAUTION/NOTE GENERAL PRECAUTIONS SUZUKI XF650V ('97-MODEL) ‘SERIAL NUMBER LOCATION FUEL AND Olt. RECOMMENDATION FUEL ... | ENGINE o/L BRAKE FLUID FRONT FORK OIL . BREAK-IN PROCEDURES INFORMATION LABELS ‘SPECIFICATIONS . COUNTRY OR AREA1-1 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 atten- tion to the messages highlighted by these signal words. AWARNING In ites a potential hazard that could resutt in death or injury. ‘A CAUTION! Indicates a potential hazard that could result in vehicle damage NOTE: Indicates special information to make maintenance easier or instructions clearer. Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In ad tion to the WARNINGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. if you are unsure about how to perform a particular service operation, ask a more experienced mechanic for advice. GENERAL PRECAUTIONS © Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the vehicle. ‘© When 2 or more persons work together, pay attention to the safety of each other, © When it is necessary to run the engine indoors, make sure that exhaust gas is forced out- doors. , make sure that the area you work in is /entilated and that you follow all of the material manufacturer's instructions. ® Never use gasoline as a cleaning solvent. '® To avoid getting burned, do not touch the engine, engine oil or exhaust system during or for a while after engine operation. © After servicing fuel, oil, exhaust or brake systems, check all system for leaks, and fittings related to theGENERAL INFORMATION 1-2 9 parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order end orientation. © Be sure to use special tools when instructed. ‘© Make sure that all parts used in reassembly are clean, and also lubricated when specified. © When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the specified type. © When removing the battery, disconnect the negative cable first and then the positive cabl When reconnecting the battery, connect the positive cable first and then the negative cable, and replace the terminal cover on the positive terminal. to electrical parts, if the service procedures not require use of battery power, ighten cylinder head and case bolts and nuts, beginning with larger diameter and ending with smaller diameter, from inside to outside diagonally, to the specified tightening torque. ‘¢ Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, cotter pins, | ciretips, and certain other parts as specified, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any teft over material from the mating surfaces. ¢ Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted. * Do not use self-locking nuts a few times ov © Use a torque wrench to tighten fasteners to the torque values when specified. Wipe off Grease or oil if a thread is smeared with them. ¢ After reassembly, check parts for tightness and operation, © To protect environment, do not unlawfully dispose of used motor oil and other fluids: batteries, and tires. © To protect Earth’s natural resources, property dispose of used vehicles and perts.1-3 GENERAL INFORMATION SUZUKI XF650V (’97-MODEL) RIGHT SIDE LEFT SIDE "Difference between photographs and actual motorcycles depends on the markets. SERIAL NUMBER LOCATION ‘The frame serial number or V.I.N. (Vehicle Identification Number) is stamped on the right side of the steering head pipe. The engine serial number ® is located on the left side of the crankcase. ‘These numbers are required especially for registering the machine and ordering spare parts. —Y FUEL AND OIL RECOMMENDATION FUEL Gasoline used should be graded 85-95 octane (Research Method) or higher. An unleaded gasoline type is recommended ENGINE OIL Make sure that the engine oil you use comes under API classification of SF or SG and that its viscosity rating is SAE 10W/40. If an SAE 10W/40 motor oil is not available, select an alternate according to the right chart.GENERAL INFORMATION 1-4 BRAKE FLUID Specification and class A WARNING Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix different types of fluid such as silicone-based and petro- leur-based fluid for refilling the system, otherwise serious damage will result. Do not use any brake fluid taken from old or used or unsealed containers. Never re-use brake fluid left over from a previous servi has been stored for a long period. FRONT FORK OIL Use fork oil #15. BREAK-IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. The general rules are as follows. ‘© Keep to these break-in engine speed limits: Initial 800 km ( 500 miles): Below 4 000 r/min Up to 1.600 km (1.000 miles): Below 6 000 r/min Over 1600 km (1.000 miles): Below 8 000 r/min ‘© Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the motorcycle to full throttle operation. However, do not exceed 8 000 r/min. * Do not maintain constant engine speed for an extended time period during any portion of the break-in. Try to vary the throttle position.1-5 GENERAL INFORMATION. INFORMATION LABELS3-7 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length + 2205 mm (86.8 in) 2.190 mm (86.2 in)... + 865 mm (34.1 in) + 1.230 mm (48.4 in) 1.200 mm (47.2 in) on. 1465 mm (57.7 in) 1.455 mm (87.2 in) ww 200 mm ( 7.9 in) 170 mm ( 6.7 in) .. 830 mm (32.7 in) 800 mm (31.5 in) .... Overall width ....0....06 Overall height Ground clearance .. Seat height Dry mass . 162 kg (357 Ibs) ENGINE Type. Four-stroke, air-cooled, Valve clearance (IN) (Ex) Number of cylinders Bore. Stroke Piston displacement Compression ratio = 100 mm (3.937 in) = 82 mm (3.228 in) + 644 cm (39.3 cu. in) 95:1 Low seat conversion Low seat conversion Low seat conversion Low seat conversion Low seat conversion with SACS, OHC .13 mm (0.003-0.008 in) 1.22 mm (0.007-0.008 in) Carburetor ..... BSR32, twin Air cleaner .. Polyurethane foam element Starter system ....... Electric Lubrication system . Wet sump TRANSMISSION Clutch «2... Wet multi-plate type Transmission .. Gearshift pattern Primary reduction ratio Gear ratios, Low 5-speed constant mesh 1-down, 4-up 2.178 (61/28) 2.416 (29/12) 2nd . 1.625 (26/16) 3rd 1.238 (26/21) ath seeess 1000 (21/21) Top .. 0.826 (19/23) Final reduction ratio . 2.866 (43/75) Drive chain DIDS25 V9, 110 linksCHASSIS Front suspension . Rear suspension Front fork stroke .. Rear wheel travel Steering angie . Caster .. Trail... Turning radius Front brake ....... Rear brake .... Front tire size ..... Rear tire size . ELECTRICAL Ignition type Ignition timing Spark plug . Banery ..... Generator Fuse .. Headlight Parking or city light Turn signal light Tail/brake light Speedometer light Turn signal indicator light . Neutral indicator light . High beam indicator Ii CAPACITIES Fuel tank, including reserve reserve . Engine oil, oil change . with filter change ... overhaul ... Front fork oil (each leg) . GENERAL INFORMATION 1-8 « Telescopic, coil spring, oil damped k type, coil spring, gas/oil damped, spring preload fully adjustable, compression damping force adjustable + 170 mm (6.7 in) 140 mm (55 in) ..... Low seat conversion = 167 mm (6.6 in} 132 mm (6.2 in) ..... Low seat conversion - 43° 28° 105 mm (4.13 in) 2.4 m (7.9 ft) Disk brake Disk brake 100/90-19 57H, tube type 130/80 R17 65H, tube type ++. Electronic ignition (CDI) + 10° B, . NGK CR10E or NIPPONDENSO U31ESR-N + 12V 28.8 KC (8 Ah)/10 HR at 1500 rpm Three-phase AC, generator = 30/15/15/10/15/104 . 12V 60/55W . 12V BW... except E24 12V 21W . 12v 5/21W 12V 1.7Wx2 12V 1.7Wx2 12V 1.7W 12 1.7W + 185 L (4.9/4.1 US/Imp gal) 4.5 1 (1.2/1.0 US/Imp gal) 2.300 mi (2.4/2.0 US/Imp at) 2.400 ml (2.5/2.1 US/Imp at) + 2600 ml (2.7/2.3 US/Imp at) 655 ml (22.1/23.1 US/Imp oz) 699 mi (23.6/24.6 US/imp 02) ..... Low seat conversion1-9 GENERAL INFORMATION COUNTRY OR AREA The series of symbols on the left stand for the count 8 oF area on the right. SYMBOL COUNTRY or AREA E-02 UK. E04 France E46 Finland E46 Norway E47 ‘Sweden E48 Switzerland £21 Belgium E22 Germany E-24 Australia E25 Netherlands E26 Denmark E34 htaly E37 Br £39 Austria E53 Spain E-21 and 53 countries are included in E-34. (Ex 16 and 26 countries are included in :) E-39 country is included in E-18.I CONTENTS PERIODIC MAINTENANCE SCHEDULE . PERIODIC MAINTENANCE CHART . LUBRICATION POINTS MAINTENANCE AND TUNE-UP PROCEDURES.............-+++++ 2 VALVE CLEARANCE SPARK PLUGS AIR CLEANER ELEMENT IDLE SPEED THROTTLE CABLE PLAY CARBURETOR SYNCHRONIZATION . FUEL LINE .. CLUTCH .. | ENGINE OIL AND OIL FILTER DRIVE CHAIN . BRAKES BONN OAM AHWHNAS 212 TIRES 2-14 | STEERING .. 216 | FRONT FORKS 2:15 REAR SUSPENSION 2:15 | EXHAUST PIPE AND MUFFLER BOLTS . 2:15 CHASSIS BOLTS AND NUTS .. 2-16 2-18 2-19 COMPRESSION PRESSURE CHECK OIL PRESSURE CHECK2:4 PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work neces- sary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilometer, miles and time for your convenience. NOTE: More frequent servicing may be performed on motorcycles that are used under severe conditions. PERIODIC MAINTENANCE CHART INTERVAL: km 7000 | 6000 | 12000 | 18600 | 24000, FeO ee OM OR oR [miles | 600 | 4000 | 7500 | 11000 | 15000 | WHICHEVER COMES FIRST months | 2 c12nen | mean, 36 4B Valve clearance T= i = o Spark plugs 7 = I a] R Air cleaner element Clean every 3 000 km (2 000 miles). idle speed hrottle cable play Carburetor synchronization Fuet fine T t t t i Clutch, Engine Engine oil fiter Drive chain i 1 R R R = R i a Clean and lubricate every 1.000 km (600 miles). R 1 | Brakes: [ee Brake hose Se es el ee Replace every 4 years. Brake fluid = ' ' : 1 ‘Change every 2 years. Tires = 1 U 1 Steering Front forks Rear suspension Exhaust pipe and muffier bolts Chassis bolts and nuts 4) 4{—|—-]-|—| ? i t cr = a NOTE: |: Inspection and adjust, clean, lubricate or replace as necessary. R: Replace T: TightenPERIODIC MAINTENANCE 2-2 LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle, Major lubrication points are indicated below. TBR ower lover notder nd clutch esbie ABU sigestond pivot “Bp rive hain ‘and spring hook NOTE: * Lubricate exposed parts which are subject to rust, with a rust preventative spray whenever the motorcycle has been operated under wet or rainy conditions. If the spray is unavailable, use either motor oil or grease. * Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.2:3 PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements. VALVE CLEARANCE Inspect Initially at 1.000 km (600 miles, 2 months) and Every 12 000 km {7 500 miles, 24 months) thereafter ~ The valve clearance specification is different for intake and exhaust valves. Valve clearance adjustment must be checked and adjusted, 1) at the time of periodic inspection, 2) when the valve Mechanism is serviced, and 3) when the camshaft turbed by removing it for servicing, Valve clearance (when cold): IN. 0.08-0.13 mm (0.003-0.005 in) EX.: 0.17-0.22 mm (0.007-0.009 in) NOTE: Valve clearance is to be checked when the engine is cold. Both intake and exhaust valves must be checked and ad- justed when the piston is at Top-Dead-Center (TDC) on the compression strake. ‘® Remove the seat and fuel tank. (Refer to page 4-3.) ¢ Remove the engine protector. ‘¢ Remove the one of each spark plug and both valve in- spection caps, ‘© Rernove the valve timing inspection plug and magneto cover plug. Turn the crankshaft counterclockwise with the box wrench to set the piston at T.D.C. on the compression stroke. (Turn the crankshaft until the “T” line @ on the magneto rotor is aligned with the center of hole on the magneto cover.) © Insert the thickness gauge into the clearance between the valve stem end and the adjusting screw on the rock- er arm, (6 02900-20803: Thickness gauge 09917-14910: Valve clearance adjusting driver @ If the valve clearance is out of the specification, bring it into the specified range. @ Securely tighten the lack nut after adjustment is com- pleted. ‘4 CAUTION Both right and left valve clearances, should closely set as possible. [ESOS Y[S0t 08, DOSSe. eee eomieeee ere | ‘* Reinstait the spark plug, valve inspection caps, valve tim- ing inspection plug and magneto cover plug.SPARK PLUGS Inspect Every 6 000 km (4.000 miles, 12 months) and Replace Every 12 000 km (7 500 miles, 24 months). ‘© Remove the spark plugs. (GB 09930-10121: spark plug socket wrench set ———— Standard Hot type NGK CRI0E CROE ND. | UstESR-N UZIESR-N CARBON DEPOSIT Check to see if there are carbon deposits on the spark plugs. If carbon is deposited, remove it with a spark plug cleaner machine or carefully using a tool with a pointed end. SPARK PLUG GAP Measure the spark plug gap with a thickness gauge. If out of specification, regap the spark plug. ‘Standard Spark plug gap (GB 09900-20803: Thickness gauge ELECTRODE’S CONDITION Check to see the worn or burnt condition of the electrodes. If it is extremely worn or burnt, replace the plug. And also replace the plug if it has a broken insulator, damaged thread, etc. (@ CAUTION Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be depos- ited on the screw portion of the plug hole and engine damage may result. PERIODIC MAINTENANCE 2- thos 8m2:5 PERIODIC MAINTENANCE. AIR CLEANER ELEMENT {Clean Every 3.000 km (2 000 mites). If the air cleaner is clogged with dust, intake resistance will be increased with a resultant decrease in power output and an increase in fuel consumption. Check and clean the element in the following manner. © Remove the seat. ‘® Remove the air cleaner case cover by removing screws ©. * Remove the air cleaner element by removing the wing nut @. ‘¢ Remove the polyurethane foam element @ from the ele- ment frame @. Fill a washing pan of a proper size with non-flammable cleaning solvent. Immerse the element in the cleaning solvent and wash it clean. ‘¢ Squeeze the cleaning solvent out of the washed element by pressing it between the palms of both hands, ‘© Immerse the element in motor aii, and squeeze the oil out of the element feaving it slightly wet with oil, NOTE: Do not twist or wring the element because it will tear or the individual cells of the element will be damaged. CAUTION ment carefully for rips, torn seams, etc. if any damage is noted, replace the element. ‘© Reinstall the cleaned or new cleaner element in the re- verse order of removal. If driving under dusty conditions, clean the air cleaner element more frequently. The surest way to acceler is to use the engine without the ele- ment or to use a torn element, Make sure that the air cleaner is in good condition at all times. Life of the engine depends largely on this component! Non-ttammabie cleaning solvent ©NOTE: When you clean the air cleaner element, drain water from the air cleaner drain hoses by removing the drain plugs. IDLE SPEED Inspect Initially at 1000 km (600 miles, 2 months) and |__Every 6 000 km (4000 miles, 12 months) thereafter. NOTE: Make this adjustment when the engine is warm. © Connect a tachometer. (GB 00000-26006; Tachometer © Start up the engine and set its speed at anywhere be- tween 1400 and 1600 r/min (1 450 and 1850 ¢/min for Switzerland and Austria) by turning the throttle stop screw D. # Turn in the pilot screw fully. Turn out the screw 3 turns. ‘© Turn and search the pilot screw position where highest engine speed is available to fine-tune the carburetor set- ting. NOTE: Turn in or out the pilot screw within 1/2 turn from the stan- dard setting. ‘© Recheck the idle speed and adjust to between 1 400 and 1600 r/min (1.450 and 1550 r/min for Switzerland and Austria) with throttle stop screw if necessary. Idle speed: 1500+ 50 r/min ... for Switzerland and Austria 1500100 r/min ... for the Others PERIODIC MAINTENANCE 2-52-7 PERIODIC MAINTENANCE THROTTLE CABLE PLAY Inspect Initially at 1.000 krn (600 miles, 2 months) and Every 6 000 km (4000 miles, 12 months) thereafter. A twin throttle cable system is used in this motorcycle. Cable @ is for pulling and cable @ is for returning. To ad- just the cable play, adjust the returning cable first and then adjust the pulling cable. The returning cable should be adjusted to have a thread length ® of 2-3 mm (0.08-0.12 in) as shown in the Fig. If the adjustment is necessary, adjust the thread length in the following way: ® Loosen the lack nut @. © Tura the nut @ to obtain the thread length @ of 2-3 mm (0.08-0.12 in), ‘* Tighten the lock nut @ securely. Pulling cable play The pulling cable should be adjusted to have a cable play @ of 0.5-1.0 mm (0.02-0.04 in) as shown in the Fig. If the adjustment is necessary, adjust the cable play in the fol- lowing way: © Turn the handlebar all the way to the left. © Loosen the lock nuts (©, ©). © Turn the adjuster @ or ® to obtain the cable play ® of 0.5-1.0 mm (0.02-0.04 in). © Tighten the lock nuts (©, ©) securely PAS After the adjustment is completed, check that han- dlebar movernent does not raise the engine idle speed and that the throttle grip returns smoothly and automatically. CARBURETOR SYNCHRONIZATION se ee coor Inspect Every 12.000 km (7 500 miles, 24 months). | (Refer to page 4-22.)FUEL LINE Inspect Initially at 1 000 km (600 miles, 2 months) and Every 6000 km (4000 miles, 12 months) thereafter. Replace Every 4 years. CLUTCH Inspect Initially at 1.000 km (600 miles, 2 months) and Every 6 000 km (4000 miles, 12 months) thereafter. © Loosen the lock nut @ and turn the clutch cable adjuster @ fully in. © Slide the cover @. © Loosen the lock nut @ and turn the clutch cable adjuster © to provide the specified clutch lever play ®. Clutch lever play @: 10-15 mm (0.4-06 in) © Tighten the lock nuts (D and @) while holding the ad- justers (@ and ©) in positions. © Slide the cover @ to original position. NOTE: Minor adjustment can be made by the adjuster @ after loosening the lock nut @. At the same intervals, lubricate the clutch cable with motor oil ERIODIC MAINTENANCE 2-82.9 PERIODIC MAINTENANCE ENGINE OIL AND OIL FILTER (ENGINE OIL) Replace (Change) Initially at 1000 km (600 miles, 2 months) and Every 6 000 km (4.000 miles, 12 months) thereat (Of. FILTER) ] Replace Initially at 1000 km (600 miles, 2 months) and Every 12.000 km (7 500 miles, 24 months) ther after. Oil should be changed while the engine is warm. Oil filter replacement at the above intervals should be done togeth- er with engine oil change. Keep the motorcycle upright, supported by jack or wooden block. * Place an oil pan below the engine and remove the en- gine oil drain plug ® and oil filler cap @ to drain engine oil. ‘* Remove the oil filter cap by removing the three bolts @. # Romove the oil filter @ and install the new one. © Install the oil filter cap and tighten the bolts @ securely. NOTE: Before installing the oil filter and oil filter cap, check to be sure that the spring © and new O-rings (® and @) are installed correctly and apply engine oil lightly to the new O-ring ©. ‘© Tighten the oil drain plug @ securely, and pour fresh oil through the oil filler. The engine will hold about 2 300 mt of oil. Use an API classification of SF or SG oil with SAE 10W/40 viscosity. (©) Drain plug: 24 N-m (2.4 kg-m, 17.5 lb-ft) © Install the oil filler cap @. © Start up the engine and allow it to run for several min- utes at idling speed. Turn off the engine and wait about one minute, then check the oil level through the inspection window ®. If the level is below mark “F”, add oil to the level. NECESSARY AMOUNT OF ENGINE OIL Oil change: 2300 mi (2.4/2.0 US/Imp qt) Filter change — : 2 400 ml (2.5/2.1 US/Imp at) Overhau! engine: 2 600 ml (2.7/2.3 US/Imp at)DRIVE CHAIN Inspect Initially at 1.000 km (600 miles, 2 months) and Every 6000 km (4000 miles, 12 months) thereafter. Clean and Lubricate Every 1000 km (600 miles). Visually check the drive chain for the possible defects listed below. (Support the motorcycle by a jack and a wooden block, turn the rear wheel slowly by hand with the trans- mission shifted to Neutral.) * Loose pins + Excessive wear * Damaged rollers * Improper chain adjustment * Dry or rusted * Missing O-ring seals ‘+ Kinked or binding links If any defects are found, the drive chain must be replaced. NOTE: When repiacing the drive chain, replace the drive chain and sprockets as a set. CHECKING © Loosen the axle nut ©. © Loosen both chain adjuster lock nuts @. ‘© Tense the drive chain fully by turning both chain adjuster bolts @. © Count out 21 pins (20 pitches) on the chain and measure the distance between the two points. If the distance ex- ceeds the service limit, the chain must be replaced. Service Limit PERIODIC MAINTENANCE 2-10 Drive chain 20-pitch length 319.4 mm. (12.6 in) ADJUSTING * Loosen or tighten both chain adjuster bolts @ until the chain has 20-30 mm (0.8-1.2 in) of slack in the middle between engine and rear sprockets. The marks ® on both chain adjusters must be at the same position on the scale to ensure that the front and rear wheels are cor- rectly aligned. ‘© Place the motorcycle on its side-stand for accurate ad- justment. ‘© After adjusting the drive chain, tighten the axle nut to the specified torque. ‘© Tighten both chain adjuster lock nuts @ securely. (B) Rear axle nut: 110 N-m (11.0 kg-m, 79.5 lb-ft)ODIC MAINTENANCE CLEANING AND LUBRICATING ‘© Wash the chain with kerosene. If the chain tends to rust quickly, the intervals must be shortened. 4 CAUTION Do not use trichlene, gasoline or any sit These fluids have too great a dissolving power for this chain and, what is more important, they can damage the “O”-rings (or seals) confining the grease in the bush to pin clearance. Remember, high durabil- ity comes from the presence of grease in that cl ance. t- © After washing and drying the chain, oil it with a heavy- weight motor oil * Do not use any oll sold commercially as “drive chain oil”. Such oll can damage the “O”-rings (or | seals). * The standard drive chain is D.1.D. 525 Vs, 170 links. SUZUKI recommends that this standard drive chain should be used for the replacement.BRAKES (BRAKE) Inspect Initially at 1000 km (600 miles, 2 months) and Every 6 000 km (4000 miles, 12 months) thereafter. (BRAKE HOSE AND BRAKE FLUID) Inspect Every 6 000 km (4.000 miles, 12 months). Replace hoses Every 4 years. Replace fluid Every 2 ve BRAKE FLUID LEVEL © Keep the motorcycle upright and place the handlebars straight. © Check the brake fluid level by observing the lower limit lines on the front and rear brake fluid reservoirs. ‘© When the level is below the lower limit line, replenish with brake fluid that meets the following specification. B Specification and Classification: DOT 4 PROGINS The brake system of this motorcycle is filled with a glycol-based brake fluid. Do not use or mix different types of fluid such as silicone-based or petroleum- based. Do not use any brake fluid taken from old, used or unsealed containers. Never re-use brake fluid left over from the last servicing or stored for a long period. | Brake fuid, if it leaks, will interfere with safe running and immediately discolor painted surfaces. Check the brake hoses and hose joints for cracks and oil leakage before riding. BRAKE PADS The extent of brake pad wear can be checked by observing the grooved limit line @ on the pad. When the wear ex- ceeds the grooved limit line, replace the pads with new ones. (Refer to pages 5-39 and 5-46.) ‘A CAUTION Replace the brake pad as a set, otherwise braking | performance will be adversely affected. BRAKE PEDAL HEIGHT © Loosen the lock nut @ and rotate the push rod @ to locate brake pedal 5 mm below the top face of the foot- rest. © Retighten the lock nut @ to secure the push rod @ in the proper position. Brake pedal height ®: § mm (0.2 in) PERIODIC MAINTENANCE 2-122-13 PERIODIC MAIKTENANCE AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the fluid circuit acts like @ cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking perfor- mance of the brake caliper. The presence of air is indicated by “sponginess” of the brake lever and also by lack of braking force. Considering the danger to which such trapped air exposes the machine and rider, it is essential that, after remounting the brake and restoring the brake system to the normal condition, the brake fluid circuit be Purged of air in the following manner: © Fill up the master cylinder reservoir to the “UPPER” Replace the reservoir cap ta prevent entry of dirt. © Attach a pipe to the caliper bleeder valve, and insert the free end of the pipe into a receptacle. (3) Air bieeder valve: 8 N-m (0.8 kg-m, 6.0 Ib-ft) 8. © Front brake: Bleed the air from the air bleeder valve. © Squeeze and release the brake lever several times in rap- id succession and squeeze the lever fully without releas- ing it. Loosen the bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle; this will remove the tension of the brake lever causing it to touch the handlebar grip. Then, close the valve, pump and squeeze the lever, and open the valve. Repeat this Process until the fluid flowing into the receptacle no longer contains air bubbles. NOTE: Replenish the brake fluid in the reservoir as necessary While bleeding the brake system. Make sure that there is always some fluid visible in the reservoir. © Close the bleeder vaive, and disconnect the pipe. Fill the reservoir with brake fluid to the “UPPER” end of the in- spection window. ‘a CAUTION Handle brake fluid with care: the fluid reacts chemi- |_ cally with paint, plastics, rubber materials etc. © The only difference between bleeding the front and rear brakes is that the rear master cylinder is actuated by a PedalTIRES Inspect Every 6 000 km (4000 miles, 12 months). TIRE TREAD CONDITION Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a danger- ous situation. It is highly recommended to replace a tire when the remaining depth of tire tread reaches the follow- ing specification. Tire tread depth limit: FRONT & REAR 3.0 mm (0.12 in) TIRE PRESSURE If the tire pressure is too high or too low, steering will be adversely affected and tire wear increased. Therefore, maintain the correct tire pressure for good roadabilit shorter tire life will result. Cold inflation tire pressure is as follows. PERIODIC MAINTENANCE 2-14 COLDINFLATION| SOLORIDING | DUALRIDING | TIRE PRESSURE | kPa |kg/cm?| psi_| kPa |kg/cm?| psi FRONT 175 | 1.75 | 25 [175 | 1.75 | 25 REAR 200 | 2.00 | 29 | 225 | 2.25 | 33 ‘A CAUTION ‘The standard tire fitted on this motorcycle is 100/90-18 57H for front and 130/80 R17 65H for rear. ‘The use of tires other than those specified may cause instabili Genuine TIRE TYPE PIRELLI (front ... MT80, rear ... MT80RS) STEERING Inspect Initially at 1 000 km (600 miles, 2 months) and Every 12 000 km (7 500 miles, 24 months) thereafter. Taper roller type bearings are used on the steering system for better handling. Steering should be adjusted properly for smooth turning of handlebars and safe running. Over- tight steering prevents smooth turning of the handlebars and too loose steering will cause poor stability. Check that there is no play in the front fork assembly by supporting the machine so that the front wheel is off the ground, with the wheel straight ahead, grasp the lower fork tubes near the axle and pull forward. If play is found, perform steering bearing adjustment as described in page 5-23 of this manual.2-15 PERIODIC MAINTENANCE FRONT FORKS Inspect Every 12.000 km (7 500 miles, 24 months). Inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defec- tive parts, if necessary. (Refer to page 5-11.) REAR SUSPENSION Inspect Every 12 000 km (7 500 miles, 24 months! Inspect the rear shock absorber for oil leakage and check that there is no play in the swingarm assembly. EXHAUST PIPE AND MUFFLER BOLTS Tighten Initially at 1000 km (600 miles, 2 months) and Every 12000 km (7500 miles, 24 months) there- atter. ‘¢ Remove the right frame cover. Tighten the exhaust pipe bolts @, muffler connection bolt @ and muffler bolts @ to the specified torque. (8) Exhaust pipe bott/Mutfler connection bolt/Muffler bolt: 26 N-m (2.6 kg-m, 19.0 Ib-ft)CHASSIS BOLTS AND NUTS | Tighten Initially at 1000 km (600 miles, 2 months) and Every 6 000 km (4 000 miles, 12 months) thereaf- ter. PERIODIC MAINTENANCE 2-16 Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-17 for the locations of the following nuts and bolts on the motorcycle.) item Nem kg-m Ib-ft @ Steering stem head nut 90 9.0 65.0 @ Front fork upper clamp bolt 29 29 21.0 @ Front fork lower clamp bolt 23 23 165 @ Front fork cap bolt 23 23 165 © Front axle | 65 65 47.0 © Front axle holder bolt 23 23 16.5 @ Handlebars clamp bolt 2B 23 165 | | © Handlebars holder set nut 25 25 18.0 @ Front brake master cylinder mounting bolt 10 10 7.0 @ Front brake caliper mounting bolt 39 39 28.0 @ Brake hose union bolt (Front & Rear) 23 23 165 @ Brake air bleeder valve (Front & Rear) 8 08 60 © Brake disc bolt (Front & Rear) 23 23 16.5 @ Rear brake caliper pad mounting bolt 18 1.8 13.0 ® Rear brake caliper mounting bolt ~ 23 23 165 @ Rear brake master cylinder mounting bolt 10 1.0 7.0 [@ Rear brake master cylinderrodlocknut | ‘18 18 30 | @ Front footrest bracket mounting bolt 55 55 40.0 @ Rear footrest bracket mounting bolt 23 23 16.5 @ Swingarm pivot nut 7 7 55.6 @ Ree stec aoa! mounting bolt | a 45 = @ Rear cushion lever/rod mounting nut 100 10.0 725 @ Rear cushion lever mounting nut (Front) 80 80 58.0 @ Rear axle nut 110 11.0 795 @ Rear sprocket nutibolt 27 27 19.52-17 PERIODIC MAINTENANCEPERIODIC MAINTENANCE 2- COMPRESSION PRESSURE CHECK The compression of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic maintenance records kept at your dealership should include compression readings for each mainte- nance service. COMPRESSION PRESSURE SPECIFICATION ‘Standard 850 kPa Approx. /8.5 kg/cm? C0 Psi ) Low compression pressure can indicate any of the following condi * Excessively worn cylinder wall * Worn-down piston or piston rings + Piston rings stuck in grooves + Poor seating of valves * Ruptured or otherwise defective cylinder head gasket COMPRESSION TEST PROCEDURE NOTE: * Before testing the engine for compression pressure, make sure that the cylinder head bolts are tightened to the specified torque values and valves are properly adjusted. * Have the engine warmed up by idling before testing. * Be sure that the battery used is in fully-charged condition. Remove the parts concerned and test the compression pressure in the following manner. ‘© Remove both spark plug caps. © Remove either one of two plugs. Fit the compression gauge in the plug hole, while taking care that the connection tight. © Keep the throttle grip in full-open position. ‘© While cranking the engine a few seconds with the start- er, and record the maximum gauge reading as the com- pression of that cylinder. 19915-63310; Adaptor2-19 PERIODIC MAINTENANCE OIL PRESSURE CHECK Check periodically the oil pressure in the engine to judge roughly the condition of the moving parts. OIL PRESSURE SPECIFICATION [Above 30 kPa (0.3 kg/em?, 4.5 pail Below 70 kPa (0.7 kg/em?, 10 psi) &t 2000 r/min., Oil temp. at 60°C (40°F) If the oil pressure is lower or higher than the specification, the following causes may be considered. LOW OIL PRESSURE * Oil leakage from the oi! passage way + Damaged O-ring * Defective oil pump * Combination of above items HIGH OIL PRESSURE * Used a engine oil which is too high viscosity * Clogged oi! passage way * Combination of above items OIL PRESSURE TEST PROCEDURE Check the oil pressure in the following manner. ¢ Remove the oil pressure inspection plug. © Install the oil pressure gauge in the position shown in the figure. ‘© Warm up the engine as follows: Summer 10 min. at 2.000 r/min. Winter 20 min. at 2.000 r/min. ¢ After warming up, increase the engine speed to 3.000 Fimin, (with the engine tachometer), and read the oil pressure gauge. (B®) 09915-74510: Oil pressure gauge 09900-26008: TachometerENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE .. ENGINE REMOVAL AND REINSTALLATION ... ENGINE DISASSEMBLY AND REASSEMBLY... CYLINDER HEAD COVER/ROCKER ARM CAMSHAFT/CYLINDER HEAD/VALVES {__CYLINDER/PISTON ‘STARTER MOTOR/GENERATOR ROTOR/GEARSHIFT CLUTCH GEARSHIFT CAM/TRANSMISSION BALANCER SHAFT/CRANKSHAFT/CRANKCASE g ENGINE LUBRICATION SYSTEM 3H i a3.1 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 s ENGINE LEFT SIDE Engine sprocket Generator cover Starter torque lit Starter idle gear Generator rotor Starter gear Gearshift pawis and cam driven gear.. ion for removal and reinstallation instructions. ENGINE CENTER Refer to page Cam chain tensioner 3-10 and 28 Cylinder head cover .. 3A-T and 4 Camshatt .. . 3B-1and 11 Cylinder head . 3B-1and 11 Cylinder 3C-1 and 3 ston. 3C-1 and 3 Starter motor 30-1 and 3 Cam chain 3-13 and 21 ENGINE RIGHT SIDE Refer to page Refer to page .33and7 Clutch cover . 3-11 and 24 3D-1and3 Clutch .. .. 3-11 and 23 30-1 Primary drive gear 3-13 and 21 soos BOA Oil pump 3-14 and 21 . 3D-1 and 3 Neutral position indicator switch .... 3-14 and 20 30-1 30-2 Oil fitter . 3H-4 . 30-2ENGINE 3.2 ENGINE REMOVAL AND REINSTALLATION 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 oil drain plug @ to drain the engine oil ‘+ Remove the seat. (Refer to page 5-2.) ‘© Remove the battery holder plate @. * Disconnect the battery © lead wire @ from the battery terminal. * Remove the engine protector @. ‘* Remove the frame covers. (Refer to page 5-4.) ‘* Remove the fuel tank. (Refer to page 4-3.) * Remove the right rear footrest ©.33 ENGINE, ‘* Remove the muffler mounting bolts ©. '» Remove the muffler @ by loosening the connecting bolt ©. * Remove the exhaust pipe. ‘* Remove the oil cooler pipe mounting bolts. ‘* Remove the left front footrest @. Remove the engine sprocket cover @ and gearshift pedal ©. * Remove the engine sprocket bolts while depressing the rear brake pedal. © Remove the plate © and damper ©. ‘* Remove the engine sprocket. NOTE: If it is difficult to remove the engine sprocket, loosen the reer axle nut and chain adjusters to provide additional chain slack.ENGINE 3-4 ‘* Remove the right front footrest O. ‘* Remove the rear brake pedal. * Remove the clutch release arm from the clutch release pinion. Remove the clutch cable @ from the clutch cable SS * Disconnect the spark plug caps. * Remove the carburetors. (Refer to page 4-12.) ‘* Disconnect the starter motor lead wire @ and crankcase breather hose @.35_ENGINE * Disconnect the pick-up coil/power source coil lead wire coupler @ from the CDI unit. * Disconnect the rear brake lamp switch lead wire coupler ©. Remove the lead wires from the clamps. © Disconnect the generator coil and neutral position in: cator switch lead wire couplers. Remove the lead wires from the clamps. © Remove the engine ground wire and lead wire clamp, ‘* Remove the clamp @. '* Remove the engine mounting nuts, bolts, spacers and brackets. * Remove the engine from the right side of the frame.ENGINE 3.6 ENGINE REINSTALLATION Reinstall the engine in the reverse order of engine removal. ‘ Insert the two long bolts from the left side. Install the brackets, spacers, bolts and nuts properly, as shown in the following illustration. NOTE: The engine mounting nuts are self-locking. Once the nuts have been removed, they are no longer of any use. Be sure to use new nuts and tighten them to the specified torque. © LENGTH ITEM Nem | kom | ibe Bolt @ 53 mm (2.1 in) ® 40 4.0 29.0 Bolt @ 100 mm (3.8 in) ®OO®! 65 | 47.0 Bolt © 235 mm (9.3 in) ©®O 40 0} 29.0 Bolt @ 235 mm (9.3 in) 3 23) 168 Bolt © 130 mm (6.1 in) Spacer © 27 mm (1.1 in) Spacer @ 65 mm (2.6 in)3:7 ENGINE © When installing the brake pedal, replace the cotter pin with a new one. * Tighten the right front footrest bolts to the specified torque. (©) Right front footrest bolt: 39 Nem (3.9 kg-m, 28.0 Ib-ft) * Apply THREAD LOCK SUPER "1303" to the engine sprocket mounting bolts and tighten them to the speci- fied torque. 5] 99000-32030: THREAD LOCK SUPER “1303” ©) Engine sprocket bolt: 6 Nem (0.6 kg-m, 4.5 Ib-ft) © Tighten the left front footrest bolts to the specified torque. (©) Lett front footrest bolt: 39 Nem (3.9 kg-m, 28.0 lb-ft) * Properly install the oil cooler pipes onto the clutch cover and cylinder head. A CAUTION Replace the O-rings @ with new ones to prevent oil leakage. * Tighten the oil pipe bolts to the specified torque. {© Oil pipe bott: 10 Nem (1.0 kg-m, 7.0 Ib-ft)© After remounting the engine, route the wire harnesses, cables and hoses properly by referring to the wire rout- ing, cable routing and hose routing sections. (Refer to pages 7-10 through 7-22.) ‘© Adjust the following item: Throttle cable play * Idle speed .. * Clutch lever play * Drive chain slack. (Refer to page 2-7.) (Refer to page 2-6.) (Refer to page 2-8.) Refer to page 2-10.) * Pour 2.6 L (2.7/2.3 US/Imp at) of engine oil SAE 10W/40 graded SF or SG into the engine after overhauling + Start up the engine and allow it run for several minutes at idle speed and then stop it. Wait a few minutes and then check that the oil level remains between the marks on the oil level inspection window ®. Oil change (without oil filter replacement) | 2300 ml (2.4/2.0USAmp at) change (with oif filter zepfacement) Engine overhaul 2.600 mi (2.7/2.3 US/Imp at) 2.400 mi (2.5/2.1 US/Imp qt)3.9 ENGINE ENGINE DISASSEMBLY AND REASSEMBLY ENGINE DISASSEMBLY * Remove the oil pipe by removing the mounting bolts. ‘* Remove the two spark plugs. ‘* Remove the generator cover by removing the bolts. ‘* Remove the dowel pin and gasket. NOTE: Before removing the cylinder head cover, the piston must be at Top Dead Center (TDC) on the compression stroke. Align the "T” mark @ on the generator rotor with the index mark @ on the crankcase. © Remove the valve inspection caps.ENGINE 3-10 © Loosen the cylinder head cover bolts in ascending order and then remove the cylinder head cover. * Remove the dowel pins. © Remove the cam chain tensioner adjuster by removing the bolts. © Flatten the camshaft sprocket lock washer and remove the camshaft sprocket bolts. ‘* Remove the C-ring ©, camshaft sprocket and camshaft. NOTE: The cam chain tensioner bolt @ is to be removed only when disassembling the engine. A CAUTION Do not drop the cam chain, sprocket into the crankcase. .. C-ring or camshaft * Loosen the cylinder head bolts and nuts in a crisscross pattern, then remove them. ‘* Remove the cylinder head. NOTE: If it is difficult to remove the cylinder head, gently pry it off while tapping the finless portion of the cylinder head with a plastic hammer. Be careful not to break the fins. ‘* Remove the dowel pins and gasket.3.11 ENGINE ‘* Remove the cam chain guide. * Remove the cylinder by removing the nuts. A CAUTION e careful not to damage the fins when removing or handling the cylinder. ‘* Remove the dowel pins and gasket. * Place a clean rag over the cylinder base to prevent the piston pin circlips from dropping into the crankcase. Remove the piston pin circlips with long-nose pliers. ‘* Remove the piston by removing the piston pin. * Remove the clutch cover by removing the bolts, ‘* Remove the clutch pressure plate by loosening the clutch spring bolts in a crisscross pattern, Remove the clutch release rack. * Remove the clutch drive and driven plates.ENGINE 3:12 © Flatten the lock washer and remove the clutch sleeve hub nut with the special tool. (09920-53740: Clutch sleeve hub holder ‘© Remove the lock washer, concave washer and clutch sleeve hub. * Remove the thrust washer © and primary driven gear assembly. © Remove the thrust washer @. ‘* Remove the clutch cable holder and starter motor. ‘* Remove the starter torque limiter @, starter idle gear @ and starter idle gear shaft. ® Loosen the generator rotor bolt with a 36 mm offset wrench. NOTE: Do not remove the generator rotor bolt after loosening it. The generator rotor bolt is used in conjunction with the rotor remover, when removing the generator rotor.313 ENGINE ‘* Remove the generator rotor with the special tool. (09930-30721: Rotor remover ‘+ Remove the key ©. ‘* Remove the starter gear. ‘* Loosen the ring nut with special tool by holding the pri- mary drive gear nut. (BB 09917-23711: Ring nut socket wrench NOTE: Do not remove the ring nut after loosening it. ‘+ Temporarily install the starter gear, key, generator rotor and generator rotor bolt onto the crankshaft. NOTE: Do not tighten the generator rotor bolt. © Remove the primary drive gear nut by holding the gen- erator rotor. A CAUTION The primary drive geer nut has left-hand threads. ‘* Remove the generator rotor, key and starter gear. ‘* Remove the cam chain.ENGINE 3.14 © Remove the concave washer, primary drive gear and cam chain @. © Remove the generator rotor bolt, generator rotor, key, starter gear, thrust washer and ring nut. * Remove the crankcase oil separator @ by removing the screws. © Remove the gearshift cover by removing the bolts. Remove the gasket and dowel pins. ‘* Remove the gearshift shaft @ and cam driven gear @ by removing the screws ©. NOTE: When removing the cam driven gear, do not lose the gear- shift pawls ®, pins @ and springs ®. * Remove the oil pump idle gear by removing the circlip. (€B 09900-06107: Snap ring pliers * Remove the oil pump by removing the mounting screws.315 ENGINE * Remove the breather cover. ‘* Remove the neutral position indicator switch. NOTE: Do not lose the neutral position indicator switch contact and spring @. » Remove the crankcase securing bolts. ‘Separate the left and right crankcases. 09920-13120: Crankcase separating tool (09910-33210: Crankshaft installer attachment NOTE: Install the crankcase separating tool, so that the tool arms ate parallel to the crankcase. ACAUTION] ‘The crankshaft and transmission components must remain in the right crankcase. This is necessary because the gearshift cam stopper is mounted on the right crankcase and will be damaged if the transmis- sion components remain in the left crankcase. © Remove the dowel pins. ‘* Remove the gearshift cam stopper.ENGINE 3-16 ‘© Remove the gearshift fork shafts and gearshift forks. ‘* Remove the gearshift cam. © Remove the driveshaft assembly and countershaft assembly. © Align the punch marks on the balancer shaft drive gear and driven gear. © Remove the balancer shaft. © Remove the crankshaft. (6B) 09920-13120: Crankshaft remover (Crankcase separating tool)S17 ENGINE ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassem- bly. The following steps require special attention or pre- cautionary measures should be taken. NOTE: Apply engine oil to each running and sliding part before reassembling. OIL SEALS Fit the respective oil seals to the crankcase, clutch cover and gearshift cover. * Apply SUZUKI SUPER GREASE “A” to the lip of each oil seal. A@H199000-32010: SUZUKI SUPER GREASE “A” A CAUTION During reassembly, replace the oil seals with new ones to prevent oil leakage. CRANKSHAFT ‘* When mounting the crankshaft, it is necessary to pull its right end into the crankcase, (Gd 09910-32812: Crankshaft installer (09910-32830: Attachment (09910-32860: Attachment [A CAUTION Never fit the crankshaft into the crankca: it with a plastic hammer. Always use the special tool, otherwise the crankshaft may be misaligned. by strikingENGINE 3-18 BALANCER SHAFT ‘© When installing the balancer shaft, align the punch marks (D and @) on the balancer shaft drive gear and driven gear. GEARSHIFT MECHANISM © After installing the countershaft assembly and driveshaft assembly into the right crankcase, fit the gearshift forks ©, ® and @ into the gearshift fork grooves. @ For Sth (Top) driven gear (No.1) @ For 4th driven gear (No.2) @ For 3rd drive gear (No.3) NOTE: Three kinds of gearshift forks, © (No.1), @ (No.2) and @ (No.3) are used. Carefully examine the illustration for correct installation positions and directions. * Position the gearshift cam, as shown, so that the gear- shift fork shafts can be installed easily. NOTE: When replacing the gearshift cam stopper bolt@, apply a small quantity of THREAD LOCK “1342” to the threaded part of the bolt. + 99000-32050: THREAD LOCK “1342” * Install the gearshift cam stopper spring.3.19 ENGINE CRANKCASE When reassembling the crankcase pay attention to the fol- lowing: © Remove any sealant material on the mating surfaces of the right and left halves of the crankcase and thoroughly remove any oil stains. ‘* Apply SUZUKI BOND NO.1215 uniformly to the mating surface of the left crankcase and assemble the cases within a few minutes. BW] 99000-31110: SUZUKI BOND NO. 1215 © Install the dowel pins © in the right crankcase. * Apply engine oil to the conrod big end of the crankshaft and to all of the transmission parts. * Tighten the crankcase bolts to the specified torque. {7) crankcase bolt: 11 N-m (1.1 kg-m, 8.0 Ib-ft) © After the crankcase bolts have been tightened, check if the driveshaft and countershaft rotate smoothly. © Ifthe shafts do not rotate smoothly, try to free the shafts by tapping the driveshaft or countershaft with a plastic hammer. CAM DRIVEN GEAR When instaiting the gearshift pawls into the cam driven gear, the large shoulder @ must face to the outside, as shown. ‘* When installing the cam guide @ and paw! lifter ©, apply a small quantity of THREAD LOCK “1342” to the threaded parts of the securing screws @. ‘33 29000-32050: THREAD LOCK “1342”ENGINE 3:20 GEARSHIFT SHAFT * Properly fit the spring to the gearshift shaft. Install the gearshift shaft. Align the center teeth of the gear on the gearshift shaft with the center teeth on the cam driven gear, as shown. Install the washer @. NOTE: When replacing the gearshift arm stopper@, apply a small quantity of THREAD LOCK SUPER “1303” to its threaded art and tighten it to the specified torque. +83 99000-32030: THREAD LOCK SUPER “1303” (©) Gearshift arm stopper: 19 Nem (1.9 kg-m, 13.5 Ib-ft) © Install the dowel pins @ and new gasket. © Install the gearshift cover and tighten the bolts diago- nally. NOTE: After the gearshift cover and gearshift lever have been installed, make sure that the gears correctly change (while turning the countershaft and driveshaft). If the gears do not change correctly, determine the cause and make the appro- priate adjustments. NEUTRAL POSITION INDICATOR SWITCH © Install the neutral position indicator switch spring @ and switch contact ©. © Install the neutral position indicator switch. © Install the breather cover.S21 EN ol PUMP * Before mounting the oil pump, apply engine oil to the sliding surfaces of the oil pump body, outer rotor, inner rotor and shaft. ‘* Apply a small quantity of THREAD LOCK "1342" to the oil pump mounting screws. +] 99000-32050: THREAD LOCK “1342” © Tighten the oil pump mounting screws. © Install the oil pump idle gear and circlip. CAM CHAIN AND PRIMARY DRIVE GEAR/GENERATOR AND STARTER MOTOR © Install the cam chain. * Fit the key © in the key slot on the crankshaft, then install the primary drive gear, concave washer and nut. NOTE: * The sunken side of the concave washer faces the crank- case. * The primary drive gear nut has left-hand threads. © Install the crankcase oil separator @. * To hold the crankshaft, temporarily install the ring nut, starter gear, key, generator rotor and generator rotor bolt.ENGINE 3.22 © Tighten the primary drive gear nut to the specified torque by holding the generator rotor. (7 Primary drive gear nut: 100 Nem (10.0 kg-m, 72.5 lb-ft) © Remove the generator rotor bolt, generator rotor, key and starter gear. © Tighten the ring nut to the specified torque with the spe- cial tool by holding the primary drive gear nut. (BB 09917-23711: Ring nut socket wrench (©) Ring nut: 80 N-m (8.0 kg-m, 58.0 Ib-ft) © Install the starter gear. '* Remove any grease from the tapered portion of the gen- erator rotor and crankshaft. * Install the key @) onto the crankshaft, then install the generator rotor while rotating the starter gear clockwise. After installation, check that the gear turns one direc- tion only. ‘© Apply a small quantity of THREAD LOCK SUPER “1303” tothe threaded part of the generator rotor bolt. 3&3 99000-32030: THREAD LOCK SUPER “1303”3.23 ENGINE ‘* Tighten the generator rotor bolt to the specified torque with the 36 mm offset wrench. (©) Generator rotor bolt: 160 N-m (16,0 kg-m, 115.5 Ib-ft) CLUTCH # Install the thrust washer ®. ‘= Install the spacer with the primary driven gear assembly. NOTE: Apply engine oil to both the inside and outside of the spacer. © Install the thrust washer ®. ‘ Install the clutch sleeve hub, lock washer @ and concave washer. NOTE: + When installing the lock washer @, align the slit @ of the lock washer with the rib of the clutch sleeve hub. ‘+ The sunken side of the concave washer faces the crank- case. « Tighten the clutch sleeve hub nut to the specified torque with the special tool. (GB 09920-53740: clutch sleeve hub holder (©) clutch sleeve hub nut: 50 Nem (5.0 kg-m, 36.0 lb-ft) ‘* After tightening the clutch sleeve hub nut, be sure to lock the nut by firmly bending the tongue of the lock washer. © Install the clutch drive plates and driven plates one by one. * Install the clutch pressure plate with clutch release rack.ENGINE 3.24 Tighten the clutch spring bolts in a crisscross pattern, to the specified torque. (© clutch spring bott: 10 Nem (1.0 kg-m, 7.0 lb-ft) © Install the dowel pins and gasket. A CAUTION Use a new gasket to prevent oi jeakag © Engage the teeth of the clutch release rack with those of the clutch release pinion at the clutch cover side, and replace the clutch cover. Make sure that the clutch release rack and clutch release pinion engage positively. To install the clutch cover, tap lightly with a plastic ham- mer, and tighten the bolts. ©: Gasket © Install the starter torque limiter and starter idle gear. ne ‘© Anstall the starter motor and clutch cable holder.3.25_ ENGINE PISTON AND CYLINDER * Position the piston ring gaps, as shown. Before inserting the piston into the cylinder, check that the gaps are prop- erly positioned. © Place a clean rag over the cylinder base to prevent the piston pin circlips from dropping into the crankcase. ‘© Apply a small quantity of SUZUKI MOLY PASTE onto the piston pin. 44SH199000-25140: SUZUKI MOLY PASTE ‘+ When fitting the piston, the arrow mark © on the piston crown points towards the exhaust side. * Install the piston pin circlips with long-nose pliers. ACAUTION Use new piston irclips to prevent circlip failur * Install the dowel pins ® and a new gasket, A CAUTION Use a new gasket to prevent oll leakage. © Make sure that the piston rings are properiy positioned, and insert the piston into the cylinder. NOTE: When mounting the cylinder, keep the cam chain @) taut. The cam chain must not be caught between the cam chain drive sprocket and crankcase when the crankshaft is rotated. + 2nd ring * Lower side \ Upper side rail rail 17 Top ring in. * SpacerENGINE 3:26 * Install the cam chain guide. NOTE: A holder for the bottom end of the cam chain guide is cast into the crankcase. Make sure that the cam chain guide @® is inserted properly. ‘* Temporarily tighten the cylinder base nuts. CYLINDER HEAD * Install the dowel pins @ and a new gasket A CAUTION Use gasket to prevent oi * Place the cylinder head onto the cylinder. © The cylinder head bolts and the new gasket must be installed in the correct position, as shown. @®: 200 mm bolt ©; 190 mm bolt ©: 180 mm bolt NOTE: Before installation, apply engine oil onto the new gasket. © Tighten the cylinder head bolts and nuts to the specified torque. (7) cylinder head bolt: 38 Nem (3.8 kg-m, 27.5 Ib-ft) Cylinder head nut: 25 Nem (2.5 kg-m, 18.0 Ib-ft) ) * After tightening the cylinder head bolts and nuts, tighten the cylinder base nuts to the specified torque. ©) cylinder base nut: 10 Nem (1.0 kg-m, 7.0 Ib-ft)3.27 ENGINE CAMSHAFT © Turn the crankshaft counterclockwise and align the “T” mark @ on the generator rotor with the index mark @ on the crankcase while keeping the cam chain tight. A CAUTION If the crankshaft is turned without drawing the cam chain upward, the cam chain will catch between the crankcase and cam chain drive sprocket. NOTE: Apply grease on the camshaft sprocket locating pin and install the pin into the camshaft. ‘+ Engage the cam chain onto the camshaft sprocket with the locating pin hole @ at two o'clock position, * Fit the camshaft to the camshaft sprocket so that the camshaft sprocket locating pin is inserted into the pin hole of the sprocket. © Make sure that the engraved marks @ on the camshaft are aligned with the upper surface of the cylinder head. NOTE: Do not rotate the generator rotor while doing this. When the sprocket is not positioned correctly, turn only the cam- shaft sprocket. When installing the camshaft into the cam- shaft sprocket, do not dislodge the locating pin or it may fall into the crankcase. * Install the C-ring © into the ring groove in the cylinder head. © Install the camshaft sprocket lock washer so that it cov- ers the camshaft sprocket locating pin * Apply THREAD LOCK SUPER “1303” to the camshaft sprocket bolts and tighten them to the specified torque. (©) camshatt sprocket bolt: 15 Nem (1.5 kg-m, 11.0 Ib-ft) +8] 99000-32030: THREAD LOCK SUPER “1303” ‘© Bend the camshaft sprocket lock washer tabs to lock the bolts.ENGINE 3-28 * Apply SUZUKI MOLY PASTE to the camshaft journals and cam faces. A@@199000-25140; SUZUKI MOLY PASTE NOTE: The cam chain tensioner adjuster maintains the proper ten- sion automatically. Before installing the cam chain ten- sioner adjuster, inspect it for smooth movement. * Remove the cap bolt and turn the cam chain tensioner push rod clockwise until it is locked. Install the cam chain tensioner adjuster onto the cylinder. (F) cam chain tensioner bolt @: 10 Nem (1.0 kg-m, 7.0 lb-ft) * Turn back the cam chain tensioner push rod with the screwdriver to unlock it. Pull out the screwdriver. © Turn the crankshaft counterclockwise to extend the cam chain tensioner. © Tighten the cam chain tensioner adjuster cap bolt @. {®) cam chain tensioner adjuster cap bolt @: 6 Nem (0.6 kg-m, 4.5 lb-ft) CYLINDER HEAD COVER ‘© Make sure that the mating surfaces of the cylinder head and cylinder head cover are free from moisture, oil, dust and other foreign materials. © Install the dowel pins © and camshaft end cap ®. * Apply SUZUKI BOND NO.1215 thinly and evenly to the mating surface of the cylinder head cover, and install the cylinder head cover within a few minutes of application. GH] 99000-31110: SUZUKI BOND NO.12153:29 ENGINE © Install the gasket © and cylinder head cover bolts cor- rectly. A Use a new gasket to prevent oil leakage. NOTE: When tightening the cylinder head cover bolts, the piston must be at Top Dead Center (TDC) on the compression stroke. © Lightly tighten the cylinder head cover bolts in ascend- ing order, and then securely tighten them with a torque wrench to the specified torque. (©) cylinder head cover bolt: 10 Nem (1.0 kg-m, 7.0 lb-ft) * Check and adjust the valve clearance. (Refer to page 2-3.) * Install the valve inspection caps and two spark plugs. NOTE: Apply engine oil lightly to the O-rings. © Install the dowel pin. © Install the gasket and generator cover. LA CAUTION Use a new gasket to prevent oil leakage. © Install the oil pipe and tighten the union bolts to the specified torque. 1) oil pipe union bolt ‘Nem (2.3 kg-m, 16.5 Ib-ft) @: 20 Nem (2.0 kg-m, 14.5 lb-ft)CYLINDER HEAD COVER/ROCKER ARM Tighioning sequence 1 1 Ces’ 5 iros— 2 4 Ss 6 3 6 1 B—g son iokg-m, 29.0 1b) OF e212 \ eS a 22Nm ‘28 kom, 200 CONTENTS CYLINDER HEAD COVER REMOVAL . ROCKER ARM REMOVAL INSPECTION AND SERVICE ROCKER ARM INSTALLATION. CYLINDER HEAD COVER INSTALLATION.3Ac1_ENGINE CYLINDER HEAD COVER REMOVAL © Drain the engine oil. (Refer to page 2-9) ‘© Remove the front frame covers (right and left). (Refer to page 5-2) © Remove the fuel tank. (Refer to page 4-3) © Remove the clamp and the upper engine mounting bracket O. ‘* Remove the oil pipe mounting bolts. ‘* Remove the engine protector @. ‘* Disconnect the spark plug caps and remove the spark Plugs. © Remove the valve tor cover cap @. ing inspection plug @ and genera- ‘© Turn the crankshaft counterclockwise and align the “T” mark © on the generator rotor in the middle of the tim- ing inspection hole © on the generator cover. NOTE: Make sure that the piston is at Top Dead Center (TDC) on the compression stroke.ENGINE 38-2 * Remove the valve inspection caps and cylinder head cover. (Refer to pages 3-9 and 10.) ROCKER ARM REMOVAL \ CAUTION Identify the position of each removed part. Organize the parts in their respective groups (i.e., exhaust or intake) so that they can be reinstalled in their original positions. ‘* Remove the cylinder head cover. (Refer to page 34-1.) ¢ Remove each rocker arm shaft set bolt. © Remove the intake and exhaust rocker arm shafts with a 6mm bolt.3A:3_ ENGINE INSPECTION AND SERVICE CYLINDER HEAD COVER DISTORTION Remove any sealant from the cylinder head cover surfaces. Place the cylinder head cover on a surface plate and check for distortion with a thickness gauge. If the distortion exceeds the limit, replace the cylinder head cover. Service Limit: 0.05 mm (0.002 in) ROCKER ARM SHAFT 0.D. Measure the diameter of the rocker arm shaft with a micrometer. (09900-20205: Micrometer (0-25 mm) ‘Standard: 11.973-11.984 mm (0.4714-0.4718 in) ROCKER ARM LD. Measure the inside diameter of the rocker arm and also check the camshaft contacting surface for wear. (Bd 09900-20605: Dial calipers Standard: 12.000-12.018 mm (0.4724-0.4731 ii ROCKER ARM INSTALLATION Install the rocker arms in the reverse order of removal. Pay attention to the following points: ‘* Apply SUZUKI MOLY PASTE to the rocker arm shafts. A@H 99000-25140: SUZUKI MOLY PASTE © Install the rocker arms and shafts, as shown. ‘© Tighten the rocker arm shaft set bolts @ to the specified torque. (©) Rocker arm shaft set bolt ©: 28 Nem (2.8 kg-m, 20.0 lb-ft) NOTE: Use a new gasket on each set bolt.ENGINE 3A-4 CYLINDER HEAD COVER INSTALLATION Install the cylinder head cover in the reverse order of removal. Pay attention to the following points: © Install the cylinder head cover. (Refer to page 3-28.) © Install the oil pipes. ACAUTION ee Replace the O-ring © with a new one to prevent oil [_ leakage. ‘* Tighten the oil pipe securing bolts and union bolt to the specified torque. ©) oil pipe bott ©: 10 Nem (1.0 kg-m, 7.0 lb-ft) Oif pipe union bolt @: 23 Nem (2.3 kg-m, 16.5 lb-ft) * Tighten the upper engine mounting bracket nuts to the specified torque. [© Upper engine mounting bracket nut: 40 Nem (4.0 kg-m, 29.0 Ib-ft) © Tighten the engine protector bolts.sai fio ort Naren © pe te Speen a0 ano won 2 dite () qui-® ont aeniqa® eens OO ‘ari ot tied nainw bre stlod griumen eqin ho ott netighT © aupes belticeges OK pegl 0.0) rater @msogeto lh EBT ergs 6.) ee OS GQ) shed naire ong HD ott oF atun tedenrd gnitnvom eaigne Tengu ett nandigit = oumnot beflloegs 00 sednmed getiuenen enigre waait 2) {9 GHR sgt 8) tl OF -thod Tomtoig onigns ot naight +ENGINE 28.0 CAMSHAFT/CYLINDER HEAD/VALVES 10m (1.0 kgem, 7.0 tt) A - gee or eS (15 kgm, 1.0m DW 2snm (25 kgm, 180 bt) CAMSHAFT/CYLINDER HEAD REMOVAI VALVE REMOVAL...... INSPECTION AND SERVIC! VALVE INSTALLATION... CYLINDER HEAD/CAMSHAFT INSTALLATION.3B-1_ ENGINE CAMSHAFT/CYLINDER HEAD REMOVAL ‘* Remove the carburetor. (Refer to page 4-12.) ‘* Remove the cylinder head cover. (Refer to page 3A-1.) ‘* Remove the oil cooler pipe @. ‘© Remove the fuel tank rubber damper ©. ‘* Remove the right rear footrest, muffler and exhaust pipe. (Refer to pages 3-2 and 3-3.) ‘* Disconnect the clutch cable by removing the clutch lever. Remove the camshaft and cylinder head. (Refer to page 3-10.) * Remove the cam chain tensioner by removing the bolt. ‘* Remove the intake manifolds @ and O-rings. ‘aENGINE 38-2 VALVE REMOVAL Using the special tools, compress the valve spring and remove the valve cotters from the valve stem. (09916-14510: Valve spring compressor (09916-14910: Valve spring compressor attachment 09916-84511: Tweezers Remove the valve spring retainer, inner spring and outer spring. '* Remove the valve from the combustion chamber side. . Remove the oil seal with long-nose pliers. ‘* Remove the spring seat. NOTE: If the valve guides have to be replaced, refer to valve guide servicing on page 3B-6. INSPECTION AND SERVICE (CAMSHAFT/AUTOMATIC DE-COMP. ASSEMBLY ‘A CAUTION | Do not attempt to disassemble the automatic de- |_ comp. assembly. It is not serviceable. BROT SECO ee ree erence eee AUTOMATIC DE-COMP. Move the automatic de-comp. weight by hand to make sure that it operates smoothly. If it does not operate smoothly, replace it.3B-3_ ENGINE CAMSHAFT If the engine produces abnormal noises, vibrates or lacks power, the camshaft may be distorted or worn to the ser- limit. The camshaft runout should be checked. Also, check the cams and journals for wear or dama: CAMSHAFT CAM WEAR Worn cams are often the cause of mistimed valve opera- tion resulting in reduced power output. Use a micrometer to measure the cam height ©). Replace the camshaft if the cams are worn to the service limit. (65) 09900-20202: Micrometer (25-50 mm) Camshaft cam height © Service Limit Intake cam: 33.390 mm (1.3146 Exhaust cam: 33.380 mm (1.3142 CAMSHAFT JOURNAL WEAR Determine whether or not each journal is worn to the ser- vice limit by measuring the camshaft journal oil clearance with the camshaft installed in place. Use the plastigauge to measure the clearance. (GB 09900.22301: Piastigauge Tighten the cylinder head cover bolts evenly and diago- nally to the specified torque. NOTE: Make sure that the gasket surface of the cylinder head and cylinder head cover are clean and free of any bond or other material. Do not apply SUZUKI BOND NO. 12078 until after the oil clearance has been determined. ©) cylinder head cover bolt: 10 N-m (1.0 kg-m, 7.0 lb-ft) NOTE: Do not rotate the camshaft with the plastigauge in place. Remove the cylinder head cover and read the width of the ‘compressed plastigauge with the envelope scale. This measurement should be taken at the widest part of the compressed plastigauge. Camshaft journal oil clearance ‘Service Limit: 0.150 mm (0.0059 in)ENGINE 38-4 If the camshaft journal oil clearance exceeds the service limit, measure the outside diameter of the camshaft. Replace either the cylinder head or the camshaft if the clearance is incorrect. (BD 09900-20205: Micrometer (0-25 mm) Camshaft journal 0.D.: 21.959-21.980 mm (Right & Center) (0.8645-0.8654 in} Camshaft journal 0.0.: 17.466-17.484 mm. (Left) (0.6877-0.6883 in) CAMSHAFT RUNOUT Measure the runout with a dial gauge. Re, shaft if the runout exceeds the service limit. 35 09900-20701: Magnetic stand (09900-20606: Dial gauge (1/100 mm) (09900-21304: V-block Service Limit: 0.10 mm (0.004 in) 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, Replace the cylinder head if the readings exceed the service limit. Service Limit: 0.05 mm (0.002 in) VALVE FACE WEAR Measure the valve face ©. If it is out of specification, replace the valve with a new one. NOTE: Visually inspect each vaive face for wear. Replace any | valve with an abnormally worn face. Service Limit: 0.5 mm (0.02 in) VALVE STEM RUNOUT Check the valve stem runout with a dial gauge. Replace the valve if the runout exceeds the service limit. 08900-20701: Magnetic stand 09900-20606: Dial gauge (1/100 mmj (09900-21304: V-biock (100 mm) Service Limit: 0.05 mm (0.002 in)3B-5_ ENGINE VALVE HEAD RADIAL RUNOUT Place the dial gauge at a right angle to the valve head face and measure the valve head radial runout. Replace the valve if it measures more than the service limit. Service Limit: 0.03 mm (0,001 in) VALVE STEM DEFLECTION Lift the vaive about 10 mm (0.39 in) off the valve seat. Measure the valve stem deflection in two directions, “ and “Y", perpendicular to each other. Position the di gauge, as shown. If the deflection exceeds the service limit, determine whether the valve or the guide should be replaced with a new one. () 09900-20606: Dial gauge (1/100 mm) (09900-20701: Magnetic stand Service Limit Intake and exhaust valves: 0.35 mm (0.014 in) VALVE STEM WEAR Measure the valve stem ©.D. If it is out of specification, replace the valve with a new one. If the valve stem O.D. is within specification, but the valve stem deflection is not, replace the valve guide. After replacing the valve or valve guide, recheck the clearance. (GB) 09900-20205: Micrometer (0-25 mm) Standard IN.: 5.475-5.490 mm (0.2156-0.2161 in) EX.: 5.455-5.470 mm (0.2148-0.2154 in)ENGINE 38-6 VALVE GUIDE SERVICING Using the valve guide remover, drive the valve guide out toward the camshaft side. (CB 09016-44910: Valve guide remover/installer NOTE: * Discard the removed valve guide subassemblies. * Only oversized valve guides are available as replace- ‘ment parts. (Part No.11115-32E70.) * Re-finish the valve guide holes in the cylinder head with the reamer ® and handle ©. 09916-34580: Valve guide reamer 09916-34542: Reamer handle * Fit a ring to each valve guide. Be sure to use new rings and valve guides. * Oil the stem hole of each valve guide and drive the guide into the guide hole with the valve guide installer. (GS 09916-44910: Valve guide remover/installer hole before driving the ew guide into place may result in a damaged guide or head. © After fitting the valve guides, re- the reamer @ and handle @. Be sure to clean and oil the. guides after reaming. 09916-34550: Valve guide reamer 09916-34542: Reamer hand VALVE SEAT WIDTH © Coat the vaive seat uniformly with Prussian blue. Install the valve and attach a valve lapper onto it. Tap the coated seat with the valve face in a rotating manner, in order to obtain a clear impression of the seating contact. © The ring-tike dye impression left on the valve face must be continuous without any breaks. In addition, the width of the dye ring, which is the valve seat width, must be within the following specification:30-7_ENGINE Standard Valve seat width @: 0.9-1.1 mm (0.035-0.043 in) If the valve seat is out of specification, re-cut the seat. VALVE SEAT SERVICING The valve seats for both the intake and exhaust valves are machined to two different angles. The seat contact surface is cut at 45°. INTAKE EXHAUST, 45° N-626 45° N-229 30" N-626 15 N-229 (BB) 09916-24900: Valve seat cutter set (09916-24810: Valve seat cutter (N-626) 09916-27720: Valve seat cutter (N-229) (09916-24480: Solid pilot (N-140-5.5) NOTE: The valve seat contact area must be inspected after each cut. © When installing the solid pilot, rotate it slightly. Seat the pilot snugly. Install the 45" cutter and T-handle. * Using the 45° cutter, descale and clean up the seat. Rotate the cutter one or two turns. * Inspect the valve seat width after every cut. If the valve seat is pitted or burned, use the 45° cutter to condition the seat some more. NOTE: Cut only the minimum amount necessary from the seat. INTAKE EXHAUST 5 e Valve seatENGINE 38-9 If the contact area is too high on the valve, or if it is too wide, use the 30° cutter (for the intake side) and the 15° cut- ter (for the exhaust side) to lower and narrow the contact area. If the contact area is too low or too narrow, use the 45° cut- ter to raise and widen the contact area. * After the desired seat position and width is achieved, use the 45° cutter very lightly to clean up any burrs caused by the previous cutting operations. [A CAUTION DO NOT use lapping compound after the final cut is made. The finished valve seat should have a velvety smooth finish and not a highly polished or shiny fin- a soft surface for the final se: il occur during the first few * Clean and assemble the cylinder head and valve compo- nents. 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. A WARNING ‘Always use extreme caution when handling gasoline. NOTE: After servicing the valve seats, be sure to check the valve clearance after the cylinder head has been reinstalled. (Refer to page 2-3.) Contact area t00 high and too wide on face of va ‘Contact area too low and too narrow on face of valve38.9. ENGINE VALVE STEM END CONDITION Inspect the vaive stem end face for pitting and wear. If pit- ting or wear of the valve stem end face are present, the valve stem end should be resurfaced, providing that the length © will not be reduced to less than 2.7 mm (0.11 in). If this length becomes less than 2.7 mm (0.11 in), the valve should be replaced. After installing a valve whose stem end has been resurfaced as above, check to ensure that the face ® of the valve stem end is above the cotters @. VALVE SPRING The force of the coil spring keeps the valve seat tight. A weakened spring results in reduced engine power output and accounts for the chattering noise coming from the valve mechanism. Check the vaive springs for proper strength by measuring their free length and also by the force required to compress them. If the spring length is less than the service limit or if the force required to compress the spring does not fall within the range specified, replace both the inner and outer springs as a set. (09900-20102: Vernier calipers Valve spring free length Service Limit INNER: 34.4 mm (1.35 in) OUTER: 38.1 mm (1.50 in) Valve spring tension Standard INNER: 5.9-6.7 kg/27.5 mm (13.0-148 Ibs/1.1 in) OUTER: 13.8-15.8 kg/31.0 mm (30.4-34.8 Ibs/1.2 in) 59-6719 (130-1481) & + 27.5 mm (1.1 In)VALVE INSTALLATION ‘Install the valve spring seat ©. Be careful not to confuse the lower seat with the spring retainer @. © Lubricate each oil seal with oil and fit the seals onto each guide, Be sure to oil each oil seal lip. A CAUTION Do not reuse the oil seal © Insert the valves, with their stems coated with high qual- ity molybdenum disulfide lubricant (SUZUKI MOLY PASTE). Coat the entire stem making sure that there are no gaps. iw 99000-25140: SUZUKI MOLY PASTE A CAUTION ‘When inserting each the lip of the oil se © Install the valve springs with the smaller pitch © facing the cylinder head. © Install the valve spring reteiner and, using the valve lifter, press down the springs, fit the cotter halves to the stem end and release the lifter to allow the cotter @ to wedge between the retainer and the valve stem. Be sure that the rounded lip © of the cotter fits snugly into the groove @ in the stem end. 09916-14510: Valve spring compressor (09916-14910: Valve spring compressor attachment 09916-84511: Tweezers3B-11_ ENGINE ‘A CAUTION] Be sure to install all of the parts in their original posi- | tions. 4 CYLINDER HEAD/CAMSHAFT INSTALLA- TION Install the cylinder head and camshaft in the reverse order of removal. Pay attention to the following points: * Replace the O-rings with new ones when removing the intake manifolds. NOTE: + Apply SUZUKI SUPER GREASE “A” to the O-rings. 99900-25010: SUZUKI SUPER GREASE “A~ ‘ Install the intake manifold so that the “1A"mark (left side)/“2A” mark (right side) faces upward. Install the cam chain tensioner. © Install the camshaft and cylinder head. (Refer to pages 3-26 and 3-27.) ‘ Install the cylinder head cover. (Refer to page 3-28.) © Install the oil cooler pipe. (@ CAUTION] Replace the O-ring © with a new one to prevent oil kage. ‘* Tighten the oil pipe securing bolts to the specified torque. (7) Oil pipe bott: 10 Nem (1.0 kg-m, 7.0 lb-ft)ENGINE 36-0 CYLINDER/PISTON 10Km Dese,..r0em 7 & PISTON/CYLINDER INSTALLATION + an cng ~~ “Core C= pe ie (aN - <=. eo tine In, * Spacer fina car rosiTion © ote Se @ Piston rings @ Oilring 9 Paton CONTENTS CYLINDER/PISTON REMOVAL ‘3C-1 INSPECTION AND SERVICE 3C-13C-1_ENGINE CYLINDER/PISTON REMOVAL © Remove the cylinder head cover. (Refer to page 34-1.) © Remove the camshaft and cylinder head. (Refer to page 3B-1.) ‘* Remove the cylinder and piston. (Refer to page 3-11.) INSPECTION AND SERVICE CYLINDER DISTORTION Check the gasket surface of the cylinder for distortion, Use a straightedge and thickness gauge. Take clearance read- ings at several places. If any clearance readings exceed the service limit, replace the cylinder. Service Limit: 0.05 mm (0.002 in) CYLINDER BORE Inspect the cylinder wall for nicks, scratches or other dam- age. (09900-20508: Cylinder bore gauge set 09900-20513: Gauge rod Standard: 100.000-100.015 mm (3.9370-3.9376 in) PISTON DIAMETER Measure the piston diameter with a micrometer at 21 mm (0.8 in) from the skirt end. If the piston diameter is less than the service limit, replace the piston. (6) 09900.20204: Micrometer (75-100 mmi Service Limit: 99.880 mm (3.9323 in) PISTON-CYLINDER CLEARANCE ‘Subtract the piston diameter from the cylinder bore diame- ter. If the piston to cylinder clearance exceeds the service limit replace both cylinder and piston. Service Limit: 0.120 mm (0.0047 in) 21mmENGINE 36-2 PISTON RING-GROOVE CLEARANCE Install the piston ring into the piston ring groove. Insert the thickness gauge under the piston ring and measure the pis- ton ring side clearance. If any of the measurements exceed the service limit, replace both the piston and piston rings. (09900-20803: Thickness gauge (09900-20205: Micrometer (0-25 mm) ston ring-groove clearance Service Limit Ast: 0.180 mm (0.0071 in) 2nd: 0.150 mm (0.0059 in) Piston ring groove width Standard Ast: 1.23-1.25 mm (0,048-0,049 in) 2nd: 1.21-1.23 mm (0.047-0.048 in) Oil: 2.81-2.83 mm (0.110-0.111 in) Piston ring thickness Standard ‘st: 1.170-1.190 mm (0.0461-0.0469 in) 2nd: 1.150-1.170 mm (0.0453-0.0481 in) NOTE: Using a soft-metal scraper, decarbon the crown of the pis- ton and the piston ring grooves. PISTON RING FREE END GAP AND PISTON RING END GAP Use vernier calipers to measure the piston ring free end gap. Next, fit the piston ring squarely into the cylinder and measure the piston ring end gap with a thickness gauge. If any of the measurements exceed the service limit, replace the piston ring with a new one. BD 09900.20102: vernier calipers Piston ring free end gap Service Limit ‘1st: 10.8 mm (0.43 in) 2nd: 9.1 mm (0.36 in) (09900-20803: Thickness gauge Piston ring end gap Service Limit ‘1st: 0.50 mm (0.020 in) 2nd: 1.00 mm (0.039 in)30:3 ENGINE PISTON PIN AND PIN BORE Measure the piston pin bore inside diameter and use a micrometer to measure the piston pin outside diameter. If ither is out of specification or the difference between these two measurements is more than the service limits, replace both the piston and piston pin (Gy 09900-20605: Dial calipers (09900-20205: Micrometer (0-25 mm) Piston pin bore Service Limit: 23.030 mm (0.9067 in) Piston pin 0.0. Service Limit: 22.980 mm (0.9047 in) PISTON/CYLINDER INSTALLATION Install the piston and cylinder in the reverse order of removal. Pay attention to the following points: OIL RING Install the spacer © into the oil ring groove first. Then install both side rails @, one on each side of the spacer. The spacer and side rails do not have a specific top or bot- tom when they are new. When reassembling used parts, install them in their original place and direction. TOP RING AND 2ND RING The top ring and 2nd ring have different ring face shapes. The top ring and 2nd ring have either “R” or “RN” marked ‘on the side. The piston rings should be installed with the mark facing up. Position the gaps of the three rings as shown in the illustra- tion, (Refer to page 3C-0.) Before inserting the piston into the cylinder, check that the gaps are located correctly. * Install the piston and cylinder head. (Refer to page 3-25.) Ree eo8 A INCORRECTENGINE 30-0 STARTER MOTOR/GENERATOR ROTOR/GEARSHIFT rm, 13.5 tb) 7 EX, 1 1008 (16.0 kg-m, 115.5 toe) © Goorshitt shaft CONTENTS STARTER MOTOR REMOVAL GENERATOR ROTOR REMOVAL GEARSHIFT SHAFT REMOVAL INSPECTION AND SERVICE .. GENERATOR ROTOR INSTALLATIO! GEARSHIFT SHAFT INSTALLATION STARTER MOTOR INSTALLATION.3D-1_ ENGINE STARTER MOTOR REMOVAL ‘* Remove the right frame covers. (Refer to pages 5-2 and 5-4.) ‘© Remove the right rear footrest, muffler and exhaust pipe. (Refer to pages 3-2 and 3:3.) ‘* Disconnect the clutch cable by removing the clutch lever. ‘* Remove the oii pipe by removing the bolts ‘* Remove the cam chain tensioner. * Disconnect the starter motor lead wire ©. © Remove the clutch cable holder @ and starter motor ©. © Disassemble the starter motor. (Refer to page 6-13.) GENERATOR ROTOR REMOVAL © Drain the engine oil. (Refer to page 3-2.) * Remove the engine protector. ‘+ Remove the left front footrest and gearshift pedal. (Refer to page 3-3.) ‘* Remove the generator cover. * Remove the starter torque limiter, starter idle gear, gen- erator rotor and starter gear. (Refer to pages 3-12 and 3- 13) * Remove the three bolts with a 6 mm hexagon wrench and a 36 mm offset wrench.ENGINE 30-2 GEARSHIFT SHAFT REMOVAL * Remove the left front footrest, engine sprocket cover and gearshift pedal. (Refer (0 page 3-3.) Remove the gearshift cover. ‘© Remove the gearshift shaft @ and remove the cam driven gear ® by removing the screws @. oT! When removing the cam driven gear, do not lose the gear- shift pawls @, pins © and springs ©. INSPECTION AND SERVICE ‘STARTER CLUTCH Inspect the stater clutch for wear or damage. STARTER TORQUE LIMITER A CAUTIO! Do not ettemat to diseasemble the starter toque km] Do not attempt to disassemble the starter toque lim- iter. It is not serviceable. Check the slip torque of the starter torque limiter. Slip torque: 42-64 Nem (4.2-6.4 kg-m, 30.5-46.5 Ib-ft) (BD 09930-73110: Starter torque limiter holder 09930-73120: Starter torque limiter holder Attach the starter torque limiter and the special tools into the vise, as shown. If the slip torque limiter is not within specification, replace the starter torque limiter with a new one. :30-3_ ENGINE. GENERATOR ROTOR INSTALLATION Install the generator rotor in the reverse order of removal. Pay attention to the following points: * Apply THREAD LOCK SUPER "1303" to the bolts and tighten them to the specified torque. 3&3 99000-32030: THREAD LOCK SUPER “1303” (Bolt: 25 Nem (2.5 kg-m, 18.0 Ib-tt) Check that the generator rotor © turns in the direction of the arrow mark @ while holding the starter gear. The gen- erator rotor should never turn in the opposite direction of the arrow mark. * Install the generator rotor. (Refer to page 3-21.) © Install the dowel pin, A CAUTION Use a new gasket to prevent oil leakage. © Install the generator cover. GEARSHIFT SHAFT INSTALLATION Install the gearshift shaft in the reverse order of removal. (Refer to page 3-20.) STARTER MOTOR INSTALLTION Install the starter motor in the reverse order of removal.CLUTCH ENGINE 3E-0 © cut © Cluer © Concave washer @ Clutch driven plate No.2 (Thicker plat, Ype) ® Stopper ring @ Ciuteh drive plate No.2 (1 pe) @ Clutch driven plate No.1 (7 pe) @ Clutch drive plate No.1 (7 pe} @ Primary driven gear ass'y NOTE: Check to be sure that the concave washer is properly installed. as oKgm. 7.0164) ot anne &. ee CLUTCH REMOVAL... INSPECTION AND SERVICE. CLUTCH INSTALLATION CONTENTS3E-1_ENGINE CLUTCH REMOVAL © Drain the engine oil (Refer to page 2-9.) * Remove the right rear frame cover. (Refer to page 5-4.) * Remove the right rear footrest, muffler and exhaust pipe. (Refer to pages 3-2 and 3-3.) * Remove the right front footrest and rear brake pedal. (Refer to page 3-4.) * Disconnect the clutch cable at the clutch cable lever. (Refer to page 3-4 * Remove the engine protector. (Refer to page 3-2.) ‘¢ Remove the oil pipe mounting bolts. © Remove the clutch cover. * Remove all of the clutch parts. (Refer to page 3-11.)ENGINE 3E:2 INSPECTION AND SERVICE CLUTCH DRIVE PLATE Measure the thickness of each drive plate with vernier cal pers, Replace any limit. e plates that are worn to the service (09900-20102: Vernier calipers Standard Thickness No.1 & No.2: 2.9-3.1 mm (0.11-0.12 in) Service Limit Thickness No.1 & No.2: .6 mm (0.10 in) CLUTCH DRIVEN PLATE Measure each driven plate for distortion with a thickness gauge. Replace any driven plates which exceed the service limit. (09900-20803: Thickness gauge Service Limit: 0.1 mm (0.004 CLUTCH SPRING FREE LENGTH Measure the free length of each clutch spring with vernier calipers. If any spring is not within the service limit, replace all of the springs. (B 02900-20102: Vernier calipers Service Limit: 33.0 mm (1.30 in) Measuring thickness “Measuring free length36-3 ENGINE CLUTCH RELEASE BEARING Inspect the clutch release bearing for any abnormality; especially cracks. When removing the bearing from the clutch, decide whether it can be reused or if it should be replaced. Smooth engagement and disengagement of the clutch depends on the condition of this bearing CLUTCH RELEASE PINION AND RACK Rotate the clutch release pinion by hand to inspect for smooth rotation. Ifa large resistance is felt when rotating it, inspect the pi ion and rack for damage or wear. If any damage or wear is. found, replace them as a set. CLUTCH INSTALLATION Install the clutch in the reverse order of removal. Pay atten- tion to the following points: * Install all of the clutch parts. (Refer to page 3-23.) ‘ Install the oll pipes. A CAUTION {Replace the O-ring @ with a new one to prevent oil leakage. © Tighten the oil pipes securing bolts and union bolt to the specified torque. ©) oil pipe bott @: 10 Nem (1.0 kg-m, 7.0 Ib-ft) Oil pipe union bott @: 20 Nem (2.0 kg-m, 14.5 lb-ft)ENGINE 3.0 GEARSHIFT CAM/TRANSMISSION © 1st low) driven gear @ Sth (Top) driven gear @ 3rd driven gear @ 4th driven gear © 2nd driven gear © Driveshatt ® Countorshatv'st (low) drive gear . © 5th (Top! drive gear © 3rd drive gear a & &th drive gear @ 2na eve gear © Gonrahit cam stopper 7 © Gaarahift cam stopper plate & Gesrahit cam SS © Gowshit fork No. 1 & Gearnitt fork No. 2 ® Gearshift fork No. 3 INSPECTION AND SERVICE .. TRANSMISSION/GEARSHIFT3E-_ENGINE GEARSHIFT CAM/TRANSMISSION REMOVAL * Remove the engine. (Refer to pages 3-2 to 3-5.) © Separate the left and right crankcases. (Refer to pages 3-9 to 3-15.) © Remove the gearshift cam, driveshaft assembly and countershaft assembly. (Refer to page 3-16.) 2ND DRIVE GEAR DISASSEMBLY * Remove the 2nd drive gear by using the gear puller and appropriate attachment. 09913-60910: Gear puller INSPECTION AND SERVICE GEARSHIFT FORK GROOVE CLEARANCE Measure the gearshift fork clearance in the groove of its respective gear with the thickness gauge. If the clearance exceeds the specification, replace the fork, its respective gear or both The clearance for each of the three gearshift forks plays an important role in the smoothness and positiveness of the shifting action. Gearshift fork groove clearance Standard: 0.10-0.30 mm (0.004-0.012 in) Service Limit: 0.50 mm (0.020 in) (Bd 02900-20803: Thickness gauge 09900-20102: Vernier calipers Shift fork groove width ‘Standard: 5.0-5.1 mm (0.197-0.200 in) Shift fork thickness ‘Standard: 4.8-4.9 mm (0.188-0.193 in) Checking clearance Checking thicknessENGINE 3.2 TRANSMISSION/GEARSHIFT CAM INSTAL- LATION Assemble the countershaft and driveshaft assemblies in the reverse order of disassembly. Pay attention to the fol- lowing points: NOTE: Before installing the gears, lightly coat the driveshaft and countershaft with moly paste or engine oil. 444 99000-25140: SUZUKI MOLY PASTE ‘* When installing a new circlip, pay attention to its direc- tion. Fit the circlip to the side where the thrust is, as shown in the illustration. The rounded side should be Thrust against the gear surface. = ‘Sharp edge * When installing a new circlip, do not expand the end gap larger than required to slip the circlip over the shaft. * After installing a circlip, make sure that it is com- pletely seated in its groove and securely fitted. 2ND DRIVE GEAR © Press-fit the 2nd drive gear @ onto the countershaft. NOTE: Coat the internal face of the 2nd drive gear with THREAD LOCK SUPER “1303” before fitting. ZI 99000-32030: THREAD LOCK SUPER “1303” NOTE: + Take care not to smear the 4th drive gear with THREAD LOCK SUPER "1303". + Inspect the 4th drive gear for smooth movement after fit- ting the 2nd drive gear. * This procedure may be performed only twice before shaft replacement is required. 3RD DRIVEN GEAR BUSHING * When installing the gear bushing onto the driveshaft, align the oil hole @ of the shaft with the bushing cil hole ©.36-3 ENGINE NOTE: When reassembling the transmission, attention must be given to the locations and positions of the washers and circlips. The cross sectional view shows the correct position of the gears, washers and circlips. 00 000 =ENGINE 36-0 BALANCER SHAFT/CRANKSHAFT/CRANKCASE © Primary drive gear 80 Nem (8oKG-n, ‘56.0 1b-A) CONTENTS BALANCER SHAFT/CRANKSHAFT/CRANKCASE REMOVAL BALANCER SHAFT DISASSEMBLY CRANKSHAFT DISASSEMBLY INSPECTION AND SERVICE CRANKSHAFT ASSEMBLY .. BALANCER SHAFT ASSEMBLY .. CRANKCASE/CRANKSHAFT/BALANCER SHAFT INSTALLATION3G-1_ ENGINE BALANCER SHAFT/CRANKSHAFT/ CRANKCASE REMOVAL ‘* Remove the engine. (Refer to pages 3-2 to 3-5.) ‘© Separate the left and right crankcases. (Refer to pages 3-9 to 3-15.) ‘* Remove the driveshaft and countershaft assemblies. (Refer to page 3-16.) ‘* Remove the balancer shaft and crankshaft. (Refer to page 3-16.) BALANCER SHAFT DISASSEMBLY * Removet the circlip © and washers (@, @). ‘¢ Remove the four springs and balancer driven gear. CRANKSHAFT DISASSEMBLY Refer to page 3-0. INSPECTION AND SERVICE CONROD SMALL END 1.D. Using dia! calipers, measure the conrod small end inside diameter. Service Limit: 23.040 mm (0.9071 in) If the conrod small end inside diameter exceeds the service limit, replace the conrod.ENGINE 36-2 CONROD DEFLECTION AND CONROD BIG END SIDE CLEARANCE Wear on the big end of the conrod can be estimated by checking the movement of the small end of the conrod. This method can also check the extent of wear on the con- rod's big end parts. (6d 09900-20701: Magnetic stand ‘09900-20606: Dial gauge (1/100 mm) 09900-21304: V-block Service Limit: 3.0 mm (0.12 in) Push the big end of the conrod to one side and measure the side clearance with a thickness gauge. (BB) 09900-20803: Thickness gauge Service Limit: 1.00 mm (0.039 in) If the measurements exceed the service limit, reduce the deflection and side clearance by replacing any worn parts {e.g., conrod, big end bearing and crank pin, etc.) or replace the crankshaft. CRANKSHAFT RUNOUT ‘Support the crankshaft with “V” blocks, as shown. Position the dial gauge, as shown, and slowly rotate the ‘crankshaft to read the runout. Correct or replace the crankshaft if the runout is greeter than the service limit. (Gd 09900-20606: Dial gauge (1/100 mm) 09900-20701: Magnetic stand 03900-21304: V-block (100 mm) ‘Service Limit: 0.05 mm (0.002 in) BALANCER SHAFT Inspect the balancer shaft for wear or damage.36.3 ENGINE CRANKCASE BEARINGS Inspect the play of the crankcase bearings while they are mounted in the left and right crankcase. Turn the inner race bby hand and check to see that it turns smoothly. If it does not turn quietly and smoothly, the bearing is defective and must be replaced with a new one. NOTE: When reassembling the bearing retainer @, apply a small quantity of THREAD LOCK “1342” to the bearing retainer screws and bolts. CRANKSHAFT ASSEMBLY Assemble the crankshaft in the reverse order of disassem- bly. Pay attention to the following points: '* When rebuilding the crankshaft, the width between the webs should be within the specified range. ‘STD width between webs: 71.0 + 0.1 mm (2.795 + 0.004 in) BALANCER SHAFT ASSEMBLY * Align the two holes when installing the balancer driven gear. NOTE: The chamfer side of the No.2 balancer driven gear should face another gear. © Install the four springs ©. Ploy Pay 71.0204 mm (2.795 = 0.004 in)ENGINE 36-4 * Install washers © & @ and circlip ©. NOTE: The sunken side of the concave washer @ should face the ® balancer driven gear. * When installing the balancer shaft, align the punch marks on the balancer drive gear and balancer driven gear. (Refer to page 3-18.) CRANKCASE/CRANKSHAFT/BALANCER SHAFT INSTALLATION Install the cranksase, crankshaft and balancer shaft in the following order: Balancer shaft @Crankshatt @Transmission @CrankcaseENGINE 3H-0 ENGINE LUBRICATION SYSTEM © ot pune @ Ol pump avon gor © Oi pump ale goat ad @ Oiler @ Oil sump iter CONTENTS OIL FILTER OIL PUMP OIL NOZZLE AND OIL JE’ OIL SUMP FILTER ...OIL FILTER ‘* Remove the oil filter cap. ‘* Remove the oil filter ©. © Install the new oil filter. NOTE: Before installing the oil filter and oil filter cap, check to make sure that the spring @ and new O-rings (@ and @) are installed correctly. OIL PUMP REMOVAL AND DISASSEMBLY ‘* Remove the clutch. (Refer to page 3-11.) ‘+ Remove the oil pump idle gear and oil pump. (Refer to page 3-14.) '* Remove the oil pump driven gear by removing the cir- clip. (Gd 09900-06107: Snap ring pliers. * Remove the oil pump screw. * Remove the oil pump outside case.ENGINE 3H-2 ¢ Remove the rotor shaft @, drive pin @, inner rator @ and outer rotor @ from the oil pump body ©. INSPECTION Inspect the rotor tip clearance and outer rotor clearance with a thickness gauge. If the clearance exceeds the service limit, replace the oil pump with a new one. (BY 09900-20803: Thickness gauge Rotor tip clearance ‘Service Limit: 0.20 mm (0.008 in) Outer rotor clearance ‘Service Limit: 0.35 mm (0.014 in), ASSEMBLY AND INSTALLATION ‘Assemble and install the oil pump in the reverse order of removal and disassembly. Pay attention to the following points: A CAUTION Wash the oil pump with fresh engine oll before reas- sembly ‘© When installing the outer rotor and inner rotor into the oil pump body, be sure the punch marks on the inner and outer rotors face inward. Insert the rotor shaft into the inner rotor by aligning the drive pin © with the slot @ in the inner rotor. te) Outer rotor clearance3H-3_ ENGINE * Apply a small quantity of THREAD LOCK “1342” to the screw and tighten it. ‘99000-32050: THREAD LOCK “1342” Install the washer, pin, oil pump driven gear and washer. ‘* Fasten the oil pump driven gear with the circlip. (€B 09900-06107: Snap ring pliers NOTE: * The bulge of the oil pump driven gear should face out- side. * After installing the oil pump driven gear, rotate the gear by hand to see if it turns smoothly. + Apply a small quantity of THREAD LOCK “1342” to the ‘screws and then install the oil pump onto the engine. ‘ 99000-32050: THREAD LOCK “1342” OIL NOZZLE AND OIL JET REMOVAL * Remove the engine. (Refer to pages 3-2 to 3-5.) ‘Separate the left and right crankcases. (Refer to pages 39 to 3-15.) * Remove the driveshaft and countershaft assemblies and the crankshaft. (Refer to page 3-16.) * Remove the oil nozzle © and oil jet @ from the right crankcase. A CAUTIO! The removed oil jet @ should be replaced with a newENGINE 31.4 INSPECTION Check the oil nozzle for damage or clogs. REASSEMBLY © Install the new oil jet @, as shown in the illustration. * Install the oil nozzle @. + Apply THREAD LOCK SUPER “1303* to the bolt and tighten to the specified torque. WB 99000-32030: THREAD LOCK SUPER “1303” (F) Bott: 10 N-m (1.0 kg-m, 7.0 lb-ft) OIL SUMP FILTER REMOVAL ‘* Remove the engine, (Refer to pages 3.2 to 3-5.) * Separate the left and right crankcases. (Refer to pages 3-9 to 3-15.) ‘* Remove the oil sump filter cover . * Remove the oil sump filter @. INSPECTION Cheek the oil sump filter for any damage or clogs. INSTALLATION Install the oil sump filter in the reverse order of removal. Pay attention to the following points: ‘* When installing the oil sump filter into the right crank- case, align points ©, ©, as shown.FUEL AND LUBRICATION SYSTEM CONTENTS: - 1 FUEL SYSTEM 4 FUEL VALVE . ~ #2 FUEL TANK .. 148 CARBURETOR . 1&5 CONSTRUCTION 1&5 SPECIFICATIONS .. 4&6 | 1.D. NO. LOCATION -46 SLOW SYSTEM . oo MAIN SYSTEM -48 DIAPHRAGM AND PISTON OPERATION . - #9 PISTON VALVE LIFT CONTROL SYSTEM - 4:10 STARTER SYSTEM ant FLOAT SYSTEM . 411 REMOVAL .. 412 | DISASSEMBLY ..... 413 CARBURETOR CLEANING 416 INSPECTION ........-- 4-18 NEEDLE VALVE INSPECTION . 418 FLOAT HEIGHT ADJUSTMENT . 4-18 SOLENOID VALVE INSPECTION 418 V.T.V. INSPECTION 4-19 THROTTLE POSITION SENSOR INSPECTION 419 REASSEMBLY AND REMOUNTING . 4-19 CARBURETOR SYNCHRONIZATION : 422 | LUBRICATION SYSTEM AND COOLING SYSTEM . 424 ENGINE LUBRICATION/CYLINDER HEAD COOLING SYSTEM CHART ..........0.000cccccttteteeseeeeeee 425 Ol COOLERFUEL AND LUBRICATION SYSTEM FUEL SYSTEM When turning starter motor, negative pressure is generated in the combustion chamber. This nega- tive pressure works on the diaphragm of fuel valve through passage way provided in the carburetor main bore and vacuum hose, and diaphragm builds up a negative pressure which is higher than the spring pressure. Valve in the fuel valve is forced to open due to diaphragm operation, and thus allows fuel to flow into carburetor float chamber. Fuel tank Vacuum hose Fuel hose[FUEL AND LUBRICATION SYSTEM 4-2 FUEL VALVE FUEL VALVE MECHANISM A valve is provided at the end of the fuel valve lever and can switch over to “ON", “PRI” and “RES” Fuel “ON position “PRI position "RES" position FUEL VALVE/FUEL FILTER REMOVAL © Remove the seat. © Remove the fuel tank. (Refer to page 4-3.) ‘© Remove the fuel valve by removing the mounting bolts. 4a WARNING Gasoline is very explosive. Extreme care must be tak- en. Gaskets and O-ring must be replaced with new ones to prevent fue! leak:4-3 FUEL AND LUBRICATION SYSTEM. INSPECTION AND CLEANING If the fuel filter is dirty with sediment or rust, fuel will not flow smoothly and loss in engine power may result. Clean the fuel filter with compressed air. FUEL TANK FUEL TANK REMOVAL © Remove the seat. @ Remove the front frame covers (right and left). © Turn the fuel valve to “ON" position. * Disconnect the fuel hose @ and vacuum hose @. WARNING jasoline is very explosive. Extreme care must be tak- ‘@ Remove the fuel tank covers (right and left).FUEL AND LUBRICATION SYSTEM 4-4 © Remove the fuel tank mounting bolts. '® Disconnect the fuel gauge lead wire coupler. © Disconnect the fuel tank drain hose. © Remove the fuel tank.4-5 FUEL AND LUBRICATION SYSTEM. CARBURETOR CONSTRUCTIONFUEL AND LUBRICATION SYSTEM 4-6 SPECIFICATIONS ‘SPECIFICATION oe E0208 E18 Ustype E-22 E37 Carburetor type | MIKUNI ~ = = BSR32SS Bore size 32mm = = = 1.D. No, O4FO 04F3, O4F4 Tale rimnin. 1500 100 1500 100 = t/min. r/min, Float height 73.0+1.0 mm = a _ (0.51+0.04 in) Main jet (M.J.) ais = _ baal Jet needle (WN) SOH23-53-3rd = = = Needle jet (N.J.) P-O - - et Throttle valve (ThV.) ‘#90 a Soke _ Pilot jet (P.J.) #20 = - =- Starter jet (G.S.) #57.5 = = #62.5 Pilot screw (PS) _ PRE-SET = a _ (3 turns back) Throttle cable play 0.5-1.0 mm. - - S (pulling cable) (0.02-0.04 in) Choke cable play 0.5-1.0 mm = = = 49.02-0.04 in) COUNTRY OR AREA E-02: U.K. E-24: Australia £-04; France E-25: Netherlands E-17; Sweden -34: Italy E-18; Switzerland E-37: Brazil E-22: Germany 1.D. NO. LOCATION Each carburetor has |.0. Number @ printed on the carbure- tor body according to its specification.4-7 FUEL AND LUBRICATION SYSTEM SLOW SYSTEM This system supplies fuel during engine operation with throttle valve @ closed or slight opened. The fuel from float chamber @ is metered by pilot jet @ where it mixes with air coming in through pilot air jet ®. This mixture, rich with fuel, then goes up through pilot passage to pilot screw ©). A part of the mixture is discharged into the main bore out of bypass ports ®. The remainder of mixture is metered by pilot screw © and sprayed out into the main bore through pilot outlet @. FUEL —S | ceamsuarr | - ‘Ol JET | ‘RIGHT-SIDE ‘Oi HOSE COUNTERSHAFT ] aon PRIMARY DRIVEN ot GEAR AND CLUTCH PLATES. ay aA ow pow on SUMPFUEL AND LUBRICATION SYSTEM 4-264-27 FUEL AND LUBRICATION SYSTEM. OIL COOLER TEM | Nem | kom | MtFUEL AND LUBRICATION SYSTEM. REMOVAL © Drain engine oil. (Refer to page 3-1.) © Remove the engine protector @. © Remove the oil cooler hose mounting bolts. ¢ Remove the oil cooler by removing its mounting bolts.CHASSIS EXTERIOR PARTS . 5-1 REMOVAL .. 5-2 REMOUNTING 5. 4 FRONT WHEEL 5-5 REMOVAL ...... - 5-7 INSPECTION AND DISASSEMBLY . 5-7 REASSEMBLY AND REMOUNTING 5-9 FRONT FORK ........... 5-11 REMOVAL AND DISASSEMBLY . 5-17 INSPECTION .......... 5-14 REASSEMBLY AND REMOUNTING 5-15 STEERING 5-18 REMOVAI 5-18 INSPECTION 5-22 REASSEMBLY AND REM( ‘i 5-23 REAR WHEEL . 5-25 REMOVAL : INSPECTION AND DISASSEMBLY . REASSEMBLY AND REMOUNTING REAR SWINGARM AND SUSPENSION . REASSEMBLING INFORMATION REMOVAL 5-33 INSPECTIO} fi 5-35 REASSEMBLY AND REMOUNTING 5-36 FINAL INSPECTION AND ADJUSTMI FRONT BRAKE .......... 5-38 BRAKE PAD REPLACEMENT 5-39 BRAKE FLUID REPLACEMENT . 5-39 CALIPER REMOVAL AND DISASSEMBLY . 5-40 CALIPER INSPECTION . 5-41 CALIPER REASSEMBLY AND REMOUNTING . BRAKE DISC INSPECTION MASTER CYLINDER REM( MASTER CYLINDER INSPECTION MASTER CYLINDER REASSEMBLY AND REMOU! REAR BRAKE.......... 5-45 BRAKE PAD REPLACEMEN' 5-46 | BRAKE FLUID REPLACEMENT . 5-46 CALIPER REMOVAL AND DISASSEMBLY . CALIPER AND DISC INSPECTION .... CALIPER REASSEMBLY AND REMOUNTING . MASTER CYLINDER REMOVAL AND DISASSEMBLY . | MASTER CYLINDER INSPECTION | MASTER CYLINDER REASSEMBLY | LOWERING THE SEAT HEIGHT 5-51 OPTIONAL PARTS SUPPLY . 5-51 | SPECIAL TOOLS 5-51 FRONT FORK . 5-52 REAR SHOCK ABSORBER SIDE STAND .. WARNING LABEL .5:1 CHASSIS EXTERIOR PARTS CONSTRUCTION 39 lower cover @ Speedometer pane! © Feiing upper bracket @ Fairing brace @ Fuel tank upper cover, @ Fuel tank cover (R) ove @ Frame cover (L)CHASSIS 5-2 REMOVAL FAIRING © Remove the seat. © Remove the front frame covers (right and left) ‘© Remove the fuel tank covers (right and left). © Remove the four screws ®. ‘© Draw out the four cushions @ and remove the screen. © Disconnect the turn signals, speed sensor and headlight lead wire couplers.5-3 CHASSIS © Remove the screws D and @. ‘© Remove the fairing. ‘© Remove the screws @ and ©. ‘* Remove the instrument panel. © Disconnect the speedometer coupler.CHASSIS 5-4 © Remove the nut ©. @ Remove the bolts @. © Remove the fairing brace with headlight ass'y. FRAME COVER, ‘© Remove the seat. ‘© Remove the frame cover mounting screws. © Unhook the hooks and remove the frame cover. REMOUNTING Remount the frame covers and fairing in the reverse order of their removal.5-5 CHASSIS FRONT WHEEL 2|2]o} 5 23 [1 23CHASSIS 5-6 2am (ester) HM | Wan-m | (ester) Desn-m (roe) L’ yf FX B® Q Spacer Sa5-7 CHASSIS. REMOVAL ‘© Remove the speed sensor guides ©. © Loosen the front axle holder bolt @ and axle shaft @. © Carefully position e jack under the chassis tubes and raise until the front wheel is slightly off the ground. ‘¢ Remove the front wheel by removing the front axle. NOTE: Do not operate the brake lever while dismounting the front wheel. ‘© Remove the disc by removing the mounting bolts. INSPECTION AND DISASSEMBLY WHEEL BEARING Inspect the play of bearing inner ring by hand while mounted in the wheel. Rotate the inner ring by hand to inspect if any abnormal noise occurs or rotating smoothly Replace the bearing if there is anything unusual. PlayCHASSIS 5-8 Remove the dust seal. Drive out the both bearing with the special tool in the following procedures. 09941-50111: Bearing remover Insert the adapter into the bearing. After inserting the wedge bar from the opposite side, lock the wedge bar in the slit of the adapter. © Drive out the bearing by knocking the wedge bar. A CAUTION ‘The removed bearing should be replaced with new ones. FRONT AXLE © Check the front axle runout with a dial gauge and re- place it if the runout exceeds the limit. (GBD 09900-20606: Dial gauge (1/100 mm) 09900-20701: Magnetic stand 09900-21304: “V” block set Service Limit: 0.25 mm (0.010 WHEEL RIM Make sure that the wheel rim runout does not exceed the service limit when checked as shown ‘An excessive runout is usually due to worn or loose whee! bearings and can be reduced by replacing the bearings. If bearing replacement fails to reduce the runout, replace the wheel. Service Limit (Axial and Radial) 2.0 mm (0.08 in) ‘SPOKE NIPPLE Check to be sure that all nipples are tight, and retighten them as necessary. [®) spoke nipple: 4.51N-m (0.45 kg-m, 3.0 lb-ft) TIRE (Refer to page 2-14.)5-9 CHASSIS REASSEMBLY AND REMOUNTING Reassemble and remount the front wheel in the reverse order of removal and disassembly, and also carry out the following steps: WHEEL BEARING © Apply grease to the bearings. AMBH 99000-25010: SUZUKI SUPER GREASE “A” ‘© Install the wheel bearings with the special tools. ‘A CAUTION | First install the left wheel bearing, then install the Fight wheel bearing. The sealed cover of the bearing must face outside. Refer to page 5-6 for details. BRAKE DISC © Make sure that the brake disc is clean and free of any greasy matter. Apply THREAD LOCK SUPER “1360” to the disc mounting bolts and tighten them to the speci- fied torque. $B 99000-32130: THREAD LOCK SUPER 1360” [B) Disc bott: 23 N-m (2.3 kg-m, 16.5 Ib-ft © Align the drive lugs @ to the recesses @ of the wheel hub. ‘© Before tightening the front axle, position the stopper @ of speed sensor against stopper @.CHASSIS 5-10 © Tighten the front axle © to the specified torque and then move the front fork up and down. © Tighten the axle holder bolt @ to the specified torque. [F) Front axle: 65 N-m (6.5 kg-m, 47.0 Ib-ft) Axle holder bolt: 23 N-m (2.3 kg-m, 16.5 lb-ft) © Reinstall the speed sensor guides @. NOTE: Clamp the speed sensor wire harness to the white marked part.5:11 CHASSIS FRONT FORK @ Was Soar rot 2 impor rs © Spring Ss @ Oil lock piece ganar ele Ol seal @ Retainer —8S Outer tube mets Inner tube metal =o Isr REMOVAL AND DISASSEMBLY © Remove the front wheel. (Refer to page 5-7.) ‘© Remove the front brake caliper. (Refer to page 5-41.) © Remove the front brake hose clamp bolt ©.CHASSIS 5-12 ‘© Remove the front fender. ‘© Remove the front fender brace. © Slightly loosen the front fork cap bolt © after loosening the front fork upper clamp bolt @ to facilitate later disas- sembly. ¢ Remove the front fork by loosening the lower clamp bolts @. ® Remove the front fork cap bolt ©, spacers @, @, washer @ and spring ©. e 85-13 CHASSIS © Invert the fork and stroke it several times to drain fork oil. © Hold the fork inverted for a few minutes to drain fork oil. © Remove the damper rod bolt with a 8 mm hexagon wrench and special tools. (6B) 09940-34520: “T” handle 09940-34592: Attachment “G’ © Remove the damper rod with spring. © Remove the dust seal ©. © Remove the oil seal stopper ring.© Separate the inner tube from the outer tube. The removed dust seal and oil seal should be re- placed. | ‘+ When separating the inner tube from the outer | \ tube, both anti-friction metals may be damaged | and must be replaced with new ones. ( © Remove the oil lock piece from the outer tube. © Remove the following parts. @Oil seal @Oil seal retainer @Anti-friction metal (Outer tube) @Anti-friction metal (Inner tube) INSPECTION FORK SPRING Measure the fork spring free length. If it is shorter than service limit, replace it. Service Limit: 371. mm (14.6 in) INNER TUBE AND OUTER TUBE Inspect the inner tube sliding surface for any scuffing and check for bend. Inspect the outer tube sliding surface for any scuffing.5-15 CHASSIS DAMPER ROD RING ‘© Inspect the damper rod ring for wear or damage. REASSEMBLY AND REMOUNTING Reassemble and remount the front fork in the reverse or- der of removal and disassembly, and also carry out the following steps: INNER TUBE METAL © Install the metal by hand as shown in the illustration. ‘A CAUTION Use special care to prevent damage to the “Teflon” coated surface of the Anti-friction metal when mounting it. © Install the damper rod with spring. meme © Install the oil lock piece.OUTER TUBE METAL, OIL SEAL AND DUST SEAL © Clean the metal groove of outer tube and metal outer surface. © Install the outer tube metal (D, oil seal retainer @ and oil seal ©. (6B) 09940.52861: Front fork oll seal installer Use special care to prevent damage to the “Teflon” coated surface of the Anti-friction meta! when mounting it. [mounting ® Install the aif seal stopper ring @, [A CAUTION Make sure that the ly. « Install the dust seal ©). ‘seal stopper ring fitted secure- CHASSIS 5-16 DAMPER ROD BOLT Apply THREAD LOCK "1342" to the damper rod bolt and tighten it to the specified torque with the special tools and 8-mm hexagon wrench. ‘GB 99000-32050: THREAD LOCK "1342" (GB 09940-34520: “T” handle 09940-34592: Attachment “G” [B) Damper rod bott: 30 N-m (3.0 kg-m, 21.5 Ib-ft) ‘A CAUTION) catage, | Use a new gasket © to prevent oil I THREAD LOCK "1342"5-17 CHASSIS FORK OIL * For the fork oil, be sure to use a front fork oil whose viscosity rating meets specifications below. Fork oil type: Fork oil #15 Fork oil capacity: 655 mi (22.1/23.1 US/Imp oz) © Hold the front fork vertical and adjust the fork oil level with the special tool. NOTE: When adjusting oil level, remove the fork spring and com- press the inner tube fully. (GB 09943-74111: Fork oil level gauge Oil level: 143 mm (5.6 in) FORK SPRING ‘© Install the fork spring D, washer @, spacers @, @ and front fork cap bolt ©. FRONT FORK REMOUNTING Align the top surface @ of the inner tube to the top sur- face @ of the steering stem upper bracket. * Tighten each bolt to the specified torque. [F) Front fork cap bolt @: 23 N+m (2.3 kg-m, 16.5 Ib-ft) Upper clamp bolt @: 29 N-m (2.9 kg-m, 21.0 lb-ft) Lower clamp bolt @: 23 N-m (2.3 kg-m, 16.5 Ib-ft)CHASSIS 5-18 STEERING @ Handlebar clamp @Handlebar holder | Cap @ Damper (Upper) @ Steering st © Damper (Lower) @ Steering stem nut ‘Upper bearing tower) e—o @ Storing stom lower bracket —~S ee, kgm | ibft 23 | 168 90 | 65.0 25 | 180 29 | 21.0 23 | 165 REMOVAL AND DISASSEMBLY ‘© Remove the firing. (Refer to page 5-2.) ‘© Remove the fuel tank. (Refer to page 4-3.) ‘© Remove the front wheel. (Refer to page 5-5.) ‘© Remove the front fork. (Refer to page 5-11.) © Remove the horn lead wire coupler.5:18 CHASSIS ‘© Remove the horn. © Remove the brake hose clamp bolt and speed sensor clamp screw. © Remove the speedometer coupler and release the lead wire from the fixed clamp. © Remove the throttle grip case screws. © Disconnect the throttle cables. © Remove the brake hose clamp bolt.CHASSIS 5.20 © Disconnect the right handlebar switch iead wire couplers and ignition switch lead wire coupler. © Loosen the clamp bolt O. © Draw out the throttle cable and right handlebar switch lead wire from the clamps. ‘© Remove the brake switch lead wire. ‘© Remove the front brake master cylinder with brake hose. © Remove the ig ion switch cover. ‘© Remove the ignition switch mounting bolts with the spe- cial tools. (09930-11920: Torx bit JT4OH (09830-11940: Bit holder © Remove the choke knob.5.21 CHASSIS © Remove the caps. ¢ Remove the handlebars by removing the four mounting bolts. ‘© Remove the handlebar holder by removing the mount- ing nuts. © Remove the steering stem upper bracket by removing the stem head nut, © Loosen the steering stem nut with the specia! tools. 09940-14911: Steering stem nut socket wrench 09940-14960: Steering stem nut socket @ Remove the steering stem lower bracket. NOTE: Hold the steering stem lower bracket by hand to prevent it from falling.CHASSIS 5.22 © Remove the upper bearing. ‘© Remove the steering stem tower bearing with a chisel. LE removed bearing should be replaced with a new one. © Remove the steering stem bearing races, upper and low- er with the special tools. (GB) 09941-54911: Steering race remover 09941-74910: Steering bearing remover and installer INSPECTION © Inspect the removed parts for the following abnorm: ties. * Handlebars distortion * Handlebar clamp wear comet * Race wear and brinelling * Abnormal noise of bearing * Distortion of steering stem Damper Inspect the play of dampers by hands while fixing it in the steering stem upper bracket. If the play can be found, re- place the dampers.5-23 CHASSIS REASSEMBLY AND REMOUNTING Reassemble and remount the steering stem in the reverse order of removal and disassembly. Pay attention to the fol- lowing points: BEARING RACES © Press in the upper and lower bearing races with the spe- cial tool. (09941-34513: Steering outer ra BEARING © Press in the lower bearing with the special tool. (GB) 09925-18010: steering be: 9 installer © Apply grease to the upper and lower bearings AHH 99000-25010: SUZUKI SUPER GREASE “A” STEM NUT © Tighten the steering stem nut to 45 N-m (4.5 kg-m, 32.5, Ib-ft) with the special tools. (GB 09940-14911: steer 19 stem nut wrench ing stem nut socket © Turn the steering stem bracket about five or six times to the left and right until it locks in position so that the ta- per roller bearing will be seated properly. ‘© Turn back the stem nut by 1/4~1/2 turn. NOTE: This adjustment will vary from motorcycle to motorcycle. W4~172 tureCHASSIS 5.24 © Tighten the steering stem nut to the specified torque. [®) steering stem head nut: 90 N-m (9.0 kg-m, 65.0 Ib-ft) NOTE: Before tightening the steering stem nut, install the front fork temporarily. © Tighten the handlebar holder nuts to the specified torque. (©) Handlebar holder nut: 25 N+m (2.5 kg-m, 18.0 Ib-tt! NOTE: Before tighten the handlebar holder nuts, instal! the han- dlebars temporarily. HANDLEBARS © Set the handlebars to match its punched mark to the mating face of the holder. © Secure the each handlebar clamp in such a way that the clearances @ ahead and behind of the handlebars are equalized. (©) Handlebar clamp bolt: 23 N-m (2.3 kg-m, 16.5 lb-ft) © Turn the handlebars all the way left and make sure that clearance between the strap ® of the left handlebar switch and fuel tank cover @ is 5 mm (0.2 in). If it is under 5 mm (0.2 in), adjust the handlebar position so that the clearance has specified one. ‘A CAUTION, After performing the adjustment and installing th | steering stem upper bracket, “rock” the front wheel | | assembly forward and back to ensure that there is no play and that the procedure was accomplished cor- rectly. Finally check to be sure that the steering stem moves freely from left to right with own weight. If play or stiffness is noticeable, re-adjust the steering | stem nut.5.25 CHASSIS REAR WHEEL 198. 27 no | 110 | 798 TEM | Nem | kgm | Ibft o [2CHASSIS 5-25 Bearing (R) REMOVAL ‘© Remove the rear lower fender by removing bolts and screws. © Loosen the axle nut. © Support the motorcycle with a jack. ‘© Remove the axle nut and axle. © Remove the rear wheel by disengaging the drive chain. ‘A CAUTION the rear wheel.5-27 CHASSIS © Remove the rear sprocket mounting drum from the wheel. © Remove the cushions. © Remove the spacer @. © Remove the rear sprocket by removing the mounting S nuts and bolts. ‘Remove the dust seal with the special tool (GB) 09913-50121: Dust seal remover ‘® Remove the brake disc by removing the mounting bolts.CHASSIS 5-28 INSPECTION AND DISASSEMBLY TIRE. 5 Refer to page 2-13. REAR WHEEL Refer to page 5- 7. WHEEL BEARING AND SPROCKET DRUM BEARING Inspect the play of bearing inner ring by hand while mounted in the wheel or sprocket drum. Rotate the inner ring by hand to inspect any abnormal noise occurs or ro- tating smoothly. Replace the bearing if there is anything unusual. Remove the both bearing with the special tool in the fol- lowing procedures. © Insert the adapter into the bearing. (BB 09941-5011 : Bearing remover © After inserting the wedge bar from the opposite side, lock the wedge bar in the slit of the adapter. © Drive out the bearing by hammering the wedge bar. ‘A CAUTION ‘The removed bearings should be replaced with new ones ‘© Remove the sprocket drum bearing with the special tool. ( 09913-75830: [a CAUTION) The removed bearing should be replaced with a new one. saring remover Play5-29 CHASSIS REAR AXLE © Using a dial gauge, check the rear axle for runout. © If the runout exceeds the limit, replace the rear axle. (6B) 02200-20606: Dial gauge (1/100 mm) (09900-20701: Magnetic stand 09900-21304: “V" block set Service Limit: 0.25 mm (0.010 in} REAR SPROCKET Inspect the sprocket teeth for wear. If they are worn as il- lustrated, replace the sprocket and drive chain. REAR SPROCKET DAMPER Inspect the dampers for wear and damage. If any defects are found, replace the dampers as a set. REASSEMBLY AND REMOUNTING Reassemble and remount the rear wheel in the reverse or- der of removal and disassembly. Pay attention to the fol- lowing points: WHEEL BEARING © Apply grease to the bearings. FMB 99000-25010: SUZUKI SUPER GREASE “A” © Install the wheel bearings with the special tools. (GB 09924-84510: Bearing installer 09924-84521: Bearing installer ‘@ CAUTION The sealed cover of Refer to page 5-26 for detaits. Normal wear Excessive wear¢ Install the rear sprocket drum bearing by using a bearing installer. GD 09913-75810: Bearing install NOTE: Seal side of bearing goes toward outside. BRAKE DISC © Apply THREAD LOCK SUPER "1360" to the disc bolts and tighten them to the specified torque. NOTE: ‘Make sure that the brake disc is clean and free of any greasy matter. ‘GG 99000-32130: THREAD LOCK SUPER 1360" (Disc bott: 23 N-m (2.3 kg-m, 16.5 lb-ft) SPROCKET ‘ Tighten the sprocket nuts to the specified torque. [®) sprocket nut: 27 N-m (2.7 kg-m, 19.5 Ib-ft) NOTE: Face the stamped mark on the sprocket to outside. REAR AXLE NUT © Adjust the chain slack after rear wheel installation. (Refer to page 2-9.) © Tighten the axle nut to the specified torque. (8) Ante nut: 110 N-m (11.0 kg-m, 79.5 Ib-ft)5.31 CHASSIS. REAR SWINGARM AND SUSPENSION @ Shock absorber @ Cushion rod @ Cushion lover Swingarm ‘Chain butfer @ Swingarm pivot shaft ® Chain cover ejelolelolg 7 | 77 _| $55REASSEMBLING INFORMATION CHASSIS 5-32 a TEM [Nm [kom | be @ | | 45 [325 ® 45 45 | 325 © | 100 | 100 | 725 @ [20 | 80 | sa0 © [100 | 100 | 725 ® [7 | 77 | ss5.33 CHASSIS REMOVAL * Remove the seat and left frame cover. (Refer to page 5-4) ‘* Remove the rear wheel. (Refer to page 5-27.) ® Disconnect the brake hose from the hose guides. © Remove the cushion lever center nut © and bolt. ‘* Remove the rear shock absorber lower mounting bolt @. © Remove the cushion lever by removing the mounting nut ® and bolt. © Take off the air cleaner drain hose from clamp. ‘¢ Remove the rear swingarm pivot nut after removing the caps. ‘* Remove the rear swingarm by removing the pivot shaft.CHASSIS 5-34 ‘® Remove the rear shock absorber reservoir tank D by Joosening its clamp screws . © Take off the hose from the clamps @. Remove the rear shock absorber by remo mounting bolt @. © Remove the cushion rods. ‘@ Remove the drive chain buffer. ‘© Remove the brake hose guides and mud guard. ‘© Remove the swingarm dust seals and spacers.5:35 CHASSIS ‘® Remove the cushion lever dust seals and spacers. INSPECTION AND DISASSEMBLY ‘SWINGARM Inspect the swingarm for wear or damage. Inspect the spacer for any flaws or other damage. Insert the spacer into the bearing and check the play to move the spacer up and down. If an excessive play is noted, replace the bearing with a new one. ‘© Draw out the swingarm bearings and spacer with the special tools. (> 0923-74510: Bearing remover (09930-30102: Sliding shaft ‘4 CAUTION The removed bearings should be replaced with new —— CUSHION LEVER Inspect the spacer for any flaws or other damage. Insert the spacer into the bearing and check the play to move the spacer up and down. if an excessive play is, noted, replace the bearing with new ones. ‘* Draw out the bearing with the special tools and ap- propriate tool. 4 CAUTION ‘The removed bearing should be replaced with new ones.‘SHOCK ABSORBER Inspect the shock absorber for oil leakage or other dam- age. If any defects are found, replace the shock absorber with new a one. ‘SWINGARM PIVOT SHAFT Using a dial gauge, check the pivot shaft runout and re- place it if the runout exceeds the limit. (6d 02200-20608: via! gauge 09900-20701: Magnetic stand 09900-21304: V.block Service Limit: 0.3 mm (0.01 in) REASSEMBLY AND REMOUNTING Reassemble and remount the rear swingarm and suspen- sion in the reverse order of removal and disassembly. Pay attention to the following points: SWINGARM BEARING © Install the new bear 19 with the special tool. (GB 09941-34513: Bearing installer NOTE: When installing the bearing, punch-marked side of bearing faces outside. CUSHION LEVER BEARING © Install the new bearing with the special tool. (68) 09924-84521: Bearing installer NOTE: When installing the bearing, punch-mark side of bearing faces outside. © Remount the rear suspension. (Refer to page 5-33.) CHASSIS 5-365-37 CHASSIS. FINAL INSPECTION AND ADJUSTMENT After installing the rear suspension and wheel, the follow- ing adjustments ere required before driving. * Drive Chain esses ceceeeesseesereessessees Page 2-10. * Rear brake pedal height ........ Page 2-12. * Tire pressure .... Page 2-14. SHOCK ABSORBER SPRING PRE-LOAD ADJUSTMENT Spring pre-load is adjustable by changing the spring ad- juster ring position after removing the shock absorber. Turning the spring adjuster ring counterclockwise or clock- wise as viewed from for increase or decrease the spring pre-load after loosening the adjuster lock ring. The stan- dard set length is 169.2 mm (6.7 in). After adjusting the pre-load, tighten the spring adjuster Jock ring securely. (6) 09910-60611: Universal clamp wrench ‘A CAUTION = Do not set the spring to the length less than 160.0 ° — mm (63 in). = ‘SPRING SETTING TABLE — ——— Spring pre-set length | Softest 180.0 mm (7.0 in) Standard 169.2 mm (6.7 in) Stiffest 160.0 mm (6.3 in) ‘SHOCK ABSORBER DAMPING FORCE ADJUSTMENT Fully turn the damping force adjuster clockwise. itis at stif- fest position and tum it out to the standard setting posi- tion. STD position: 13 clicks turns out A: Rubber cap B: AdjusterCHASSIS 5-38 FRONT BRAKE QPistoncup set @ Brake hose 3D Pad Piston set 7.0 165 60 | 28.0 PROT * This brake system is filled with a ethylene glycol-based DOT 4 brake fluid. Do not use or mix different types of fluid such as silicone-based or petroleum-based. * Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored for long periods. * When storing the brake fluid, seal the container completely and keep away from children. * When replenishing brake fluid, take care not to get dust into fluid. ‘* When washing brake components, use fresh brake fluid. Never use cleaning solvent. * A contaminated brake disc or brake pad reduces braking performance. Discard contami- nated pads and clean the disc with high quality brake cleaner or neutral detergent. ‘4 CAUTION Handle bral etc. he fluid reacts chemically with paint, plastics rubber materials5-39 CHASSIS. BRAKE PAD REPLACEMENT # Remove the caliper by removing the mounting bolts ©. ‘A CAUTION * Do not operate the brake lever while dismounting the pads. | * Replace the brake pad as a set, otherwise braking cted. ‘* Remove the cotter pin @ and remove the mounting pin @. ‘© Remove the brake pads and replace with new ones. © Install the mounting pin and cotter pin. © Tighten the mounting bolts to the specified torque. ©) Front brake caliper mounting bolt: 39 N-m_ (3.9 kg-m, 28.0 lb-ft) NOTE: After replacing the brake pads, pump with the brake lever few times to operate the brake correctly and then check the brake fluid level. BRAKE FLUID REPLACEMENT * Place the motorcycle on a level surface and keep the handlebars straight. ‘* Remove the master cylinder reservoir cap and dia- phragm. ‘© Suck up the old brake fluid as much as possible. Fill the reservoir with fresh brake fluid. B specitication and Classification: DOT 4 © Connect a clear hose @ to the air bleeder valve ©, and insert the free end of hose into a receptacle. © Loosen the bleeder valve and pump the brake lever until no more old brake fluid flows out of the bleeder valve. © Close the air bleeder valve, and disconnect a clear hose. Fill the reservoir with fresh brake fluid to the upper end of the inspection window.CALIPER REMOVAL AND DISASSEMBLY ‘© Remove the brake hose from the caliper by removing the union bolt @ and catch the brake fluid in a suitable re- ceptacle. © Remove the brake caliper by removing the caliper mounting bolts @. A CAUTION Never reuse the brake fluid left over from previous servicing and stored for long periods. FRG Brake fluid, if it leaks, ferfere with safe running and discolor painted surfaces. Check the brake hose and hose joints for cracks and oil leakag ‘¢ Remove the pads. (Refer to page 5-39.) ‘© Remove the caliper holder @. © Remove the spring. © Place a rag over the pistons to prevent it from popping out and then force out the piston with compressed air. A CAUTION Do not use a ‘© Remove the dust seals and piston seals. A CAUTION Do not reuse the dust seals and piston seals to pre- it fluid leaks5.41 CHASSIS CALIPER INSPECTION CALIPER Inspect the caliper cylinder wall for nicks, scratches or oth- er damage. PISTON Inspect the piston surface for any scratches or other dam- age. CALIPER REASSEMBLY AND REMOUNTING Reassemble the caliper in the reverse order of removal and disassembly. Pay attention to the following points: © Wash the caliper bores and pistons with specified brake fluid. Particularly wash the dust seal grooves and piston seal grooves. B specitication and Classification: DOT 4 \UTION] * Wash the caliper components with fres fluid before reassembly. * Do not wipe the brake fluid off after washing the components. When washing the components, use the specified |. Never use different types of fluid or cleaning solvent such as gasoline, kerosine or the others. iston seals and dust seals with new sssembly. Apply the brake fluid to installing them. '* Apply SUZUKI SILICONE GREASE to the caliper axles. ASH 99000-25100: SUZUKI SILICONE GREASE © Tighten each bolt to the specified torque. (%) Caliper mounting bolt (: 39 N-m (3.9 kg-m, 28.0 lb-ft) Brake hose union bolt @: 23 N-m (2.3 kg-m, 16.5 Ib-ft) NOTE: Before remounting the caliper, push the piston all the way into the caliper. \UTION Bleed air from the system after reassembling the cali- per. (Refer to page 2-12.)BRAKE DISC INSPECTION © Remove the front and rear wheels. (Refer to pages 5-7 and 5-27.) Visually check the brake disc for damage or cracks. Measure the thickness with a micrometer. Replace the disc if the thickness is less than the service limit or if damage is found. ( 09900-20205: Micrometer (0-25 mm) Service Limit Front disc: 4.0 mm (0.16 in) Rear disc: 4.0 mm (0.16 in} Measure the runout with a dial gauge. Replace the disc if the runout exceeds the service limit. 03900-20606: Dial gauge (1/100 mm) (08900-20701: Magnetic stand Service Li Front and Rear disc: 0.3 mm (0.012 in) ¢ Remove the disc. (Refer to pages 5-7 and 5-27.) Install the disc. (Refer to pages 5-9 and 5-30.) MASTER CYLINDER REMOVAL AND DISASSEMBLY © Loosen the brake master cylinder mounting bolts and remove the rear view mirror. © Remove the brake lever. © Disconnect the front brake switch lead wires, CHASSIS 5-42.5-43 CHASSIS. © Place a rag underneath the union bolt on the master cyl- inder to catch any spilled drops of brake fluid. Remove the union bolt and disconnect the brake hose/master cyl- inder joint. fely and completely wipe off any brake fluid contacting any part of the motorcycle. The flui reacts chemically with paint, plastics and rubber m: |_ terials, ete. and will damage them severely. ‘* Remove the master cylinder assembly. © Remove the front brake switch. ‘© Remove the reservoir cap and diaphragm. © Drain brake fluid. Remove the dust boot. # Remove the circlip with the special tool. (BB 09900-06108: Snap ring pliers Remove the piston/secondary cup, primary cup and spring,MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other damage. Inspect the piston surface for any scratches or other dam- age. Inspect the primary cup, secondary cup and dust seal for wear or damage. MASTER CYLINDER REASSEMBLY AND REMOUNTING ‘© Reassemble the master cylinder in the reverse order of removal and disassembly. Pay attention to the follo points: ‘A CAUTION ‘* Wash the master cylinder components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to wash them. + Do not wipe the components with a rag. * Apply brake fluid to the cylinder bore and all the component to be inserted into the bore. B specitication and Classification: DOT 4 © When remounting the master cylinder on the handle- bars, align the master cylinder holder's lower mating surface with punched mark @ on the handlebars and tighten the upper clamp bolt first as shown. (8) master cylinder mounting bolt: 10 N-m_ (1.0 kg-m, 7.0 Ib-ft) NOTE: Install and adjust the rear view mirror before tightening the master cylinder mounting bolts. Bleed sir from the system after reassembling master | cylinder. (Refer to page 2-12.) | CHASSIS 5-44 “UP* mark Clearance5.45 CHASSIS. REAR BRAKE Te ® ® © o © : [eee [70 Sree Bee ar on © 23 23 | 165 @ shim Broke hose @ wis fase ete see a maeeatea * This brake system is filled with a ethylene glycol-based DOT 4 brake fluid. Do not use or mix different types of fluid such as silicone-based or petroleum-based. * Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing ot stored for long periods. ‘* When storing the brake fluid, seal the container completely and keep away from children. * When replenishing brake fluid, take care not to get dust into fluid. | * When washing brake components, use fresh brake fluid. Never use cleaning solvent. * A contaminated brake disc or brake pad reduces braking performance. Discard contami- | nated pads and clean the disc with jh quality brake cleaner or neutral detergent. {& CAUTION Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials ete.CHASSIS 5-46 BRAKE PAD REPLACEMENT © Remove the rear lower fender O. ‘© Remove the screws @. ‘* Remove the brake pad mounting pin @. Remove the mounting bolt @. © Slide the caliper housing to outside then remove the pads ©. * Do not operate the brake pedal while dismounting | the pads. * Replace the brake pad as a set, otherwi performance will be adversely affected. © Install the new pads correctly. ‘© Tighten the caliper mounting bolt and pad mounting pin to the specified torque. [®) Brake caliper mounting bolt: 23 N-m. (2.3 kg-m, 16.5 Ib-ft) Pad mounting pin: 18 N-m (1.8 kg-m, 13.0 Ib-ft) NOTE: After replacing the brake pads, pump with brake pedal few times to operate the brake correctly and then check the brake fluid level. BRAKE FLUID REPLACEMENT © Remove the reservoir tank mounting bolt. ® Replace brake fluid in the same manner of the front brake. (Refer to page 5-40.) B Specification and Classification: DOT 4 ‘A CAUTION] a" the brake fluid circuit. (Refer to page5-47 CHASSIS CALIPER REMOVAL AND DISASSEMBLY © Place a rag underneath the union bolt on the brake cali- per to catch any spilled drops of brake fluid, ‘© Remove the union bolt and catch brake receptacle. ‘4 CAUTION fluid in a suitable Never reuse the brake fluid left over from previous |_ servicing and stored for long periods. PROGINS Brake fluid, if it leaks, interfere with safe running | and discolor painted surfaces. Check the brake hose and hose joints for cracks and fluid leak: @ Remove the caliper by removing the mounting bolts. © Remove the pads. (Refer to page 5-46. ) © Place a rag over the piston to prevent popping up. Force out the piston with an air gun: 4 CAUTION nt piston dam- ‘© Remove the dust seal and piston seal. Do not reuse the removed seals to prevent fluid leak-CALIPER AND DISC INSPECTION Inspect the caliper cylinder bore wall for nicks, scratches or other damage. Inspect the pistons for damage and wear. Disc .... -» Refer to page 5-43. CALIPER REASSEMBLY AND REMOUNTING Reassemble and remount the caliper in the reverse order of removal and disassembly. Pay attention to the following points: A CAUTION ‘* Wash the caliper components with fresh bral fluid before reassembly. Never use cleaning solvent or gasoline to wash them * Apply brake fluid to the c be inserted into the bore. B Specification and Classification: DOT 4 © Install the brake pads and remount the brake caliper. (Re- fer to page 5-47.) © Tighten the brake hose union bolt to the specified torque. n bolt: 23 N-m (2.3 kg-m, 16.5 Ib-ft)5.49 CHASSIS MASTER CYLINDER REMOVAL AND DISASSEMBLY © Place a cloth underneath the union bolt on the master cylinder to catch spilled drops of brake fluid. © Remove the union bolt ©. Loosen the rear brake rod lock nut @. Remove the master cylinder mounting bolts @. Disconnect the brake rod by rotating brake rod @. Disconnect the brake hose ©. ‘* Remove the connector by removing the circlip ©. (09900-06108: Snap ring pliers © Remove the O-ring @. CAUTION. ‘The removed O-ring should be replaced with a new on ‘@ Remove the dust boot. © Remove the circlip with the special tool. BD 09900-06108: Snap ring pliers ¢ Remove the rod, piston, primary cup and spring.CHASSIS 5-50 MASTER CYLINDER INSPECTION Inspect the cylinder bore wall for any scratches or other damage. Inspect the piston surface for scratches or other damage. Inspect the primary cup for damage. MASTER CYLINDER REASSEMBLY AND REMOUNTING Reassemble and remount the master cylinder in the re- verse order of removal and disassembly. Pay attention to the following points: ‘A CAUTION ‘* Wash the master cylinder components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to wash them. to the cylinder bore and all the (B specitication and Classification: DOT 4 MASTER CYLINDER © Tighten the bolts and nut to the specified torque. () Master cylinder mounting bolt ©: 10 N-m. (1.0 kg-m, 7.0 tb-ft) inder rod lock nut @: 18 N-m (1.8 kg-m, 13.0 Ib-ft) n bolt @: 23 N-m (2.3 kg-m, 16.5 Ib-ft) Master Brake hose ur ‘A CAUTION.5-51 CHASSIS, LOWERING THE SEAT HEIGHT The seat height can be lowered 30 mm by changing the location of the inner parts of the front fork and rear shock absorber and replacing the side-stand with optional one. OPTIONAL PARTS SUPPLY Part No. Part Name PCS Non Side-stand (Silver painting) 1 (09248-10006 | Plug 1 -04821 42300-04820 62184-32E00 _| Plate 7 68380-04F00 _ | Label set 7 PRUGS When installing the optional center-stand, install the shorter, silver-colored on If the optional center-stand has been installed to the motorcycle, replace the center-stand with shorter, silver-colored one. SPECIAL TOOLS — &Y / & This special too! is used with too! (09940-34520) This special tool is used for loosening andtight- | for loosening and tightening the front fork ening the front fork damper rod bolt. damper rod bolt. (09940-34520: “T” handle 09940-34592: Attachment “G" SUN This special tool is used for adjusting the front | This special tool is used for loosening and tight- fork oil level. ening the rear shock absorber ring. 09943-74111: Front fork oil level gauge 09910-60611: Universat clamp wrenchCHASSIS 5-52 FRONT FORK @ Spacer @ Front brake caliper a trem [Nem | kg-m | tht @ [3 [23 [165 6 © ® © 30 | 30 | 25 6s | 65 | 470 2 | 23 | 165 39 | 39 | 2805-53 CHASSIS REMOVAL AND DISASSEMBLY @ Remove the front brake caliper mounting bolts O. © Remove the speed sensor guides @. © Loosen the front axle holder bolts @ and axle @. © Carefully position a jack under the chassis tubes and raise until the front wheel is slightly off the ground, ‘© Remove the front wheel by removing the axle. [a CAUTION Do not operate the brake lever while dismounting the front wh ‘© Remove the front brake hose clamp bolt ©. © Remove the front fender.CHASSIS 5-54 ‘© Remove the front fender brace. © Slightly loosen the front fork cap bolt © after loosening the front fork upper clamp bolt @ to facilitate later dis- assembly. © Remove the front fork by loosening the lower clamp bolts @. ‘© Remove the other side front fork the same way. © Remove the front fork cap bolt @, spacers © and ©, washer ( and spring @. © Invert the front fork and stroke it several times to drain fork oil5.55 CHASSIS © Remove the damper rod bolt with a 8 mm hexagon wrench and special tools. (GB 09940-34520: “T” handle 09940-34592: Attachment “G" ‘© Remove the damper rod @ with spring @. REASSEMBLY AND REMOUNTING Reassemble and remount the front fork and front wheel in the reverse order of removal and disassembly. Pay atten- tion to the following points: # Install the removed spacer @ and spring @ to the damp- er rod as shown in the photo. © Insert the damper rod assembly to the inner tube with the special tool. (GB 09940-34520: “T” handle (09940-34592: Attachment “G” ‘* Apply THREAD LOCK “1342” to the damper rod bolt ZB 99000-32050: THREAD LOCK “1342” (4 CAUTION) THREAD LOCK "1342"CHASSIS 5-56 © Tighten the damper rod bolt to the specified torque with a 8 mm hexagon wrench and special tools. () Damper rod bott: 30 N-m (2.0 kg-m, 21.5 Ib-ft) (GB 09940-34520: “T” handle 09940-34592: Attachment “G” ‘© Pour specified fork oil into the inner tubs. W@Bl Fork oli type: Fork oil #15 :99000-99044-15G: SUZUKI FORK OIL #15 Capacity (each leg): 699 ml (23.6/24.6 US/Imp oz) © Hold the front fork vertical and adjust the fork oil level with the special tool. 09943-74111: Fork oil level gauge Oil level: 92 mm (3.6 in) NOTE: When adjusting the oil level, remove the fork spring and compress the inner tube fully. ‘© Install the fork spring. © Install the washer and fork cap bolt, and tighten the cap bolt your hand. ‘© When remounting the front fork, align the upper surface @ of the inner tube with the upper surface @ of the steering stem upper bracket. ‘© Tighten the front fork lower clamp bolts and fork cap bolt to the specified torque. ‘© Tighten the front fork upper clamp bolt to the specified torque. (©) Front fork cap bolt: 23 N-m (2.3 kg-m, 16.5 Ib-ft) Upper clamp bolt: 23 N-m (2.9 kg-m, 21.0 Ib-ft) Lower clamp bolt: 23 N-m (2.3 kg-m, 16.5 Ib-ft)5-57 CHASSIS © Reassemble the front fender brace and front fender. © Install the brake hose clamp ©. © Align the drive lugs © with the recesses @ of the wheel hub. Before tightening the front axle, position the stopper @ of the speed sensor against stopper @.CHASSIS 5-58 © Tighten the front axle @ to the specified torque and then move the front fork up and down. © Tighten the axle pinch bolt @ to the specified torque. {F) Front axte: 65 N-m (6.5 kg-m, 47.0 Ib-ft) Axle pinch bolt: 23 N-m (2.3 kg-m, 16.5 lb-ft) © Reinstall the speed sensor guides @. NOTE: Clamp the speed sensor wire harness to the white markad part. © Tighten the front brake caliper mounting bolts to the specified torque. [© Brake caliper mounting bolt: 39 N-m (3.9 kg-m, 28.0 lb-ft)5-59 CHASSIS REAR SHOCK ABSORBER @ Rear shock absorber Plate (Options! part) ‘@ Plug (Optional part) © Spring seat ® 45 45 | 325 ® 30 3.0 21.6 [= Nem | kom | loft Standard spring sest @ and mounting Changed spring seat @ and mounting position position.CHASSIS 5-60 REMOVAL AND DISASSEMBLY ‘© Remove the seat and left frame cover. ‘* Remove the rear shock absorber reservoir tank © by loosening its clamp screws @. ‘* Take off the hose from the clamps @. © Remove the rear shock absorber by removing the mounting bolts @. '* Loosen the spring pre-load adjuster lock ring and adjust- er ring fully with the special tool 09910-60611: Universal clamp wrench aoe © Remove the spring seat D and plate @ by moving the cushion @ to the shock absorber cylinder side. NOTE: The removed plate @ will not be used when reassembling the shock absorber. REASSEMBLY AND REMOUNTING Reassemble and remount the rear shock absorber and air cleaner in the reverse order of removal and disassembly. Pay attention to the following points: ‘© When installing the spring seat @ to the shock absorber, invert it from standard position.5.61 CHASSIS © Position the cushion @ against washer @. © Tighten the spring adjuster ring and adjust the spring pre-load with the special tool. The standard set length is 169.2 mm (6.7 in). © After adjusting the pre-load, tighten the adjuster lock ring securely. (6B 09910-60611: Universal clamp wrench SPRING SETTING TABLE Spring pre-set length Softest 180.0 mm (7.0 in) Standard 169.2 mm (6.7 in) Stiffest 160.0 mm (6.3 in) ‘© Tighten the plug © (optional part) to the lower mount: ing part of shock absorber @ to the specified torque. [F) Plug: 30 N-m (3.0 kg-m, 21.5 Ib-ft) Install the shock absorber lower plate @ (optional part) as shown in the illustration. install the rear shock absorber and tighten it to the speci- fied torque. [(B) Mounting bott: 45 N-m (4.5 kg-m, 32.5 Ib-ft) (Upper and lower) SIDE-STAND Wott 36.0 40.0CHASSIS 5-62 SIDE-STAND REMOVAL AND INSTALLATION © Support the motorcycle with jack or wooden block. © Remove the original side-stand by removing mounting nut and bolt. Apply SUZUKI SUPER GREASE “A” to the side-stand pivot portion and spring hooks. AWB 99000-25010: SUZUKI SUPER GREASE “A” © Install the optional shorter side-stand (silver-colored) and springs correctly as shown in the illustration. © Tighten the side-stand mounting bolt and nut to the spe- cified torque. (8) Bott: 50 N-m (5.0 kg-m, 36.0 Ib-ft) Nut: 55 N-m (5.5 kg-m, 40.0 Ib-ft) A new, shorter, silver-colored optional side-stand must be installed for safe parking. NOTE: ‘Make sure that the side-stand switch operation after instal- ling the side-stand. WARNING LABEL © Attach the warning label (optional part) to the swingarm as shown in the illustration. NOTE: Select the appropriate language label for your country. Warning labe! Tire pressure labelELECTRICAL SYSTEM CAUTIONS IN SERVICING LOCATION OF ELECTRICAL COMPONENTS CHARGING SYSTEM DESCRIPTION ... TROUBLESHOOTING INSPECTION STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK | | | SYSTEM .. STARTER SYSTEM DESCRIPTION SIDE-STAND/IGNITION INTERLOCK SYSTEM DESCRIPTION .... 6-10 TROUBLESHOOTING STARTER MOTOR REM(¢ STARTER MOTOR INSPECTION STARTER MOTOR REASSEMBLY . STARTER RELAY INSPECTION .. ‘SIDE-STAND/IGNITION INTERLOCK SYSTEM INSPECTION IGNITION SYSTEM DESCRIPTION . TROUBLESHOOTING INSPECTION COMBINATION METER REMOVAL .. DISASSEMBLY INSPECTION FUEL METER ... FUEL METER INSPECTION . FUEL LEVEL GAUGE REMOVAL/INSTALLATION FUEL LEVEL GAUGE INSPECTION .. ot LAMPS .. HEADLIGHT . TAIL/BRAKE LIGHT, TURN SIGNAL LIGHT AND LICENSE PLATE LIGHT . TURN SIGNAL RELAY . SWITCHES BATTERY ‘SPECIFICATIONS INITIAL CHARGING SERVICING ..... RECHARGING OPERATION .6-1 ELECTRICAL SYSTEM. CAUTIONS IN SERVICING CONNECTOR ‘© When connecting a connector, be sure to push it in unti) a click is felt. © Inspect the connector for corrosion, contamination and breakage in its cover. COUPLER © With a lock type coupier, be sure to release the lock be- fore disconnecting it and push it in fully till the tock works when connecting it. © When disconnecting the coupler, be sure to hold the coupler itself and do not pull the lead wires. ‘* Inspect each terminal on the coupler for being foose or bent. © Inspect each terminal for corrosion and contamination, CLAMP '* Clamp the wire harness at such positions as indicated in "WIRE HARNESS ROUTING" (Refer to pages 7-10,11,12 and 13 © Bend the clamp properly so that the wire harness is clamped securely. © In clamping the wire harness, use care not to allow it to hang down. © Do not use wire or any other substitute for the band type clamp. FUSE © When a fuse blows, always investigate the cause, correct it and then replace the fuse. © Do not use a fuse of a different capacity. Do not use wire or any other substitute for the fuse. SEMI-CONDUCTOR EQUIPPED PART ‘© Be careful not to drop the part with 2 semi-conductor built in such as a CD) unit and regulator/rectifier, ‘© When inspecting these parts, follow inspection instruc- tion strictly. Neglecting proper procedure may cause damage to these parts. Click connect aC INCORRECT INCORRECTBATTERY ‘© The MF battery used in this vehicle does not require maintenance as inspection of electrolyte level and re- plenishment of water. '® No hydrogen gas is produced during normal charging of the battery, but such gas may be produced when it i overcharged. Therefore, do not bring fire near the bat- tery while it is being charged. '® Note that the charging system for the MF battery is dif- ferent from that of an ordinary battery. Do not replace with an ordinary battery. CONNECTING BATTERY ‘© When disconnecting terminals from the battery for dis- assembly or servicing, be sure to disconnect the nega- tive (©) terminal first. © When connecting terminals to the battery, be sure to connect the positive (®) terminal first. ¢ If the terminal is found corroded, remove the battery, pour warm water over it and clean with a wire brush. Upon completion of connection, apply grease lightly. Put a cover over the positive (®) terminal. WIRING PROCEDURE * Route the wire harness properly according to “WIRE HARNESS ROUTING” (Refer to pages 7-10,11,12 and 13). USING MULTI CIRCUIT TESTER © Be sure to use positive (©) and negative (©) probes of the tester properly. Their false use may cause damage in the tester. © If the current values are not known, start measuring in the higher range. © Toking a measurement where voltage is applied in the resistance range may cause damage in the tester. When measuring resistance, check to make sure that no volt- age is applied there. © After using the tester, turn the switch to the OFF po: tion. [a CAUTION Before using the multi tion manu: ELECTRICAL SYSTEM 6-2 ‘Mutt circuit tester6:3 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS @Battery @Fuses @Turn signal relay @COI unit @Stanter relay @©Main fuse @Generator @Starter motor @Side-stand switchELECTRICAL SYSTEM-6-4 @Horn ignition coil @Throttle position sensor @Solenoid valve ©@Diode @Regulator/rectifier @Side-stand interlock relay6-5 ELECTRICAL SYSTEM. CHARGING SYSTEM DESCRIPTION The circuit of the charging system is indicated in the figure, which is composed af an AC generator, regulator/rectifier unit and battery. ‘The AC current generated from AC generator is converted by recti then it charges the battery. F and is turned into DC current, Ignition switch Loao. |ELECTRICAL SYSTEM 6-6. TROUBLESHOOTING Check accessories which excessively |_ waste electric power. Not installed 4 Inspect battery leak current. Installed —~ + Remove accessories. s een ane * Short circuit of wire harness. [Seferto page 67) | * Loose or disconnected wires. * Faulty battery. No le ——— Inspect charging voltage between battery terminals. Faulty battery. (Refer to page 6-7.) Abnormal driving condition. Incorrect 2 aint ] isp aly = |__ yo county —~+ ny anno o 7 - disconnected lead wires. Se I Correct | Inspect generator no-load voltage. (Refer to page 68.) Incorrect + Faulty generator rotor. Correct —_ Inspect regulatorirectifi Eo (Refer to page 6-9.) Incorrect + Faulty regulator/rectifier. Correct _ Inspect wirings. |+— Incorrect ———~ + Short circuit of wire harness. ~ + Poor contact of couplers. Correct (___________... Fautty battery. Battery overcharge + Faulty regulator/rectifier + Faulty battery + Poor contact of generator lead wire coupter6-7 ELECTRICAL SYSTEM INSPECTION BATTERY LEAK CURRENT INSPECTION ‘© Remove the seat and battery holder plate ©. ‘© Turn the ignition switch to the OFF position. @ Disconnect the battery © lead wire. © Connect the multi circuit tester between the © terminal and © lead wire of the battery. Note that leakage is indicated if the tester reads over 1mA. (BB 09900-25008: ulti circuit tester sot Battery leak current: Under 1.5mA. (G2) Tester knob indication: Current ( == , 20mA) ‘A CAUTION * Because the leak current might be large, turn the tester to high range first when connecting an am- meter. * Do not turn the ignition switch to the ON position | when measuring current. When leakage is found, look for the part where the tester read under 1mA through the couplers and connectors are removed one by one. CHARGING OUTPUT INSPECTION ‘© Remove the seat and battery holder plate. © Start the engine and keep it running at 5 000 r/min. with lighting switch turned ON and dimmer switch turned HI position, Measure the DC voltage between the battery terminals © and © with a pocket tester. If the tester reads under 13.5V or over 15.0V, inspect the generator coil and regutator/recti- fier. NOTE: When making this test, be sure that the battery is fully charged condition. 09900-25008: Multi Charging output Standard: 13.5-15.0 at 5 000 r/min. {GD Tester knob indication: Voltage ( = ) Red lead wire Black lead wire TesterELECTRICAL SYSTEM 6-8 GENERATOR COIL CONTINUITY INSPECTION © Remove the seat. ‘© Disconnect the generator coupler ©. Using a multi circuit tester, inspect the continuity between the three lead wires. Also check that the stator core is insulated. If there is no continuity, replace the stator with a new one. “a Y- (GB 03900-25008: Multi circuit tester set i = (3) Tester knob indication: Continuity test (+0) ) \ v¥— NOTE: © When making above test, it is not necessary to remove the AC generator. GENERATOR NO-LOAD PERFORMANCE INSPECTION © Remove the seat and frame cover. ‘© Disconnect the generator coupler ©. — © Start the engine and keep it running at 5 000 r/min. i a Using a multi circuit tester, measure the voltage between | / the three lead wires. \ If the tester reads under the specified value, replace the AC generator with a new one. (6B 09900.25008: Multi circuit tester set Generator no-load performance: More than 75V at 5000 r/min (When engine is cold) {EDD Tester knob indication: Vottage (~)6-9 ELECTRICAL SYSTEM. REGULATOR/RECTIFIER INSPECTION ‘© Remove the seat and right frame cover. © Disconnect the regulator/rectifier coupler ©. Using a multi circuit tester, measure the voltage between the lead wires in the following table. If voltage is incorrect, replace the regulator/rectifier. (GB) 02900-25008: Mutti circuit tester set (GH) Tester knob indication: Diode test (++ ) Unit: V Prabe of tester 1 8 [or Yr Ye ve [ew - a BAW sr | oat-07 | 04-07 | 04-07 | 05-12 ET eporont laporox.1S|approx15| 04-07 3 |_¥? [approx tSlapproxt.5 lepproxt| 04-07 2 [Yo _japprox 18 approx.1.8 approx.8 04-07 1G [BW _lapprox.15|approx.1.5 japprox.15 [approx 6 7 Ye Yellow, Ri Red, B/W: Black with White tracer vow Ys NOTE: LT If the tester read under 1.4V, replace the battery of multi circuit tester when do not connecting the tester probes.ELECTRICAL SYSTEM 6-10 STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM STARTER SYSTEM DESCRIPTION The starter system is shown in the diagram below: namely, the starter motor, starter relay, side- stand relay, side-stand switch, neutral switch, clutch lever position switch, starter switch, engine stop switch, IG switch and battery. Depressing the starter switch (on the right handlebars switch box) energizes the relay, causing the contact points to close which connects the starter motor to the battery. The motor draws about 70 amperes to start the engine. Clutch lever Engine Ignition position switch switch swith 0: R. lanition 9 signal fuse “ Main VIG Starter Side-stand ‘ ; » , ES switch SIDE-STAND/IGNITION INTERLOCK SYSTEM DESCRIPTION This side-standjignition interlock system is to prevent starting the motorcycle with the side-stand left down. The system is operated by an electric circuit provided between the battery and CDI unit. Side-stand Engine stop rela {anition switeh u switch on ue To CDI unit starter switeh vis R relay Cluteh lover L [ 4 Position switch Bw Battery Side-stand : switch w | WIRE COLOR "6 BI: Blue Rc Red V8 : Orange with Black tracer O/Y : Orange with Yellow tracer G Green BMV: Black with White tracer O/G : Orange with Green tracer Y/G : Yellow with Green tracer © Orange BUB : Blue with Black ‘ON: Orange with White tracer6-11 ELECTRICAL SYSTEM The circuit consists of relay, lamp, diode and switches and decides to live CDI unit depending on the position of the TRANSMISSION and SIDE-STAND with the neutral and side-stand switches working mutually. The CDI unit lives only in two situations as follows. 1. Transmission: “NEUTRAL (ON)" Side-stand: “DOWN (OFF)" The current flow @ turns “ON” the relay and CDI unit lives even the side-stand is kept down. This is or warming up the engine. | SIDE-STAND IGNITION Sw. RELAY “ON” Sone BATTERY col uNIT NEUTRAL INDICATOR LGHT DIODE NEUTRAL SW. "ON" SIDE-STAND SW. ‘SIDE-STAND 7 *DOWN POSITION" 2. Side-stand: "UP-RIGHT (ON)” The current flow @ turns “ON” the relay and the CDI unit lives. The engine can be easily started at any transmission position. ‘SIDE-STAND IGNITION SW. RELAY “ON” cone BATTERY cl UNIT SSIDE-STAND ‘SW. "UP-RIGHT POSITION”ELECTRICAL SYSTEM 6-12 TROUBLESHOOTING ‘Starter motor will not run. ——__| [ The transmission is in neutral. | Turn on the ignition switch with | the engine stop switch in “RUN” | Clicks position. Check whether to hear the click noise from the starter relay when the starter button is pushed. No click 1 — ‘Measure the starter relay voltage at the starter relay connectors (between Y/G @ and BW ©) when the starter button is pushed. = Voltage measured | [ Check the starter relay. (Refer to page 6-15.) Correct No voltage —~ Check whether to run the starter motor when connect the starter motor terminal to the battery ® terminal directly. {Do not use thin wire, because a large amount of current flows.) — oo Run Not run } + Faulty starter motor + Faulty starter relay * Loosen or disconnected starter motor lead wire + Faulty ignition switch + Faulty engine stop switch + Faulty neutral switch + Faulty diode + Faulty side-stand relay + Faulty starter button + Faulty clutch lever position switch + Poor contact of connector + Open circuit in wiring harness Incorrect ——> + Faulty starter relay * Poor contact of the starter relay Starter motor runs when the transmission is in neutral, but does not run with the transmission in any position except neutral, with the side-stand up position. Check the side-stand switch. (Refer to page 6-17.) —T Correct Incorrect—— + Faulty side-stand switch + Open circuit in wiring harness * Poor contact of connector Engine does not turn though starter motor runs. Faulty starter clutch6-13 ELECTRICAL SYSTEM STARTER MOTOR REMOVAL AND. DISASSEMBLY ‘* Remove the exhaust pipe. ‘® Remove the cam drive chain tensioner. Disconnect the starter motor lead wire and remove the starter motor by removing the mounting bolts. (Refer to page 3-11.) STARTER MOTOR INSPECTION CARBON BRUSH Inspect the brushed for abnormal wear, crack or smooth- ness in the brush holder. If the brush has failed, replace the brush sub ass'y. Qo-ing @ Housing end (inside) @Washer set @ O-ring (2 pes) @® Starter motor case @ Armature @ Washer set @ Brush holder @ Brush spring @ Housing end (outside)COMMUTATOR Inspect the commutator for discoloration, abnormal wear or undercut @. If the commutator is abnormally worn, replace the arma- ture. When surface is descolored, polish it with #400 sand paper and clean it with dry cloth. If there is no undercut, scrape out the insulator © with saw blade. ARMATURE COIL INSPECTION Check for continuity between each segment. Check for continuity between each segment and the arma- ture shaft. If there is no continuity between the segments or there is continuity between the segments and shaft, replace the ar- mature with a new one. OIL SEAL INSPECTION Check the seal lip for damage or leakage. If any damage is found, replace the bracket. STARTER MOTOR REASSEMBLY Reassemble the starter motor in the reverse order of disas- ‘sembly. Pay attention to the following points: [A CAUTION Replace the O-rings with new ones to prevent oil leakage and moisture. | © Apply SUZUKI SUPER GREASE “ seal. MDH 99000-25010: SUZUKI SUPER GREASE “A” to the lip of the oil ELECTRICAL SYSTEM 6-14 Segment ® i6-15 ELECTRICAL SYSTEM © Apply a small quantity of MOLY PASTE to the armature shaft. Aa 99000-25140: SUZUKI MOLY PASTE © Apply a small quantity of THREAD LOCK “1342" to the starter motor housing bolts. SG 99000-32050: THREAD LOCK "1342" STARTER RELAY INSPECTION © Remove the left frame cover, © Remove the starter relay cover. © Disconnect the starter motor lead wire and battery lead wire at the starter relay. ‘© Disconnect the lead wire coupler from the starter relay. Apply 72 volts to D and @ terminals, inspect the conti between the terminals, positive and negative. If the starter relay is in sound condition, continuity is found. ity 09900-25008: Multi circuit tester set (GB) Tester knob indication: Continuity test (+1) ) ‘4 CAUTION Do not apply a battery voltage more than 5 seconds to the starter relay as it may overheat and cause damage to the relay coil. Check the coil for “open”, “ground” and ohmic resistance. The coil is in good condition if the resistance is as follows. 09900-25008: Multi circuit tester set {G) Tester knob indication: Starter relay resistance Standard: 3-59 lesistance (Q)STARTER RELAY CIRCUIT DIAGRAM To starter motor ELECTRICAL SYSTEM 6-16 To battery SIDE-STAND/IGNITION INTERLOCK SYSTEM INSPECTION If the interlock system does not operate properly, check each component. If any abnormality is found, replace the component with a new one, DIODE The diode @ is located behind the right frame cover. ‘© Remove the seat and right frame cover. © Disconnect the diode. Using a multi circuit, tester, measure the voltage between the terminals in the following table. et on ott @ Probe of Bs @ ® 82 gs @ 14-15 lo2! @ 0.4-06 (GB 09900.25008: Muti circuit tester set (GH) Tester knob indication: Diode test (+¢ ) NOTE: If the tester read under 1.4V, replace the battery of multi circuit tester when do not connecting the tester probes.6-17 ELECTRICAL SYSTEM NEUTRAL SWITCH The neutral lead wire coupler is located under the fuel tank. ‘© Remove the seat, ‘© Disconnect the neutral switch lead and check the conti- nuity between Blue and Ground with the transmission in “NEUTRAL”, Blue Ground ON O Oo (Neutral) oO — OFF (Except neutral) SIDE-STAND SWITCH The side-stand switch lead wire coupler is located under the fuel tank. ‘® Remove the seat. © Disconnect the lead wire coupler. © Check the voftage between Green (® Probe) and Black! White (© Probe) with the side-stand switch in Up-right position. If any abnormality is found, replace it with a ew one. (GB) 09900-25008: Multi circuit tester set (GB) Tester knob indication: Diode test (++ ) Green Black\White (@ Probe) (© Probe) oN (UP-right position) 0.4-0.6V OFF (Down position) eel NOTE: If the tester read under 1.4V, replace the battery of multi sireuit tester when do not connecting the tester probes. NOTE: When replacing the side-stand switch, apply small quantity of THREAD LOCK SUPER “1342” to its mounting bolts. ‘BB 99000-32050: THREAD LOCK “1342”ELECTRICAL SYSTEM 6-16 SIDE-STAND/IGNITION INTERLOCK RELAY The side-stand/ignition interlock relay is located behind the right trame cover. @ Remove the seats and the right frame cover. isconnect the lead wire coupler from the side-stand/ ignition interlock relay. First, check the insulation between © and @ terminals with a tester. Then apply 12 volts to @ and @ terminals, ® to @ and © to @, and check the continuity between @ and @. If there is no continuity, replace it with a new one. CLUTCH LEVER POSITION SWITCH Yellow/Green | Yellow/Green ON oO —_ (Squeeze) 0 TO OFFELECTRICAL SYSTEM IGNITION SYSTEM DESCRIPTION In the capacitor discharged ignition system, the electrical energy generated by the magneto charges the capacitor. This energy is released in a single surge at the specified ignition timing point, and current flows through the primary side of the ignition coil. A high voltage current is induced in the secondary windings of the ignition coil resulting in strong spark between the spark plug gap. Ignition Side-stand | ‘switch bese relay 5 Oe Se on o | oe Engine stop wen 6 om: wre i ‘Side: stand vie switch Spark Pickup coi Neutral oe poner ence ach peor aw an 1 we: white OW: Orange with White tracer | BIW : Black with White tracer ONY : Orange with Yellow tracer BIB Blue with Black vocer WEBI: White with Blue tracer © : Orange OB: Orange with Black tracer IG : Yellow with Green tracer | Ro Red O1G : Orange with Green tracerTROUBLESHOOTING No spark or poor s Il [ Check the ignition system couplers for poor connection. Correct —_+_________ | Inspect the battery voltage between input lead wires (OW and BMW) at the CDI unit with the ignition switch “ON” Position, Correct Inspect the ignition coil primary peak voltage. (Refer to pages 6-21.) NOTE: This inspection method is ap- plicable using only for Multi circuit tester and peak volt adaptor. Incorrect | Inspect the ignition oc (Refer to page 6-22.) Correct Inspect the resistance of pick-up c (BI and G) and power source oil (B and Wi. (Refer to page 6-23.) Correct }—— Incorrect —~ + ELECTRICAL SYSTEM 6-20 * Check that the transmission is in neutral the engine stop switch is in the RUN posi that the fuse is not blown and battery is fully-charged condition before the diagnosi —Looseness——> + Poor connection of couplers Incorrect ——> + Faulty ignition switch + Faulty side-stand relay * Faulty engine stop switch * Broken wire harness or poor connection of related circuit couplers Inspect the spark plug. (Refer to page 6-24.) Correct Incorrect | + Faulty spark plug Correct Po ign Faulty ignition coil/plug cap connection of n coil/plug cay Incorrect ——> + Faulty pick-up coil + Faulty power source coil Poor connection of ignition couplers.6.21 ELECTRICAL SYSTEM INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE ‘® Remove the fuel tank. (Refer to page 4-3.) ‘© Remove the two spark plug caps. '* Connect new two spark plugs to the each spark plug cap and ground them. NOTE: Be sure that all couplers and spark plugs are connected properly and the battery used is in fully-charged condition. Inspect the ignition coil primary peak voltage in the follow- ing procedure. © Connect the multi tor as follow. Ignition coil: Black terminal- Ground (© Probe) (® Probe) uit tester with peak voltage adap- NOTE: Do not disconnect the ignition coil primary wire. (6d 09900-25008: multi circuit tester set = RUTION] CAUTION When using the multi circuit tester and peak volt ptor, follow the instruction manu ‘© Shift the transmission into the neutral and turn ignition switch “ON”. © Crank the engine a few seconds with starter motor by depressing starter button and then check the ignition coil primary peak voltage © Repeat the above inspection a few times and measure the highest ignition coil primary peak voltage. (G2) Tester knob indication: Voltage ( ==} More than 200V Ignition coil primary peak volta Do not touch the tester probes and spark plugs to Prevent an electric shock while testing. If they are lower than the specified vatues, inspect the igni- tion eoit, power source coil and pick-up coil. (Refer to page 6-22) [Toa] Penk vt ecapor “8 pam 1) 7 Cor f unit Bw — Dy Jgnition New spark plugIGNITION COIL (Checking with Electro Tester) ‘© Remove the fuel tank. © Remove the ignition coil. NOTE: Make sure that the three-needle sparking distance of elec- tro tester is see at 8 mm (0.3 in). With the tester and jumper wire, test the ignition coil for sparking performance in accordance with the following two steps. STEP: Connect the jumper wire to the spark plug cap and ignition coil ground. STEP@: Switch over the jumper wire to the other plug cap and ground. if no sparking or orange color sparking occurs in the above conditions, it may be caused by defective coil. (GB 09900-28108: Electro tester ‘Spark performance: Over 8 mm (0.3 in) AWARNING ELECTRICAL SYSTEM 6.22 Do not touch the wire clips to prevent an electric shock when testi IGNITION COIL RESISTANCE * An ohm meter may be used, instead of the electro tester. In either case, the ignition coil is to be checked for conti- nuity in both primary and secondary windings. Exact ohmic readings are not necessary, but, if the windings are in sound condition, their continuity will be noted with these approximate ohmic values. it tester set Ignition coil resistance Primary: 0.07-0.120 (@ Black lead-© Black/white lead) ‘Secondary: 23-25 kQ (Plug cap-Plug cap) GB) Tester knob indi : Resistance (2)6-23 ELECTRICAL SYSTEM. POWER SOURCE COIL AND PICK-UP COIL © Remove the seat. © Disconnect the lead wire coupler @ from the CDI unit. ‘© Measure each coil resistance between lead wiras. If the resistance is infinity or less than the specifications, the power source coil and pick-up coil must be replaced. (® 09900-25008: multi circuit teste Power source coil resistance: 0.1-0.2 (Yellow-White} Pick-up coil resistance: 170-2560 (Blue-Green) (GB) Tester knob indication: Resistance (Q) setELECTRICAL SYSTEM 6.24 SPARK PLUG © Remove the spark plugs. 09930-10121: Spark plug socket wrench set Carbon Deposit Check to see the carbon deposit on the plug. If the carbon is deposited, remove it with a spark plug cleaner machine or carefully using a tool with a pointed end. Spark Plug Gap Measure the plug gap with a thickness gauge if it is cor- rect. If not, adjust it to the following gap. (GBB 09900-20803: Thickness gauge ‘Standard: 0.7-0.8 mm (0.028-0.031 in) Electrode’s Condition Check to see a worn or burnt condition of the electrode. If it is extremely worn or burnt, replace the plug. Also replace the plug if it has a broken insulator, damaged thread, etc. Heat Range NGK CR10E or NIPPONDENSO U31ESR-N should be used as the standard. However, the heat range of the spark plug should be selected to meet the requirements of speed, ac- tual load, fuel and ete. Proper heat range would be indi- cated if all insulators were LIGHT BROWN in color. If they are blackened by carbon, they should be replaced with a hot type plug NGK CRSE or NIPPONDENSO U27ESR-N. C Standard Hot type NGK ‘CRIOE ROE NIPPONDENSO USTESR-N UZTESR-N ‘4 CAUTION Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be depos- ited on the screw portion of the plug hole and engine damage may result. =a (0.028-0.031 in}6-25 ELECTRICAL SYSTEM COMBINATION METER REMOVAL ‘© Remove the instrument panel. (Refer to pages 6-2 and -3.) © Remove the combination meter by removing its mount- ing four bolts. DISASSEMBLY © Disassemble the combination meter as follows. @Combinstion @ Combination © Combination met @ Bulb (12 1.70) @Oring © Rubber cap_ELECTRICAL SYSTEM 6-26 INSPECTION Using the tester, check the continuity between terminals in the following diagram. If the continuity measured is incorrect, remove and check the bulb. If the bulb is failure, install the new bulb and check the continuity again. If the bulb is correct, replace the unit with a new one. 201918 17 16 15 14131211 a.1GNTION 2: POWER GROUND 3 ILLUMI @ 4 Blank | 5. Blank 6. Blank 7: Blank 2: Blank 8. Blank 10. NEUTRAL © 1 BATTERY 12: SPEED Voc 13 SIGNAL GROUND Tem |S Frabeot | SFrobe af 14. TURN (U festorto: | tester to 18. HIGH BEAM HIGHBEAM 5 13 416 TURN (A) NEUTRAL 1 10 17. FUEL a is a 18. SPEED SIGNAL 18. TACHO | TURN (0) 14 3 20. SPEED DISPLAY SWITCH TLLUMI 3 13 (for €-02),6-27 ELECTRICAL SYSTEM ‘SPEEDOMETER INSPECTION If the speedometer, odometer or tripmeter does not func- tion properly. Inspect the speed sensor and connection of couplers. If the speed sensor and connection is all right, replace the unit with a new one. ‘SPEED SENSOR INSPECTION © Remove the front wheel. (Refer to page 5-5.) ‘© Remove the fuel tank left cover. ‘© Disconnect speed sensor lead wire coupler. ‘© Remove the speed sensor by taking off its clamps. * Connect 12V battery (between O/R and B/W), 10k2 resis- tor (between O/R and P) and the multi circuit tester (® probe of tester to O/R and © to P) as shown right il- lustration. O/R:: Orange with Red tracer B/W: Black with White tracer PB ink (GB) 09900-25008: Multi circuit tester set ‘Tester knob indication: Voltage ( © Under above condition, by rotating the drive lugs of speed sensor slowly, the tester reading voltage relatively changes (0V—-12V or 12V-+0V). If the tester reading volt- age does not change, replace the speed sensor with a new one. NOTE: The highest tester reading voltage (12V) while testing is same as battery voltage. Battery voltage)ELECTRICAL SYSTEM 6-28 FUEL METER FUEL METER INSPECTION © Disconnect the fuel level gauge lead wire coupler. (Refer to page 4-4.) To test the fuel meter two different checks may be used. The first, connect a jumper wire between B/W and Y/B wires coming from the main wiring harness. With the ign tion switch turned ON, the fuel meter should indicate °F The second test will check the accuracy of the meter in the full and empty positions. Connect a new fuel level gauge as shown in the illustration Fuel meter is normal if its display indicates the E (empty) position when the specified resistance is applied to the cir- cuit and if its display indicates the F (full) position when the resistor is changed to the specified values. If either one or both indications are abnormal, replace the combination meter with a new one. New fuel level gauge Resistance [10-159 88-1002 Float position | __ Full (F) Empty (E) la GAUTION] ‘& CAUTION ‘When inspecting the gauge resistance, be sure to dis- | connect the battery lead wire, or a tester may be |_ damaged. B/BI: Black with Blue tracer BIW Black with White tracer O/G: Orange with Green trecer YIB : Yellow with Black tracer FUEL LEVEL GAUGE REMOVAL/ INSTALLATION © Remove the fuel tank. (Refer to page 4-3.) ‘© Remove the fuel level gauge @ by removing the bolts. © Install the fuel level gauge in the reverse order of remov- al. [A CAUTION Replace the gasket with a new one.6.29 ELECTRICAL SYSTEM FUEL LEVEL GAUGE INSPECTION ‘® Remove the fuel tank and fuel level gauge. (Refer to Pages 4-3 and 6-27.) Check the resistance of each float position with multi cir- cuit tester. If the resistance measured is incorrect, replace the fuel gauge assembly with a new one. The relation between the position of the fuel gauge float and resistance is shown in the following table. Float position Resistance Full (F) 10-159 Empty (E) 88-1009 (GB) 09900-25008: Multi circuit tester set () Tester knob indication: Resistance (Q) LAMPS HEADLIGHT AND POSITION LIGHT Headlight bulb: 12V 60/55W Position light bulb: 12V 4W (Except E-24) NOTE: Adjust the headlight, both vertical snd horizontal, after reassembling.ELECTRICAL SYSTEM 6-30 BULB REPLACEMENT Headlight © Disconnect the socket D and remove the rubber cap @. ‘© Remove the bulb @ by unlocking the bulb holder spring ®. © Reassemble the bulb in the reverse order of removal. ‘A CAUTION When replacing the headlight bulb, do not touch the glass. Grasp the new bulb with a clean cloth. If you | touch the bulb with your bare hands, clean it with a | cloth moistened with alcohol or soapy water to pre- vent early failure. Position light (Except E-24) © Pull off the socket ©. © Pull off the bulb from the socket631 ELECTRICAL SYSTEM. TAIL/BRAKE LIGHT, TURN SIGNAL LIGHT AND LICENSE PLATE LIGHT Tail/Brake light bulb: 12V 5/21W i) ‘Turn signal light bulb: 12V 21W BULB REPLACEMENT Tail/Brake light ‘© Remove the rubber cap ©. © Turn the socket to the left and pull it out. ‘© Push in on the bulb, turn it to the left, and pull it out.ELECTRICAL SYSTEM 6-32 Turn signal light © Remove the lens by removing the screw. © Turn the socket to the left and remove it. © Push in on the bulb, turn it to the left, and pull it out. TURN SIGNAL RELAY The turn signal relay is located under the seat. If the turn signal light does not light. Inspect the bulb or repair the circuit connection. If the bulb and circuit connection checked are correct, the turn signal relay may be faulty, replace it with a new one. NOTE: Be sure that the battery used is in full-charged condition.6-33 ELECTRICAL SYSTEM SWITCHES Inspect each switch for continuity with a tester, If any abnormality is found, replace the respective switch assemblies with new ones. IGNITION SWITCH (For E-24) STARTER BUTTON Color coer ow iG Position Ee OFF PUSH FS ‘ON os HORN BUTTON tock (For others) a on Color Toy lew! om | Position a |e ent ee ed PUSH SS Orr FRONT BRAKE SWITCH (ON 5 7 Color T “Tock Position C8 ee P. OFF 7 LIGHTING SWITCH ON ——s——e) (Except E-24) REAR BRAKE SWITCH Color Position ore Position] OG wre OFF OFF . ON + on CLUTCH LEVER POSITION SWITCH DIMMER SWITCH Color Color] yaw Ww 7 Position <— el Position OFF Hi OS ‘ON ——s Lo {> oS TURN SIGNAL SWITCH erie Color Brown lg Lol B aoe ight blue : Light green © : Orange o=5 R i Red PASSING LIGHT SWITCH ee ane Color lack with Blue tracer are] on Y ek nh Whe ter . - OBI: Orange with Blue tracer O/G: Orange with Green tracer Push g ) O/R : Orange with Red tracer ENGINE STOP SWITCH OM: Orange with White tracer Eat ON : Orange with Yellow tracer onal ov Ow W/B: White with Black tracer YIG : Yellow with Green tracer YAW: Yellow with White tracer oFBATTERY SPECIFICATIONS Type designation YTX9-BS Capacity 12V, 28.8 KC (8 Ah)/10HR Standard electroive 1.320 at 20°C (68°F) INITIAL CHARGING Filling electrolyte ‘© Remove the aluminum tape @ sealing the battery efec- trolyte filler holes. © Remove the caps @. NOTE: * After filling the electrolyte completely, use the removed cap @ as the sealed caps of battery-filler holes. * Do not remove or pierce the sealed areas @ of the elec- trolyte container. © Insert the nozzles of the electrolyte container into the battery's electrolyte filler holes, holding the container firmly so that it does not fall. Take precaution not to al- low any of the fluid to spill ¢ Make sure air bubbles are coming up each electrolyte container, and leave in this position for about more than 20 minutes. ELECTRICAL SYSTEM 6-34 ‘Anode plates Electrotye containers:§:35 ELECTRICAL SYSTEM. NOTE: If no air bubbles are coming up from a filler port, tap the bottom of the two or three times. ‘Never remove the container from the battery. © After confirming that the electrolyte has entered the bat- tery completely, remove the electrolyte containers from the battery. Weit for around 20 minutes. © Insert the caps into the filler holes, pressing in firmly so that the top of the caps do not protrude above the upper Surface of the battery's top cover. Never use anything except the specified battery. * Once install the caps to the battery; do not remove the caps. | Conese Womecr wy {at 25°C) 2 © Using SUZUKI pocket tester, measure the battery volt- | 11 age. The tester should indicate more than 12.5-12.6V (OC) as shown in the Fig. If the battery voltage is lower than the specification, charge the battery with a battery + charger. (Refer to the recharging operation.) Ce ee Time NOTE: Initial charging for a new battery is recommended if two years have elapsed since the date of manufacture. 10 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, then this can be cleaned away with sandpaper,RECHARGING OPERATION © Using the pocket tester, check the battery voltage. If the voltage reading is less than the 12.0V (DC), recharge the battery with a battery charger. ‘A CAUTION When recharging the battery, remove the battery | | from the motoreyel NOTE: Do not remove the caps on the battery top while recharg- ing Recharging time: 4A for one hour or 0.9A for 5-10 hours ‘A CAUTION ELECTRICAL SYSTEM 6-36 | 18 7 16 15 13 2 Charging period Stop charging 10-20-3040 7 3060 ene «sinutes) wy) 14 x 1 | 40°C) 1 | v0 | © After recharging, wait for more than 30 minutes and check the battery voltage with a pocket tester. « If the battery voltage is less than the 12.5Y, recharge the battery again. If battery voltage is still less than 12.5V, after recharging, replace the battery with a new one. © When the motorcycle is not used for a long period, check the battery every 1 month to prevent the battery discharge, 700 75 60 25 01%) Battery charged conditionRVICING INFORMATION TROUBLESHOOTING ... WIRING DIAGRAM ... | WIRE, CABLE AND HOSE ROUTING . . 7-10 | WIRE ROUTING . 7-10 CABLE ROUTING . . 714 CARBURETOR AND AIR CLEANER HOSE ROUTING 716 | PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING ... 7-17 FRONT BRAKE HOSE ROUTING 7-18 REAR BRAKE HOSE ROUTING............-...+ 7-19 FUEL TANK WATER DRAIN HOSE ROUTING . 7-20 OIL HOSE ROUTING . 7-20 FAIRING SET-UP ... + 7-22 FUEL TANK COVER SET-UP .. 7-22 PROTECTOR AND HEAT SHIELD ADHERING ... 7-23 SIDE STAND SPRING SET-UP 7-24 SPECIAL TOOLS... 7-25 TIGHTENING TORQUE . 728 SERVICE DATA . . 7347-1 SERVICING INFORMATION TROUBLESHOOTING ENGINE ‘Complaint ‘Symptom and possible causes Remedy Engine will not start, | Compression too low or is hard to start. Out of adjustment valve clearance. Adjust. . Worn valve guides or poor seating of valves. Repair or replace. . Mistiming valves. Adjust. Excessively worn piston rings, Replace, Worn-down cylinder bores, Slow rotating starter motor. Poor seating of spark plugs Plugs not sparking |. Fouled spark plugs. ‘Wet spark plugs. Defective ignition coil Open or short in high-tension cords. Defective generator or CDI unit. Defective side-stand switch or side stand relay. eg aeNe No fuel reaching the carburetor Clogged fuel tank cap. Clogged or defective fuel valve. Replace or rebore, See electrical section. Retighten. Cle Clean and dry. Clean or replace. Clean or replace. Noise seems to come from piston 1. Worn down piston or cylinder. 2. Fouled with carbon combustion chamber. 3. Worn piston pins or piston pia bore. 4, Worn pistan rings or ring grooves. ing chai Noise seems to come from ti 1. Stretched chain. 2. Worn sprocket. 3. Not working cam chain tensioner adjuster. Noise seems to come from clutch 1. Worn splines of countershaft or hub. 2. Worn teeth of clutch pilates. 3, Distorted clutch plates, driven and drive, 4, Worn clutch release bearing. 5. Weakened clutch dampers. Defective carburetor needle valve. Replace. Clogged fue! hose or vacuum hose. Clean oF replac Clogged fuel filter. Glean oF replac Engine stalls easily. | 1. Fouled spark plugs. Clean. 2. Defective signal generator or CDI unit. Replace. 3. Clogged fuel hose Clean 4. Clogged jets in carburetor. Clean 5. Out of adjustment valve clearance. Adjust. Noisy engine. Excessive valve chatter 1. Too large valve clearance. Adjust. 2. Weakened or broken valve springs. Replace. 3. Worn down rocker arm or rocker arm shaft. Replace. 4. Worn and burnt camshaft journal, Replace. Replace. Replace. Replace, Replace, Repair or replace. Replace, Replace. Replace. Replace. Replace the primary driven gear,