Обзор мотоцикла Suzuki RM 125

Модель кроссового мотоцикла Suzuki RM 125 выпускалась с 1970 по 2007 гг. Наиболее интересны версии с начала 90-х годов выпуска по 2007 г. Более старые модификации мотоцикла очень редки и практически не встречаются в РФ, поэтому в данном обзоре речь пойдет именно о моделях Suzuki RM 125 с 1991 по 2007 годы выпуска.

Главной особенностью Suzuki RM 125 является 1-цилиндровый 2-тактный двигатель жидкостного охлаждения, выдающий около 41 л.с. мощности и более 30 Нм крутящего момента. Как и на всех моделях данного класса, двигатель Suzuki RM 125 настроен на работу в верхнем диапазоне и выдает максимальные характеристики на 10000-11000 об/мин.

Из других важных особенностей Suzuki RM 125 следует выделить стальную раму, лепестковый клапан с изменяемыми фазами газораспределения, дисковые тормоза и продвинутые спортивные подвески (у последних версий). Модель Suzuki RM 125 используется в основном в качестве начального спортивного снаряда для обучения мотокроссом.

Основные конкуренты Suzuki RM 125 в классе:

Содержание

Краткая история модели

• 1970 г. - начало появления серии Suzuki RM 125.
• 1999 г. - модель Suzuki RM 125 получает вилку перевернутого типа.
• 2007 г. - последний год выпуска модели. Мотоцикла выдает 41,06 л.с. мощности и 30,2 Нм крутящего момента.

Начиная с 90-хх годов прошлого века и заканчивая последними годами выпуска, модель Suzuki RM 125 претерпевала множество изменений, касающихся как двигателя (увеличение производительности), так и ходовой части. К сожалению, найти более точную информацию изменений по годам не удалось.

Технические характеристики

Технические характеристики Suzuki RM 125:

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• Обзор и тест-драйв мотоцикла Suzuki RM 125.

Цена на Suzuki RM 125 с пробегом по РФ начинается от 100 000 руб.

Отзывы

Отзывы о Suzuki RM 125:

До сих пор являюсь владельцем сего чудо аппарата, но езжу на нем редко. Не потому что есть 450, а потому что тяжело. Я уже привык тошнить на большом моторе). Этот же нужно всегда держать выше средних и не ошибаться с передачами. Проморгал-начинай заново. Но тем не менее он меня многому научил. Хороший мот, но только в начале карьеры мотоциклиста). Мотор быстро устаёт и просит новых поршней и колец, а иначе - "уже не едет". В цилиндре никасиль.

И так что за зверь и с чем едят! Близкий аналог Кавы! Мотор простой и весьма удачный, очень шустрый и надежный! Ходовка вся от Шовы, но немного другая чем на Хонде! Не разбирался, но похоже другие наборы клапанов! По виражам просто ныряет! В воздухе управляемая и предсказуемая! Едет одинаково хорошо и с гильзой и с никасилем Если брать для эндуро то лучше гильзу! Никасиль имеет высокую твердость но и низкую хрупкость, а при износе поршня он начинает стучать по никасилю! Как бы вот так в черновике и в общем!

Материалы: http://bikeswiki.ru/Suzuki_RM125

Двигатель Suzuki RM 125 1992

Трансмиссия Suzuki RM 125 1992

Размеры и масса Suzuki RM 125 1992

Ходовая часть и тормоза Suzuki RM 125 1992

Динамические характеристики Suzuki RM 125 1992

Прочие характеристики Suzuki RM 125 1992

Описание мотоцикла Suzuki RM 125 1992 находится в очереди на публикацию статьи.

Сегодня чуть ли не под каждый нарождающийся на свет мотоцикл маркетологи стремятся выкроить свою нишу. Тот — дорожный спорт, этот — прогулочный эндуро. А вот к какому классу отнести мотоцикл, в котором всего понемногу? Хороший байк должен обладать надежным двигателем, иметь удобную эргономику и простое управление .

Несмотря на то, что хорошие модели мотоциклов отличаются весьма солидной ценой, а сезон их использования относительно короткий, рынок мототехники стремительно развивается. А если верить словам дилеров, то некоторые модели недавно выпущенных мотоциклов в начале сезона расходятся как горячие пирожки, и привезенных в Россию моделей явно не хватает для полного удовлетворения потребительского спроса.

Мотоцикл давно перестал быть альтернативой автомобиля, и забыты те времена, когда эту технику покупали только потому, что не хватало денег на полноценный автомобиль. Сейчас двухколесные транспортные средства во многих случаях можно назвать чудесами техники, и их стоимость может сравниваться с ценой на престижные автомобили.

Многие люди стали покупать мотоциклы для увлечений, так как езда на них или даже коллекционирование стали хорошим развлечением для многих людей. Многие мотоциклы, например Suzuki RM 125 технические характеристики которого позволяют назвать модель престижной маркой, пользуются спросом как у начинающих, так и у опытных мотоциклистов.

В настоящее время приобрести новый мотоцикл Suzuki RM 125 1992-го модельного года нереально, так как их производство остановлено еще 24 лет назад. При этом Suzuki RM 125 технические характеристики имеет отличные, поэтому многие стремятся приобрести если не новый, то хотя бы подержанный вариант.

Перейти ко всему модельному ряду мотоциклов Suzuki, на этой странице вы сможете найти мотоциклы Suzuki RM 125 других годов выпуска и информацию о них

среди найденых объявлений

среди найденых объявлений

среди найденых объявлений

* Внимание! Под максимальной, средней и минимальной мотоцикла Suzuki RM 125 на данной странице указывается средняя стоимость по объявлениям о продаже в интернете, без учета года выпуска, комплектации и поколения модели мотоцикла.

Ниже представленны запасные части и расходники для мотоцикла Suzuki RM 125 , Воздушный/маслянный фильтр, З/ч для двигателя, Тормозные колодки, Система зажигания, Амортизатор. З/ч для амортизатора, Карбюратор/система впрыска, Ремни и компоненты привода, Клапан, клапан в сборе, Rocker. Рычаг вала, Топливный бак, Элемент тормозной системы, Аккумуляторы и зарядное устройства, Наклейки и стикеры, Цепь, Фильтры, Диски сцепления. А так же другие товары, которые пригодятся во время ремонта и обслуживания мотоцикла Suzuki RM 125 .

Использование кожуха цепи от мотоцикла Восход на Ява 634

Чехлы для Явы На некоторых мотоциклах Ява-634 (из первых партий поставки) довольно быстро выходят из строя чехлы цепи, а приобрести новые пока еще трудно. Вместо них для защиты цепи можно использовать чехлы от мотоцикла Восход. Переделка кожуха:1— рамка; 2— пластина; 3— распорная втулка; 4 — старая часть кожуха; 5 — удлинитель Чтобы закрепить их. надо изготовить два удлинителя 5 (см. рисунок) и две распорные втулки 3, посредством которых соединяем половины кожуха. Удлинители делаем, пользуясь оправкой. К ним привариваем (или припаиваем) рамки 1, которые предварительно при помощи тонкого зубила срубаем со старыхкожухов. Все соединения на кожухе желательно загерметизировать пайкой или другим способом. Для более надежного крепления кожухов следует изготовить новые хомутики или усилить старые, приварив к ним металлические пластинки.На моем мотоцикле после пробега 5000 километров чехлы имеют первоначальный вид.А. КОРНИЛОВ 606230, Горьковская обла.

Ява 891.5. Мотоцикл для гонок по льду

Jawa для гонок по льду За всю историю первенств мира в мотоциклетных гонках по льду те, кто становились чемпионами, выступали на мотоциклах ЯВА. Это лучшая рекомендация завода в Дивишове, выпускающего трековые гоночные мотоциклы. Что же представляет собой специальная модель ЯВЫ для гонок по льду? Разрабатывая ее конструкцию, чехословацкие специалисты опирались на богатый опыт советских спортсменов. За основу была взята рама, созданная в свое время В. Карнеевым. С годами она, естественно, совершенствовалась, изменялась также конструкция передней вилки, некоторых второстепенных деталей. Сегодня после пяти модернизаций модель Jawa-891.5 (она выпускается с 1978 года) продолжает оставаться машиной чемпионов, и значительное количество этих мотоциклов поступает в СССР. Ежегодно советские спортивные клубы, располагающие сильнейшими в мире спортсменами в гонках по льду, получают более ста этих машин.Помимо рамы, передней вилки, масляного бака измененной конструкции ЯВА-891.5 отличается от .

Ява 680 Триал ( 250 кубов )

Jawa-680 250 кубов для триала Среди поклонников мотоциклетного спорта все больше становится людей, увлекающихся триалом. Соответственно растет доля машин для триала в мировом производстве спортивных мотоциклов. Сейчас их делают такие заводы, как итальянские «Априлиа», «Бета», «Гарелли», японский «Хонда», «Симсон» — в ГДР, ЧЗ и ЯВА — в Чехословакии. Один из крупнейших производителей спортивных мотоциклов, итальянская фирма «Фантик», выпускает ежегодно 5000 машин, специально сконструированных для подобных соревнований. В масштабах Западной Европы это довольно внушительная цифра. ЯВА-680 — специальный мотоцикл модели 1987 года. Мотор рабочим объемом 246 см3 с диаметром цилиндра 70 мм и ходом поршня 64 мм — дальнейшая модификация двигателя ЯВА-125. При его создании преследовалась цель обеспечить минимальные внешние размеры и массу. Цилиндр — из сплава легких металлов, смесь в нем р.

Переделка кроссового мотоцикла ЧЗ-250 в многодневный

Переделка кроссового CZ-250 в многодневный Многодневные мотоциклетные соревнования — самый универсальный вид мотоспорта. Они требуют от гонщика отличной физической подготовки, мастерства кроссовика и шоссейника, а от машины — надежности, хороших ходовых качеств и выносливости. Недаром международные шестидневные соревнования называют мотоолимпиадой, подчеркивая тем самым их значимость. В 1972 году советская команда заняла на «шестидневке», проходившей в ЧССР, четвертое место. Это, конечно, успех: наши спортсмены, как и победители, не получили штрафных очков в основных соревнованиях (призеров выявили лишь специальные испытания). Но чтобы подняться на пьедестал почета, многое предстоит еще сделать.В нашей стране проводятся городские, республиканские и всесоюзные многодневки. Число участвующих в них спортсменов сравнительно невелико. Росту массовости, помимо организационных трудностей, препятствует отсутствие технически совершенных мотоциклов. К сож.

ИЖ Юпитер-3 регулировка для достижения полной мощности

Выполните регулировку «Мотоцикл «ИЖ — Юпитер-3» прошел уже более 5000 км, но полной мощности, как я могу судить по Другим таким же машинам, не выдает. Какие могут быть причины?» — спрашивает К. Усольцев из Магнитогорска.Если обкатка мотоцикла была проведена правильно, то есть в соответствии с инструкцией, и заметных дефектов двигатель не имеет, вероятно, удастся повысить его мощность, выполнив следующие работы.Выверните свечу и осмотрите. Если на ней много нагара, значит, в цилиндр поступает слишком богатая смесь, и нагар отложился также в камере сгорания и в выпускных каналах. Снимите цилиндр и удалите нагар с его головки, днища поршня и выпускных каналов. По отпечаткам на прокладке цилиндра проверьте, полностью ли совпадают контуры перепускных каналов картера и цилиндра и не перекрывает ли их прокладка. При необходимости подгоните каналы и прокладку.Проверьте и, если надо, установите одинаковое опережение зажигания в обоих цилиндрах (2,6.

Материалы: http://bazamoto.ru/suzuki/rm-125_1992

Also See for Suzuki RM125

Related Manuals for Suzuki RM125

Summary of Contents for Suzuki RM125

Page 1

RM125 OWNER’S SERVICE MANUAL Part No. 99011-36F56-01A April, 2006.

Page 2

This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator. The manual contains important safety information and instructions which should be read carefully before operating the motorcycle.

Page 3

Please read this manual and follow its instructions This manual is presented as a means whereby you carefully. To emphasize special information, the can maintain your RM125 in top working condition symbol  and the words WARNING, CAUTION at all times. Your riding skill and the maintenance and NOTE have special meanings.

Page 4

You need to prepare for the unex- pected by wearing a helmet and other protective gear, and practicing safe riding techniques to minimize the damage to you and your machine. May all of your rides on your new Suzuki be winning rides!

Page 5: Serial Number Location

SERIAL NUMBER LOCATION The frame number 1 is stamped on the steering head as shown in the photograph. The engine serial num- ber 2 is stamped on the right side of the crankcase assembly. Write down the serial numbers here for your future reference. Frame No.

Page 6

WARNINGS FOR SERVICING  WARNING  WARNING Never run the engine indoors or in a Fuel can catch on fire if you do not handle garage. Exhaust gas contains carbon mon- it properly. Gasoline vapors can catch fire oxide, a gas that is colorless and odorless easily.

Page 7: Replacement Parts

NOTE: installing a circlip. Use of replacement parts which are not equivalent • Use special tools where specified. in quality to genuine SUZUKI parts can lead to per- • Use genuine SUZUKI parts and recommended formance problems and damage. oil.

Page 8

SYMBOL DEFINITION SYMBOL DEFINITION Torque control required. Use SUZUKI FORK OIL SS-05 or Data beside it indicates specified equivalent fork oil. torque. 99000-99001-SS5 Use SUZUKI REAR SUSPENSION OIL Apply oil. Use engine oil or transmission SS-25 or equivalent rear suspension oil.

Page 9

GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE TROUBLESHOOTING MACHINE TUNING ENGINE REMOVAL AND INSTALLATION CYLINDER, PISTON AND EXHAUST VALVE CLUTCH KICK STARTER GEARSHIFTING TRANSMISSION AND CRANKSHAFT FUEL SYSTEM COOLING SYSTEM ELECTRICAL SYSTEM FRONT AND REAR WHEELS FRONT AND REAR BRAKES FRONT FORK AND STEERING REAR SUSPENSION SERVICING INFORMATION.

Page 10

GENERAL INFORMATION 1-1 GENERAL INFORMATION CONTENTS LOCATION OF PARTS . 1- 2 FUEL AND OIL RECOMMENDATION . 1- 3 OPERATING INSTRUCTIONS . 1- 4 STARTING THE ENGINE . 1- 4 STOPPING THE ENGINE . 1- 4 TRANSMISSION . 1- 5 BREAK-IN (RUNNING-IN) .

Page 11: General Information, Location Of Parts

1-2 GENERAL INFORMATION LOCATION OF PARTS 1 Clutch lever 2 Engine stop switch 3 Front brake fluid reservoir 4 Throttle grip 5 Front brake lever 6 Fuel tank cap 7 Fuel valve 8 Carburetor starter knob 9 Gearshift lever 0 Rear brake fluid reservoir A Rear brake pedal B Kick starter lever C Front suspension compression damp-.

Page 12: Fuel And Oil Recommendation

(R/2 + M/2 method)..For USA and Canada Use only unleaded gasoline of at least 95 octane (Research method). For other countries. Engine oil: SUZUKI CCI SUPER 2-CYCLE MOTOR LUBRI- CANT or equivalent Two Cycle Racing Lubricant . For USA.

Page 13: Operating Instructions, Stopping The Engine

1-4 GENERAL INFORMATION OPERATING INSTRUCTIONS STARTING THE ENGINE Inspect the transmission oil level, coolant level and air cleaner condition before starting the engine. When the engine is cold: 1) Turn the fuel valve lever to the “ON” position. 2) Shift the transmission into neutral. 3) Pull the starter knob 1.

Page 14

GENERAL INFORMATION 1-5 TRANSMISSION This motorcycle has a 6-speed transmission. Neutral is located between low and 2nd. Engage first gear by pressing the lever down from the neutral position. You can shift into higher gears by lifting on the shift lever once for each gear. When neutral is desired, press or lift the lever to a position halfway between low and 2nd gear.

Page 15

Page 16: Periodic Maintenance

PERIODIC MAINTENANCE 2-1 PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE . 2- 3 INSPECTION BEFORE PRACTICE . 2- 3 INSPECTION BEFORE RACE (All items of inspection before practice above plus) . 2- 3 PERIODIC MAINTENANCE CHART . 2- 4 SPARK PLUG . 2- 6 AIR CLEANER .

Page 17: Table Of Contents

PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS SPROCKET INSPECTION . 2-17 DRIVE CHAIN GUIDE, BUFFER, TENSIONER ROLLER . 2-17 DRIVE CHAIN GUIDE . 2-17 DRIVE CHAIN GUIDE BUFFER . 2-18 DRIVE CHAIN TENSIONER ROLLER . 2-18 BRAKES . 2-18 BRAKE FLUID LEVEL . 2-18 BRAKE PAD .

Page 18: Periodic Maintenance, Inspection Before Practice, Inspection Before Race

PERIODIC MAINTENANCE 2-3 PERIODIC MAINTENANCE INSPECTION BEFORE PRACTICE WHAT TO CHECK CHECK FOR Spark plug • Heat range, fouled electrode, tightness • Loose high-tension cord Air cleaner element Lubrication Transmission oil Oil level Coolant Coolant level Cooling system • Radiator hose damage •.

Page 19: Periodic Maintenance Chart

2-4 PERIODIC MAINTENANCE PERIODIC MAINTENANCE CHART It is very important to inspect and maintain the machine regularly. Follow the guideline in the chart. The life of parts varies depending on the riding conditions. Perform more often than shown in the chart if you use the motorcycle under severe conditions.

Page 20

PERIODIC MAINTENANCE 2-5 Interval Every Every Every races race 3 races 5 races Remarks Service Every Every Every hours Item 2 hours 6 hours 10 hours Tire — — Inspect every 20 min. up to initial 2 hours Spoke nipple —.

Page 21: Spark Plug

2-6 PERIODIC MAINTENANCE SPARK PLUG • Inspect the spark plug condition, electrode color, carbon deposits, spark plug gap, and washer damage, after removing the spark plug. NOTE: Remove the dirt around the spark plug before removing the spark plug to prevent dirt from entering the combustion cham- ber.

Page 22: Air Cleaner, Air Cleaner Element Removal

PERIODIC MAINTENANCE 2-7 AIR CLEANER AIR CLEANER ELEMENT REMOVAL • Remove the seat. (5-3) • Remove the air cleaner box lid. (2-8) • Remove the wing nut 1. • Remove the element 2 from the element holder. WASHING • Fill a washing pan large enough to hold the element with a non-flammable cleaning solvent A.

Page 23: Transmission Oil

2-8 PERIODIC MAINTENANCE • Install the air cleaner box lid properly as shown. NOTE: Running the engine without the air cleaner box lid can vary the carburetion. Do not run the engine without the air cleaner box lid. Cap to the front. Air cleaner box front wall NOTE.

Page 24: Transmission Oil Change, Transmission Oil Level Inspection/replenishment

PERIODIC MAINTENANCE 2-9 WARNING New and used oil and solvent can be hazardous. Chil- dren and pets may be harmed by swallowing new or used oil or solvent. Repeated, prolonged contact with used engine oil may cause skin cancer. Brief contact with used oil or solvent may irritate skin.

Page 25: Engine Coolant, Engine Coolant Level Check

2-10 PERIODIC MAINTENANCE ENGINE COOLANT ENGINE COOLANT LEVEL CHECK WARNING You can be injured by scalding fluid or steam if you open the radiator cap when the engine is hot. Do not open the radiator cap when the engine is hot. Wait until engine cools.

Page 26: Cooling System Inspection, Engine Coolant Replenishment

PERIODIC MAINTENANCE 2-11 ENGINE COOLANT REPLENISHMENT • Use an anti-freeze and Summer engine coolant which is com- patible with aluminum radiator, mixed with distilled water at the ratio of 50:50. NOTE: The radiator, cylinder and cylinder head are made of aluminum alloy.

Page 27: Clutch Cable, Throttle Cable, Major Adjustment, Minor Adjustment

2-12 PERIODIC MAINTENANCE CLUTCH CABLE Adjust the clutch cable play as follows: MAJOR ADJUSTMENT • Loosen lock-nut 1. • Turn adjuster 2 so the clutch lever has 10 – 15 mm (0.4 – 0.6 in) play at the clutch lever end before pressure is felt. •.

Page 28: Fuel Hose, Fuel Valve

PERIODIC MAINTENANCE 2-13 • Apply oil to the throttle cable. • Apply grease to the throttle cable spool.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) FUEL HOSE • Inspect the fuel hose for damage and fuel leakage. If any defects are found, the fuel hose must be replaced.

Page 29: Cylinder Head, Cylinder Head, Cylinder And Piston

2-14 PERIODIC MAINTENANCE CYLINDER HEAD, CYLINDER AND PISTON CYLINDER HEAD • Remove the cylinder head. (6-3) • Remove carbon deposits from the combustion chamber sur- face. • Inspect for pinholes, cracks and other damage. CYLINDER • Remove the cylinder. (6-4) •.

Page 30: Exhaust Silencer, Exhaust Valve, Silencer Reassembly

• Fit the glass wool 1 and the black frontal pipe to the alumi- num case. • Tighten three bolts. NOTE: To seal between the black frontal pipe flange and the aluminum case, apply SUZUKI BOND to the contact area of the flange.  99000-31140: SUZUKI BOND “1207B”.

Page 31: Drive Chain Slack, Drive Chain Adjustment, Drive Chain Lubrication, Drive Chain And Sprockets

2-16 PERIODIC MAINTENANCE DRIVE CHAIN AND SPROCKETS DRIVE CHAIN SLACK • Place the motorcycle on the side stand. • Inspect the drive chain slack at the middle point between the drive chain buffer and rear sprocket.  Drive chain slack: 40 – 50 mm (1.6 – 2.0 in) 0 –.

Page 32: Drive Chain Guide, Sprocket Inspection, Drive Chain Guide, Buffer, Tensioner Roller

• Clean the drive chain with non-flammable cleaning solvent. • Do not use gasoline to clean the drive chain. • Dry the drive chain. • Apply Suzuki Chain Lube or equivalent to the link plates and rollers. • Reassemble the drive chain.

Page 33: Drive Chain Guide Buffer, Drive Chain Tensioner Roller, Brake Fluid Level

2-18 PERIODIC MAINTENANCE DRIVE CHAIN GUIDE BUFFER • Inspect the drive chain guide buffer 1 for wear and cracks. NOTE: The drive chain can touch the swingarm directly if the chain guide buffer is worn out. This will cause drive chain and swing- arm damage.

Page 34: Front Brake Lever Adjustment, Brake Pedal Height Adjustment, Brake Pad

PERIODIC MAINTENANCE 2-19 BRAKE PAD Wear limit • Inspect the brake pads for wear. If the brake pads are worn, replace them with new ones. (15-5) NOTE: * Pump the brake lever/pedal several times to restore the brake Wear limit pads after replacing the brake pads.

Page 35: Front Fork, Rear Suspension, Wheels And Tires, Wheel Rim

2-20 PERIODIC MAINTENANCE FRONT FORK • Move the front fork up and down several times and inspect for smooth movement. • Inspect for damage and oil leaks. • Inspect the bolts and nuts for tightness. • Place a stand under the chassis tube to lift the front wheel off the ground.

Page 36: Tire Pressure, Spoke Nipple And Rim Lock

PERIODIC MAINTENANCE 2-21 SPOKE NIPPLE AND RIM LOCK • Inspect the spokes for tension by squeezing the spoke nip- ples. • Retighten the spoke nipples with a spoke nipple wrench so as all spokes have same tension.  Spoke nipple: 4 N·m (0.4 kgf-m, 3.0 lb-ft) CAUTION Improperly tightening of the spoke nipples can dam- age the wheel.

Page 37

2-22 PERIODIC MAINTENANCE STEERING • Inspect the steering by moving the front fork up and down, and right and left. If the steering has play or binds, inspect steering stem head nut tightness and steering bearings. (16-20)

Page 38

A. Lightweight oil such as WD-40 or penetrating oil. B. Aerosol type Chain Lube. C. SUZUKI SUPER GREASE “A” or Water-proof wheel bearing grease. Follow the schedule closely. The disassembly necessary to lubricate many components is in itself valuable preventative maintenance. It allows you to inspect for wear, fatigue, adjustment and fastener tightness and it.

Page 39

Page 40: Troubleshooting

TROUBLESHOOTING 3-1 TROUBLESHOOTING CONTENTS TROUBLESHOOTING . 3- 2 ENGINE . 3- 2 CHASSIS . 3- 5.

Page 41: Troubleshooting

3-2 TROUBLESHOOTING TROUBLESHOOTING ENGINE Complaint Possible Cause Remedy Engine does not start Fuel deterioration Replace or hard to start No fuel flow to the carburetor • Fuel valve clogged Clean • Fuel hose clogged Clean or replace • Fuel tank cap breather hose clogged Clean •.

Page 42

TROUBLESHOOTING 3-3 Complaint Possible Cause Remedy Engine runs poorly in Exhaust valve maladjustment Adjust low speed range Wide spark plug gap Adjust or replace Carburetor air screw maladjustment Adjust Incorrect carburetor fuel level Adjust Improper jet needle size Replace Incorrect ignition timing Adjust CDI unit malfunction Replace.

Page 43

3-4 TROUBLESHOOTING Complaint Possible Cause Remedy Overheating Low engine coolant level Replenish Engine coolant leak Repair Too lean air/fuel mixture Adjust Incorrect ignition timing Adjust Water pump malfunction Adjust or replace Cylinder head carbon deposits Clean Exhaust pipe carbon deposits Clean or replace Improper spark plug heat range Replace.

Page 44

TROUBLESHOOTING 3-5 CHASSIS Complaint Possible Cause Remedy Heavy handling Steering stem nut overtightened Adjust Steering head bearings damaged or rusted Replace Steering stem distortion Replace Front wheel wobbling Loose spoke nipples Adjust Wheel distortion Replace Front wheel bearing damage Replace Incorrect axle tightening torque Retighten Rear wheel wobbling.

Page 45

Page 46: Machine Tuning

MACHINE TUNING 4-1 MACHINE TUNING CONTENTS CARBURETOR TUNING . 4- 2 PRINCIPLES OF CARBURETOR TUNING . 4- 2 CARBURETOR TUNING IN PRACTICE . 4- 6 FRONT FORK TUNING . 4- 9 COMPRESSION DAMPING FORCE ADJUSTMENT . 4- 9 REBOUND DAMPING FORCE ADJUSTMENT . 4- 9 OIL QUANTITY MINOR ADJUSTMENT .

Page 47: Carburetor Tuning, Principles Of Carburetor Tuning

Riders who are not familiar with the operation and ing of them for proper carburetor tuning. jetting procedures of the MIKUNI carburetor should have their local authorized Suzuki dealer perform these alterations. Mechanically experienced riders can alter the carburetor settings based on the fol- lowing information and specifications.

Page 48

MACHINE TUNING 4-3 As shown below, each tuning part is located between the air/fuel passage and has its own air/fuel mixture adjustable range in terms of the throttle valve opening. The chart indicates that the carburetor can supply correct air/fuel mixture to the engine in any range because of the overlapping adjustable range of the each part.

Page 49

4-4 MACHINE TUNING NEEDLE CLIP POSITION JET NEEDLE O.D. of needle Lean Needle clip Rich Taper portion Clip The jet needle is linked to the throttle valve by means of the needle clip. Its lower part is tapered and it has five grooves cut in the upper part where the needle clip fits.

Page 50

MACHINE TUNING 4-5 THROTTLE STOP SCREW The throttle stop screw determines the full close position of the throttle valve and should be adjusted in the following proce- dures. • Loosen the throttle stop screw lock-nut. • Adjust the throttle stop screw as follows: * Turn in (to raise the throttle valve).

Page 51: Carburetor Tuning In Practice

4-6 MACHINE TUNING CARBURETOR TUNING IN PRACTICE In the previous section, basic principles of carburetor tuning have been discussed. Described in this section are the bases for carburetor tuning required when coping with variations in air (oxygen) concentration. VARIATION IN AIR (OXYGEN) CONCENTRATION AND CARBURETOR CONDITIONS As the air, affected by the temperature, altitude and humidity, gets expanded or compressed, air (oxygen) concentration varies accordingly.

Page 52

MACHINE TUNING 4-7 JUDGING AIR/FUEL MIXTURE INCLUDED PARTS AND OPTIONAL PARTS For proper carburetor tuning, it is necessary to Main jet know how to judge the air/fuel mixture made in the Air/fuel carburetor; whether too rich, too lean or properly SIZE P/NO mixture.

Page 53

4-8 MACHINE TUNING Cable holder and washer Ex. Main jet #370 ITEM P/NO Color If air/fuel mixture is rich, replace it with Cable holder * 13518-36F20 Yellow #360 main jet. If air/fuel mixture is lean, Washer * 13394-36F20 replace it with #380 main jet. The cable holder and washer must be used as a 3 Adjustment of intermediate system set.

Page 54: Front Fork Tuning, Compression Damping Force Adjustment

MACHINE TUNING 4-9 FRONT FORK TUNING The front fork compression and rebound damping force, and oil level are adjustable for rider’s preference, rider’s weight and course condition. NOTE: * Break-in new front forks before attempting adjustment. * Be sure to adjust both right and left front forks equally. * Inspect the following items before attempting adjustment.

Page 55: Oil Quantity Minor Adjustment

 Front fork oil quantity (With standard fork spring used) Standard: 357 ml (12.07 / 12.57 US/lmp oz) Oil quantity adjustable range: 314 – 408 ml (10.61/11.06 – 13.79/14.37 US/lmp oz)  99000-99001-SS5: SUZUKI FORK OIL SS-05 (or equivalent fork oil)

Page 56: Oil Change

MACHINE TUNING 4-11 OIL CHANGE (Only for outer tube oil chamber) • Remove the front forks. (16-4) • Thoroughly clean the fork before disassembly. CAUTION The fork oil quantity must be adjusted equally on both fork legs to provide equal performance. Scratches or other damage on the inner tube or on the oil seal lip will cause oil leak.

Page 57

4-12 MACHINE TUNING • Slide down the outer tube. • Pour the specified amount of fork oil into the outer tube.  99000-99001-SS5: SUZUKI FORK OIL SS-05 (or equivalent fork oil) Identification Oil quantity Parts No. Spring rate (Slit mark.

Page 58: Spring Change

MACHINE TUNING 4-13 SPRING CHANGE • Remove the front forks. (16-4) • Thoroughly clean the fork before disassembly. CAUTION The fork oil quantity must be adjusted equally on both fork legs to provide equal performance. Scratches or other damage the on inner tube or on the oil seal lip will cause oil leak.

Page 59

314 – 408 ml 357 ml (10.61/11.06 – 51171-37FD0 (12.07/12.57 13.79/14.37 US/Imp oz) US/Imp oz) 309 – 403 ml 352 ml (10.44/10.88 – Hard 51171-37FC0 (11.90/12.39 13.62/14.19 US/Imp oz) US/Imp oz)  99000-99001-SS5: SUZUKI FORK OIL SS-05 (or equivalent fork oil)

Page 60: Front Fork Tuning Procedure

MACHINE TUNING 4-15 FRONT FORK TUNING PROCEDURE Test ride the motorcycle and find out how the front suspension reacts on various types of surface. According to the symptom noticed, adjust the front fork to the best setting for rider and race track conditions. To adjust, attempt changing fork oil capacity and compression/rebound damping following the instructions below.

Page 61: Rear Suspension Tuning

4-16 MACHINE TUNING REAR SUSPENSION TUNING The rear suspension compression and rebound damping force, and spring pre-load are adjustable for rider’s preference, rider’s weight and course condition. NOTE: * Break-in the rear suspension when riding with a new rear cushion unit. (1-5) * Inspect the following items before attempting adjustment.

Page 62: Spring Pre-load Adjustment

MACHINE TUNING 4-17 SPRING PRE-LOAD ADJUSTMENT (For E-19, 000) (For E-19, 000) • Place a block under the chassis tube. • Remove the silencer and rear frame assembly. (17-3) • Loosen the lock-nut 1 with the special tool.  09910-60611: Universal clamp wrench •.

Page 63: Rear Suspension Tuning Procedure

4-18 MACHINE TUNING REAR SUSPENSION TUNING PROCEDURE • Adjust the rear suspension according to the rider’s weight and preference by referring to the table below. Spring Part No. Spring rate Marking paint Set-length adjustable range 46 N/mm 62211-36F60 Green (4.6 kgf/mm) Soft 48 N/mm 62211-37FH0.

Page 64

MACHINE TUNING 4-19 After the sag measurement has been set between 95 mm (3.74 in) to 105 mm (4.13 in), test ride the motor- cycle and adjust the suspension for the rider and track conditions referring to the guide below. SYMPTOM SECTION ADJUSTMENT PROCEDURE.

Page 65: Suspension Balance, Balance Test, Balancing Tips

4-20 MACHINE TUNING SUSPENSION BALANCE Balancing the front to rear suspension properly is the most critical adjustment for suspension performance. If the front forks are adjusted harder than the rear suspension, such as changing to heavier front fork oil, stiffer compression and rebound setting, air pressure build up in the forks and so on, the front forks will collapse less on bumps.

Page 66: Engine Removal And Installation

ENGINE REMOVAL AND INSTALLATION 5-1 ENGINE REMOVAL AND INSTALLATION CONTENTS EXTERIOR PARTS . 5- 2 ENGINE REMOVAL AND INSTALLATION . 5- 3 REMOVAL . 5- 3 INSTALLATION . 5- 7.

Page 67: Exterior Parts

5-2 ENGINE REMOVAL AND INSTALLATION EXTERIOR PARTS 10 N·m (1.0 kgf-m, 7.0 lb-ft) For E-03, 28 For E-19, 000 10 N . m 1.0 kgf-m 7.0 lb-ft 5 N·m (0.5 kgf-m, 3.5 lb-ft) 10 N . m 1.0 kgf-m 7.0 lb-ft 10 N .

Page 68: Engine Removal And Installation

ENGINE REMOVAL AND INSTALLATION 5-3 ENGINE REMOVAL AND INSTALLATION REMOVAL • Drain transmission oil. (2-9) • Drain engine coolant. (12-3) • Remove the seat. • Turn the fuel valve lever to the “OFF” position. • Disconnect the fuel hose 1. •.

Page 69

5-4 ENGINE REMOVAL AND INSTALLATION • Remove the exhaust pipe. • Remove the exhaust pipe gasket 3. • Remove the radiator covers 4 and mounting bolts (LH and RH). • Disconnect the radiator hoses 5 6 7. • Disconnect the spark plug cap 8. •.

Page 70

ENGINE REMOVAL AND INSTALLATION 5-5 • Disconnect the magneto lead wire coupler 9 and clamp. • Unclamp the magneto lead wire and breathers hoses from the frame. • Remove the drive chain by removing the clip 0. • Remove the cotter pins A. •.

Page 71

5-6 ENGINE REMOVAL AND INSTALLATION • Unhook and extract the clutch cable D. NOTE: Loosen the clutch cable adjuster when disconnecting. (2-12) • Remove the engine mounting bolts and plates. • Remove the swingarm pivot nut E and washer. • Extract three quarters of the swingarm pivot shaft so as to keep the swingarm in position.

Page 72

* Apply THREAD LOCK SUPER to the engine mounting bolt 3.  99000-32110: THREAD LOCK SUPER “1322” (or equivalent thread lock) • Apply grease to the brake pedal pivot bolt.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the spring. (18-15) • Install the brake pedal.

Page 73

5-8 ENGINE REMOVAL AND INSTALLATION • Reassemble the drive chain clip so the slit end faces opposit the direction of rotation. Direction of travel • Fit the projection of carburetor to the depression of intake pipe. • Install a new O-ring 6 and connector rubber 7 to the exhaust pipe.

Page 74: Cylinder, Piston And Exhaust Valve

CYLINDER, PISTON AND EXHAUST VALVE 6-1 CYLINDER, PISTON AND EXHAUST VALVE CONTENTS CONSTRUCTION . 6- 2 ENGINE TOP END . 6- 3 CYLINDER HEAD REMOVAL . 6- 3 CYLINDER REMOVAL . 6- 3 PISTON REMOVAL . 6- 4 EXHAUST VALVE REMOVAL . 6- 5 CYLINDER HEAD INSPECTION .

Page 75

6-2 CYLINDER, PISTON AND EXHAUST VALVE CONSTRUCTION 17.5 N . m (1.75 kgf-m, 12.5 lb-ft) 25 N . m 45 N . m (2.5 kgf-m, 18.0 lb-ft) (4.5 kgf-m, 32.5 lb-ft) 1216 25 N . m (2.5 kgf-m, 18.0 lb-ft) 1216 4.5 N .

Page 76: Engine Top End, Cylinder Head Removal, Cylinder Removal

CYLINDER, PISTON AND EXHAUST VALVE 6-3 ENGINE TOP END CYLINDER HEAD REMOVAL • Remove the seat. (5-3) • Remove the fuel tank. (5-3) • Drain engine coolant. (12-3) • Disconnect the radiator hose 1. • Disconnect the spark plug cap 2 and remove the spark plug .

Page 77: Piston Removal

6-4 CYLINDER, PISTON AND EXHAUST VALVE • Remove the exhaust valve rod bolt 7 using the pin A as a stopper. NOTE: The pin A is one of the included parts. • Remove the cylinder nuts diagonally. • Remove the cylinder 8. •.

Page 78: Exhaust Valve Removal

CYLINDER, PISTON AND EXHAUST VALVE 6-5 • Remove the conrod small end bearing 4. EXHAUST VALVE REMOVAL • Remove the cylinder head and cylinder. (6-3, -4) • Remove the exhaust valve shaft stop retainer 1. • Remove the breather hoses 2. •.

Page 79: Cylinder Head Inspection

6-6 CYLINDER, PISTON AND EXHAUST VALVE • Remove the side valves and spacers. CYLINDER HEAD INSPECTION • Remove carbon deposits from the cylinder head. • Inspect the cylinder head for cracks around the spark plug hole. • Inspect for cylinder head distortion. .

Page 80: Piston And Piston Ring Inspection

CYLINDER, PISTON AND EXHAUST VALVE 6-7 • Measure the cylinder bore for wear with a cylinder gauge 20 mm (0.8 in) from the top surface. NOTE: The cylinder bore must be measured perpendicular to the crank- shaft axis direction.  Cylinder bore 20 mm (0.8 in) Standard: 54.000 –.

Page 81: Exhaust Valve Inspection, Conrod Inspection

6-8 CYLINDER, PISTON AND EXHAUST VALVE • Measure the piston ring free end gap.  Piston ring free end gap Service Limit: 3.4 mm (0.13 in)  09900-20101: Vernier calipers PISTON-TO-CYLINDER CLEARANCE As a result of the previous measurement, if the piston to cylinder clearance exceeds the following limit, replace both cylinder and piston.

Page 82: Piston Ring And Piston Reassembly

CYLINDER, PISTON AND EXHAUST VALVE 6-9 • Fit the piston pin and bearing into the conrod small end and inspect the play. • Inspect the bearing for smooth movement. PISTON RING AND PISTON REASSEMBLY • Apply engine oil to the piston ring and piston ring groove. •.

Page 83: Cylinder Reassembly

6-10 CYLINDER, PISTON AND EXHAUST VALVE • Install the exhaust valve assembly to the cylinder. • Inspect the main and side valves for smooth movement. • Inspect if the side valves are closed when the main valve is lowered and, at the same time, see if the side valvs are open when the main valve is lifted.

Page 84

• Install a new gasket and tighten the exhaust valve rod cover bolts. • Apply grease to new O-rings and install them to the cylinder.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the cylinder head. NOTE: Apply Bond to the stud bolt threads when assembling the removed stud bolts into the cylinder.

Page 85

6-12 CYLINDER, PISTON AND EXHAUST VALVE EXHAUST VALVE GOVERNOR REMOVAL AND DISASSEMBLY • Drain transmission oil. (2-9) • Drain engine coolant. (12-3) • Remove the exhaust pipe. (5-3, -4) • Remove the exhaust valve rod bolt. (6-4) • Remove the right crankcase cover. (8-3) •.

Page 86: Exhaust Valve Governor Inspection

CYLINDER, PISTON AND EXHAUST VALVE 6-13 EXHAUST VALVE GOVERNOR INSPECTION • Inspect hte bearings for abnormal noise, wear and damage. • Replace the bearing if there is anything unusual. • Inspect the governer for wear and damage. • Replace the governer if there is anything unusual. •.

Page 87

6-14 CYLINDER, PISTON AND EXHAUST VALVE • Tighten the exhaust valve rod bolt. (6-11)  Exhaust valve rod bolt: 4.5 N·m (0.45 kgf-m, 3.0 lb-ft) • Reassemble the exhaust pipe. (5-8) • Transmission oil level (2-9) • Engine coolant level (2-10) •.

Page 88: Clutch

CLUTCH 7-1 CLUTCH CONTENTS CONSTRUCTION . 7- 2 CLUTCH PLATE . 7- 3 REMOVAL . 7- 3 INSPECTION . 7- 4 REASSEMBLY . 7- 5 PRIMARY DRIVEN GEAR AND CLUTCH SLEEVE HUB . 7- 6 REMOVAL . 7- 6 INSPECTION . 7- 7 REASSEMBLY .

Page 89

7-2 CLUTCH CONSTRUCTION 4.5 N . m (0.45 kgf-m, 3.0 lb-ft) 70 N . m (7.0 kgf-m, 50.5 lb-ft) No. 1 drive plate (Black paint) No. 2 drive plate (Purple paint)

Page 90: Clutch Plate

CLUTCH 7-3 CLUTCH PLATE REMOVAL • Drain transmission oil. (2-9) • Remove the rear brake pedal. (5-5) • Remove the clutch cover 1. • Loosen the bolts diagonally and remove them. • Remove the clutch springs. • Remove the pressure plate 2. •.

Page 91

7-4 CLUTCH INSPECTION DRIVE PLATE • Measure the drive plate thickness.  Drive plate thickness Service Limit: 2.42 mm (0.095 in)  09900-20101: Vernier calipers • Inspect the drive plates for wear, distortion and discoloration. • Measure the drive plate claw width. .

Page 92

 Clutch spring bolt: 4.5 N·m (0.45 kgf-m, 3.0 lb-ft) • Replace the O-ring with a new one. • Apply grease to the O-ring.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Fit the clutch outer cover 2 and tighten the bolts diagonally.

Page 93: Kick Starter

7-6 CLUTCH PRIMARY DRIVEN GEAR AND CLUTCH SLEEVE HUB REMOVAL • Remove the clutch outer cover. • Remove the pressure plate and clutch plates. (7-3) • Flatten the lock washer 1. • Hold the clutch sleeve hub with the special tool and loosen the nut 2.

Page 94

CLUTCH 7-7 INSPECTION • Inspect the clutch sleeve hub and primary driven gear assem- bly for wear and cracks. • Inspect the kick starer idle gear, needle bearing and spacer for damage and wear. REASSEMBLY • Apply transmission oil to the spacer 1 and needle bearing 2. •.

Page 95

• Reassemble the clutch plates and pressure plate. (7-5) • Replace the O-ring with a new one. • Apply grease to the O-ring.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Fit the clutch outer cover and tighten the bolts diagonally.

Page 96: Clutch Release Camshaft

CLUTCH 7-9 CLUTCH RELEASE CAMSHAFT REMOVAL • Remove the magneto rotor and stator. (13-8) • Loosen the clutch cable adjuster and unhook the clutch cable. (5-6) • Remove the clutch release camshaft 1. INSPECTION CLUTCH RELEASE CAMSHAFT • Inspect the clutch release camshaft for abnormal deflection and damage.

Page 97

Page 98

KICK STARTER 8-1 KICK STARTER CONTENTS CONSTRUCTION . 8- 2 REMOVAL . 8- 3 INSPECTION . 8- 4 OIL SEAL . 8- 4 KICK STARTER . 8- 4 KICK STARTER IDLE GEAR . 8- 4 REASSEMBLY . 8- 5 INSPECTION AFTER REASSEMBLY . 8- 6.

Page 99

KICK STARTER CONSTRUCTION 23 N . m (2.3 kgf-m, 16.5 lb-ft) 10 N . m (1.0 kgf-m, 7.0 lb-ft)

Page 100

KICK STARTER 8-3 REMOVAL • Drain transmission oil. (2-9) • Drain engine coolant. (12-3) • Remove the brake pedal. (5-5) • Remove the kick starter lever. • Disconnect the radiator hose 1. • Remove the crankcase cover. • Remove the clutch and primary driven gear assembly. (7-3, -6) •.

Page 101: Kick Starter

KICK STARTER INSPECTION OIL SEAL • Inspect the oil seal for oil leakage and damage. • Remove the oil seal using the special tool.  09913-50121: Oil seal remover • Install the oil seal using the special tool.  09913-70210: Bearing installer set KICK STARTER •.

Page 102

KICK STARTER 8-5 REASSEMBLY Reassemble the kick starter assembly in the reverse order of disassembly. Pay attention to the following points: • Apply transmission oil to the kick starter shaft. • Install the kick starter drive gear 1 and washer to the kick starter shaft.

Page 103

KICK STARTER • Install the kick starter assembly to the crankcase. Hook the return spring 2. • Reassemble the kick idle gear 5. • Reassemble the primary driven gear assembly and clutch. (7-5, -7) • Install the crankcase cover.  Crankcase cover bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft) •.

Page 104: Gearshifting

GEARSHIFTING 9-1 GEARSHIFTING CONTENTS CONSTRUCTION . 9- 2 REMOVAL . 9- 3 INSPECTION . 9- 5 REASSEMBLY . 9- 6.

Page 105

9-2 GEARSHIFTING CONSTRUCTION 23 N . m (2.3 kgf-m, 16.5 lb-ft) 24 N . m (2.4 kgf-m, 17.5 lb-ft) 10 N . m (1.0 kgf-m, 7.0 lb-ft)

Page 106

GEARSHIFTING 9-3 REMOVAL • Drain transmission oil. (2-9) • Drain engine coolant. (12-3) • Remove the gearshift lever 1. NOTE: Mark the gearshift shaft head at which the gearshift lever slit set for correct reinstallation. • Remove the right crankcase cover. (8-3) •.

Page 107

9-4 GEARSHIFTING • Remove the gearshift cam bolt 9 and stopper plate 0. • Remove the gearshift arm stopper bolt A and washer. • Remove the gearshift cam stopper B and spring C. • Remove the gearshift return spring D by removing the snap ring.

Page 108

GEARSHIFTING 9-5 INSPECTION • Inspect the gearshift shaft 1 for bends and damage. • Inspect the return spring 2 for damage. • Inspect the pawls 3, pins 4 and springs 5 for damage.

Page 109

9-6 GEARSHIFTING REASSEMBLY • Temporarily install the spring 1, washer 2 and gearshift cam stopper 3. • Hook the spring 1 to the projection A. • Tighten the gearshift cam stopper bolt.  Gearshift cam stopper bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) •.

Page 110

GEARSHIFTING 9-7 • Fit the springs 6, pins 7 and pawls 8 to the gearshift cam driven gear 9. Wider side D of pawls should be positioned outside. • With the pawls held in pushed position, install the pawl lifter •.

Page 111

9-8 GEARSHIFTING • Align the center teeth on the gearshift shaft with the center teeth on the gearshift cam shifter. • Reassemble the clutch and crankcase cover. (7-5, -7, 8-6) • Install the gearshift lever.  Gearshift lever bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) •.

Page 112: Transmission And Crankshaft

TRANSMISSION AND CRANKSHAFT 10-1 TRANSMISSION AND CRANKSHAFT CONTENTS CONSTRUCTION . 10- 2 ENGINE BOTTOM END . 10- 3 PRIMARY DRIVE GEAR REMOVAL . 10- 3 CRANKCASE SEPARATION . 10- 4 TRANSMISSION REMOVAL . 10- 4 CRANKSHAFT REMOVAL . 10- 5 TRANSMISSION INSPECTION .

Page 113

10-2 TRANSMISSION AND CRANKSHAFT CONSTRUCTION 70 N . m (7.0 kgf-m, 50.5 lb-ft)

Page 114: Engine Bottom End, Primary Drive Gear Removal

TRANSMISSION AND CRANKSHAFT 10-3 ENGINE BOTTOM END • Dismount the engine. (5-3) NOTE: The following parts must be removed before disassembling the engine bottom side (crankcase). • Remove the gearshift lever. (9-3) • Remove the kick starter lever. (8-3) • Remove the cylinder head, cylinder and piston. (6-3, -4) •.

Page 115: Crankcase Separation, Transmission Removal

10-4 TRANSMISSION AND CRANKSHAFT CRANKCASE SEPARATION • Remove the engine sprocket spacer 1 and two O-rings 2. • Remove the crankcase bolts. • Separate the crankcase with the special tool.  09920-13120: Crankcase separating tool NOTE: * Set the crankcase separating tool to the clutch side of the crankcase.

Page 116: Crankshaft Removal, Transmission Inspection

TRANSMISSION AND CRANKSHAFT 10-5 • Remove the driveshaft assembly 6 and countershaft assem- bly 7. CRANKSHAFT REMOVAL • Remove the crankshaft with the special tool.  09920-13120: Crankcase separating tool CAUTION Be careful not to damage the thread part of the crank- shaft.

Page 117: Crankshaft Inspection

10-6 TRANSMISSION AND CRANKSHAFT • Measure the gearshift fork thickness with a vernier calipers.  Gearshift fork thickness Standard: 4.80 – 4.90 mm (0.189 – 0.193 in)  09900-20101: Vernier calipers • Measure the gearshift fork groove width with a vernier cali- pers.

Page 118: Crankshaft Runout, Oil Seal Inspection, Removal And Installation

TRANSMISSION AND CRANKSHAFT 10-7 • Measure the crankshaft runout with V-blocks and dial gauge.  Crankshaft runout Service Limit: 0.05 mm (0.002 in)  09900-20607: Dial gauge (1/100 mm) 09900-20701: Magnetic stand 09900-21304: V-block NOTE: * Place the crankshaft on to the V-blocks so that it becomes hor- izontally.

Page 119

• Install new oil seal using the special tool. • Apply grease to each oil seal lip.  09913-70210: Bearing installer set  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) NOTE: Be sure to check the direction of the crankshaft bearing oil seals before fitting them.

Page 120: Bearing Inspection, Removal And Installation

TRANSMISSION AND CRANKSHAFT 10-9 BEARING INSPECTION, REMOVAL AND INSTALLATION • Inspect the bearings for play, discoloration, wear and seizure. • Move the inner race by finger and inspect for smooth move- ment. • Remove the bearing retainers. • Remove the bearings 1 to 4 by hitting out from the other side using the special tool.

Page 121: Crankshaft Installation

10-10 TRANSMISSION AND CRANKSHAFT • Remove the bearings 9 and 0 using the special tool.  09917-50410: Bearing remover • Remove the bearing A using the special tools.  09921-20200: Bearing remover 09930-30104: Sliding shaft • Install the bearings with the special tool. .

Page 122: Transmission Reassembly

TRANSMISSION AND CRANKSHAFT 10-11 TRANSMISSION REASSEMBLY NOTE: Seat the circlip in the groove and locate its end as shown in the Thrust illustration. Sharp edge • Apply transmission oil to the following parts: driveshaft, countershaft, transmission gears, bearings. • Reassemble the driveshaft 1 and countershaft 2 with gears installed.

Page 123: Crankcase Reassembly

• Inspect the crankshaft, countershaft and driveshaft for smooth movement. • Apply grease to the oil seal lip and new O-rings. • Fit the O-rings 1 and spacer 2 to the driveshaft.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease)

Page 124: Primary Drive Gear Installation

TRANSMISSION AND CRANKSHAFT 10-13 PRIMARY DRIVE GEAR INSTALLATION • Reassemble the clutch release camshaft. (7-9) • Reassemble the stator and magneto rotor. (13-9) • Install the washer and primary drive gear. NOTE: The washer is directional. Assemble the washer 1 as shown in the illustration.

Page 125

Page 126: Fuel System

FUEL SYSTEM 11-1 FUEL SYSTEM CONTENTS CARBURETOR . 11- 2 CONSTRUCTION . 11- 2 REMOVAL AND DISASSEMBLY . 11- 3 CLEANING . 11- 7 INSPECTION . 11- 7 REASSEMBLY AND REMOUNTING . 11- 8 CARBURETOR SOLENOID . 11-10 REMOVAL AND INSPECTION . 11-10 REASSEMBLY .

Page 127

11-2 FUEL SYSTEM CARBURETOR CONSTRUCTION 10 N . m (1.0 kgf-m, 7.0 lb-ft)

Page 128: Removal And Disassembly

FUEL SYSTEM 11-3 REMOVAL AND DISASSEMBLY • Disconnect the throttle position sensor coupler and solenoid coupler. • Open the clamp. • Disconnect the fuel hose. (5-3) • Loosen the carburetor clamp screws and remove the carbure- tor. • Drain fuel by removing the drain plug. •.

Page 129

11-4 FUEL SYSTEM • Remove the cable holder 5 and jet needle 6. • Remove the fuel hose 7, air vent hoses 8 and overflow hoses 9. • Remove the float chamber. • Remove the holder 0. • Remove the floats A and needle valve B. •.

Page 130

FUEL SYSTEM 11-5 • Remove the power jet G. • Remove the starter knob H. • Remove the lock-nut and throttle stop screw I. • Remove the air screw J and spring. • Remove the filter K. • Remove the solenoid L. NOTE: Prior to disassembly, mark the sensor’s original position with a paint or scribe for accurate reinstallation.

Page 131

11-6 FUEL SYSTEM • Flatten the plate M. • Remove the throttle lever shaft bolt. • Remove the dust seal N. • Remove the throttle lever shaft O. • Remove the throttle lever P, spacer Q and return spring R.

Page 132

FUEL SYSTEM 11-7 CLEANING WARNING Some carburetor cleaning chemicals, especially dip- type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical man- ufacturer’s instructions on proper use, handling and storage. • Clean all jets with a spray-type carburetor cleaner and dry them using compressed air.

Page 133

11-8 FUEL SYSTEM NEEDLE VALVE INSPECTION If foreign matter is caught between the valve seat and the nee- dle valve, the fuel will continue flowing and overflow. If the valve seat and needle valve are worn beyond the permissible limits, similar trouble will occur.

Page 134

FUEL SYSTEM 11-9 • Fit the projection on the carburetor body to the depression of the intake pipe. After reinstalling the carburetor body assembly, inspect the fol- lowings. • Throttle position sensor adjustment (11-11) • Idle adjustment (4-5) • Throttle cable play (2-12) •.

Page 135

11-10 FUEL SYSTEM CARBURETOR SOLENOID REMOVAL AND INSPECTION • Remove the carburetor solenoid 1. Make sure the coupler 2 is connected. • Connect the tachometer sensor. • Shift the transmission into neutral. • Start the engine. • Inspect if the solenoid valve switches according to the follow- ing engine RPM.

Page 136

FUEL SYSTEM 11-11 THROTTLE POSITION SENSOR INSPECTION THROTTLE POSITION SENSOR INPUT VOLTAGE • Disconnect the throttle position sensor coupler 1. • Shift the transmission into neutral. • Start the engine. • Measure the throttle position sensor input voltage with the B/Br B/Br multi circuit tester.

Page 137: Reed Valve

11-12 FUEL SYSTEM REED VALVE REMOVAL • Remove the carburetor. (11-3) • Remove the intake pipe and reed valve. INSPECTION • Inspect the reeds for damage. • Inspect the reed valve stoppers for damage. • Inspect the valve seat rubber for damage. NOTE: Be careful not to damage the removed reed valve assembly.

Page 138: Cooling System

COOLING SYSTEM 12-1 COOLING SYSTEM CONTENTS CONSTRUCTION . 12- 2 COOLING CIRCUIT . 12- 3 INSPECTION . 12- 3 ENGINE COOLANT . 12- 3 REPLACEMENT . 12- 3 RADIATOR . 12- 4 REMOVAL . 12- 4 INSPECTION . 12- 4 INSTALLATION .

Page 139

12-2 COOLING SYSTEM CONSTRUCTION 5.5 N . m (0.55 kgf-m, 4.0 lb-ft) 10 N . m (1.0 kgf-m, 7.0 lb-ft)

Page 140: Cooling Circuit

COOLING SYSTEM 12-3 COOLING CIRCUIT INSPECTION • Remove the radiator cap. • Connect the tester 1 to the filler.  WARNING Do not remove the radiator cap when the engine is hot. • Give a pressure of about 120 kPa (1.2 kgf/cm , 17.1 psi) and see if the system holds this pressure for 10 seconds.

Page 141

12-4 COOLING SYSTEM RADIATOR REMOVAL • Remove the seat and fuel tank. (5-3) • Drain engine coolant. (12-3) • Remove the radiator covers 1. (LH & RH) • Remove the hoses. • Remove the radiators. INSPECTION RADIATOR • Visually inspect the radiator for damage. •.

Page 142: Water Pump

COOLING SYSTEM 12-5 WATER PUMP REMOVAL • Drain the engine coolant. (12-3) • Drain the transmission oil. (2-9) • Remove the kick starter lever. (8-3) • Remove the brake pedal. (5-5) • Disconnect the radiator hose 1. • Remove the water pump cover 2. •.

Page 143

• Apply THREAD LOCK SUPER to the outer surface of the oil seal.  99000-32110: THREAD LOCK SUPER “1322” (or equivalent thread lock) • Press the oil seal with the suitable size socket wrench. • Apply grease to the oil seal lip.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease)

Page 144

COOLING SYSTEM 12-7 • Press the bearing with the special tool.  09913-70210: Bearing installer set NOTE: When installing the bearing the stamped mark on the bearing must face outside. • Hold the water pump shaft with a wrench and tighten the impeller to the specified torque.

Page 145

12-8 COOLING SYSTEM • Reassemble the clutch cover and water pump cover. After reinstalling the water pump, check the followings. • Kick starter lever (8-6) • Brake pedal (2-19, 5-7) • Transmission oil level (2-9) • Engine coolant level (2-10)

Page 146: Electrical System

ELECTRICAL SYSTEM 13-1 ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING . 13- 2 CONNECTOR . 13- 2 COUPLER . 13- 2 SEMI-CONDUCTOR EQUIPPED PART . 13- 2 USING THE MULTI-CIRCUIT TESTER . 13- 2 SWITCH . 13- 2 LOCATION OF ELECTRICAL COMPONENTS . 13- 3 CONSTRUCTION .

Page 147: Cautions In Servicing, Semi-conductor Equipped Part

13-2 ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTOR • When connecting a connector, be sure to push it in until a click is felt. Click • Inspect the connector for corrosion, contamination and break- age in its cover. COUPLER Click • With a lock type coupler, be sure to release the lock when dis- connecting, and push in fully to engage the lock when con- necting.

Page 148: Location Of Electrical Components

ELECTRICAL SYSTEM 13-3 LOCATION OF ELECTRICAL COMPONENTS 1 Engine stop switch 3 CDI unit 2 Ignition coil 4 Magneto, pick-up coil.

Page 149: Electrical Circuit

13-4 ELECTRICAL SYSTEM CONSTRUCTION 35 N . m (3.5 kgf-m, 25.5 lb-ft) ELECTRICAL CIRCUIT Throttle position sensor Engine stop switch B/Br B/Br B/Bl B/Bl Magneto W/Bl W/Bl Ignition coil CDI unit Y Y Y Spark plug Carburetor solenoid Wire color: B: Black B/Bl: Black with Blue B/R: Black with Red tracer.

Page 150: Troubleshooting (no Spark Or Poor Spark)

ELECTRICAL SYSTEM 13-5 TROUBLESHOOTING (No spark or poor spark) Step 1 1) Check the ignition system couplers for poor connections. Is there connection in the ignition system couplers? Go to Step 2. Poor connection of couplers Step 2 1) Measure the peak voltage of ignition coil. (13-6) Is the peak voltage OK? Go to Step 3.

Page 151: Ignition System, Ignition System Peak Voltage Inspection

13-6 ELECTRICAL SYSTEM Step 8 1) Measure the exciter coil and charge coil resistance. (13-7) Is the exciter coil and charge coil OK? Faulty CDI Faulty magneto IGNITION SYSTEM IGNITION SYSTEM PEAK VOLTAGE INSPECTION • Remove the seat and fuel tank. (5-3) •.

Page 152: Ignition Coil Inspection, Stator Coil Inspection

ELECTRICAL SYSTEM 13-7 IGNITION COIL INSPECTION • Remove the seat and fuel tank. (5-3) • Disconnect the ignition coil lead wire coupler 1. Measure the ignition coil electrical resistance.  White/Blue – 0.17 – 0.70 Ω Primary Black/White Plug cap – Secondary 13 –.

Page 153: Magneto Rotor And Stator Removal

13-8 ELECTRICAL SYSTEM MAGNETO ROTOR AND STATOR REMOVAL • Remove the seat and fuel tank. (5-3) • Disconnect the magneto lead wire coupler and clamp. • Remove the bolts and magneto cover 1. • Remove the nut with a special tool. .

Page 154: Magneto Rotor And Stator Reassembly

ELECTRICAL SYSTEM 13-9 MAGNETO ROTOR AND STATOR REASSEMBLY • Fit the key 1 into the crankshaft. • Align the line on the stator with the line on the crankcase to set the ignition timing correctly. • Install the magneto rotor. •.

Page 155

Page 156: Front And Rear Wheels

FRONT AND REAR WHEELS 14-1 FRONT AND REAR WHEELS CONTENTS CONSTRUCTION . 14- 2 FRONT WHEEL . 14- 3 REMOVAL . 14- 3 INSPECTION . 14- 3 BEARING REPLACEMENT . 14- 4 DISC PLATE REPLACEMENT . 14- 5 INSTALLATION . 14- 5 REAR WHEEL .

Page 157

14-2 FRONT AND REAR WHEELS CONSTRUCTION 100 N . m (10.0 kgf-m, 72.5 lb-ft) 10 N . m (1.0 kgf-m, 7.0 lb-ft) 30 N . m (3.0 kgf-m, 21.5 lb-ft) 35 N . m (3.5 kgf-m, 25.5 lb-ft) 10 N . m (1.0 kgf-m, 7.0 lb-ft)

Page 158: Front Wheel

FRONT AND REAR WHEELS 14-3 FRONT WHEEL REMOVAL • Place the motorcycle on a block to lift front wheel off the ground. • Remove the front axle nut 1. • Loosen the left axle holder bolts 2. • Loosen the right axle holder bolts 3. •.

Page 159: Bearing Replacement

14-4 FRONT AND REAR WHEELS WHEEL RIM • Measure the wheel rim runout with the dial gauge.  Service Limit: 2.0 mm (0.08 in) . axial and radial  09900-20607: Dial gauge (1/100 mm) 09900-20701: Magnetic stand WHEEL BEARING • Turn the inner race by finger and inspect it for smooth move- ment.

Page 160: Disc Plate Replacement

• Reassemble the bearings with the special tools. • Fit the dust seals and apply grease to their lips.  09941-34513: Steering race installer 09924-84521: Bearing installer set  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) NOTE: Left Right * Install the left side (disc side) bearing first and then the right side bearing.

Page 161: Rear Wheel

14-6 FRONT AND REAR WHEELS REAR WHEEL REMOVAL • Place the motorcycle on a block to lift the rear wheel off the ground. • Remove rear axle nut 1 and washer 2. • Remove the rear axle shaft 3 and chain adjuster washers 4. •.

Page 162

• Fit the dust seals and apply grease to their lips.  09941-34513: Steering race installer 09913-70210: Bearing installer set  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) NOTE: * Install the right side (disc side) bearing first and then the left.

Page 163: Rear Sprocket Replacement

14-8 FRONT AND REAR WHEELS REAR SPROCKET REPLACEMENT • Remove the rear sprocket. NOTE: Install the rear sprocket as the letter on the sprocket surface faces outside. • Tighten the bolts/nuts to the specified torque.  Rear sprocket bolt/nut: 30 N·m (3.0 kgf-m, 21.5 lb-ft) INSTALLATION Left Right.

Page 164: Front And Rear Brakes

FRONT AND REAR BRAKES 15-1 FRONT AND REAR BRAKES CONTENTS CONSTRUCTION . 15- 2 BRAKE FLUID AIR BLEEDING . 15- 3 BRAKE FLUID REPLACEMENT . 15- 4 BRAKE PADS REPLACEMENT . 15- 5 FRONT BRAKE PADS . 15- 5 REAR BRAKE PADS . 15- 5 BRAKE DISC INSPECTION .

Page 165

15-2 FRONT AND REAR BRAKES CONSTRUCTION 10 N·m 23 N·m (1.0 kgf-m, 7.0 lb-ft) (2.3 kgf-m, 16.5 lb-ft) 10 N·m (1.0 kgf-m, 7.0 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft) 23 N·m (2.3 kgf-m, 18 N·m 16.5 lb-ft) (1.8 kgf-m, 13.0 lb-ft) 29 N·m (2.9 kgf-m, 21.0 lb-ft)

Page 166: Brake Fluid Air Bleeding

FRONT AND REAR BRAKES 15-3 BRAKE FLUID AIR BLEEDING WARNING Brake fluid can be hazardous to humans and pets. Brake fluid is harmful or fatal if swallowed, and harm- ful if it comes in contact with your skin or eyes. Keep brake fluid away from children.

Page 167: Brake Fluid Replacement

15-4 FRONT AND REAR BRAKES NOTE: Do not release the brake lever/pedal while the bleeder valve is opened. • Replenish brake fluid to the UPPER line when the brake fluid level drops below LOWER line. • Tighten the air bleeder valve. .

Page 168: Front Brake Pads, Rear Brake Pads, Brake Pads Replacement

FRONT AND REAR BRAKES 15-5 BRAKE PADS REPLACEMENT FRONT BRAKE PADS • Remove the cap 1 and pad mounting pin 2. • Remove the brake pads. NOTE: Replace the two brake pads as a set. • Fit the new brake pads into the caliper. •.

Page 169

15-6 FRONT AND REAR BRAKES • Apply SUZUKI SILICONE GREASE to the O-ring.  99000-25100: SUZUKI SILICONE GREASE • Fit the new brake pads into the caliper. • Tighten the brake pad mounting pin to the specified torque.  Brake pad mounting pin: 18 N·m (1.8 kgf-m, 13.0 lb-ft) NOTE: * Inspect not to pinch the O-ring of brake pad mounting pin.

Page 170: Brake Disc Inspection

FRONT AND REAR BRAKES 15-7 BRAKE DISC INSPECTION • Inspect the brake disc for damage. • Measure the front and rear brake disc thickness.  Brake disc thickness Service limit (Front): 2.5 mm (0.10 in) (Rear): 3.5 mm (0.14 in) .

Page 171: Front Caliper Removal And Disassembly

15-8 FRONT AND REAR BRAKES FRONT CALIPER REMOVAL AND DISASSEMBLY • Drain brake fluid. (15-4) • Place a rag under the brake hose union bolt to catch spilled brake fluid. • Disconnect the brake hose. • Remove the caliper mounting bolts 1. •.

Page 172: Rear Caliper Removal And Disassembly

FRONT AND REAR BRAKES 15-9 • Remove the dust seals 6 and piston seals 7. REAR CALIPER REMOVAL AND DISASSEMBLY • Remove the rear wheel. (14-6) • Remove the disc cover 1 and caliper protector 2. • Drain brake fluid. (15-4) •.

Page 173: Caliper Inspection

15-10 FRONT AND REAR BRAKES • Wrap the caliper with a rag to prevent brake fluid scatter and piston pop-out. • Apply low-pressure air into the caliper through the hole to remove the piston. WARNING Fingers can get caught between piston and caliper body when removing the piston.

Page 174: Caliper Cleaning, Front Caliper Reassembly

 Specification and classification: DOT 4 • Install the springs and boots. • Apply SUZUKI SILICONE GREASE to the caliper axles.  99000-25100: SUZUKI SILICONE GREASE • Install the caliper bracket.

Page 175: Rear Caliper Reassembly

 Specification and classification: DOT 4 • Install the springs and boots. • Apply SUZUKI SILICONE GREASE to the caliper axles.  99000-25100: SUZUKI SILICONE GREASE • Install the caliper bracket.

Page 176: Master Cylinder, Front Master Cylinder Removal And Disassembly

FRONT AND REAR BRAKES 15-13 MASTER CYLINDER WARNING Brake fluid can be hazardous to humans and pets. Brake fluid is harmful or fatal if swallowed, and harm- ful if it comes in contact with your skin or eyes. Keep brake fluid away from children. Call your doctor immediately if brake fluid is swallowed, and induce vomiting.

Page 177: Rear Master Cylinder Removal And Disassembly

15-14 FRONT AND REAR BRAKES • Remove the master cylinder cap. • Remove the diaphragm. • Remove the dust boot 1. • Remove the snap ring 2 with snap ring pliers. • Remove the washer 3 and piston/cup set 4. .

Page 178: Master Cylinder Inspection, Master Cylinder Cleaning, Front Master Cylinder Reassembly

FRONT AND REAR BRAKES 15-15 MASTER CYLINDER INSPECTION • Inspect the cylinder bore and piston for scuffing, wear and damage. • Inspect the piston rod and spring for damage. MASTER CYLINDER CLEANING • Flush the master cylinder ports with pressurized air. •.

Page 179: Rear Master Cylinder Reassembly

• Apply grease to the contact point between piston and push rod.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Set the brake hose end between the hose stopper, then tighten the brake hose union bolt 1 to the specified torque.

Page 180: Brake Lever

• Apply grease to the brake lever adjuster return spring, pivot bolt and contact point between piston and brake lever.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Tighten the pivot bolt and pivot nut to the specified torque.

Page 181: Brake Pedal

• Remove the washer and master cylinder rod pin 3. • Remove the brake pedal pivot bolt 4. REASSEMBLY • Apply SUZUKI SUPER GREASE to the oil seal and brake pedal pivot bolt.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) •.

Page 182: Front Fork And Steering

FRONT FORK AND STEERING 16-1 FRONT FORK AND STEERING CONTENTS CONSTRUCTION . 16- 2 FRONT FORK, STEERING . 16- 2 HANDLEBAR CONTROLS . 16- 3 REMOVAL . 16- 4 DISASSEMBLY . 16- 5 INSPECTION . 16- 9 REASSEMBLY . 16-11 INSTALLATION .

Page 183

16-2 FRONT FORK AND STEERING CONSTRUCTION FRONT FORK, STEERING 25 N . m (2.5 kgf-m, 18.0 lb-ft) 100 N . m (10.0 kgf-m, 72.5 lb-ft) 23 N . m (2.3 kgf-m, 16.5 lb-ft) 45 N . m 30 N . m (3.0 kgf-m, 21.5 lb-ft) (4.5 kgf-m, 32.5 lb-ft) 35 N .

Page 184: Handlebar Controls

FRONT FORK AND STEERING 16-3 HANDLEBAR CONTROLS Adhesive agent 25 N·m (2.5 kgf-m, 18.0 lb-ft) 6 N·m (0.6 kgf-m, 4.4 lb-ft) Adhesive agent 6 N·m (0.6 kgf-m, 4.4 lb-ft)

Page 185

16-4 FRONT FORK AND STEERING REMOVAL • Place the motorcycle on a block to lift front wheel off the ground. • Remove the front wheel. (14-3) • Remove the protector 1. • Remove the front number plate band. • Remove the handlebars. (16-18) •.

Page 186

FRONT FORK AND STEERING 16-5 DISASSEMBLY • Set rebound and compression damper settings to the mini- mum settings (softest) before disassembling. Record the set- ting before turning the adjuster. • Thoroughly clean the fork before disassembly. CAUTION Scratches or other damage on the inner tube or on the oil seal lip will cause oil leak.

Page 187

16-6 FRONT FORK AND STEERING • Clamp the axle holder 2 with a vise. Protect the axle holder with a rag when using a vise. • Loosen the center bolt 3 completely with a 21 mm socket wrench.  WARNING Clamping the axle holder too tight can damage it which will affect riding stability.

Page 188

FRONT FORK AND STEERING 16-7 • With the outer tube compressed by hands, remove the special tool. CAUTION Removing the lock-nut 4 and pushing the inner rod thread into the damper rod will damage the inner rod oil seal. Do not remove the lock-nut 4 from the inner rod. •.

Page 189

16-8 FRONT FORK AND STEERING INNER TUBE • Separate the inner tube out of the outer tube. • Remove the slide bushing from the inner tube. • Remove the following parts from the inner tube. Guide bushing 1 Seal retainer 2 Oil seal 3 Stopper ring 4 Dust seal 5.

Page 190

FRONT FORK AND STEERING 16-9 • Remove the compression damper unit from the sub-tank. NOTE: Slowly compress the inner rod until it stops so that the compres- sion damper unit can be removed easily. • Drain the fork oil from the damper rod assembly by moving the inner rod several strokes.

Page 191

16-10 FRONT FORK AND STEERING INNER TUBE AND OUTER TUBE • Inspect the inner tube for scratches. If it has scratches, replace it with a new one. • Inspect the outer tube for dent. If it is dented all the way to the inner side, replace it with a new one.

Page 192

FRONT FORK AND STEERING 16-11 SLIDE BUSHING AND GUIDE BUSHING Inspect the “teflon coating metals” (slide bushing and guide bushing) for wear or damage. If they are worn or damaged, replace them with new ones. Inspect the metal particles on the “teflon coating metals”. If they are not clean, clean them with a nylon brush and fork oil.

Page 193

• With the damper rod in fully extended position, pour the spec- ified amount of fork oil.  Fork oil quantity (Inside the damper rod): 193 ml (6.52/6.80 US/lmp oz)  99000-99001-SS5: SUZUKI FORK OIL SS-05 (or equivalent fork oil)

Page 194

FRONT FORK AND STEERING 16-13 • Apply fork oil to the O-rings and bushing on the compression damper unit. • With the damper rod held immovable in fully extended posi- tion, gently install the compression damper unit to the sub- tank.

Page 195

16-14 FRONT FORK AND STEERING • Force out the remaining oil (discharged oil) using compressed air completely. • With the damper rod in horizontal position, move the inner rod by hand to inspect it if operating smoothly. • If the inner rod is not extend, repeat the “COMPRESSION DAMPER UNIT”.

Page 196

FRONT FORK AND STEERING 16-15 • Clamp the axle holder with a vise. Protect the axle holder with a rag when using a vise.  WARNING Clamping the axle holder too tight can damage it which will affect riding stability. Do not clamp the axle holder too tight.

Page 197

• Pour the specified amount of fork oil into the outer tube.  Oil quantity (When standard fork spring is used): 357 ml (12.07/12.57 US/lmp oz)  99000-99001-SS5: SUZUKI FORK OIL SS-05 (or equivaient fork oil) • Raise the outer tube and temporarily tighten the fork cap bolt (sub-tank).

Page 198

FRONT FORK AND STEERING 16-17 INSTALLATION • Install the front fork with the line T aligned with the upper sur- face of the upper bracket. • Check that the air valve A is positioned at the front. • Tighten the fork lower clamp bolts to the specified torque. .

Page 199

16-18 FRONT FORK AND STEERING STEERING REMOVAL HANDLEBARS • Place the motorcycle on a block to lift front wheel off the ground. • Remove the front number plate and protector. (5-2, 16-4) • Remove the clamps. • Remove the clutch lever 1. •.

Page 200

FRONT FORK AND STEERING 16-19 STEERING STEM • Remove the front wheel. (14-3) • Remove the front forks. (16-4) • Remove the front fender. • Remove the steering stem head nut. • Remove the steering stem upper bracket. • Remove the steering stem nut with the special tools. .

Page 201

16-20 FRONT FORK AND STEERING INSPECTION STEERING STEM • Inspect the needle bearings for wear. • Inspect the steering stem for distortion. • Inspect the bearing outer races for wear. BEARING REPLACEMENT NOTE: Replace the outer race and bearing as a set. •.

Page 202

09924-84510: Bearing installer set INSTALLATION STEERING STEM • Apply grease to the bearings.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Fit the steering stem lower bracket, upper bearing and steer- ing stem nut. • Tighten the steering stem nut with the special tools.

Page 203

16-22 FRONT FORK AND STEERING HANDLEBARS • Apply adhesive agent to the left handlebar end and inside of the left grip. HANDLE GRIP BOND (commercial available) ” mark on the left grip with the paint mark A on • Align the “ the left handlebar end.

Page 204

FRONT FORK AND STEERING 16-23 • Apply grease to the throttle cable and their hole.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Align the “ ” mark on the throttle grip with the hole on the throttle rotor.

Page 205

16-24 FRONT FORK AND STEERING Inspect the following items. • Front fork (2-20) • Steering (2-22) • Wire, cable and hose routing (18-12, -13, -17)

Page 206: Rear Suspension

REAR SUSPENSION 17-1 REAR SUSPENSION CONTENTS CONSTRUCTION . 17- 2 REAR SUSPENSION . 17- 2 REAR SHOCK ABSORBER . 17- 3 REMOVAL . 17- 3 SPRING REPLACEMENT . 17- 4 INSPECTION . 17- 5 BEARING REPLACEMENT . 17- 5 OIL REPLACEMENT . 17- 6 DISASSEMBLY AND INSPECTION .

Page 207

17-2 REAR SUSPENSION CONSTRUCTION REAR SUSPENSION 80 N . m (8.0 kgf-m, 58.0 lb-ft) 55 N . m (5.5 kgf-m, 40.0 lb-ft) 80 N . m (8.0 kgf-m, 58.0 lb-ft) 80 N . m 55 N . m (8.0 kgf-m, (5.5 kgf-m, 58.0 lb-ft) 40.0 lb-ft)

Page 208: Rear Shock Absorber

REAR SUSPENSION 17-3 REAR SHOCK ABSORBER REMOVAL • Place a block under chassis tube. • Remove the seat. (5-3) • Loosen the air cleaner clamp screw. • Remove the right frame cover. (5-2) (For E-19, 000) (For E-19, 000) • Remove the silencer and rear frame assembly. •.

Page 209: Spring Replacement

17-4 REAR SUSPENSION • Remove the rear shock absorber lower mounting bolt and nut. • Remove the rear shock absorber. NOTE: If necessary, move the swingarm up or down to facilitate this mounting bolt/nut removal. SPRING REPLACEMENT • Loosen the lock-nut 1 with the special tool and turn it fully to the end of the thread.

Page 210

REAR SUSPENSION 17-5 INSPECTION • Inspect the rear shock absorber for oil leakage. • Inspect the damper rod for bends and smooth movement. • Inspect the bump rubber for deterioration and damage. • Inspect the damper rod hidden by the bump rubber by moving the bump rubber.

Page 211

• Apply grease to the dust seals and spacers. • Install the spacers A and B. A for Right side B for Left side  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) OIL REPLACEMENT TOOLS AND EQUIPMENT • Following tools and equipment are required to perform oil replacement.

Page 212

REAR SUSPENSION 17-7 OIL REPLACEMENT PROCEDURE • Remove the rear shock absorber unit from the frame (17-4), clean and dry it. • Remove the spring from the rear shock absorber unit. (17-4) NOTE: Inspect the rear shock absorber unit for oil leak. Turn the rebound damping force adjuster screw counterclock- wise until it stops so that the rear suspension oil can be poured easily.

Page 213

Be sure to extend the rod after filling the oil. • Tilt the shock absorber unit as shown and pour the fresh rear suspension oil fully into the reservoir tank. 99000-99001-S25: SUZUKI REAR SUSPENSION OIL SS-25 (or equivalent rear suspension oil) .

Page 214

REAR SUSPENSION 17-9 • Reinstall the compression adjuster assembly 1.  Compression adjuster assembly: 30 N·m (3.0 kgf-m, 21.5 lb-ft) • Fill the rear shock absorber unit with nitrogen gas to 981 kPa (9.8 kgf/cm , 139.5 psi). • Tighten the gas valve cap. •.

Page 215

17-10 REAR SUSPENSION • Vise the rear shock absorber unit in inverted position. • Depress the bump rubber fully to protect the damper rod. • Evenly hammer the stopper 1 with a screwdriver or equiva- lent and remove it from the rear shock absorber body. •.

Page 216

• Fit the stopper to the shock absorber body. • Fill the specified rear suspension oil in the rear shock absorber. (17-8) 99000-99001-S25: SUZUKI REAR SUSPENSION OIL SS-25 (or equivalent rear suspension oil)  Oil capacity: Approx. 380 ml (12.84/13.38 US/Imp oz) •.

Page 217

17-12 REAR SUSPENSION DISPOSAL High pressure nitrogen gas is sealed in the rear shock absorber unit. Be sure to release gas before disposing the rear shock absorber unit. • Remove the valve cap. • Press the valve with a screwdriver. WARNING Releasing high pressure gas from the rear shock absorber unit can be hazardous.

Page 218

REAR SUSPENSION 17-13 SWINGARM REMOVAL • Place the motorcycle on a block to lift rear wheel off the ground. • Remove the rear wheel. (14-6) • Remove the chain guide. • Remove the rear brake hose guide. • Remove the rear brake caliper from the swingarm. •.

Page 219

17-14 REAR SUSPENSION • Remove the chain buffer. • Remove the plates. • Remove the following parts from the swingarm. Spacer 1 Oil seal 2 Washer 3 Thrust bearing 4 Dust seal 5 Spacer 6 INSPECTION PIVOT SHAFT • Measure the pivot shaft runout with the dial gauge and V-blocks.

Page 220

REAR SUSPENSION 17-15 SWINGARM • Inspect the swingarm for cracks and damage. BEARING, SPACER, DUST SEAL, OIL SEAL • Inspect the bearings, spacers, dust seals and oil seals for damage. • Insert the spacer into the bearings and inspect them for play and smooth movement.

Page 221

17-16 REAR SUSPENSION • Apply grease to the bearings.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) INSTALLATION • Reassemble the following parts into the swingarm. 1 Oil seal 5 Washer 2 Spacer 6 Dust seal 3 Washer 7 Spacer 4 Thrust bearing •.

Page 222: Rear Suspension Linkage

REAR SUSPENSION 17-17 REAR SUSPENSION LINKAGE REMOVAL • Place a block under the chassis tubes. • Remove the lower drive chain control roller 1. • Remove the rear cushion rod bolt and nut. • Remove the cushion lever bolt and nut. •.

Page 223

17-18 REAR SUSPENSION INSPECTION • Inspect the cushion rod and cushion lever for damage. • Inspect the dust seals and spacers for damage. • Insert the spacers into the bearings and inspect them for excessive play and smooth movement. BEARING REPLACEMENT •.

Page 224

When installing the needle roller bearing cages, the stamped mark on the bearing must face outside. • Apply grease to the needle roller bearings and install them.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Press fit the needle roller bearing cages with the special tool and a suitable size socket wrench.

Page 225

17-20 REAR SUSPENSION • Tighten the cushion lever, cushion rod and swingarm nuts to the specified torque. Left Right 5 mm 4 mm 4 mm 4 mm  Tightening torque: A: 55 N·m (5.5 kgf-m, 40.0 lb-ft) B: 55 N·m (5.5 kgf-m, 40.0 lb-ft) C: 80 N·m (8.0 kgf-m, 58.0 lb-ft) D: 80 N·m (8.0 kgf-m, 58.0 lb-ft) E: 80 N·m (8.0 kgf-m, 58.0 lb-ft)

Page 226

REAR SUSPENSION 17-21 Left Right CAUTION Improperly reassembled rear suspension linkage bolts can interfere with suspension move- ment and damage the rear suspension linkage. * Make sure that the rear shock absorber rebound damping adjuster on the bottom bracket of the rear shock absorber is located to the right side.

Page 227

Page 228: Servicing Information

SERVICING INFORMATION 18-1 SERVICING INFORMATION CONTENTS SERVICE DATA . 18- 2 CYLINDER + PISTON + PISTON RING. 18- 2 CONROD + CRANKSHAFT . 18- 2 CLUTCH . 18- 2 RADIATOR . 18- 3 TRANSMISSION . 18- 3 DRIVE CHAIN. 18- 3 CARBURETOR .

Page 229: Service Data, Cylinder + Piston + Piston Ring, Conrod + Crankshaft

18-2 SERVICING INFORMATION SERVICE DATA CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Piston to cylinder clearance 0.030 – 0.040 0.120 (0.0012 – 0.0016) (0.0047) Cylinder bore 54.000 – 54.015 Nicks or (2.1260 – 2.1266) Scratches Measure 20 (0.79) from the top surface.

Page 230: Drive Chain

SERVICING INFORMATION 18-3 RADIATOR ITEM STANDARD LIMIT Radiator cap valve release 95 – 125 kPa — pressure (0.95 – 1.25 kgf/cm , 13.5 – 17.8 psi) TRANSMISSION Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3.368 (64/19) —.

Page 231: Brake + Wheel

18-4 SERVICING INFORMATION ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Ignition timing 5° B.T.D.C. at 1 000 r/min. Spark plug Type NGK: R6918B-8 0.55 – 0.65 (0.022 – 0.026) Spark performance Over 8 (0.3) at 1 atm. Pick-up coil resistance 72 –.

Page 232

SERVICING INFORMATION 18-5 ITEM STANDARD LIMIT 1.60 × 21 Wheel rim size Front 1.85 × 19 Rear Wheel axle runout 0.25 Front — (0.010) 0.25 Rear — (0.010) SUSPENSION Unit: mm (in) ITEM STANDARD LIMIT NOTE Front fork stroke — (12.2) Front fork inner tube 47 mm.

Page 233: Fuel + Oil + Coolant

750 ml Change (0.8/0.7 US/Imp qt) 800 ml Overhaul (0.8/0.7 US/Imp qt) Front fork oil type SUZUKI fork oil SS-05 or equivalent fork oil Front fork oil capacity 357 ml Outer tube oil (each leg) (12.07/12.57 US/Imp oz) quantity 193 ml Damper rod (6.52/6.80 US/lmp oz)

Page 234: Tightening Torque

SERVICING INFORMATION 18-7 TIGHTENING TORQUE PART N·m kgf-m lb-ft Cylinder head nut 18.0 Magneto rotor nut 25.5 Cylinder nut 18.0 Crankcase bolt Clutch sleeve hub nut 50.5 Primary drive gear bolt 50.5 Spark plug 17.5 1.75 12.5 Transmission oil drain plug 14.5 Transmission oil level bolt 0.55.

Page 235

18-8 SERVICING INFORMATION PART N·m kgf-m lb-ft Handlebar holder set nut 11.0 Seat rail nut (upper) 16.5 Seat rail bolt (lower) 16.5 Brake lever pivot bolt Brake lever pivot nut For other bolts and nuts not listed in the table, refer to this chart. Conventional or “4”.

Page 236: Special Tools

SERVICING INFORMATION 18-9 SPECIAL TOOLS 09900-20101 09900-00410 09900-06107 09900-06108 09900-09003 Vernier calipers Hexagon wrench set Snap ring pliers Snap ring pliers Impact driver set (150 mm) 09900-20203 09900-20205 09900-20605 09900-20607 Micrometer Micrometer 09900-20508 Dial gauge Dial gauge (50 – 75 mm) (0 –.

Page 237

18-10 SERVICING INFORMATION 09925-18011 09921-20200 09921-20240 09924-84510 09924-84521 Steering bearing Bearing remover Bearing remover set Bearing installer set Bearing installer set installer 09930-10121 09930-30104 09930-30113 Spark pulg wrench 09930-11960 Rotor remover slide Flywheel rotor 09930-40113 Torx wernch (T20) shaft remover Rotor holder 09940-14911 09940-14960.

Page 238: Wiring Diagram

SERVICING INFORMATION 18-11 WIRING DIAGRAM IGNITION COIL CARBURETOR CDI UNIT ENGINE SOLENOID STOP SWITCH : Pickup THROTTLE coil POSITION SENSOR MAGNETO WIRE COLOR Black Blue Green White Yellow B/Bl: Black with Blue tracer B/Br: Black with Brown tracer B/G: Black with Green tracer B/O: Black with Orange tracer B/R.

Page 239

18-12 SERVICING INFORMATION WIRE, CABLE AND HOSE ROUTING Clamp Pass through the clutch cable under the radiator breather hose. Clutch cable Throttle cable Pass through the clutch cable between the engine mounting plates. Throttle cable Clutch cable Clutch cable Throttle cable.

Page 240

SERVICING INFORMATION 18-13 Clamp Engine stop switch lead wire FRONT Ignition coil coupler Clamp Wiring harness Engine stop switch lead wire Frame Clamp CDI unit Wiring harness Engine stop switch lead wire Throttle cable Clamp Wiring harness Engine stop switch lead wire Clamp Carburetor solenoid lead wire Throttle position sensor lead wire.

Page 241

18-14 SERVICING INFORMATION.

Page 242

SERVICING INFORMATION 18-15 NOTE: Face each clamp end to the downward. Clamp Fuel tank cushion rubber Fuel tank Clamp cushion rubber Clamp SECT AA Protector 10 mm (0.4 in)

Page 243

18-16 SERVICING INFORMATION Quick adjuster Turn to tighten Turn to tighten the clutch cable tension. the clutch cable tension. When the movement is felt heavier, Turn to loosen Turn to loosen clean this and apply grease. the clutch cable tension. the clutch cable tension.

Page 244

SERVICING INFORMATION 18-17 Front brake master cylinder Washer Front brake hose Hose guide Set the brake hose end between the hose stopper, then tighten the brake hose union bolt to the specified torque. Front brake hose Clamp Clamp the upper difference portion in brake hose diameter.

Page 245

18-18 SERVICING INFORMATION.

Page 246

SERVICING INFORMATION 18-19.

Page 247: Specifications, Dimensions And Dry Mass

18-20 SERVICING INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length . 2 145 mm (84.4 in) Overall width . 830 mm (32.7 in) Overall height . 1 275 mm (50.2 in) Wheelbase . 1 450 mm (57.1 in) Ground clearance . 350 mm (13.8 in) Seat height.

Page 248

SERVICING INFORMATION 18-21 CHASSIS Front suspension. Telescopic, pneumatic/coil spring, oil damped Rear suspension . Link type Steering angle . 45° (right & left) Caster. 27° 30’ Trail. 115 mm (4.53 in) Turning radius. 2.3 m (7.5 ft) Front brake . Disc brake, hydraulically operated Rear brake.

Page 249: Optional Parts, Spare Parts List

18-22 SERVICING INFORMATION SPARE PARTS LIST ITEM PART NAME PART NUMBER Q’TY PARTS SET, SPARE 19900-36F70 O-RING, CYLINDER HEAD No. 1 11147-27C11 O-RING, CYLINDER HEAD No. 2 11148-27C11 GASKET, CYL COVER, No. 1 11233-27C34 GASKET, CYL COVER, No. 2 11238-36E01 GASKET, CYLINDER 11241-36F00 GASKET, CRANKCASE.

Page 250: Setting Data

SERVICING INFORMATION 18-23 SETTING DATA DATE RACE/COURSE TEMP./HUMIDITY WHETHER COURSE COUDITION MAIN JET JET NEEDLE PILOT JET AIR SCREW FLOAT LEVEL SPARK PLUG OIL LEVEL COMP. ADJ. POSITION RE-BOUND ADJ. POSITION SPRING SPRING SPRING SET LENGTH COMP. ADJ. POSITION LOW COMP.

Page 251

Page 252

Failure to follow these safety precautions may increase your risk of injury: ! Wear a helmet, eye protection, and bright protective clothing. ! Don’t ride after consuming alcohol or other drugs. ! This owner’s service manual contains important safety information. Please read it carefully. Printed in Japan 300 TAKATSUKA, HAMAMATSU, JAPAN.

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