HOW TO USE THIS MANUAL

TO LOCATEWHAT YOU ARE

LOOKINGFOR:
1 . T h e t e x t o f t h i s m a n u a li s d i v i d e di n t o s e c t i o n s .
2 . T h e s e c t i o nt i t l e s a r e l i s t e di n t h e G R O U PI N D E X .
3 , H o l d i n gt h e m a n u a la s s h o w n a t t h e r i g h tw i l l a l l o w
you to find the first page of the section easily.
4. The contentsare listedon the first pageof eachsec-
tion to help you find the item and page you need,

COMPONENTPARTSAND WORK TO BE DONE

Underthe name of each system or unit, is its explodedview, Work instructionsand other service
informationsuch as the tighteningtorque,lubricatingpointsand lockingagentpoints,are provided.

Example:Front wheel

@ Front axle spacer

Front brake disc
Bearing
Front wheel
Speacer
Bearing
Speedometergearbox

@ Disc plate bolt

4< @ Front axle
O Axte pinch bolt
A5:J
pn/),1
aJ"q5

ITEM N'm kg-m lb-ft

@ 23 2.3 16.5
@ 65 6.5 47.O
o 23 2.3 23.0
SYMBOL
Listedin the table below are the symbolsindicatinginstructionsand other informationnecessary
for servicing.

SYMBOL DEFINITION SYMBOL DEFINITION

g Torque control is required.

Data besideit indicates
specifiedtorque.
I
lffl
A p p l y o r u s e b r a k ef l u i d .

A p p l y o i l . U s e e n g i n eo i l u n l e s s M e a s u r ei n v o l t a g er a n g e .

E otherwisespecified.

A p p l y S U Z U K IS U P E RG R E A S E M e a s u r ei n c u r r e n tr a n g e .
tt
At, ,

99000-25030
A p p l y S U Z U K IM O L Y P A S T E . Measurein resistancerange.

9 9 0 0 0 - 2 5 14 0
"12078" Measurein continuitytest range.
A p p l y S U Z U K IB O N D

99104-31140
"1216" M e a s u r ei n d i o d et e s t r a n g e .
A p p l yS U Z U K B
I OND

9 9 0 0 0 - 3 116 0
" U s e s p e c i a tl o o l .
Apply THREADLOCK 1342"

99000-32050
L OC KS UPER
A p p l yT H R E A D U s e e n g i n ec o o l a n t .
" 13 0 3 " .
99000-32030
A p p l yT H R E A D
L OC KS UPER U s ef o r k o i l .
" 1360".
99 0 0 0 -3 2310 99000-99044-15G
 CONTENTS
WARN\NG/CAUT|ON/NOTE.......'.. "' 1- I

GENERALPRECAUTIONS......,. "..,.' 1- 1
...'..'.....
suzuKtvz800v('97-MoDEL) .......'..
7- 3
SEBIALNUMBERLOCATION ,."".... 7- 3

FUEL. OIL AND ENGINECOOLANT RECOMMENDATION..".,....''' 1- 3

FUEL . . . . . . . . . - . .1. -. 3

E N G T NO
EIL'....' . . ' . . . . ' . . . .1. .- 4

BR A K EF L U ID .,".,,.,......1- 4

FRONT FORK OIL .. .." 1- 4

ENGINECOOLANT ........". 1- 4

WATERFOR MIXING .....,.".. 4

COOLANT......'."..
ANT|-FREEZE/ENG|NE .... 1- 4

COOLANT......."....."..". 1- 4
LIOUIDAMOUNT OF WATER/ENGINE
BREAK-INPROCEDURES ..,".. 1- 5

CYLINDERIDENTIFICATION ",.....," 1- 5

INFORMATIONLABELS .... 1- 6

SPECnF|CATIONS ..........1- 7

COUNTRYOR AREA "1"""" "' 1- I

1-1 GEITIEBAI.
IIIFORMATIOI'I

WARNING/CAUTION/NOTE
Pleasereadthis manualand follow its instructionscarefully.To emphasizespecialinformation,the
symbol and the words WARNING,CAUTIONand NOTEhave specialmeanings.Pay specialatten-
tion to the messageshighlightedby these signalwords.

Indicatesa potential hazard that could result in death or injury.

CAUTION
Indicatesa potential hazard that could result in motorcycle damage.

NOTE:
Indicates special information to make maintenance easier or instructions clearer.

Pleasenote,however,that the warningsand cautionscontainedin this manualcannotpossiblycover

all potentialhazardsrelatingto the servicing,or lack of servicing,of the motorcycle.In additionto
the WARNINGSand CAUTIONSstated,you must use goodjudgementand basicmechanicalsafety
principles.lf you are unsureabout how to perform a particularserviceoperation,ask a more ex-
periencedmechanicfor advice.

GENERALPRECAUTIONS

* Properservice and repair proceduresare important for the safety of the service mechanic
and the safety and reliabilityof the motorcycle.
x When 2 or more persons work together, pay attention to the safety of each other.
* When it is necessaryto run the engineindoors,make surethat exhaustgas is forced outdoors.
* When working with toxic or flammablematerials,make sure that the areayou work in is well-
ventilated and that you follow all of the material manufacturer'sinstructions.
* Never use gasolineas a cleaningsolvent.
* To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system
until they have cooled.
* After servicingthe fuel, oil, water, exhaust or brake systems, check all lines and fittings related
to the system for leaks.
 1.2
II'IFORMATION
GEIIEBAT

A CAUTION
* lf parts replacementis necessary, replace the parts with Suzuki Genuine Parts or their
equivalent.
* When removingparts that are to be reused,keepthem arrangedin an orderlymannerso that
they may be reinstalledin the proper order and orientation.
* Be sure to use specialtools when instructed.
* Make sure that all parts used in reassemblyare clean. Lubricatethem when specified-
* Use the specifiedlubricant, bond, or sealant.
* When removingthe battery, disconnectthe negativecable first and then the positive cable.
When reconnectingthe battery, connect the positivecablefirst and then the negativecable,
and reptacethe terminal cover on the positive terminal.
* When performingserviceto electricalparts, if the serviceproceduresnot requireuse of bat-
tery power, disconnectthe negative cable the battery.
* When tighteningthe cylinderhead and case bolts and nuts, tighten the largersizesfirst. Al-
ways tighten the bolts and nuts fnorn the inside working @ut,in a crisscrossmanner.
x Wheneveryou removeoil seals,gaskets,packing,O-rings,lockingwashers,self-lockingnuts,
cotter pins, circlipsand certain other parts as specified,be sure to replacethem with new
ones. Also, before installingthese new parts, be sure to remove any left over materialfrom
the mating surfaces.
* Never reusea circlip.When installinga new circlip,take care not to expandthe end gap larg-
er than requiredto slip the circlip over the shaft. After installinga circlip, always ensurethat
it is completely seated in its groove and securelyfitted.
* Use a torque wrench to tighten fasteners to the specifiedtorque. Wipe off greaseand oil
if a thread is smearedwith them.
* After reassembling,check parts for tightness and proper operation.

* To protect the environment,do not unlawfully disposeof used rnotor oil, enginecoolant and
other fluids: batteries,and tires.
* To protect Earth's natural resources,properly disposeof used motorcycle and parts'
I-3 GE]IIERAI
I]iIFOBMATIOIil

SUZUKIVZSOOV('g7-MODEL}

RIGHTSIDE LEFTSIDE
"Difference.betweenphotographsand actual motorcyclesdependson the markets.

SERIALNUMBERLOCATION
T h e f r a m e s e r i a ln u m b e ro r V . l . N . ( V e h i c l el d e n t i f i c a t i o n
N u m b e r )O i s s t a m p e do n t h e r i g h t s i d e
of the steeringhead pipe.The engineserialnumber@ is locatedon the rearside of the crankcase.
Thesenumbersare requiredespeciallyfor registeringthe machineand orderingspare parts.

F U E L .O I L A N D E N G I N EC O O L A N T R E C O M M E N D A T I O N
FUEL
1 . U s eo n l yu n l e a d e d g a s o l i n eo f a t l e a s t8 7 p u m po c t a n et t r # f m e t h o do r 9 1 o c t a n eo r h i g h e rr a t e d
by the researchmethod.
2 . S u z u k ir e c o m m e n d st h a t c u s t o m e r su s e a l c o h o lf r e e , u n l e a d e dg a s o l i n ew h e n e v e rp o s s i b l e .
3 . U s e o f b l e n d e dg a s o l i n ec o n t a i n i n gM T B E ( M e t h l yT e r t i a r yB u t y l E t h e r )i s p e r m i t t e d .
4 . U s e o f b l e n d e dg a s o l i n e / a l c o hfoule l i s p e r m i t t e d p , r o v i d e dt h a t t h e f u e l c o n t a i n sn o t m o r et h a n
1 0 % e t h a n o lG . a s o l i n e / a l c o hf o
u le l m a y c o n t a i nu p t o 5 % m e t h a n oilf a p p r o p r i a tceo s o l v e n t sa n d
corrosioninhibitorsare presentin it.
5 . l f t h e p e r f o r m a n coef t h e v e h i c l ei s u n s a t i s f a c t o rw y h i l e u s i n gb l e n d e dg a s o l i n e i a l c o hfoule l ,y o u
s h o u l ds w i t c h t o a l c o h o l - f r e ue n l e a d e dg a s o l i n e .
6 . F a i l u r et o f o l l o w t h e s e g u i d e l i n ec o u l d p o s s i b l yv o i d a p p l i c a b l e
w a r r a n t yc o v e r a g e C . h e c kw i t h
your fuel supplierto makesurethat the fuel you intendto use meetsthe requirements listedabove.
 1-4
It'IFOBMAT!OIU
GE]'IERAI

E N G I N EO I L
S U Z U K Ir e c o m m e n d tsh e u s e o f S U Z U K IP E R F O R M A N C E I
4 M O T O RO I L o r a n o i l w h i c h i s r a t e d S F o r S G u n d e rt h e il t
API (AmericanPetroleumlnstitute)serviceclassification' The
i,IUITIGRADE
E tr)
recommended viscosityis SAE 1OW/4O.lf an SAE 1OW/40
oil is not available,selectan alternativeaccordingto the right
l t l
E
I ?I
chart. -30 -20 -ro o 10 20 30 40
TEllP. .- #
-22 -4 14 32 50 6E 86 104

BRAKEFLUID
Specificationand classification:DOT 4

Sincethe brakesystemof this motorcycleis filledwith a glycol-basedbrakefluid by the manufac-

and petroleum-based
turer, do not use or mix different types of fluid such as silicone-based fluid
for refilling the system, otherwise serious damage will result.
Do not use any brake fluid taken from old or used or unsealedcontainers'
Never re-usebrake fluid left over from a previousservicing,which has been stored for a long
period.

F R O N TF O R KO I L
U s ef o r k o i l # 1 5

E N G I N EC O O L A N T
coolantcompatiblewith an aluminumradiator,mixedwith distilledwater
Use an anti-freeze/engine
only.

WATER FOR MIXING

Usedistilledwater only.Water otherthan distilledwater can corrodeand clogthe aluminumradiator'

E COOLANT
ANTI-FREEZE/ENGIN
The enginecoolantperformas a corrosionand rust inhabitas well as anti-freeze. Therefore,the en-
g i n ec o o l a n ts h o u l db e u s e da t a l lt i m e s e v e nt h o u g ht h e a t m o s p h e r itce m p e r a t u r ien y o u r a r e ad o e s
n o t g o d o w n t o f r e e z i n gP o i n t .

COOLANT
LIOUIDAMOUNT OF WATER/ENGINE
Sofutioncapacity(total): 1 460 ml (1.5/1.3 US/lmp qt)
For enginecoolantmixture information,refer to coolingsystem section,page 5-4'

C A U T I ON
Mixing of anti-freeze/engine coolant should be limited to 60%. Mixing beyond it would reduce
its efficiency. lf the anti-freeze/enginecoolant mixing ratio is below 5Oo/o,rust inhabitingper-
formance is greatly reduced. Be sure to mix it above 507o even though the atmospherictem-
peraturedoes not go down to the freezing point.
I.5 GE]IIERAL
IilFORMATIOITI

BREAK-INPROCEDURES
Duringmanufactureonly the best possiblematerialsare used and all machinedparts are finished
to a very highstandardbut it is still necessaryto allow the movingpartsto "BREAK-IN"beforesub-
jecting the engineto maximum stresses.The future performanceand reliabilityof the enginede-
pendson the care and restraintexercisedduring its early life. The generalrules are as follows.
o Keepto these break-inthrottle openinglimits:

Initial 8OOkm ( 500 miles):Less than 1/2 throttle

Up to 1 600 km (1 000 miles): Less than 3/4 throttle
. Upon reachingan odometerreadingof 1 600 km (1 OOOmiles)you can subjectthe motorcycle
to full throttle operation.

CYLINDERIDENTIFICATION
T h e t w o c y l i n d e r so f t h i s e n g i n ea r e i d e n t i f i e da s N o . 1 a n d N o . 2 c y l i n d e r a
, s c o u n t e df r o m r e a rt o
front (as viewed by the rider on the seat).
 I-6
ITUFORMATION
GEIIERAT

LABELS
INFORMATION

q,t

(g

-
-

Cf)
cf)
s @
+ (f) cf)
(r,
(f)
c{ (f)
N cf)
cf)
(Y)
(\ o O
N
@
N c'o
(f)
uJ
\ir
o I
lrJ Cf) @
llJ C\
N UJ
o u- (r)
L

(Y)
L

o u- u- uJ
o
II o L
o IIJ
I
I
o) 6
E 6
IIJ
o F
L

o ; l!
ll- o P
q) :
o
; tr (It x
F
tr o o
o
@
C
UJ

o o = o) b
; E '= O ;
P
U' ; c v, o +
o ts o o llJ

z - LL F o @

v @@I @ @ (F) @ @
 I-7 GEIIEBAT
IIIFORMATIOII

SPECIFICATIONS
DIMENSIONS
AND DRY MASS
O v e r a llle n g t h . . 2 4 O Sm m ( 9 4 . 7 i n ) , . . . . E - 1 7 , 1 8 , 2 2 , 2 5
2 3 6 5 m m ( 9 3 . 1i n ) . . . . . O t h e r s
O v e r a l lw i d t h 7bOmm (29.b in)
Overallheight . 1 1 1O mm (43.7 inl
Wheelbase , . . . . . .1 6 4 5 m m ( 6 4 , 8 i n )
G r o u n dc l e a r a n c e 135 mm ( 5.3 in)
S e a t h e i g h t. . . . . . . 7 O Om m ( 2 7 . 6 i n )
Dry mass 2O7 kg (456 lbs)

ENGINE
Type . . . . . F o u r - s t r o k eW
, a t e r - c o o l e dO, H C ,
45-degreeV-twin
N u m b e ro f c y l i n d e r .s. . . . . . . . . .2
B o r e. 8 3 . 0 m m ( 3 . 2 6 8i n )
Stroke . . . . .7 4 . 4 m m ( 3 . 1 6 9i n )
P i s t o nd i s p l a c e m e n. t, . . . . . . . .8 0 5 c r n 3( 4 9 .1 c u , i n )
Carburetor . . . . . .M I K U N B I D S 3 6 S S . . . .f .r o n t
M I K U N I8 5 3 6 5 5 . . . . . r e a r
A i r c l e a n e r. . . . . . . . N o n - w o v e nf a b r i ce l e m e n t
Startersystem .. Electricstarter
Lubrication system .... Wet sump

TRANSMISSION
Clutch . . . . . . W e t m u l t i - p l a t et y p e
Transmission ... . . b - s p e e dc o n s t a n tm e s h
G e a r s h i fpt attern ....... l-down, 4-up
P r i m a r yr e d u c t i o nr a t i o . ...... 1.886 (83/44)
F i n a lr e d u c t i o nr a t i o .. 3.200 (48115]'
G e a rr a t i o s ,L o w . . . . . .2 . 4 6 1 ( 3 2 1 1 3 ] l
2nd . . . , . . . .1 . 5 7 8( 3 0 / 1 9 )
3rd .. . . . . . . ,1 . 2 O OQ 4 l 2 O \
4th .. . . . . . .0 . 9 5 6 Q 2 t 2 3 l
T o p. , . . . . .o. . 8 o oQ o l 2 l l
D r i v ec h a i n . . . . . . .D I D 5 O V A z1. 1 6 l i n k s
 GENERAT I.8
IITIFORMATIO]II

CHASSIS
F r o n ts u s p e n s i o n. . . . . . . . . . . . . . .T e l e s c o p i cc,o i l s p r i n g ,o i l d a m p e d
R e a rs u s p e n s i o n S w i n g a r m ,c o i l s p r i n g ,o i l d a m p e d ,s p r i n gp r e - l o a d
5-way adjustable
Steeringangle 4Oo (right & left)
Caster ......35o
T r a i l. 146 mm (5'7 in)
T u r n i n gr a d i u s .. 3.1 m (9'9 ft)
F r o n tb r a k e . . . . . " Discbrake
Rearbrake lnternalexPanding
F r o n tt i r e s i z e . " ' 1 3 0 / 9 0 - 1 66 7 H
R e a rt i r e s i z e . . " 1 5 0 / 9 0 - 1 5M I C 7 4 H
F r o n tf o r k s t r o k e . . . . . . .1 4 0 m m ( 5 ' 5 i n )
R e a rw h e e lt r a v e l . . . . . . 1 O 2m m ( 4 ' O i n )

ELECTRICAL
l g n i t i o nt y p e . . . . . E l e c t r o n i lcg n i t i o n( T r a n s i s t o r i z e d )
l g n i t i o nt i m i n g . . . 5 0 B . T ' D . C .b e l o w 1 5 O Or / m i n
S p a r kp l u g . . . . . . .D P R S E A or X24EPR-U9
Battery . ' . . 1 2 V 3 6 . 0 k C ( 1 OA h ) / 1 0 H R
Generator . T h r e e - p h a sA e. C . G e n e r a t o r
Fuse 3 o l 1 5 l 1 5 l 1 5 l 1 o1iO A
Headlight " 12V 6O/55W
P o s i t i o nl i g h t . . ... 12V 4W
F r o n tt u r n s i g n a ll i g h t . 1 2 V 5 1 2 1 W. . . E - 0 3 , 2 8 , 3 3
12V 21W ... Others
R e a rt u r n s i g n a ll i g h t . . . 12V 21W
Tail/Brake light. .. 12V 5121W
S p e e d o m e t el irg h t .... 12V 1.7W
N e u t r a li n d i c a t o rl i g h t . 12V 3'4W
H i g hb e a mi n d i c a t o lri g h t . ... 12V 1.7W
T u r n s i g n a li n d i c a t o rl i g h t .
O i l p r e s s u r ei n d i c a t o rl i g h t . ' 12V 1-7W
E n g i n ec o o l a n t e m p . i n d i c a t o lri g h t . .... 12V 1.7W

CAPACITIES
F u e lt a n k , i n c l u d i n gr e s e r v e 1 3 . 0 L ( 3 ' 4 1 2 ' 9U S / l m pg a l )
reserve 3 . O L ( 0 . 8 / 0 . 7 U S / l m pg a l )
E n g i n eo i l ,o i l c h a n g e . 1 7 O O m l ( 1 . 8 i 1 . 5U S / l m pq t )
w i t h f i l t e rc h a n g e . . . . . . .2 1 O 0m l ( 2 ' 2 1 1 . 8U S / l m pq t )
overhaul . , . 2 5 O Om l Q . 6 1 2 ' 2U S / l m pq t )
E n g i n ec o o l a n t i, n c l u d i n gr e s e r v e . 1 4 6 0 m l ( 1 . 5 / 1 ' 3U S / l m pq t )
F r o n tf o r k o i l ( e a c hl e g ) . 8 3 8 m l ( 2 8 ' 3 1 2 9 . 5U S i l m po z )

These specificationsare subjectto change without notice'

1.9 GEl'lERAt
lNF0RMATlolll

COUNTRYOR AREA
The seriesof symbols on the left stand for the countriesand areason the right.

SYMBOL C O U N T R Yo r A R E A
E-O2 U.K.
E-03 U.S,A,
E-O4 France
E - 15 Finland
E-16 Norway
E-17 Sweden
E-18 Switzerland
E-21 Belgium
E-22 Germany
E-24 Australia
E-25 Netherlands
E-26 Denmark
E-28 Canada
E-33 C a l i f o r n i (aU . S . A . )
E-34 Italy
E-37 Brazil
E-39 Austria
E-53 Spain

E - 1 5 , 1 6a n d 2 6 c o u n t r i e sa r e i n c l u d e di n E - 1 7 .
E - 2 1 a n d 5 3 c o u n t r i e sa r e i n c l u d e di n E - 3 4 .
E - 3 9 c o u n t r yi s i n c l u d e di n E - 1 8 .
 CONTENTS
PERIODICMAINTENANCE SCHEDIJLE.."..' ..., 2- 1

PERIODICMAINTENANCECTTART "'".,", .,.. 2. 1

LTJBRICATIONPOINTS . 2- 2

MAINTENANCE AND TIJNE-IJPPROCEDURES 2- 3

AIR C L E A N E R ." .... 2- 3
VALVE CLEARANCE 2- 4
9 PA R KP L I|G """"""' 2- 7
ENGINEOIL AND OIL FILTER ."",, .. 2- 8

FTJELHOSE 2- 9

CARBURETOR"..." 2- 9
CARBURETORSYNCHRONIZATION 2-1O
CLUTCH 2-1O
EN G1 ,NCEOOL A N T..........' 2- 10

DRIVECHAIN ,... 2-11

BRAKE 2-13
TIR E.'" ..,
9TEER1NG """' 2- 16

FRONT FORK . 2-16

REARsusPENsloN"""""' 2-16
E X H A U S TP \ P EB O L T S . ' . . . . " ' """'2-16

aHASS\S BOLTSAND NUTS """' 2-17

CHECK
COMPRESSIONPRESSTJRE .,,... 2-19

OIL PRESSURECHECK 2-2O

2.I PERIODIC
MAI]'ITEI'IA]'ICE

PERIODIC
MAINTENANCE
SCHEDULE
IMPORTANT:The periodicmaintenanceintervalsand servicerequirementshave been established
in accordancewith EPA regulations.Followingthese instructionswill ensurethat the motorcycle
w i l l n o t e x c e e de m i s s i o ns t a n d a r d sa n d i t w i l l a l s o e n s u r et h e r e l i a b i l i t ya n d p e r f o r m a n c eo f t h e
motorcycle.
The chartbelow liststhe recommendedintervalsfor allthe requiredperiodicservicework necessary
to keepthe motorcycleoperatingat peakperformanceand economy.Mileagesare expressedin terms
, i l e sa n d t i m e f o r y o u r c o n v e n i e n c e .
o f k i l o m e t e rm
NOTE:
More frequent servicing may be performed on motorcycles that are used under severe conditions.

PERIODIC
MAINTENANCE
CHART
Interval km 1 000 6 000 1 2 0 0 0 1 8 0 0 0 24 000
miles 600 4 000 7 500 1 1 0 0 0 1 5 0 0 0
Item months 1 6 12 1B 24
Air cleaner R I R
V a l v ec l e a r a n c e
S p a r kp l u g R I
I R
E n g i n eo i l R R R R R
E n g i n eo i l f i l t e r R R
I
Fuel hose
Replaceevery 4 years
E n g i n ei d l e r p m I
Throttle cable play I I
C a r b u r e t osr y n c h r o n i z a t i o n *l I
Clutch I I
Radiatorhose I I

E n g i n ec o o l a n t C h a n g ee v e r y 2 y e a r s
I I
D r i v ec h a i n C l e a na n d l u b rrcate
every 1 OOOk. (6O Om i l e s )
Brake I I
I
B r a k ef l u i d
Replaceevery 2 years
I I
Brakehose
Replaceevery 4 years
Tire I I
Steering I
Frontfork I
R e a rs u s p e n s i o n I
Exhaustpipe bolts T T T
Evaporativeemissioncontrol system I
( C a l i f o r n im
a o d e lo n l y )
Replacevapor hose every 4 years
PAIR (Air supply)system
( C a l i f o r n im
a o d e lo n l y )
Chassisbolts and nuts T T T T T
l: lnspection and adjust, clean, lubricate or replace as necessary
C = Clean R: Replace T: Tighten
Asterisk mark (*) indicates the California model only.
 2-2
MAII'ITENANCE
PERIODIC

POINTS
LUBRICATION
Properlubricationis importantfor smooth operationand long life of each working part of the
motorcycle.
Major lubricationpoints are indicatedbelow.

6 e r a k e l e v e rh o l d e r

Throttle cable

,.6q erafe pedal pivot and brake cable link

/6 Footrest pivot

,6t ctutcnl e v e rh o l d e r

,6 Sioe-standpivot and spring hook

NOTE:
* Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.
" Lubricate exposed parts which are subject to rust, with a rust preventative spraY whenever the
motorcycle has been operated under wet or rainy conditions.
2-3 PERIO
DICMAIIIITEI'IA]iICE

MAINTENANCE
AND TUNE.UP
PROCEDURES
This sectiondescribesthe servicingproceduresfor eachitem
of the PeriodicMaintenancerequirement.

AIR CLEANER
Inspect Every 6 OO0km (4 O0Omiles, 6 months) and
ReplaceEvery 12 OO0km {7 500 miles, 12 rnonths}.

. Removeframe covers,fueltank and steeringheadcovers.

( R e f e rt o p a g e s4 - 4 a n d 6 - 1 . )
No.1 AIR CLEANERELEMENTREMOVAL
o Removethe air cleaner element O OV removing the
SCTEWS.

No.2 AIR CLEANERELEMENTREMOVAL

. Loosenthe air cleanerclamp screw @.
o Removethe air cleanermounting bolts (@, @).
. Removethe throttle cable clamp screw @.
o R e m o v et h e a i r c l e a n e r .
. Removethe air cleaner element @ nV removing the
screws.

AIR CLEANERELEMENTCLEANING
r Carefullyuse an air hose to blow the dust from the air
cleanerelementsoutside.

CAUTION
Always use air pressureon the outside of the air cleaner
elements.lf air pressureis used on the inside,dirt will
be forced into the pores of the cleaner element thus
restrictingair flow through the cleaner element.
 MAIIllTE]{4l{
PERIODIC CE 2.4

AIR CLEANERELEMENTREMOUNTING
r Reinstallthecleanedelementsor new ones in reverseordr
er of removal.
o Facethe arrow mark@ on the elementto the upperwhen
i n s t a l l i n gt h e N o . 1 a i r c l e a n e re l e m e n t .
o Facethe arrow mark@ on the elementto the lower when
i n s t a l l i n gt h e N o . 2 a i r c l e a n e re l e m e n t .

A CAUTION
lf driving under dusty conditions,clean the air cleaner
elementsmore frequently.The surest way to acceler-
ate engine wear is to use the engine without the ele-
ments or to use rupturedelements.Make sure that the
air cleanersare in good condition at all times. Life of
the engine dependslargely on these components!

VALVE CLEARANCE
InspectInitiallyat 1 OOOkm t6OOmiles, 1 month) and
Every 12 000 km (7 5OOmiles, 12 months)thereafter.

Valveclearancealso must be checkedand adjustedwhen:

( 1 ) t h e v a l v e m e c h a n i s mi s s e r v i c e d ,a n d
(2) the camshaftare disturbedby removingthem for ser-
vicing,
Excessivevalveclearanceresultsin valvenoiseand insuffi-
cient valve clearanceresultsin valve damageand reduced
power. Checkand adjustthe clearanceto the specification.

Valve clearance(when cold): lN. & EX. 0.08-0.13 mm

(0.003-0.005 in)
NOTE:
* The clearance specification is for COLD state.
* Both intake and exhaust valves must be checked and ad-
justed when the piston is at Top Dead Center (TDC) ot
the compression stroke.
. Removethe fuel tank and frame covers.(Referto pages
4-4 and6-1.)
r R e m o v et h e N o , 2 a i r c l e a n e r .( R e f e rt o p a g e 2 - 3 . )
o Disconnectthe spark plug caps.
o Removethe cylinderhead cover caps (e, @).
o Removethe frame bracket@.
2.5 PERIODIC
MAIIilTEf{AltICE

o Removethe starter cable @ from the No.1 carburetor.

o Disconnectthe No.2 carburetorfrom the intakepipeand

then put it on the intake pipe.

CAUTION
Do not pull strongly when disconnecting the carbure-
tor to keep the balance of two carburetors.

a Removeall the inspectioncaps @.

a Removeall the s p a r kp l u g s .

Removethe generatorc o v e r p l u g @ a n d t h e t i m i n g i n -
spectionplug @.
 PERI0 2-6
DICMAlltlTEltlAltlCE

o Rotatethe generatorrotorto set the No.1 engine'spiston

at TDC of the compressionstroke. (Rotatethe rotor until
the "R I F I T" lineon the rotor is alignedwith the center
of hole on the generatorcover.)

I T o i n s p e c t h e N o . 1 e n g i n e ' sv a l v ec l e a r a n c ei ,n s e r tt h e
thicknessgaugeto the clearancebetweenthe valvestem
end and the adjustingscrew on the rocker arms'
a

@ 0990O-2O806:Thicknessgauge
o lf the clearance is out of the specificatlon,bring it into
the specified range by u s i n gt h e s p e c i a tl o o l .

@! ossr 740410: Valveadiustdriver

A CAUTION
Both right and left vlave clearancesshould be as closely
set as possible.
o Rotatethe generatorrotor 45O degrees(1-1/q turns) and
alignthe "F I F I T" line on the rotor with the center of
hole on the generatorcover.

Inspectthe No.2 engine's valve clearanceas the same man-

ner above.

NOTE:
lJse the thickness gauge from the arrow marks as shown
in the illustration.

No.1Engine
N o . 2E n g i n e
2.7 PERIODIC
MAIITITEITIATTCE

SPARKPLUG
InspectEvery 6 000 km (4 000 miles, 6 monthsl and
ReplaceEvery 12 OOOkm (7 5OOmiles, 12 months).

o Removethe spark plugs with spark plug wrench.

@ ossso-10141:Socketwrench
09930-1 4530: Universaljoint
09914-24510: T-handle

o Checkto see the heat range of the plug.

lf the electrodeof the plug is wet appearingor dark color,
replacethe plug with hotter type one. lf it is white or
glazedappearing,replacethe plug with coldertype one.

NGK NIPPONDENSO
Hotter type DPRTEA-9 X22EPR- U9
Standard DPR8EA.g X24EPR-U9
Coldertype DPR9EA-9 X27EPR-U9

NOTE:
"R" type spark plug hasa resistorlocated at the center elec-
trode to prevent radio noise.
r Checkto see the carbondepositon the plug. lf the car-
bon is deposited,remove it with a spark plug cleaner
machineor carefullyusing a tool with a pointed end.

o Measurethe plug gap with a thicknessgaugeif it is cor-

rect. lf not, adjust it to the following gap.

@! ossoo-20803:Thickness
sause
Standard
S p a r kp l u g g a p : 0 . 8 - 0 . 9 m m ( 0 . O 3 1 - 0 . 0 3 5 i n )
Gap:
0.8-O.9 mm
( O , 0 3 1 - O . O 3 5i n )

o Check to see the worn or burnt condition of the elec-

trodes.lf it is extremelyworn or burnt, replacethe plug.
And also replacethe plug if it has a broken insulator,
d a m a g e dt h r e a d .

A CAUTION
Confirm the thread size and reach when replacingthe
plug. lf the reachis too short, carbonwill be deposited
on the screw portion of the plug hole and engine
damage may result.
 2-8
MAI]IITENAITICE
PERIODIC

E N G I N EO I L A N D O I L F I L T E R
{ENGINE OIL)
ReplaceInitiallyat 1 OOOkm (600 miles,1 monthsland
Every 6 OOOkm (4 000 miles, 6 months) thereafter.

(OIL FILTER}
ReplaceInitiallyat 1 OOOkm (6O0 miles, 1 months) and
Every 18 OOOkm (1 lOO miles, 18 months)thereafter.

O i l s h o u l db e c h a n g e dw h i l e t h e e n g i n ei s w a r m . O i l f i l t e r
replacement at the aboveintervals,shouldbe donetogether
w i t h t h e e n g i n eo i l c h a n g e .
r KeeFthe motorcycleupright.
o P l a c ea n o i l p a n b e l o w t h e e n g i n e ,a n d d r a i nt h e o i l b y
r e m o v i n gt h e d r a i np l u g O a n d f i l l e rc a p @ .
. Removethe oil filter @ by usingthe oil filter wrench@.
. Apply engineoil lightlyto the gasketof the new f ilter be-
fore installation.
o Installthe new filter turning it by hand until you feel that
the filtergasketcontactsthe mountingsurface.Thentight-
en it 2 turns using the oil filter wrench @.

@! ossrs-4oo1o:oil fitterwrench

NOTE:
To properly tighten the filter, use the special tool. Never
tighten the filter by hand.
o Fit the drainplug @ securely,and pour fresh oil through
t h e o i l f i l l e r .T h e e n g i n ew i l l h o l d a b o u t 2 . 1 L ( 2 . 2 1 1 . 8
US/lmpqt) of oil. Use an API classificationof SF or SG
oil with SAE 1OW/40viscosity.
. Startup the engineand allow it to run for severalseconds
a t i d l i n gs p e e d .
o Turn off the engineand wait aboutone minute,then check
the oil levelthroughthe inspectionwindow @ . lf the level
i s b e l o w t h e l o w e r l i n e ,a d d o i l t o t h a t l e v e l .

Necessaryamount of engine oil

O i f c h a n g e :1 . 7 L ( 1. 8 / 1. 5 U S / l m pq t )
Fifterchange:2.1 L 12.211.8US/lmp qt)
@e
Overhaulengine:2.5 L Q.612.2 US/lmp qt)
A CAUTION
Use SUZUKIMOTORGYGLE GENUINEOIL FILTERonlv,
sincethe other make's genuinefilters and after-market
parts may differ in thread specifications (thread di-
ameter and pitchl, filtering performanceand durabili-
ty, which could cause engine damage or oil leaks.
Suzuki automobilegenuineoil filter is also not usable After contactingthe gasket,
tighten 2 turns.
for the motorcycles.
2-g PEBIODIC
MAI]IITENANCE

F U E LH O S E
Inspect Every 6 OOOkm {4 OO0 miles, 6 months)
thereafter. ReplaceEvery 4 years.

I n s p e c tt h e f u e l h o s e f o r d a m a g e a n d f u e l l e a k a g e .l f a n y
defects are found, the fuel hose must be replaced.

CARBURETOR
Inspect Initiallyat 1 OOOkm (600 miles, 1 month)
and Every6 OOOkm (4 OOOmiles, 6 months)thereafter.

ENGINEIDLERPM (ldle adjustment)

NOTE:
The engine idling speed should be adiusted when the en-
gine is hot.

. Connecta tachometer.
. Startup the engineand set its speedat idlespeedby turn-
ing throttle stop screw @ .

Engineidle speed: 1 2OO+ 1OOr/min

Returningcable play @
T h e r es h o u l db e 0 . 5 - 1 . 0 m m ( 0 . 0 2 - O . 0 4i n )p l a y@ i n t h e
throttle cable.Adjust the throttle cable play with the fol-
l o w i n gp r o c e d u r e s .
o Loosenthe lock nut @ and turn the adjuster@ in or out
u n t i lt h e s p e c i f i e dp l a y i s o b t a i n e d .
r T i g h t e nt h e l o c k n u t @ w h i l e h o l d i n gt h e a d j u s t e r .

Pullingcable play @
o A d j u s tt h e p u l l i n gc a b l et o t h e s p e c i f i e dp l a yi n t h e s a m e
m a n n e ra s t h e r e t u r n i n gc a b l e p l a y a d j u s t m e n t .
Throttlecableplay(Oand @)' O.S- 1 .Omm (O.O2-O.04in)

After the adjustmentis completed,check that handle-

bar movementdoes not raisethe engineidle speedand
that the throttle grip returns smoothly and automat-
ically.
 2-10
MAlltlTE[tlAttlCE
PERI0DIG

SYNCHRONIZATION
CARBURETOR
(Californiamodel only)
Inspect Initially at 1 0OOkm (6O0 miles, 1 month)
and Every12 OO0km (7 5OOmiles, 12 months)there
after.
(Other models)
InspectEvery 12 OOOkm (7 5OOmiles, 12 months).

( R e f e rt o p a g e 4 - 2 8 . 1

CLUTCH
Inspect Every 6 OOOkm (4 OOOmiles, 6 months)'
o Turn in the adjusterO all the way into the clutch lever
after looseningthe lock nut @.
o Loosenthe lock nuts @, and adjustthe clutch cable@
t o o b t a i n1 O - 1 5 m m ( O . 4 - O . 6i n ) o f f r e ep l a y@ a t t h e
clutch lever end.
o Tightenthe lock nuts (@, @).

G l u t c hl e v e rp l a y @ : 1 O - 1 5 m m ( 0 . 4 - 0 . 6 i n )

ENGINECOOLANT
Change engine coolant Every 2 years.
a Removethe right steeringhead cover.
a Removethe radiatorcap @.
a Drain coolant by disconnectingthe radiatorhose @'

Do not open the radiatorcap when the engineis hot,

as you may be injuredby escapinghot liquid or vapor.
Goolantmay be harmful if swallowed or if it comes
in contact with skin or eyes. lf coolant gets into the
eyesor in contact with the skin, flush thoroughlywith
plenty of water. lf swallowed, inducevomitting and
call physicianimmediately!

*: hooked part
2-I1 PERIODIC
MAI|IITEIIAIICE

o Flushthe radiatorwith fresh water if necessary.

r Connectthe radiatorhose and tighten it with clamp.
o Pourthe specifiedcoolant up to the radiatorinlet.

NOTE:
For coolant information, refer to page 5-4.
e Closethe radiatorcap @ securely.
o After warming up and coolingdown the engine,add the
specifiedcoolant up to the radiatorinlet.

CAUTION
Repeatabove procedureseveraltimes and make sure
that the radiatoris filled with coolantup to the inlet hole.

@fngine coolantcapacity:1 460 ml(1.5/1.3 US/lmpqtl

DRIVECHAIN
InspectInitiallyat 1 OO0km (6OOmiles, I month) and
Every 6 OOOkm (4 000 miles, 6 months) thereafter.
Gleanand lubricate Every 1 OOOkm {600 miles).

Visuallycheckthe drive chainfor the possibledefects list-

ed below. (Supportthe motorcycleby a jack and a wooden
block,turn the rear wheel slowly by hand with the trans-
missionshifted to Neutral,)
" Loosepins * Excessivewear
* Damagedrollers * lmproperchain adjustment
* Dry or rusted links * MissingO-ringseals
* Kinkedor bindinglinks

lf any defectsare found, the drive chain must be replaced,

NOTE:
When replacing the drive chain, replace the drive chain and
sprockets as a set.

CHECKING
e Removethe axlecotterpin. (ForE-O3,28 and 33 models)
o Loosenthe axle nut.
o Loosenboth chain adjusterlock nuts @.
o Tensethe drivechainfully by turningboth chainadjusters
@.
12 3 192021

r C o u n to u t 2 1 p i n s ( 2 O p i t c h e s )o n t h e c h a i n a n d m e a s -
ure the distancebetweenthe two points.lf the distance
exceedsthe servicelimit, the chain must be replaced.

Service Limit (Drive chain 2O-pitch length):

3 1 9 . 4 m m ( 1 2 . 6i n )
 PERIODIC CE 2.12
MAIIIITE]'IA]II

ADJUSTING
o Loosenor tighten both chainadjusters@ until the chain
h a s 1 5 - 2 5 m m ( 0 . 6 - 1 . 0 i n ) o f s l a c ki n t h e m i d d l eb e -
tween engineand rearsprockets.The marks@ on both
chainadjustersmust be at the samepositionon the scale
to ensurethat the front and rear wheels are correctly
aligned.
o Placethe motorcycleon its side-standfor accuratead-
justment.
o After adjustingthe drive chain, tighten the axle nut se-
curely.
o Tighten both chain adjusterlock nuts @ securely'

p n"", axle nut: 65 N'm {6.5 kg-m, 47.O lb-ft}

15-25 mm
( 0 . 6 - 1. O i n )

CLEANINGAND LUBRICATING
r Wash the chainwith kerosene.lf the chaintendsto rust
quickly, the intervalsmust be shortened.

A CAUTION
Do not use trichlene, gasoline or any similar fluids:
Thesefluids havetoo great a dissolvingpower for this
chain and, what is more important, they can damage
the "O"-rings (or seals)confiningthe greasein the bush
to pin clearance.Remernber,high durabilitycomesfrom
the presenceof greasein that clearance.
r After washingand dryingthe chain, oil it with a heavy-
weightmotoroil.

A CAUTION
"drive chain
Do not use any oil sold commerciallyas
"O"-rings (or seals).
oil". Such oil can damagethe
The standarddrive chain is D.l.D. SOVAz.SUZUKI
recommendsthat this standard drive chain should
be used for the replacement.
2.I 3 PERIODIC
MAIITITEIUAIIICE

BRAKE
(BRAKE)
InspectInitiallyat I OOOkm (6OOmiles, 1 months)and
Every 6 OOOkm (4 OOOmiles, 6 months) thereafter.

(BRAKEFLUIDAND BRAKEHOSE)
lnspectEvery6 OOOkm (4 OO0miles,6 months).Replace
fluid Every 2 years. Replacehoses Every 4 years.

FRONTBRAKE
Brakefluid level
r Keep the motorcycleupright and place the handlebars
straight.
r Checkthe brakefluid level by observingthe lower limit
lines on the front brakefluid reservoir.
e Whenthe levelis belowthe lower limitline,replenishwith
brakefluid that meets the following specification.

@ Specificationand Glassification:DOT 4

The brake system of this motorcycle is filled with a

glycol-basedbrake fluid. Do not use or mix different
types of fluid such as silicone-basedor petroleum-
based.Do not use any brakefluid taken from old, used
or unsealedcontainers.Neverre-usebrakefluid left over
from the last servicingor stored for a long period.

Brakefluid, if it leaks, will interfere with safe running

and immediatelydiscolorpainted surfaces.Gheck the
brakehosesand hosejoints for cracks and oil leakage
before riding.

Brake pads
o Removethe brake caliper.
The extentof brakepad wear can be checkedby observing 'l',;G
- '
r':ili
the groovedlimit e on the pad. When the wear exceeds
the groovedlimit, replacethe pads with new ones. (Refer iw.
t o p a g e6 - 1 2 . 1

A CAUTION
Replacethe brakepad as a set, otherwise brakingper-
formance will be adverselyaffected.
 CE 2-l4
C MAlltlTEtrlAttl
PERI0Df

Air bleedingthe brake fluid circuit

Air trappedin the fluid circuitacts like a cushionto absorb
a largeproportionof the pressuredevelopedby the master
cylinderandthus interfereswith the full brakingperformance
of the brake caliper.The presenceof air is indicatedby
"sponginess" of the brakelever and also by lack of brak-
ing force.Considering the dangerto which suchtrappedair
exposesthe machineand rider,it is essentialthat, after re-
mountingthe brakeand restoringthe brakesystemto the
normalcondition,the brakefluid circuit be purgedof air in
t h e f o l l o w i n gm a n n e r :
o Fill uF the mastercylinderreservoirto the upperend of
the inspectionwindow. Replacethe reservoircap to pre-
vent entry of dirt.
o Attach a pipeto the caliperair bleedervalve, and insert
the free end of the pipe into a receptacle.
. Squeezeand releasethe brakeleverseveraltimesin rapid
successionand squeezethe leverfully without releasing
it. Loosenthe bleedervalve by turning it a quarterof a
turn so that the brakefluid runs into the receptacle;this
will removethe tensionof the brake lever causingit to
touchthe handlebar grip.Then,closethe valve,pumpand
squeezethe lever,and openthe valve. Repeatthis process
until the fluid flowing into the receptacleno longercon-
tainsair bubbles.

NOTE:
Replenish the brake fluid in the reservoir as necessary while
bteeding the brake sYstem.Make sure that there is always
some fluid visible in the reservoir.
. C l o s et h e b l e e d evr a l v e ,a n d d i s c o n n e ctth e p i p e .F i l lt h e
reservoirwith brakefluid to the upperend of the inspec-
tion window.
(0.75 kg-rn,5.51b-ft)
[t C"tip", air bleedervalve:7.5 N'm
CAUTION
Handlebrakefluid with care: the fluid reacts chemically
with paint, plastics, rubber mat'erialsetc.

REARBRAKE
Brake pedal height and free travel
o Loosenthe lock nut @ and rotate the adjustingbolt @
to locatethe brakepedalheight@above the footrestas
s h o w n i n p h o t o .B es u r et o t i g h t e nt h e l o c k n u t g o o da n d
hard after setting the bolt.
o Set the pedalfree travel@as measuredat pedaltip, by
r e p o s i t i o n i ntgh e a d j u s t e rn u t @ o n t h e b r a k ec a b l e .
Brakepedal height @: 6O mm (2'4 in)
B r a k ep e d a lf r e e t r a v e l@ : 2 O - 3 0 m m ( 0 . 8 - 1 . 2 i n l
2.I 5 PEBIODIC
MAIIIITE]IIANCE

Brake light switch

Adjustthe rearbrakelight switch @ so that the brakelight
will come on just beforepressureis felt when the brakepe-
dal is depressed.

Brake shoe wear

This motorcycleis equippedwith brakeliningwear limit in-
dicator@ on rear brakepanel.At the conditionof normal
liningwear,the extensionlineof the indexmark@ on brake
cam shaft shouldbe within the rangeembossedon the brake
panelwith brakeon. To checkwear of the brakelining,per-
form the following step.
r First check if the brake system is properlyadjusted.
o While operatingthe brake,check to see that the exten-
sion line of the index mark @ is within the rangeon the
b r a k ep a n e l .
o lf the indexmark is beyondthe range,the brakeshoeas-
semblyshouldbe replacewith new ones. (Referto page
6-33.)

TIRE
Inspect Every 6 OO0 km (4 OO0 miles, 6 months).

TIRETREADCONDITION
Operatingthe motorcyclewith excessivelyworn tires will
decreaseridingstabilityand consequentlyinvite a danger-
ous situation.lt is highlyrecommended
to replacea tire when
the remainingdepth of tire tread reachesthe following
specification.
@! ossoo-2o8ob:
Tiredepthsause
Tire tread depth limit: FRONT1.6 mm (0.06 inl
REAR 2.0 mm {0.08 in}
TIREPRESSURE
lf the tire pressureis too high or too low, steeringwill be
adverselyaffectedand tire wear increased.Therefore,main-
tain the correcttire pressurefor good roadabilityor shorter
tire life will result.Coldinflationtire pressureis as follows.

COLD INFLATION S O L OR I D I N G DUALRIDING

T I R EP R E S S U R E kPa <g/cm2 p s l kPa <g/cmr psl
FRONT 200 2.OO 29 200 2.OO 29
REAR 225 2.25 33 225 2.25 33

A CAUTION
The standardtire fitted on this motorcycleis 130/90-16
67H for front and 150/90-15 M/C 74H tor rear. The
use of tires other than those specified may cause in-
stability. lt is highly recommendedto use a SUZUKI
GenuineTire.
 2.16
MAII{TENANICE
PERIODIC

STEERING
InspectInitiallyat 1 O00 km (600 miles, 1 months)and
Every12 0OOkm (7 5OOmiles, 12 months)thereafter'

Taperrollertype bearingsare used on the steeringsystem

for betterhandling.Steeringshouldbe adjustedproperlyfor
smooth turning of handlebarsand safe running.Overtight
steeringpreventssmoothturningof the handlebars andtoo
loosesteeringwill causepoor stability.Checkthat there is
no play in the front fork assemblyby supportingthe motor-
cycle so that the front wheel is off the ground, with the
wheel straightahead,graspthe lower fork tubes nearthe
axleand pullforward.lf playis found, performsteeringbear-
ing adjustmentas describedin page 6-29 of this manual'

FRONTFORK
lnspectEvery 12 000 km (7 50O miles, 12 months).

Inspectthe front forks for oil leakage,scoringor scratches

on the outersurfaceof the innertubes. Replaceany defec-
t i v e p a r t s ,i f n e c e s s a r y(.R e f e rt o p a g e 6 - 1 9 . )

R E A RS U S P E N S I O N
InspectEvery 12 OOOkm (7 5OOmiles, 12 months)'

Inspectthe rear shock a b s o r b e rf o r o i l l e a k a g ea n d c h e c k

that there is no play in t h e s w i n g a r ma s s e m b l y .

EXHAUSTPIPEBOLTS
TightenInitiallyat 1 O0Okm (6OOmiles,1 month)and
Every12 OOOkm (7 5OOmiles,12 months)thereafter.

o Tightenthe exhaustpipeclamp boltsto the specifiedtor-

q u e w i t h t o r q u ew r e n c h .

C I e *n u u "tp i p ecl a mpb o l t:2 5 N 'm (2.5kg- m ,18.0lb- ft)

EVAPORATIVE EMISSIONCONTROLSYSTEM
(Californiamodel only)
InspectEvery 12 OOOkm (7 5OOmiles, 12 months).
Replacevapor hoses every 4 years.

Referto page 9-4.

PAIR (AIR SUPPLY)SYSTEM

(Californiamodel only)
InspectEvery 12 OOOkm (7 5OOnniles,12 months).

R e f e rt o p a g e s9 - 6 a n d 9 - 7 .
2.17PEBIODIC
MAII'ITENAilCE

CHASSISBOLTSAND NUTS
TightenInitiallyat 1 OO0km (6OOmiles, 1 months)and
Every 6 000 km (4 000 miles, 6 months) thereafter.

The nuts and bolts listed below are importantsafety parts.They must be retightenedwhen neces-
sary to the specifiedtorque with a torque wrench. (Referto page 2-18 for the locationsof the fol-
l o w i n gn u t s a n d b o l t s o n t h e m o t o r c y c l e . )

ITEM N.m kg-m lb-ft

@ Steeringstem head nut 90 9,0 65.0
@ Front fork cap bolt 23 2.3 16.5
@ F r o n tf o r k l o w e r c l a m p b o l t 33 3.3 24.O
@ F r o n tf o r k u p p e rc l a m p b o l t 23 2.3 16.5
@ H a n d l e b am
r o u n t i n gn u t 54 5.4 39.O
@ Front axle 65 6.5 47.O
@ Front axle pinch bolt 23 2.3 16.5
@ F r o n tm a s t e rc y l i n d e rm o u n t i n gb o l t 10 1.0 7.O
@ B r a k eh o s e u n i o n b o l t 23 2.3 16.5
@ C a l i p e rm o u n t i n gb o l t 39 3.9 28.O
@ C a l i p e r a i r b l e e d e rv a l v e 7.5 o.75 5.5
@ Brake disc plate bolt 23 2.3 16.5
@ R e a rs h o c k a b s o r b e fr i t t i n g b o l t ( u p p e r ) 23 2.3 16.5
@ R e a rs h o c k a b s o r b e fr i t t i n g n u t ( l o w e r ) 50 5.0 36.0
@ R e a ra x l e n u t 65 6.5 47.O
@ Rear brake cam lever bolt 10 1.O 7.O
@ R e a rt o r q u e l i n k n u t ( f r o n t ) 35 3.5 25.5
@ R e a rt o r q u e l i n k n u t ( r e a r ) 25 2.5 18.0
@ Rearswingarmpivot nut 100 10.0 72.5
@ Front footrest bolt 39 3.9 28.O
@ Rearsprocketnut 60 6.0 43.5
 2.I 8
MAIIIITEilAIUCE
PERIODIC
2-19 PERIODIC
MAII'ITENAIIICE

COMPRESSION
PRESSURE
CHECK
The compressionof a cylinderis a good indicatorof its internalcondition.
The decisionto overhaulthe cylinderis often basedon the resultsof a compressiontest. Periodic
maintenancerecordskept at your dealershipshould includecompressionreadingsfor each main-
tenanceservice.

C O M P R E S S I OPNR E S S U RS
EP E C I F I C A T I O N

Standard Limit Difference

1 5OOkPa 1 1 O Ok P a 2O0 kPa
15.0kg/cm2 11 . 0 k g i c m 2 2 kglcm2
213 psi 1 56 psi 28 psi

Low compressionpressurecan indicate any of the following conditions:

* Excessivelyworn cylinderwall
" Worn-downpiston or piston rings
* Pistonrings stuck in grooves
" Poor seatingof valves
* Rupturedor otherwisedefectivecylinderhead gasket
" Valve clearanceout of adjustment
" Startermotor crankstoo slowly

Overhaulthe enginein the following cases:

* C o m p r e s s i o pn r e s s u r ei n o n e o f t h e c y l i n d e r si s l e s st h a n 1 1 0 0 k P a ( 1 1 k g / c m 2 ,1 5 6 p s i ) .
* Differencein compressionpressurebetweenany two cylindersis more than 2OOkPa (2 kg/cm2,
28 psi).

COMPRESSION
TEST PROCEDURE
NOTE:
" Before testing the engine for compression pressure, make
sure that the cylinder head bolts are tightened to the speci-
fied 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.

T e s t t h e c o m p r e s s i o np r e s s u r ei n t h e f o l l o w i n gm a n n e r ,
o R e m o v et h e f u e l t a n k . ( R e f e rt o p a g e 4 - 4 . )
o R e m o v ea l l t h e s p a r kp l u g s .
o F i tt h e c o m p r e s s i ogna u g ei n o n e o f t h e p l u gh o l e s ,w h i l e
t a k i n gc a r e t h a t t h e c o n n e c t i o nt i g h t .
r K e e pt h e t h r o t t l eg r i p i n f u l l - o p e np o s i t i o n .
. W h i l ec r a n k i n gt h e e n g i n ea f e w s e c o n d sw i t h t h e s t a r t -
e r , a n d r e c o r dt h e m a x i m u mg a u g er e a d i n ga s t h e c o m -
p r e s s i o no f t h a t c y l i n d e r .
o R e p e a t h i s p r o c e d u r ew i t h t h e o t h e r c y l i n d e r .
g gauge
0 9 9 1 5 - 6 4 5 1 O :C o m p r e s s i o n
0991 5-63210: Compressiongauge adaptor
 PERIODIC CE 2.20
MAINTE]IIAIII

O I L P R E S S U RC
EH E C K
the oil pressurein the engineto judge roughlythe conditionof the moving parts.
Checkperiodically

O I L P R E S S U RSEP E C I F I C A T I O N

Above 450 kPa (4.5 kg/cm2,64 psi)

a t 3 0 0 0 r / m i n . ,O i l t e m p . a t 6 O o C( 1 4 0 o F )
Below 750 kPa (7.5 kg/cm2,1O7 psi)

l f t h e o i l p r e s s u r ei s l o w e ro r h i g h e r t h a nt h e s p e c i f i c a t i o nt h, e f o l l o w i n gc a u s e sm a y b e c o n s i d e r e d .

LOW OIL PRESSURE

* Cloggedoil filter
* Oil leakagefrom the oil passageway
* D a m a g e dO - r i n g
* Defectiveoil pump
* Combinationof above items

HIGH OIL PRESSURE

* Used a engineoil which is too high viscosity
* Cloggedoil passageway
* lmproperinstallationof the oil filter
* Combinationof above items

TEST PROCEDURE
OIL PRESSURE
Startthe engineand check if the oil pressureindieatorlight
i s t u r n e do n . l f i t k e e p so n l i g h t i n g ,c h e c kt h e o i l p r e s s u r e
indicatorlight circuit. lf it is in good condition,check the
o i l p r e s s u r ei n t h e f o l l o w i n gm a n n e r .
o R e m o v et h e m a i n o i l g a l l e r yp l u g .
o lnstalltheoil pressuregaugewith adaptorin the position
shownin the figure.
o W a r m u p t h e e n g i n ea s f o l l o w s :
S u m m e r1 O m i n . a t 2 O O Or i m i n .
Winter 2O min. at 2 OO0r/min.
o After warming up, increasethe enginespeedto 3 OOO
r/min. (with the tachometer),and read the oil pressure
gauge.

@D oggr s-74s10:oit pressure

gauge
O9915-74531:Oil pressuregauge adaptor
09915-77330: Meter (for high pressure)
 CONTENTS
ENGINE COMPONENTS REMOVABLE WITH THE ENGINE
tN PLACE ' ....." 3- I

ENGINE REMOVAL AND REINSTALLATION ., 3. 2

ENGINEREMOVAL...,.,".. 3- 2
ENGINE REINSTALLATION 3- 8
ENGINEDISASSEMBLY,..... 3-11
COMPONENTSI\VSPECTIONAIUD SERVIANG ....,
EILIGINE 3-24
CYLINDERHEAD COVER AND ROCKERARM 3-24
CAMSHAFT.., 3-26
CAM CHAIN TENSIONERAND GUIDE . 3-27

CYLINDERHEAD, VALVE AND VALVE SPRING 3.28

CYLINDERAND PISTON .....' 3-35

CONRODAND CRANKSHAFT .' ,.' 3-38

CLUTCH 3-44
GENERATOR,SIGNAL GENERATORAND STARTER CLUTCH .. 3-45
OIL PUMP 3-46
TRANSMTSSrcN .... 3-47

FORK
GEAR-SHIFTING .."'3-50

OIL JET AND NOZZLE 3-5O

EN GIN ER E A S S E MB L Y .' ""' .3- 51
3.1 EIilGIIIIE

ENGINE REMOVABLE
COMPONENTS IN PLACE
WITHTHEENGINE
The partslistedbelow can be removedand reinstalledwithout removingthe enginefrom the frame.
Referto the page listed in this sectionfor removaland reinstallationinstructions.

ENGINECENTER
PARTS REMOVAL INSTALLATION
Radiator 5- 5 and- 6 5-7
Oil filter 2-8 2-8
Carburetor 4- 14 thr ough- 17 4-27
Oil pressureswitch 3-21 3-55
Startermotor assembly 3- 14 3-63

ENGINERIGFITSIDE
PARTS REMOVAL INSTALLATION
Clutch cover 3-17 3-60
Clutch pressure,drive and driven plates 3 - 17 a n d - 1 8 3-59
O i l p u m p d r i v e ng e a r 3-20 3-56
Oil pumpassembly 3-20 3-56
Primarydrive gear 3 - 19 3-56
Gearshiftshaft 3-20 3-55
Exhaustpipe and muffler 3-4 and - 5 3 - 10
Clutch sleevehub 3-18 3-57 and -58
Primarydriven gear assembly 3 - 1I 3-57

ENGINELEFTSIDE
PARTS REMOVAL INSTALLATION
Gearshiftlever 3-4 3 - 10
Generatorcover 3 - 15 3-61
Generatorrotor 3 - 16 3-61
Generatorstator 3-45 3-45
Starterclutch 3-46 3-46
Starteridle gear 3 - 16 3-61
Signalgeneratorstator 3-45 3-45
Neutralswitch 3-15 3-62
Water pump assembly 5 - 1 2a n d- 1 3 5 - 1 6a n d- 1 7
Exhaustpipe 3-4 3 -1 0
 ElrlGlNE3-2

ENGINEREMOVALAND REINSTALLATION
E N G I N ER E M O V A L
Beforetakingthe engineout of the frame,thoroughlyclean
the enginewith a suitablecleaner.The procedureof engine
removalis sequentiallyexplainedin the following steps'
. R e m o v et h e s e a t . ( R e f e rt o p a g e 6 - 1 . )
o R e m o v et h e f r a m e c o v e r s .( R e f e rt o p a g e 6 - 1 . )
o Removethe fuel tank. (Referto page 4-4.)
. Removethe manualbox,
o Disconnectthe batteryQ and @ leadwiresfrom the bat-
tery terminals,removethe battery.

A CAUTION
Be sure to disconnectthe O lead wire first.

Removethe frame head coversO.

o R e m o v et h e o i l d r a i n p l u g @ t o d r a i no u t e n g i n eo i l .
r Disconnectthe water hose@ to drainout enginecoolant'

o Removethe radiator.(Referto pages 5-5 and -6.)

3'3 ElrlGlltlE

. Removethe box cover @.

. Removethe box @ and bracket@.

Removethe PAIR (AlR SUPPLY)system cover @.

( F o r E - 0 3 , 1 8 , 2 8a n d 3 3 m o d e l s )

( F o r E - 0 3 , 1 8 , 2 8a n d 3 3 m o d e l s )
r Disconnectthe PAIRreedvalve hoses@ and PAIRcon-
trole valve vacuum hose @.
. Removethe PAIRsystem bracket.
o Removethe PAIRcontrolvalvevacuum hose@ from the
i n t a k ep i p e . ( F o rE - 0 3 , 1 8 , 2 8a n d 3 3 m o d e l s )

(For E-O3,18,28and 33 models)

R e m o v et h e N o . 1 a n d N o . 2 P A I Ra i r p i p e .
( F o rE - 0 3 , 1 8 , 2 8a n d 3 3 m o d e l s )

( F o rE - , 0 3 , 1 8 , 2 8
and 33 models)
 EtuGiltIE
3.4

r Removethe swingarmpivot covers O, @.

o Removethe enginesprocketcover @.
. Removethe gearshiftlever.

. Removethe left and right front footrest brackets.

. Removethe rearbrakecableguidebolt and rearbrakelight
switch cable.

. Removethe exhaustpipes and mufflers,left and right.

3.5 ElrlGfirtE

NOTE:
x Whensparating the mufflers, remove the nuts and loos-
@
en the joint nut @.
* After reassemble the mufflers, lock the joint nut
@.

o Removethe tool holder@.

Disconnectthe breatherhose @ from the rear cylinder

head.

\
'5

ffi
Removethe front and rearair cleanerboxes@, @. (Refer
t o p a g e s4 - 1 4 a n d - 15 . )
Removethe front and rear carburetorsO, @ by loosen-
i n g t h e c l a m ps c r e w s .

r Removethe spark plug caps @, front and rear.

 ElrlGlilE
3.6

a Removethe clutch releaselever @ and clutch cable.

o Removethe startermotor lead wire @ and the oil pres-
sure switch lead wire.

a Removethe coolingfan mounting bolts @.

a Disconnectthe coolingfan lead wire coupler.

Disconnectthe following lead wires.

* Generator
* S i g n a lc o i l
* Neutralindicator

r Flattenthe washerand removethe enginesprocketnut.

o Removethe enginesprocket@.

o Remove the ground lead wire @.

3-7 E]rlGlll|E

o Remove the w a t e r p u m p i n l e t p i p e @ .

o R e m o v et h e e n g i n em o u n t i n gn u t @ .
o Removethe right frame down tube @ by removingthe
bolts (@, @ and @),

r R e m o v et h e e n g i n em o u n t i n gb r a c k e t@ .

a R e m o v et h e e n g i n em o u n t i n gb o l t @ .
a R e m o v et h e e n g i n em o u n t i n gb o l t @ .

a S u p p o r tt h e e n g i n ew i t h a p r o p e rj a c k .
a D i s m o u n t h e e n g i n eb y p u l l i n gs l i g h t l yf o r w a r d a n d t o
right-side.

CAUTION
When holding the engine with a jack,
o avoid applying a jack to the oil filter, or the oil filter
may be damaged.
e place a wooden piece on a jack, or the oil pan may
be damaged.
 E]IIGIIIIE
3.8

ENGINEREINSTALLATION
R e i n s t a l l t h e n g i n ei n t h e r e v e r s eo r d e ro f e n g i n er e m o v a l .
o Installthe brackets,bolts and nuts properly,as shown
in the following illustration.
NOTE:
The engine mounting nuts are self-locking. Once the nut has
been removed, it is no longer of any use. Be sure to use new
nuts and tighten them to the specified torque.
. A p p l y T H R E A DL O C K S U P E R" 1 3 0 3 " t o t h e e n g i n e
mountingbolts.
"l303"
tt6iggoo0-32030: THREADLocK suPER
o After remountingthe engine,routewiringharness,cables
and hosesproperlyby referringto the sections,for wire
routing,cable routingand hose routing.(Referto pages
8 - 1 2 t h r o u g h- 1 9 . )

p so trt'. (5.okg-m,36.o lb-ft)

9o
rly

,s
\"
[tas r.r'.
(8'8 kg-m'

50 N'm (5.0 kg-m,36.0 lb-ft)

63.5 lb-ft)

S (so
5.0
ru''n
kg-m,36.0 lb-ft)

E l z s N ' m( 2 . 5k g - m1, 8 . 0l b - f t )
3.9 EtuGttrtE

. Appfy greaseto the "O-ring", when install the water

p u m p i n l e tp i p e .

fu99000-2b030:suZUKr "A"
supERGREAsE

o Tightenthe enginesprocketnut to the specifiedtorque.

[ l e n g i n e s p r o c k e nt u t : 1 1 5 N . m ( 1 1 . 5 k g - m , 8 3 . 0 l b - f t )
o Bend up the washer to lock the engine sprocket nut.

l n s t a l tl h e c l u t c hr e l e a s el e v e ra s s h o w n i n t h e r i g h tp h o -
tograph.

Be carefulnot to pullandtwist the carburetorcables,while

remounting.
Locatethe carburetorclamps correctly. (Referto page
8-17.)
 El'lGlNE
3-10

. Apply gas sealerto the insideand outsideof the exhaust

pipe/mufflerconnector.

EXHAUSTGAS SEALER:PERMATEX1372
o Tightenthe exhaustpipenut and muffler bolt to the speci-
fied torque.
ple*narst pipenut: 25 N.m (2.5 kg-m, 18.Olb-ft)
Muffler mounting bolt: 25 N'm (2.5 kg-m, 18.0 lb-ft)

. Tightenthe left and right front footrest bracketbolts to

the specifiedtorque.
ptfront footrestbracketbolt: 39 N'm (3.9 kg-m, 28.0 lb-ftl

r Installthegearshiftleveras shown in the rightphotograph.

o Adjust the following items t o t h e s p e c i f i c a t i o n .

Page
* F i l l i n ge n g i n ec o o l a n t . 2 - 1 Oa n d - 1 1
* Throttlecable play . . 2- I
* l d l i n ga d j u s t m e n .t . . . . .... 2- I
" B a l a n c i n gc a r b u r e t o r s. . . . 4 - 2 8 , - 2 9a n d - 3 0
* R e a rb r a k ep e d a lh e i g h t ... 2-14

P o u r2 . 5 L ( 2 . 6 1 2 . 2U S / l m pq t ) o f e n g i n eo i l S A E 1 O W / 4 0
gradedSF or SG into the engineafteroverhaulingengine.
Start up the engineand allow it run for severalminutes
at idle speed.About severalminutes after stoppingen-
gine,checkthat the oil levelremainsbetweenthe marks
of oil level inspectionwindow.

Change 1 7 O Om l ( 1 . 8 / 1 . 5U S / l m pq t )
Filterchange 2 1 O Om l ( 2 . 2 1 1 . 8U S / l m pq t )
Overhaul 2 5 O Om l ( 2 . 6 1 2 . 2U S / l m pq t )
3-11 EItlGlttlE

E N G I N ED I S A S S E M B L Y
A CAUTION
Be sure to identify each removed part such as intake
pipe, camshaft, piston, conrod etc. as to its location
and lay the parts out in groups so that each will be re-
stored to the original location during assembly.

. Removethe head cover caps O and @.

a Remove the valve i n s p e c t i o nc a p s @ .

a Remove the head cover caps @.

. R e m o v et h e w a t e r o u t l e tu n i o n@ a n d t h e c y l i n d e rh e a d
cover.
NOTE:
When removing the cylinder head covers, the piston must
be at top dead center on the compression stroke.

No.2(FRONT)

. Removethe breathercover@ andthe cylinderheadcover.

No.1(REAR)
 EITIGINE
3.12

Flattenthe lock washers@ and removethe camshaft

sprocketbolts.
Removethe camshaftsand sprockets.

o Removethe front intake pipe @.

O Removethe water hose u n i o n@.

a Loosenthe water hose cl a mpscre ws@.

Removethe water pipe@ and the water hose by remov-

ing the water pipe bolts and looseningthe water hose
c l a m ps c r e w .

o R e m o v e t h e N o . 1 ( R e a r )c y l i n d e rh e a d n u t s .
3.I3 EITGIIilE

o R e m o v et h e N o . 1 ( R e a r )c y l i n d e rh e a d b o l t s .

o After releasingthe ratchet,push the chaintensionerrod

fully to compressthe springand inserta specialtool be-
tween ratchetand chain tensionerbody.

@! ossr3-53810:chain tensionerlockingtoot
I S e p a r a t et h e N o . 1 ( R e a r )c y l i n d e r h e a d .

a Removethe cylinderhead gasket and dowel pins.

a Removethe chain tensioner@ and the chain tensioner
g u i d e@ .
Removecylinder.

o Removethe cylinderbase g a s k e ta n d d o w e l p i n s .
a Removethe oil jet @.
 EltGttrtE
3-14

o Removethe No.2 (Front)cylinderhead and cylinderin

s a m e m a n n e ro f N o . 1 ( R e a r c) y l i n d e rh e a da n d c y l i n d e r
removal.

o Placea cleanrag overthe cylinderbaseto preventpiston

pin circlipsfrom droppinginto crankcase.Removethe
piston pin circlipswith long-nosepliers.
o Drive out the piston pins by using proper drift.
NOTE:
Scribe the cylinder position on the head of the respective
pistons.

. Removethe starter motor.

o Remove the water pump.

3-l5 ElrtGtitE

o Removethe neutralswitch assembly

@.
NOTE:
Do not lose the "O-ring" @, the neutral switch contact @
and its spring @.

o Removethe drive shaft oil seal retainer

@.
r R e m o v et h e d r i v e c h a i n g u i d e@ .

o Removethe generatorcover.
 3-I6
EIilGINE

o Loosenthe rotor bolt,

NOTE:
When removing the rotor, do not remove the rotor bott af-
ter loosening the bolt. The rotor bolt is used in coniunction
with the rotor remover.

. Removethe rotor by using the specialtool.

@ ossso-8497o:Rotorremover

r Removethe key @.
o Removethe starter driven gear @.

o Removethe starteridle gear@, s p a c e r@ a n d s h a f t@ .

*,,

o Remove the cam c h a i ng u i d e@ a n d c a m c h a i nO .

3.17 ENGIIIIE

. Removethe clutch cover bolts.

o Remove the clutch cover by tapping with a plastic
hammer.

R e m o v et h e c l u t c hr e l e a s ep i n i o nO , o i l s e a l @ a n d b e a r -
ing@.

o Removethe oil jet @.

o Removethe clutch cover gasketand dowel pins.

. R e m o v et h e c l u t c h s p r i n gm o u n t i n gb o l t s d i a g o n a l l y .
o Removethe pressureplate @.

@! ossso-4o113:
Roterhotder

Removethe clutch releaserack@, thrust washer@ and

b e a r i n g@ .
 3-18
EtrlcllrlE

a Removethe clutch drive and driven plates.

a Removethe wave washerO and the wave washerseat
@.

o Removethe clutch sleevehub nut @ UVusing the spe-

c i a lt o o l .

@! osszo-b3740: Glutchsleevehub holder

o R e m o v et h e w a s h e r@ a n d N o , 1 c l u t c h c a m @ .

. R e m o v et h e N o . 2 c l u t c h c a m @ .

o Removethe clutch sleeveh u b O a n d s p a c e r@ .

 3-19 EltlGllUE

r Removethe thrust washer

@.
I Removethe primarydrivengearassembly with the
@ oil
pump drive gear.

o Remove the oil p u m p d r i v e g e a r

@.

Removethe needle roller bearing@, collar @, thrust

washer@ and spacer@.

r Removethe primary drive gear bolt while holding the

primarydrive gear with the specialtool and removethe
primarydrive gear.

@ ossso-4o113:
Rotorhotder
A CAUTION
This bolt has left-hand thread. Turning it counter-
clockwise it may cause damage.

o R e m o v et h e c a m c h a i ng u i d e@ a n d c a m c h a i n@ .
a Removethe camshaftdrivesprocket@ and thrust washer
@.
 ElrlGlNE3-20

o R e m o v et h e o i l p u m p d r i v e ng e a r c i r c l i p@ .

@ snapringptiers
ossoo-06107:

a Removethe pin @ a n d t h e w a s h e r@ ,
a Removethe oil p u m p@ .

o Removethe gearshiftshaft @.

. Removethe following parts from the gearshiftshaft.

@ Circlip
@ Washer
@ Spring
@ Gearshiftarm
@ Wahser
@ Circlip
@ Returnspring

o Removethe gearshiftcam stopper plate @.

. Removethe gearshiftcam stopper@ with spring.
o Removethe gearshiftarm stopper@.
3.2t ElrtGtitE

o Removethe oil filter @ by using the specialtool.

@! ossrb-4oo1o:oit fitterwrench
r Removethe oil pressureswitch @.

NOTE:
When reinstalling the oil pressure switch, apply the SUZUKI
BOND "f 2078" to thread part.

991 04-31 14o: suZUKt BoND " 1zo7B"

{{{{{{{{{{{{{{{{tfiEEEEEEEEEEEEEEEE!
o Removethe drive shaft spacer@.

o Removethe crankcasesecuringbolts.
 EITIGINE
3-22

. Separatethe crankcaseinto 2 parts, right and left with

a crankcaseseparatingtool.

@ Crankcase
oSSzO-13120: tool
separating
NOTE:
Fit the crankcase separating tool, so that the tool arms
parallel the side of the crankcase. The crankshaft and trans-
mission components must remain in the left crankcase half.
Put a metal piece @or socket tool to protect the end face
of the countershaft.
r Removethe gearshiftfork shafts@ and gearshiftforks@.
o Removethe gearshiftcam @.
r Removethe driveshaftassembly@, countershaftassem-
blv @.
. Removethe crankshaft@ and thrust washer @.
o R e m o v et h e O - r i n g s@ .

o Removethe oil nozzleretainers@ and oil nozzles@ from

the left and right crankcase.

. R e m o v et h e o i l s u m p filter stopper@.
3.23 EIUGI{E
o R e m o v et h e o i l s u m p f i l t e r @ .
o Removethe oil pressureregulator@.

NOTE:
When reinstalling the oilpressure regulator. Tighten it to the
specified torque.

[tOll pressureregulator:28 N'm (2.8 kg-m, 2O.Olb-ft)

o R e m o v et h e o i l s e a l sb y u s i n gt h e s p e c i a tl o o l .

oil seatremover
@! ossr3-s0121:

. Removethe bearingretainerscrews.

NOTE:
When reinstalling the bearingretainers, apply THREADLOCK
"f 342" to the bearing retainer bolts or screws.
"
tti.?l 99990-32050:THREADIOCK 1342"

o Removethe bearingsby using the specialtools.

@! osszg-7s210:Bearing
remover
09930-301O2: Slidingshaft
 EtuGtilE
3.24

E N G I N EC O M P O N E N T ISN S P E C T I O A
NN D S E R V I C I N G
CYLINDERHEAD COVERAND ROCKERARM
DISASSEMBLY

A CAUTION
Be sure to identify each removed part as to its loca:
tion, and lay the parts out in groups designatedas
"No.1
cylinder", "No.2 cylinder", "Exhaust",
"ln-
take", so that each will be restoredto the originallo-
cation during assembly.
ffiW
r Loosenthe rockerarm shaftsand pull out the rockerarm
shafts. (Referto page 3-25 for reassembly.)

6
trF/ 6
CYLINDERHEAD COVERDISTORTION
I O N D" 1 2 1 6 " ) f r o m t h e
A f t e r r e m o v i n gs e a l a n t( S U Z U K B
fitting surfaceof the cylinderheadcover,placethe cylinder
headcoveron a surfaceplateand checkfor distortionwith
a t h i c k n e s sg a u g e .

ServiceLimit: O.05 mm (O.OO2in)

6-
@ 09900-20803: Thickness gauge

lf the distortionexceedsthe limit, replacethe cylinderhead

cover.

ROCKERARM SHAFT O.D,

Measurediameterof rocker arm shaft.

S t a n d a r d1: 1 . 9 6 6 - 1 1 . 9 8 4 m m
( O . 4 7 1 1 - 0 . 4 7 1 8i n )

@! ossoo-2oao:c= (o-25 mm)

Micrometer

ROCKER ARM I.D.

When checkingthe valve rocker arm, the insidediameter
of the valve rockerarm and wear of the camshaftcontact-
ing surfaceshould be checked.

S t a n d a r d :12 . O O O -1 2 . 0 1 8 m m
@.4724-0.4731 in)

@! ossoo-2ooos:
Diatcatipers
3-25 ENGilIE

REASSEMBLY
. A p p l y S U Z U K IM O L Y P A S T Et o t h e r o c k e ra r m s@ a n d
their shafts @.
MoLy pAsrE
fu99ooo-2s140: sUZUKT
r Installthe new gasket@ to the rockerarmshaftas shown @
in illustration. J
o After insertingthe shafts, tighten the shafts.

Q nocter arm shaft: 28 N.m (2.8 kg-m, 20.O lb-ft)

A CAUTION
* Do not forget the wave washer
@.
* Use a new gasketon the rockerarm shaft to pre-
@
vent oil leakage.

NOTE:
The rocker arms have embossed-letters, "F" or "R", "F"
for No.2 (Front) cylinder and "R" for No.1 (Rear)cylinder.
r Installthe rubbercaps@ to the exhaustrockerarm shaft
e n d sa s s h o w n i n t h e p h o t o s .
NOTE:
Whenreplacingthe No. I and No.2 cylinder head cover stud
bolts @, apply SUZUKI BOND "f 216" to the thread of
cylinder head cover side.
f l , E l 9 9 o o o - 3 1 1 6 0 :S U Z U K TB o N D " 1 2 1 6 "

o Installthe O-ring@ to the No.2 (front)cylinderheadcover.

. A p p l y g r e a s et o t h e O - r i n g@ .
"A"
6rggoo0-2so3o:suzuKrsupERGREASE

o I n s t a l l t h ep l a t e@ t o t h e N o . 1 ( r e a r )c y l i n d e rh e a d c o v e r .
 ElrlGlilE
3-26

CAMSHAFT
The camshaftsshould be checkedfor wear and also for
runout of cams and journalsif the enginehas been noted
to produceabnormalnoiseor vibrationor to lackoutput pow-
er. Any of these malconditionscould be causedby a worn
camshafts.
The camshaftcan be distinguishedby the embossed-letters,
"F" and "R", on thg camshaft.
" F " : F r o n t( N o . 2 ) c a m s h a f t
" R " t R e a r( N o . 1 ) c a m s h a f t

CAMSHAFT CAM WEAR

Worn-downcams are often the cause of mistimedvalve

g
operationresultingin reducedoutput power.The limit of cam
wear is specifiedfor both intakeand exhaustcams in terms
of cam height@, which is to be measuredwith a microrne-
ter. Replacecamshaftsif found worn down to the limit.

Gam height @
Intake cam : 35.660 mm (1.4039 in)
Service Limit
Exhaust cam: 36.62O mm 11.4417 inl

@ Micrometer(25-50 mm)
ossoo-2O2o2=

CAMSHAFTJOURNALWEAR
Determinewhether eachjournalis worn down to the limit
or not by measuringcamshaftjournaloil clearancewith the
camshaftinstalled.Use plastigaugeto readthe clearance,
which is specifiedas follows:

Camshaftjournal oil clearance

ServiceLimit: O.150 mm (O.OO59in)

@! ossoo-223o2:
Ptastisause
NOTE:
To properly measure the oil clearance with plastigauge, all
gasket material must be removed from fitting surfaces of
cylinder head and cover. Do not apply SUZUKI BOND
"1216" until after the oil clearancehas been determined.

r Tightenthe cylinderheadcoverboltsevenlyand diagonal-

ly to the specifiedtorque.

Q CylinOerhead cover bolts

( M 6 ) :1 1 N ' m ( 1 . 1 k g - m , 8 . 0 l b - f t l
(M8):23 N'm (2.3 kg-m, 16.5 lb-ft)
NOTE:
Do not rotate the camshafts with the plastigauge in place.

Removethe cylinderheadcover,and readthe width of the

compressedplastigaugewith envelopscale.This measure-
ment should be taken at the widest part.
3-27E]{GtilE

lf the camshaftjournaloil clearancemeasuredexceedsthe

limit, measurethe outsidediameterof camshaft.
Replaceeitherthe cylinderhead set or the camshaftif the
clearanceis incorrect.

CamshaftjournalO.D.(Sprocketside)24359-24.980 mm
(0.9826-0.9835 in)
( O t h e rs i d e ) 1 9 . 9 5 9 - 1 9 . 9 8 0 m m
(O.7858*0.7866 in)

@ ossoo-2o2o5: (0-25 mm)

Micrometer

CAMSHAFTRUNOUT
Measurethe runoutwith a dialgauge.Replacethe camshaft
if the runout exceedsthe limit.

Camshaftrunout (lN. & EX.)

ServiceLimit: O.1Omm (O.OO4in)

@ : i a lg a u g e(1 /1 0 0,1o m m )
o s s o o - 2 06 0 6D
09900-20701: Magneticstand
09900-213O4V : - b l o c k( 1 O Om m )

C A M C H A I NT E N S I O N E R
AND GUIDE
CAM CHAINTENSIONER
For drivingthe camshafts,two cam chain tensionersare
usedon the respectivecam drive chains.Unlockthe ratch-
et mechanism,and move the push rod in placeto see if it
slidessmoothly.lf any stickinessis noted or ratchetmechan-
ism is faulty,replacethe cam chaintensionerassemblywith
a new one.
T h e c a m c h a i n t e n s i o n e rc a n b e d i s t i n g u i s h e db y t h e
embossed-letters, "F" and "R", on the cam chain ten-
sioners.
" F " i F r o n t ( N o . 2 ) c a m c h a i nt e n s i o n e r
" R " : R e a r( N o . 1 ) c a m c h a i nt e n s i o n e r

CAM CHAIN GUIDE

Checkthe contactingsurface of the cam chain guide for
w e a r a n d d a m a g e .l f i t i s f o u n d t o b e d a m a g e d ,r e p l a c ei t
with a new one.
Two kinds of cam chain guide are used on the respective
c a m d r i v ec h a i n s .
" F " : F r o n t ( N o . 2 ) c a m c h a i ng u i d e
" R " ; R e a r( N o . 1 )c a m c h a i ng u i d e
 EIl|GllrlE
3-28

CYLINDER
HEAD,VALVEAND VALVESPRING
VALVE AND VALVE SPRINGDISI\SSEMBLY
o Usingspecialtools, compressthe valve springsand re-
move the two cotter halves@ from valve stem.

@! ossr6-14b1o: Vatvespringcompressor
0991 6-1491O: Valvespringcompressorattachment
09916-8451 1 : Tweezers

o Removethe valve springretainer,innerspringand outer

spring.
r Pull out the valve from the other side.
. Removethe valve stem seal and valve spring seat.

NOTE:
Removal of valves completes ordinary disassembling work.
lf valve guides have to be removed for replacement after
inspecting relatedparts, carry out the steps shown in valve
guide servicing. (Refer to page 3-3O.)

CYLINDERHEAD DISTORTION
o Decarbonizethe combustionchambers.
Checkthe gasketedsurfaceof the cylinderheadfor distor-
tion with a straightedge andthicknessgauge,takinga clear-
ancereadingat severalplacesindicated.lf the largestreading
at any positionof the straightedgeexceedsthe limit, replace
t h e c y l i n d e rh e a d .

$erviceLimit: O.O5mm (O.OO2in)

@! ossoo-2o8o3:Thickness
sause
VALVE FACE WEAR
Visuallyinspect each valve for wear of its seatingface.
Replaceany valve with an abnormallyworn face.
Thethickness@decreasesas the wear of the face advances.
Measurethe thicknessand,if the thicknessis foundto have
been reducedto the limit, replaceit.
S e r v i c eL i m i t @ : 0 . 5 m m ( 0 . 0 2 i n )

@ ossoo-2o101:
verniercalipers
3-29EitGtt'tE

VALVE STEM RUNOUT

Supportthe valve with "V" blocks,as shown, and check
its runout with a dial gauge.
The valvemust be replacedif the runoutexceedsthe limit,

ServiceLimit: 0.05 mm {O.OO2in}

@! ossoo-2o7o1:Masneticstand
09900-20606: Dial gauge {1/100 mm)
09900-21304: V-block

VALVE HEAD RADIAL RUNOUT

Placethe dial gaugeat right anglesto the valve headface,
and measurethe valve head radialrunout.
lf it measuresmore than limit, replacethe valve.
ServiceLimit: O.O3mm (O.O01in)

@! ossoo-zo7ol:Magnetic
stand
0 9 9 0 0 - 2 0 6 0 6 :D i a lg a u g e( 1 i 1 0 0 m m l
09900-21304: V-block

VALVESTEM DEFLECTION
Lift the valve about 1O mm (O.39in) from the valve seat.
Measurethe valve stem deflectionin two directions,"X"
and "Y", perpendicular to each other, by positioningthe
dial gaugeas shown. lf the deflectionmeasuredexceeds
the limit, (seebelow)then determinewhetherthe valveor
t h e g u i d es h o u l db e r e p l a c e dw i t h a n e w o n e .

ServiceLimit
Intakeand exhaustvalves:0.35 mm (0.014 in)

Diatsause(r/1oo mm)
@! ossoo-20606:
09900-20701: Magneticstand

VALVE STEM WEAR

lf the valve stem is worn down to the limit, as measured
with a micrometer,where the clearanceis found to be in
excessof the limit indicatedreplacethe valve, if the stem
is within the limit, then replacethe guide.After replacing
valve or guide, be sure to re-checkthe clearance.

Standard
Valve stem O.D.
lN. : 5.475-5.490 mm (0.2156-0.2161 in)
EX.:5.455-5.47O mm (0.2148-O.2154 in)

@ (O-25 mm)
oggo0-20205:Micrometer
 EfrlGltUE
3-30

VALVE GUIDESERVICING
I Usingthe valveguideremover,drivethe valve guideout
toward the intake or exhaustrocker arm side.

@! oSSl 6-4491o:Vatveguideremover/lnstalter
NOTE:
* Discard the removed valve guide subassemblies.
* Qnly oversized valve guides are available as replacement
parts. (PartNo. llll5-38471)

o Re-finish the valveguideholesin cylinderheadwith a 10.8

m m r e a m e ra n d h a n d l e .

@ oSS16-34580:Valve guide hole reamer

O9916-34541: Reamerhandle

o Oil the stem hole,too, of each valve guideand drivethe

guideintothe guideholewith the valveguideinstallerand
attachment.

Gb oggr 6-4491o:Vatveguideremover/instatler
0991 6-4492O: Valve guide installerattachment

A CAUTION
Failureto oilthe valveguidehole beforedrivingthe new
guide into placemay resultin a damageguide or head.

o After fitting all valveguides,re-finishtheir guidingbores

w i t h a 5 . 5 m m r e a m e rB
. e s u r et o c l e a na n d o i l t h e g u i d e
afterreaming.

@! ossr 6-34sbo:Vatveguidereamer
09916-34541: Reamerhandle
NOTE:
lnsert the reamer from the combustion chamber and always
turn the reamer handle clockwise.
3-3t ENGtlllE

VALVE SEAT WIDTH

o Coatthe valve seat with prussianblue uniformly.Fit the
valve and tap the coated seat with the valve face in a
rotatingmanner,in order-toobtaina clearimpressionof
the seatingcontact. In this operation,use the valve lap-
per to hold the valve head.
o The ring-likedye impressionleft on the valve face must
be continuous- without any break.ln addition,the width
seat"width", must
of the dye ring,which is the visualized
be within the following specification:

Valve seat width

S T D .@ : 0 . 9 - 1 . 1 m m ( 0 . 0 3 5 - 0 . O 4 3 i n )

@! ossro-10911:
Vatvetapper
set
lf eitherrequirementis not met, correctthe seat by servic-
ing it as follows:

VALVE SEAT SERVICING

The valve seats for both intake and exhaust valves are
machinedto two differentangles.The seat contactsurface
is cut 45o and the areaabovethe contact surface(closest
t o t h e c o m b u s t i o nc h a m b e r )i s c u t t o 1 5 o .

INTAKE EXHAUST
150 N -2 2 9 N - 11 6 o r N - 1 2 0
450 N-229 N - 11 6 o r N - 1 2 2
Solid
N-140-5.5 N-100-5.52
pilot
Adapter N-503-1
T-handle N -5 0 3 N- 503

NOTE:
The valve seat contact area must be inspected after each
cut.

@! oSSr6-2772o:Vatveseatcutter(N-2291
09916-20620: Valve seat cutter (N-122)
09916-24480: Solid pilot (N-140-5.5)
09916-211 1O: Valve seat cutter set
eeS
( i n c l u d eN - 12 0 , N - 10 0 - 5 . 5 2 ,
N-503-1 and N-503)
 EIUGIilIE
3.32

o Insertthe solidpilot@ with a slightrotation.Seatthe pi-

l o t s n u g l y . I n s t a l lt h e 4 5 o c u t t e r , a t t a c h m e n ta n d T -
handle.
o U s i n gt h e 4 5 o c u t t e r ,d e s c a l ea n d c l e a nu p t h e s e a tw i t h
one or two turns.
o Inspectthe seat by the previouslydescribedseat width
measurementprocedure.lf the seat is pitted or burned,
additionalseat conditioningwith the 45o cutter is re-
quired.
NOTE:
Cut only the minimum amount necessary from the seat to
prevent the possibility of the tappet shim replacement.
lf the contact area is too high on the valve, or if it is too
w i d e , u s et h e 1 5 o c u t t e rt o l o w e r a n d n a r r o wt h e c o n t a c t
area.

C o n t a c ta r e at o o h i g h
and too wide on face of
valve

lf the contact area is too low or too narrow, use the 45o
cutter to raiseand widen the contact area.

r After the desiredseat positionand width is achieved,use

t h e 4 5 o c u t t e rv e r y l i g h t l yt o c l e a nu p a n y b u r r sc a u s e d
Contact areatoo low
by the previouscutting operations. and too narrow on face
of valve
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 polishedor shiny finish.
This will providea soft surfacefor the final seatingof
the valve which willoccur duringthe first few seconds
of engine operation.

o C l e a na n d a s s e m b l e
t h e h e a da n d v a l v ec o m p o n e n t sF. i l l
the intakeand exhaustports with gasolineto check for
leaks.lf any leaksoccur,inspectthe valveseat and face
for burrsor otherthingsthat couldpreventthe valvefrom
sealing,

Always use extreme caution when handlinggasoline.

. ,],::,il
,.. r.!i;ilili!1'.
NOTE: . . ;
After servicing the valve seats, be sure to check the valve
clearanceafter the cylinderhead and head cover have been
reinstalled. (See page 2-4, -5 and -6.)
3-33EIIGINE

VALVE STEM END CONDITION

lnspectthe valvestem end face for pittingand wear. lf pit-
ting or wear of the stem end face are present,the valvestem
end may be resurfaced,providingthat the length@ will not
be reducedto less than the servicelimit. lf this length be-
comeslessthan the servicelimit,the valvemust be replaced.

S e r v i c eL i m i t :3 . 1 m m ( O . 1 2i n )

VALVE SPRING
The force of the coil spring keeps the valve seat tight.
Weakenedspringresultin reducedenginepower output, and
often accountfor the chatteringnoisecomingfrom the valve
mechanism.
Checkthe valve springsfor properstrength by measuring
theirfree lengthand alsoby the force requiredto compress
them. lf the springlength is less than the servicelimit, or
if the force requiredto compressthe springdoesnot fall wi-
thin the rangespecified,replaceboth the inner and outer
springsas a set. 6 . 5 1 - 7 . 4 9 k s ( 1 4 . 3 5 - 1 6 . 5 1l b s )

@ Verniercalipers
ossoo-2o101: +
Valve spring free length {lN. & EX.} 3 2 . 5 m m ( 1 . 2 8i n )
S e r v i c el i m i t I N N E R :3 8 . 3 m m ( 1 . 5 1 i n )
O U T E R4 : 0.1 mm (1.58 in)

Valve springtension (lN. & EX.l

I N N E R 6: . 5 1 - 7 . 4 9 k g / 3 2 . 5 m m
standard
ourER,(11:33_i3 ili
3iffiJJ.;
(26.65-30.67 lbs/I.42 inl

VALVE AND VALVE SPRINGREASSEMBLY

o Fit the valve spring lower seats @.
r Oil eachoil seal,and press-fitthe oil seal@ into position
with the valve guide installer.

@ OSSf 6-44910: Valve guide remover/installer

CAUTION
Do not reuse the oil seal.
 EltlGllrlE3-34

VALVE AND VALVE SPRINGREASSEMBLY

o Insertthe valves,with their stemscoatedwith highquality
m o l y b d e n u md i s u l f i d el u b r i c a n (t S U Z U K M
I O L YP A S T E )
all around and along the full stem length without any
break.

fu99ooo-2b140:suZUKr
MoLYPAsrE
CAUTION
When inserting each valve, take care not to damage
the lip of the stem seal.
o I n s t a l l t h e v a l v e s p r i n g s with the small-pitchportion@
facing cylinderhead.
@: Large-pitch portion.

r Puton the valvespringretainerand,usingthe valvespring

compressor,press down the spring, fit the two cotter
halvesto the stem end, and releasethe compressorto
allow the cotter@ to wedge in betweenseat and stem.
Be sure that the roundedlip @ of the cotter fits snugly
into the groove@ in the stem end.

Gb oggr G-14s10:Valvespringcompressor tl
O9916-1491O: Valve springcompressorattachment
0 9 9 1 6 - 8 4 5 11 : T w e e z e r s

A Gnunoru
Be sureto restoreeach spring,valve and spring retain-
er to their originalpositions.

NOTE:
* When installing the water union
@ to the cylinder head,
apply grease to the new O-rings @.
* Tighten the water union bolts to the specified torque.

fu99ooo-2s030:suZUKr "A"
supERGREAsE
[lW"t", u n i o nb o l t : 1 O N . r n ( 1 . Ok g - m , 7 . 0 l b - f t )
3.35 EllGllrlE

CYLINDERAND PISTON
CYLINDERDISTORTION
Checkthe gasketedsurfaceof the cylinderfor distortionwith
a straightedgeand thicknessgauge,taking a clearanceread-
ing at severalplacesas indicated.lf the largestreadingat
any positionof the straightedgeexceedsthe limit, replace
the cylinder.

Cylinderdistortion
ServiceLimit: 0.05 mm (0.002 in)
Thickness
@! ossoo-2oeo3: sauge
CYLINDERBORE
Measurethe cylinderborediameterat six places.lf any one
of the measurementsexceedsthe limit,overhaulthecylinder
and replacethe piston with an oversize,or replacethe
cylinder.Once the reboringis done on any one cylinder
which measurementsis beyond the limit, the remaining
cylindersmust be also reboredaccordingly.Otherwisethe
imbalancemight cause excessvibration.

Cylinderbore
S e r v i c eL i m i t :8 3 . 0 8 5 m m ( 3 . 2 7 1 1 i n )

@! ossoo-20508:cytindergaugeset

O
NOTE:
" When installing the water union to the cylinder, apply
grease to new O-ring.
* Tighten water union bolts to the specified torque.
"A"
6rggooo-25030:suzuKrsupERGREASE
p: W a t e r u n i o nb o l t : 1 O N ' m ( 1 . 0 k g - m , 7 . 0 l b - f t )

PISTONDIAMETER
Usinga micrometer,measurethe piston outsidediameter
at the placeshown in Fig. lf the measurementis less than
the limit, replacethe piston.

Pistonoversize:0.5, 1.0 mm
ServiceLimit: 82.880 mm (3.263O in)
1 5 m m ( 0 . 6i n )
I
@ Miqometer175-1oo mm)
oSsOo-2O2o4t
 Etrtc[llE3-36

PISTONTO CYLINDERCLEARANCE
As a resultof the aforesaidmeasurement,if the pistonto
cylinderclearanceexceedsthe followinglimit,overhaulthe
cylinderand use an oversizepiston,or replaceboth cylinder
and piston.

ServiceLimit: O.12Omm (O.OO47in)

PISTONRINGTO GROOVECLEARANCE
Usinga thicknessgauge,measurethe sideclearances of the
exceedsthe limit,
1st and 2nd rings.lf any of the clearances
replaceboth piston and piston rings.
Piston ring-grooveclearance
$ e r v i c el i m i t ( 1 s t ) : 0 . 1 8 m m ( O . O O 7 1
in)
( 2 n d ) :0 . 1 5 m m ( O . O O 5 9in)

Piston ring groove width

S t a n d a r d{ 1 s t ) : 1 . 0 1 - 1 . 0 3 m m ( 0 . 0 3 9 8 - O . O A O Gi n }
( 2 n d ) :1 . 2 1 - 1 . 2 3 m m { O . O 4 7 6 - 0 . 0 4 8 4i n }
(Oil) : 2.51-2.53 mm (0.0988-O.0996 in)

Piston ring thickness

S t a n d a r d( 1 s t ) : 0 . 9 7 0 - 0 . 9 9 O m m ( 0 . 0 3 8 2 - O . O 3 9 Oi n )
( 2 n d ) :1 . 1 7 0 - 1 . 1 9 0 m m { 0 . 0 4 6 1 - 0 . 0 4 6 9 i n )

@ 09900-20803: Thicknessgauge
09900-20205: Micrometer(O-25 mm)

PISTONRINGFREEEND GAP AND END GAP

Beforeinstallingpiston rings,measurethe free end gap of
each ring using verniercalipers.Next, fit the ring in the
c y l i n d e ra, n d m e a s u r ee a c hr i n ge n d g a p u s i n ga t h i c k n e s s
gauge.
l f a n y r i n g h a s a n e x c e s se n d g a p , r e p l a c et h e r i n g .
Piston ring free end gap
Servicelimit (1st) : 8.40 mm (0.331 in)
(2ndl:9.44 mm (0.372 in)
Piston ring end gap
Servicelimit (1st) : O.5Omm {O.020 in)
( 2 n d ) :0 . 5 0 m m ( 0 . 0 2 0 i n )

@! ossoo-2o101:
verniercalipers
09900-20803: Thicknessgauge
3-37ElrtGttrtE

r Oversize piston ring

The followingtwo types of oversizepistonringsare used.
They bear the following identificationnumbers.

SIZE 1st 2nd 0.5 mm O.S.

0.5 mm O.S. 50 50
1 . 0m m O . S . 100 100
o Oversizeoil ring
The followingtwo types of oversizeoil rings are availa-
ble as optionalparts.They bearthe followingidentifica- 1.0mm O.S.
tion marks.

SIZE COLOR
STD NIL
O . 5m m O . S . PaintedRed
1 . 0m m O . S . PaintedYellow Oil ringspacer

o Oversizeside rail
Just measureoutsidediameterto identifythe side railas Paint
t h e r e i s n o m a r k o r n u m b e r so n i t .

PISTONPIN AND PIN BORE

Usinga small bore gauge,measurethe piston pin bore in-
sidediameter,and usinga micrometer,measurethe piston
pin outsidediameter.lf the readingexceedsfollowinglimit,
replaceboth piston and piston pin.

Piston pin bore LD.

ServiceLimit: 20.030 mm (0.7886 in)

@! ossoo-2oilol:Diatgauge(1/100omm, 1 mm)
O99OO-22403:Small bore gauge (18-3b mm)

Usinga micrometer,measurethe pistonpin outsidediameter

at three positions.
Pistonpin O.D.
ServiceLimit: 19.980 mm (0.7866 in)
(o- 2b mm)
@! ossoo-2o2o5:Micrometer
 3-38
EttlGttrtE

CONRODAND CRANKSHAFT
CONRODSMALL END I.D.
Usinga smallboregauge,measurethe conrodsmallend in-
side diameter.
Conrod small end l.D.
Service Limit: 2O.O4Omm {0.789O in}
Dialgauge(1/1ooomm, 1 mml
Gb oggoo-2o6o2:
O99OO-22403:Small bore gauge (18-35 mm)
lf the conrodsmallend insidediameterexceedsthe above
mentionedlimit, replacethe conrod.

CONRODBIG END THRUSTCLEARANCE

Check the conrod thrust clearanceby using a thickness
gauge.lf the clearanceexceedsthe limit, replaceconrodor
crankshaft.

ServiceLimit: 0.30 mm (0.012 in)

EE 09900-20803:Thicknessgauge
Big end width
Standard:21.95-22.00 mm (0.864-0.866 in)
Crank pin width
Standard2 : 2.10-22.1 5 mm (0.870-0.872 inl

@ oSSoo-2o2o5: (o-25 mm)

Micrometer
09900-20605: Dial calipers{1O-34 mm)

CONROD-CRANK PIN BEARINGSELECTION

. Loosenthe bearingcap nuts and tap the bolt end lightly
with plastichammerto removethe bearingcap.

r Removethe rods and mark them to identifythe cylinder

position.
. Inspectthe bearingsurfacesfor any sign of fusion, pit-
ting, burn,or flaws. lf any, replacethem with a specified
set of bearings.

NOTE:
Never try to remove or loosen the conrod cap bolts due to
their possible loosening in the rod. Once displaced, the bear-
W@
ing cap will not be fitted properly.
3-39 EI'IGil'lE

r Placeplastigaugeaxiallyon the crankpin avoidingthe oil

h o l e ,a t T D C o r B D C s i d e a s s h o w n .
. Tightenthe bearingcap with two-step torque values.

NOTE:
When fitting the bearing cap to crank pin, be sure to dis-
criminate between its two ends, LD. code side and the other.
l.D. code always faces intake valve side.
(ltconrod nut
Initialtighteningtorque: 25 N'm
(2.5 kg-m, 18.0 lb-ft)
Finaltighteningtorque: 51 N'm
( 5 . 1 k g - m ,3 7 . 0 l b - f t )

Ptastigauge
@! osso o-223o2=
NOTE:
Never rotate the crankshaft or conrod when a piece of
plastigauge is in the clearance.

. Removethe caps and measurethe width of compressed

p l a s t i g a u g ew i t h e n v e l o p es c a l e . T h i s m e a s u r e m e n t
should be taken at the widest part.
Grank pin bearing oil clearance
ServiceLimit: 0.080 mm (O.OO31in)
o lf oil clearanceexceedsthe servicelimit,selectthe speci-
f i e d b e a r i n g sf r o m t h e f o l l o w i n gt a b l e .
o C h e c kt h e c o r r e s p o n d i ncgo n r o dL D . c o d e n u m b e r@ ,
tt1", tt2t' "3",
or
r C h e c kt h e c o r r e s p o n d i n cgr a n k p i n O . D . c o d e n u m b e r
"1", "2" ol "3".
@ ,
r T h e c r a n kp i n O . D . c o d e n u m b e r@ , " 1 " , " 2 " o r " 3 "
which are stampedon the left crank web,

Bearingselectiontable
C r a n kp i n O . D . @
Code 1 2 3
1 Green Black Brown
Conrod
l.D. code 2 Black Brown Yellow
o 3 Brown Yellow Blue

Oil clearance
: . O 2 4 - O . 0 4 2 m m ( O . O O O 9 - 0 . 0 O 1 i7n )
S t a n d a r dO
 3.40
ENGII'IE

Conrodl.D. specification

Code O l.D. specification

44.OOO-44.006 mm
1
fi.7323-1.7325 inl
44.006-44.012 mm
2
fi.7325-1.7328 inl
44.012-44.018 mm
3
n . 7 3 2 8 - 1 . 7 3 3 0i n )

Crank pin O.D. specification

Code @ O.D. specification
4 0 . 9 9 4 - 4 1 . O O Om m
1
( 1 . 6 1 3 9 -1 . 6 1 4 2i n l
40.988-40.994 mm
2 ( 1 . 6 1 3 7- 1 . 6 1 3 9 i n )
40.982-40.988 m m
3
{ 1. 6 13 5 - 1 . 6 1 3 7 i n )

Mioometer(25-5o mm)
@! oSsoo-2o2o2=
A CAUTION
Bearingshould be replacedas a set.

Bearingthickness
Color (PartNo.) Thickness
Green 1 . 4 8 5 - 1 . 4 8 8m m
(12164-38EOO-OAO) ( 0 . O 5 8 5 - 0 . O 5 8 6i n )
Black 1 . 4 8 8 - 1 . 4 9 1m m
n2164-38EOO-0BO) (0.0586*0.0587 in)
Brown 1 . 4 9 1 - 1 . 4 9 4m m
t12164-38EOO-OCO) (0.0587-0.0588 in)
Yellow 1:494-1.497 mm
(2164-38EOO-ODO) (0.0588-0.0589 in)
Blue 1 . 4 9 7- 1 . 5 O Om m
112164-38EOO-OEO) ( 0 . 0 5 8 9 - O . 0 5 9 1i n )
 3-41ElrlGttrtE

CONROD-CRANK PIN BEARINGASSEMBLY

o When fitting the bearingto the bearingcap and conrod,
be sure to fix the stopper part @ tirst and press in the
other end.

. A p p l y e n g i n eo i l o r S U Z U K IM O L Y P A S T Et o t h e c r a n k
pin and bearingsurface.

,6rggooo-2814o:suzuKrMoLypAsrE

When mountingthe conrodon the crankshaft,makesure

that l.D. code @ of the conrod faces rearward.
Tightenthe conrodfitting nuts with specifiedtorque af-
t e r a p p l y i n ge n g i n eo i l t o t h e n u t t h r e a d ,

CI conrodnut
Initialtighteningtorque:2b N.m (2.8 kg-m, 1B.Olb-ft)
Finaltighteningtorque: 51 N.m (b.1 kg-m, g7.O tb-ft)
o Checkthe conrod movementfor smooth turning.

CRANKCASE-CRANKSHAFT BEARINGSELECTION
o lnspectthe crankshaftand crankshaftjournalbearingsfor
any damage.

o M e a s u r et h e c r a n k s h a fj to u r n a O
l . D .@ U Vu s i n gt h e s p e ,
c i a lt o o l .

Crankshaftjournal O.D. @
S t a n d a r d4: 7 . 9 6 5 - 4 7 . 9 8 0 m m ( 1 . 8 8 8 4 - 1 . 8 8 9 0 i n )

@! ossoo-2o2o2: (2s-5o mm)

Micrometer
 EruGrilE
3-42

o Measurethe crankshaftjournalbearingLD. O by using

the specialtool

Crankshaftjournal bearingt.D. e
: 8.000-48.015 mm (1.8898-1.8904 in)
S t a n d a r d4

@! ossoo-2oso8: sauseset
cytinder

lf eachcrankshaftjournalbearingLD. is not within the stan-

dard range,replacethem with new ones,

Removethe crankshaftbearingwith taking care not to

d a m a g et h e c r a n k c a s ej o u r n a lb e a r i n gh o l e .
lnspectthe journalbearingholeof crankcasefor any sign
of pitting or flaw.
lf any, repairit with emery paper.
Installthe new journalbearingsinto the crankcasesby
hydraulicpress.
o Hone the new journalbearingswith the specifiedvalue
b y h o n i n gm a c h i n e .

A CAUTION
When honingthe new journalbearings,be sureto mate
the left and right crankcases.
3-43 EIlIGIIUE

CRANKSHAFTTHRUSTCLEARANCE
lnstallthe crankshaftin the rightcrankcasehalf afterinstall-
ing the thrustshim on the crankshaft.

NOTE:
The oil grooved face @of thrust shim @ is faced to crank-
shaft web side.
o Placethe thrust washer, camshaft drive sprocket and
primarydrivegearon the right end of the crankshaftand
tighten primarydrive gear bolt to the specifiedtorque.
( R e f e rt o p a g e 3 - 5 6 . )

@ ossso-40113:
Rotorhotder
Qleri-"ry drive gear bolt: 95 N.m (9.5 kg-m, 68.5 lb-ft)

o Use a thicknessgaugeto measuret h e t h r u s t c l e a r a n c e

between right cankcaseand thrust w a s h e r .

Grankshaftthrust clearance
S t a n d a r d 0: . 0 5 - 0 . 1 0 m m ( 0 . 0 0 2 - 0 . 0 0 4 i n )

@ 09900-20803: Thicknessgauge
lf the thrust clearanceexceedsthe standardrange,adjust
t h e t h r u s t c l e a r a n c eb y t h e f o l l o w i n gp r o c e d u r e s :

Removethe thrust shim, and measureits thicknesswith

a micrometer.
C h a n g et h e t h r u s ts h i m w i t h t h e o t h e rs h i m i f t h e t h r u s t
clearanceis incorrect.
. Perform the thrust clearancemeasurementdescribed
a b o v eo n c e a g a i n .
(o- 25 mm)
@! ossoo-2o2ob:Micrometer
Checkingto make sure it is within standard
U n i t :m m ( i n )
Part number Thrust shim thickness
09160-48001 1. 9 2 5 - 1. 9 5 0 ( O . O 7 5 8 - 0 . 0 7 6 8 )
0 9 16 0 - 4 8 0 0 2 1. 9 5 0 - 1. 9 7 5 ( 0 . 0 7 6 8 - O . O 7 7 8 l
09160-48003 1. 9 75 - 2 . O O O( 0 . 0 7 78 - O . O 78 7 ] '
09160-48004 2 .OOO-2 .0 2 5 rc.O787 - O.0797)
09160-48005 2 . 0 2 5 - 2 . O 5 0r c . 0 7 9 7- 0 . 0 8 0 7 )
0 9 16 0 - 4 8 0 0 6 2 . 0 5 0 - 2 . O 75 ( O , 0 8 0 7 - 0 , O 817 )
09160-48007 2 . O 75 - 2 . 10 0 ( O . 0 817 - O . 0 8 2 7 )
09160-48008 2 . 10 0 - 2 . 12 5 Q . 0 8 2 7 - O . O 8 3 7 )
09160-48009 2 . 12 5- 2 . 15 0 ( 0 . 0 8 3 7
* 0.0846)
09160-48010 2 . 15 0 - 2 . 17 5 ( 0 . 0 8 4 6- 0 . 0 8 5 6 )
 ElrlGlltlE3-44

CLUTCH
CLUTCHDRIVEAND DRIVENPLATES
NOTE:
Wipe off the engine oilfrom the drive and driven plates with
a clean rag.
Measurethe thicknessof driveplateswith a verniercalipers.
lf eachdriveplateis not within the standardrange,replace
it with a new one.
Measuringthickness
Thickness
S t a n d a r d( N o . 1 d r i v e p l a t e s l : 2 . 9 2 - 3 . 0 8 m m
( 0 . 11 5 - 0 . 1 2 1 i n )
{ N o . 2 d r i v e p l a t e l z3 . 4 2 - 3 . 5 8 m m
(0.135-0.141in)

@ OsSoo-2a101:
Vernlercalipers
Measurethe claw width of drive plates with a vernier
calipers.Replacethe driveplatesfound to haveworn down
to the limit.
Measuring claw width
Claw width (No.1 and No.2 drive platesl
S e r v i c eL i m i t : 1 5 . 1 m m ( O . 5 9 4i n )

@! ossoo-zo1o1:verniercatipers
Measureeach driven plate for distortionwith a thickness
gauge and surfaceplate.
Replacedriven plateswhich exceedthe limit.
ServiceLimit: 0.1 mm (O.004 in)

@ 09900-208O3:Thicknessgauge Measuringdistortion

CLUTCHSPRINGFREELENGTH
Measurethe free lengthof each coil springwith a vernier
calipers,and comparethe elasticstrengthof eachwith the
specifiedlimit. Replaceall the springsif any spring is not
withinthe limit.
Glutch spring free length
S e r v i c eL i m i t ( N o . 1 l : 2 4 . 6 m m ( O . 9 7i n )
( N o . 2 ) :2 3 . 3 m m ( 0 . 9 2 i n )

@! ossoo-2o101:Verniercatipers
CLUTCHBEARING
lnspectthe clutch releaserack bearingfor any abnormali-
ty, particularly cracks,upon removalfrom the clutch,to de-
cide whether it can be reusedor should be replaced.
Smoothengagementand disengagementof the clutch de-
p e n d sm u c h o n t h e c o n d i t i o no f t h i s b e a r i n g .

NOTE:
Thrust washer is located between the pressure plate and
thrust bearing.
3-45 EttlGllllE

CLUTCHRELEASERACK AND PINION

. I n s p e c t h e c l u t c h r e l e a s er a c k a n d p i n i o nf o r w e a r a n d
damage.
. lnspectthe clutchreleasepinionbearingfor any damages.

G E N E R A T O R .S I G N A L G E N E R A T O RA N D
STARTERCLUTCH
GENERATOR STATOR
STATORAND SIGNALGENERATOR
INSPECTION
Referto pages 7-8 and -22.

GENERATOR STATORAND SIGNAL

GENERATOR STATORSERVICING
When replacingthe generatorstatoror signalgeneratorsta-
tor, tightenthe generatorstator set bolts @, clamp bolt @
and signalgeneratorstatorset bolt @ to the specifiedtorque.

[lG"n"r"tor statorset bolt O: 10 N'm

(1.0 kg-m,7.0 lb-ft)
Generatorstator clamp bolt @: 1O N'm
(1.0 kg-m,7'O lb-ft)
Signalgeneratorstator set bolt @: 4.5 N'm
{0.45 ks-m, 3.5 lb-ft)

STARTERCLUTCHINSPECTION
Installthe starterdrivengearonto the starterclutch and turn
the starterdrivengearby handto inspectthe starterclutch
f o r a s m o o t hm o v e m e n tT . h e g e a rt u r n s o n e d i r e c t i o no n l y '
lf a large resistanceis felt to rotation, inspectthe starter
clutch for damageor inspectthe starter clutch contacting
surfaceof the starter driven gear for wear or damage'
l f t h e y a r e f o u n d t o b e d a m a g e d ,r e p l a c et h e m w i t h n e w
ones.
 Elrlc[rlE3.46

STARTERDRIVENGEARBEARINGINSPECTION
Inspectthe starterdriven gear bearingfor any damages.

STARTERCLUTCHSERVICING
. Holdthe rotor with off-setwrench and removethe start-
er clutch securingbolts.

t@
oxq
When fitting the one way clutch@ to the guidee, posi-
t i o n f l a n g es i d e @ o f o n e w a y c l u t c h t o t h e r o t o r s i d e .

. A p p l y T H R E A DL O C KS U P E R" 1 3 0 3 " t o t h e s e c u r i n g
boltsandtightenthem to the specifiedtorquewhile hold-
ing the rotor with off-set wrench.

LocK supER"1303"
tffi!99ooo-32030:THREAD
PlStarter clutchsecuringbolt: 26 N.m
(2.6 kg-m, 19.0 lb-ft) M
Oroo

O I LP U M P
A CAUTION
Do not attemptto disassemble the oilpump assembly.
The oil pump is availableonly as an assembly.
3.47 ENGIIIIE

TRANSMISSION
DISASSEMBLY
o D i s a s s e m b lteh e t r a n s m i s s i o n
g e a r sa s s h o w n i n t h e i l l u s t r a t i o n '

@ 1 s t d r i v e ng e a r
@ 4th driven gear
@ s r o d r i v e ng e a r
@ strr driven gear
@ 2nd driven gear
@ Driveshaft
@ C o u n t e r s h a f t / 1 sdtr i v e g e a r
@ +ttr drive gear
@ sro drive gear
@ strr drive gear
@ 2 n d d r i v eg e a r
 EilGlfrlE
3-48

REASSEMBLY
Assemblethe countershaftand driveshaftin the reverseord-
er of disassembly.Pay attentionto following points:
NOTE:
Always use new circlips.
NOTE:
Before installing the gears, coat lightly moly paste or engine
oil to the driveshaft and countershaft.
,6rggooo-zs14o: sUZUKT
MoLYPAsrE

A CAUTION
* Neverreusea circlip.After a circliphas been removed
from a shaft, it should be discardedand a new cir-
clip must be installed.
* When installinga new circlip,caremust be taken not
to expandthe end gap largerthan requiredto slip the
circlip over the shaft.
* After installinga circlip,alwaysensurethat it is com-
pletely seated in its groove and securelyfitted.

o W h e ni n s t a l l i n g a new circlip,pay attentionto the direc-

t i o n o f t h e c i r c l i p .Fit it to the side where the thrust is as
shown in figure.
;=?'rhrust
r-1
t t l
&
S h a r pe d g e

A CAUTION
When installingthe top drive gear bushing,align the
bushingoil hole @ with the countershafthole @.

When installingthe 3rd drivengearonto the driveshaft,in-

s t a l lt h e l o c k w a s h e rN o . 2@ o n t o t h e d r i v e s h a f ta, n d t u r n
and fit it into the groove.
Then,fit the lockwasherNo.1@ in the lockwasherNo.2@.
3-49 EttlGtilE

C AU T I O N
When installingthe 3rd driven gear bushings,alignthe
bushing oil hole @ with the driveshaft oil hole @.

GEARSAND RELATEDPARTS
TRANSMISSION

0@@00@re

re@0@@
@@@
@re@
 3-50
ENGttrlE

FORK
GEAR.SHIFTING
GEAR-SHIFTING FORKCLEARANCE
Usinga thicknessgauge,checkthe shiftingfork clearance
in the groove of its gear.
The clearancefor each of the three shiftingforks playsan
importantrole in the smoothnessand positivenessof shift-
ing action.
lf the clearancecheckedis notedto exceedthe limit speci-
fied, replacethe fork or its gear, or both.

Thickness
@! ossoo-20803: sause
099O0-2O1O1: Verniercalipers
Shift fork- Groove clearance
: . 1 O - O . 3 0m m ( O . O O 4 - 0 . 0 1 2i n )
S t a n d a r dO
ServiceLimit: O.5Omm (O.O2Oin)

Checking clearance
Shift fork groove width
S t a n d a r d :5 . 5 0 - 5 . 6 0 m m @.217 -O.224 inl

Checking groove width

Shift fork thickness
S t a n d a r d :5 . 3 0 - 5 . 4 0 ( 0 . 2 0 9 - 0 , 2 1 3i n )

OILJET AND NOZZLE

Checkthe all oiljets and nozzlesfor cogging.lf it is clogged,
clean its oil passagewith a compressedair.

A cRurloru
Use new O-rings to prevent the oil pressuredown.

NOTE:
When installing the oil jets and nozzles, apply oil to the
O-rings.
3-51 EfrlGllllE

ENGINEREASSEMBLY
by carryingout the steps of dis-
This engineis reassembled
assemblyin the reverseorder, but there are a number of
steps which demandspecialdescriptionsor precautionary
measures.
NOTE:
Apply engine oilto each running and sliding part before reas-
sembling.
o Installthe bearingsto the crankcaseby usingthe special
tools.

6b oggr g-8s210: Bearinginstatter(O @)

O 9 9 1 3 - 7 6 0 1 0 :B e a r i n gi n s t a l l e r( @ @ @ )
NOTE:
The sealed side of the bearing @ faces outside.

o I n s t a l tl h e b e a r i n gr e t a i n e r s .

NOTE:
ApplV a small quantity of THREAD LOCK "1342" to the
bearing retainer screws and tighten them to the specified
torque.
"1342"
tfifi 99ggo-320b0:THREADLocK
[lSearing retainerscrew: 8 N'm (O.8 kg-m, 6.0 lb-ft)

Installthe oil seals@ to the crankcaseby usingthe spe-

c i a lt o o l .
"
A p p l y S U Z U K IS U P E RG R E A S E A " t o t h e o i l s e a l l i p .

@b oggr g-gsz1o: Bearinginstatler

"A"
supERGREAsE
fu99ooo-2b030:suZUKr
 3-52
EtlIGmE

o Tighten the oil pressureregulatorO to the specified

torque.

[tOil pressureregulator:28 N'm (2.8 kg-m,20.Olb-ft]

o Installthe oil sump filter @ and its cover @.

NOTE:
The projection @of the oil sump filter faces to the bottom.

o Tightenthe oil sumpfiltercover boltsto the specifiedtor-

que after applyinga small quantity of THREADLOCK
" 1342" .

LocK "1342"
THREAD
X@ ssooo-32obo:
[t Oil sump filter cover bolt: 1O N'm (1 .O kg-in, 7.O lb-ft)

o Fit the new O-ringst o e a c h o i l n o z z l e .

A CAUTION
Use new O-ringsto prevent the oil pressuredown.

NOTE:
When installing the oil nozzles, applY engine oil to the
O-rings.

. Installthe oil nozzles@ to the left and right crankcases'

NOTE:
"f 342" to the
ApplV a small quantity of THREAD LOCK
bolts and tighten them to the specified torque.

pOil n o z z l er e t a i n e rb o l t : 1 0 N ' m ( 1 . 0 k g - m , 7 . 0 l b - f t )

r lnstallthe thrust shim @ on the crankshaft.

NOTE:
* The oil grooved face
@of thrust shim @ faces to crank'
shaft web side.
" The thrust shim
@ is chosen by the crankshaft thrust
clearance. (Refer to Page 3-43.)

@
3.53 ElrlGllllE

r lnstallthe crankshaftinto the left crankcasehalf.

NOTE:
Coat lightly moly paste to the crankshaft journal bearings.

fu99ooo-2b14o:suZUKr
MoLYPAsrE
A CAUTION
Neverstrike the crankshaftwith a plastic hammerwhen
insertingit into the crankcase.tt should be easy to in-
stall the crankshaft to left crankcase.

Installthe countershaftassembly@, driveshaftassem-

bly @ and reductiondriven gear.
l n s t a l lt h e w a s h e r@ t o t h e c o u n t e r s h a f t .

o lnstallthe gearshiftforks (@, O, @) gearshiftfork shafts

(@, @) and gearshiftcam @.

@ for 4th driven gear

@ f o r S t h d r i v e ng e a r
@ for 3rd drive gear

' ' ' ' ' 1

o I n s t a l tl h e n e w O - r i n g s@ .
NOTE:
Apply grease to the O-rings.

fu99ooo-2b030:suZUKr "A"
supEnGREAsE

o Cleanthe mating surfacesof the left and right crankcases.

e Fit the dowel pins @ on the left crankcase.
 3-54
ENGttrlE

. A p p l yS U Z U K B "
I O N D 1 2 O 7 B "t o t h e m a t i n gs u r f a c eo f
the right crankcase.
"
99104-31 140: SUZUKT BOND 12O7B"
{{{{{{{{{{{{{{{{16rqqqqqqqqqqqqqqqq!lllllllllllllll

NOTE:
"12O78" is as follows:
lJse of SUZUKI BOND
* Make surfaces free from moisture, oil, dust and other for-
eign materials.
* Spread on surfaces thinly to form an even layer, and as-
semble the crankcases within few minutes.
* Take extreme care not to apply any BOND "l2O7B" to
the oil hole, oil groove and bearing.
" Apply ta distorted surfaces as it forms a comparatively
thick film.
o Whensecuringthe rightand left crankcases, tighteneach
bolt a little at a time to equalizethe pressure'Tightenall
the securingbolts to the specifiedtorque values.
(1.5 kg-m, 11.0 lb-ft]
[ t C r a n t c a s e b o l t : ( l n i t i a l )1 5 N ' m
( F i n a l )2 2 N ' m l 2 . 2 k g - m , 1 6 . 0 l b - f t )

NOTE:
Fit the clamp @to the correct position as shown in Fig.

After the crankcasebolts have beentightened,check if

crankshaft,driveshaftand countershaftrotatesmoothly'
lf a largeresistanceis felt to rotation,try to free the shafts
by tappingthe crankshaft,driveshaftor countershaftwith
a plastichammer.

r Installthe O-ringO to the engine sprocketspacer@.

o Installthe enginesprocketspacer@.

NOTE:
* The chamfer side
@of the engine sprocket spacer faces
crankcase side.
* Apply grease to the oil seal lip and O-ring.
"A"
supERGREASE
fuggooo-2bo3o:suZUKr
3-55 ENGINE

Apply engineoil lightly to the gasket of the oil filter be-

fore installation.
I n s t a ltlh e o i l f i l t e rt u r n i n gi t b y h a n du n t i lf e e l i n gt h a t t h e
filter gasketcontactsthe mountingsurface.Then tight-
e n i t 2 t u r n s u s i n gt h e o i l f i l t e r w r e n c h .

@b oggts-4oo1o:oit fitterwrench
NOTE:
To properly tighten the filter, use the special tool. Never
tighten the filter by hand.
. Apply SUZUKIBOND" 12078" to the threadpart of the
oil pressureswitch @ and tighten it to the specified
torque.
991 04-31 140: SUZUKTBOND " 1207E."
rit-o?!!

E l O i f p r e s s u r es w i t c h : 1 4 N . m ( 1 . 4 k g - m , 1 O . Ol b - f t )
. Apply a smallquantityof THREADLOCKSUPER" 13O3
to the gearshiftarm stopper@ and tightenit to the speci-
fied torque.

t@ ggooo-32o3o: LocK supER"Isog"

THREAD
U G e a r s f r i f t a r m s t o p p e r :1 9 N . m ( 1 . 9 k g - m , 1 4 . O l b - f t )
. A p p l ya s m a l lq u a n t i t yo f T HR E A DL O C K' ' 1 3 4 2 " t o t h e
gearshiftcam stopper@ bolt and tighten it to the speci-
fied torque.
"1942"
t@ggooo-32050: THREADLocK
[tGearstrift cam stopper bolt: 1O N.m
(1.0 kg-m,7.0 lb-ft)
a H o o k t h e g e a r s h i f tc a m s t o p p e rs p r i n g .
a Checkthe neutraloosition.
a Installthe gearshiftcam stopperplate after aligningthe
gearshiftcam pins@with the gearshiftcam stopperplate
h o l e s@ .
A p p l ya s m a l lq u a n t i t yo f T H R E A DL O C K" 1 3 4 2 " t o t h e
gearshiftcam stopperplatebolt and tighten it to the speci-
fiedtorque.
"1g4z"
d'*-f 99990-32oso:THREADLocK
QGearsnift cam stopper plate bolt: 1O N.m
( 1 . 0 k g - m ,7 . 0 l b - f t l
Installthe stopper@of the gearshiftshaft @ between
the return spring@ properly.
lnstallthe gearshiftshaft @ as shown in the photograph.
 Et'tG[l|E
3-56

o Installthe oil pump to the crankcase.

. Apply a smallquantityof THREADLOCK" 1342" to the
oil pump securingbolts and tighten it to the specified
torque.
"
ttig?'l99990-32ObO:THREADLOCK 1342"

Q Oil pump bolt: 8 N'm (0.8 kg-m, 6.0 lb-ft)

o I n s t a ltlh e w a s h e r@ , t h e p i n@ , t h e o i l p u m pd r i v e ng e a r
@ a n d t h e c i r c l i p@ t o t h e o i l p u m p .
snapringpliers
@! ossoo-06107:
. lnstallthe thrust washer onto the crankshaft'

NOTE:
The chamfer side of thrust washer@ faces crankcase side.

Alignthe punchmark@onthe crankshaftwith the punch

mark @on the camshaftdrive sprocket.

"R"
Installthe cam chain@ and cam chainguide@ with
mark.
Tighten the cam chain guide set bolt to the specified
torque.

QlC". chainguideset bolt: 1O N'm (1.0 kg-m, 7'O lb-ft)

NOTE:
The cam chain guide can be distinguished by the embossed-
letters, "F" and "R", on its back side.

o Tightenthe primarydrive gear bolt to the specifiedtor-

q u e w i t h t h e s p e c i a tl o o l .

Rotorholder
@! ossso-4o113:
pteri-ary drivegearbolt:95 N'm (9.5 kg-m,68.5 lb-ft)
NOTE:
This bolt has left-hand thread.
3.57 EIl,|GIITIE

r lnstallthe spacer@ and thrust washer@ onto the coun-

tershaft.

NOTE:
The chamfer side of thrust washer @ faces crankcase side.

r Installthe oil pumpdrivegearonto the primarydrivengear.

NOTE:
When installing the oilpump drive gear, align the pin groove
with the pin @.

Applyengineoilto the primarydrivengearbearing@ and

c o l l a r@ .
I n s t a l tl h e p r i m a r yd r i v e ng e a ra s s e m b l yo n t o t h e c o u n -
tershaft.
iilii
lir':ti:l

o Installthe thrust washer @ onto the countershaft.

NOTE:
The oil grooved face of the thrust washer @ faces outside
(clutch sleeve hub side).

I n s t a l tl h e s p a c e r@ t o t h e c l u t c h s l e e v eh u b a s s h o w n
in the photograph.
lnstalltheclutchsleevehub and spaceronto the counter-
shaft.
 EI'IGINE
3-58

o Installthe No.2 clutch cam after engagingthe boss@of

c l u t c h s l e e v eh u b w i t h d o g @ o f N o . 2 c l u t c h c a m .

r I n s t a l tl h e N o . 1 c l u t c hc a m a f t e r e n g a g i n gt h e d o g @ o f
N o . 2 c l u t c h c a m w i t h b o s s@ o f N o . 1 c l u t c h c a m '
NOTE:
Flat surface of the No. I clutch cam faces outside.

o I n s t a l tl h e w a s h e r .

NOTE:
The convex side @of the washer faces outside.

o Tightenthe clutchsleevehub nut to the specifiedtorque

b y u s i n gt h e s p e c i a tl o o l .

[lCtut"tl sleevehub nut: 95 N'm (9.5 kg-m, 68.5 lb-ft]

@! osszo-53740:clutch sleevehub holder

3-59EilGIIIIE

o Installthe wave washerseat@, the wave washer@ and

the drive plate No. 2 @ (tfricLerplate as shown in the
figure)onto the clutch sleevehub.

NOTE:
lnstallthe clutch drive plate and driven plate one by one into @ Wave washer
seaT
the clutch sleevehub in the prescribed order, drive plate No.2 @ Wave washer
first. @ D r i v ep l a t e
No.2

Installthe clutch releaserack @, b e a r i n g@ a n d t h r u s t

washer @ to the pressureplate.
A p p l y e n g i n eo i l t o t h e b e a r i n g .
6)
l @

"_--Wffi6
o Putthe pressureplateonto the clutch sleevehub securely.
o Tightenthe clutchspringmountingboltsto the specified
torque by using the specialtool.
NOTE:
Set "A (No.l)" is used for clutch sleeve hub side.
Set "B (No.2)" is used for No.2 clutch cam side.
"A (No.1)"B : o l t L : 4 0 m m ( 1 , 5 8i n )
S p r i n g L : 2 5 . 8 5 m m ( 1 . O 1 8i n )
(White paint)
S p a c e rL : 2 4 m m ( O . 9 5i n )
" B ( N o . 2 ) ": B o l t L : 3 3 m m ( 1 . 3 0i n )
S p r i n g L : 2 4 . 5 m m ( 0 . 9 6 5i n )
SpacerL : 2 4 m m ( 0 . 9 5 i n )
p Clut"tl springmountingbolt: 1ON.m (1.Okg-m, 7.0 lb-ft)

@! ossso-40113:
Rotorhorder
NOTE:
Tighten the clutch spring mounting bolts in the criss-cross
manner, tightening them by degrees until they attain a uni-
form tightness.
 EftlGllrlE3-60

a A p p l y e n g i n eo i l t o t h e n e w O - r i n g@ .
a Installthe oil jet @ as s h o w n i n t h e p h o t o g r a p h .

o Installthe new clutchcovergasket@ and dowel pins@.

lnstall the clutch release p i n i o n@ , o i l s e a l@ a n d b e a r -

ing @.
@

o Align the clutch releaserack teeth w i t h t h e p i n i o ng e a r .

o Tightenthe clutch cover bolts to the specifiedtorque.
p C l u t c t t c o v e rb o l t : 1 1 N ' m ( 1 . 1 k g - m , 8 . 0 l b - f t )

NOTE:
Fit the new gaskets@, clutch cable stopper @ and clamps
@ to the correct positions as shown in Fig.

A CAUTION
Use new gaskets to prevent oil leakage.
3-61EilGll'IE

. I n s t a l l t h ec a m c h a i n@ a n d c a m c h a i ng u i d e@ w i t h " F "
mark.
r Tighten the cam chain guide set bolt to the specified
torque.

[lC"- chainguide set bolt: 1O N'm (1.0 kg-m, 7.0 lb-ft)

NOTE:
The cam chain guide can be distinguished by the embossed-
"R", on its back side.
letters, "F" and

o Fit the key @ in the key slot on the crankshaft.

r Installthe starter idle gear @, spacer@ and shaft @.

Degreasethe tapered portion of the rotor and also the

crankshaft.Use nonflammablecleaningsolventto wipe
off the oily or greasymatterto makethesesurfacescom-
pletelydry.
Installthe rotor with the starter driven gear onto the
crankshaft.
"1303" to the rotorbolt
A p p l y T H R E A DL O C KS U P E R
and tighten it to the specifiedtorque.
(T Generatorrotor bolt: 160 N'm (16.0 kg-m, 1 15'5 lb-ft)

t6l ggoo0-3203o:THREADLocK sUPER"1303"

r lnstallthenew generatorcovergasketand dowel pins@'

. Installthe generaotcover.
NOTE:
Fit the new gaskets@ and clamp@ to the correctpositions
as shown in Fig.

CAUTION
Use new gaskets to prevent oil leakage.
 E]ilG|IUE
3-62

r Installthe water pump@ and tighten its mountingbolts

to the specifiedtorque.
NOTE:
* Apply grease to the water pump O-ring.
" Sef the water pump shaft to the oilpump shaft as shown
in the illustration.

[tW"t", pump mountingbolt: 1ON.m (1.Okg-m, 7.Olb-ftl

fu99ooo-2s030:suZUKr "A"
supERGREASE

r Installthe spring@, the neutralswitch contact @ and

t h e O - r i n g@ .
NOTE:
Apply grease to the O-ring.

fu99ooo-2b030:suZUKr "A"
supERGREASE

o lnstallthe neutralswitch assembly@ as shown in the pho-

tograph.

o l n s t a l lt h e d r i v e c h a i n g u i d e @ .
o lnstall the drive shaft oil seal retainer @.
3-63 EtrtGilrlE

o lnstallthe startermotor and tightenits mountingboltsto

the specifiedtorque.
NOTE:
* Apply grease to the new O-ring.
* Place the clamp
e ," shown in the photograph.
CIlSt"rt", motormountingbolt: 1O N'm
(1.0 kg-m,7.0 lb-ft)
"A"
supERGREAsE
fu99ooo-2b030:sUZUKt

lnstallthe piston rings in the order of oil ring, 2nd ring

andtop ring.
T o p r i n g a n d 2 n d ( m i d d l e r) i n g d i f f e ri n t h e s h a p eo f t h e
-%m1s,
ring face, and the face of top ring is chrome-plated
whereasthat of 2nd ring is not. The color of 2nd ring ap-
pearsdarkerthan that of the top one.

" R " m a r k e do n t h e s i d e .
2 n d ( m i d d l er)i n g sh a v ea l e t t e r
Be sureto bringthe markedsideto top when fitting them
to the Diston.
/

----

T h e f i r s t m e m b e rt o g o i n t o t h e r i n g g r o o v e i s s p a c e r
@. Rfter placingthe spacer,fit the two siderails@' Side
designations,top and bottom, are not applied to the
s p a c e ra n d s i d er a i l s :y o u c a n p o s i t i o ne a c he i t h e rw a y .
 EI'IGINE
3-64

o Positionthe gaps of the three rings as shown. Before

insertingeachpistoninto the cylinder,checkthat the gaps
are so located. a 2nd ring
a Lower side
rail

o Rub a small quantityof SUZUKIMOLY PASTEonto the

p i s t o np i n . r Top ring
lN . Spacer

Placea clean rag over the cylinderbase to preventthe

piston pin circlipsfrom droppinginto the crankcase.
When installingthe piston,the arrow mark on the piston
head is locatedto exhaustside.
Installthe piston pin circlipswith long-nosepliers.

A CAUTION
Use new piston pin circlips to prevent circlip failure
which will occur with a bent one.

a A p p l y e n g i n eo i l t o t h e n e w O - r i n g .
o Installthe oil jet O a s s h o w n i n t h e p h o t o g r a p h .

i':,,

a A p p l y e n g i n eo i l t o t h e s l i d i n gs u r f a c eo f t h e p i s t o n .
a Fit the dowel pins@ and new gasketsto the crankcase.

A C AU T I ON
Use new gaskets to prevent oil leakage.
3.65 Etl|GttrtE

o I n s t a l lt h e c a m c h a i n t e n s i o n e r s o n e a c h c y l i n d e r .

NOTE:
The cam chain tensioner can be distinguished by the
embossed-letters, "F" and "R".
"F": Front (No.2 cylinder)
"R": Reai (No. I cylinder)

pC"* chain tensionerbolt: 1O lU.m

( 1 . Ok g - m , 7 . 0 l b - f t )

o Compressthe chaintensionerspringby releasingratch-

et. Insertthe specialtool betweenratchetand chainten-
s i o n e rb o d y .

@b oggr3-53810:Chaintensionertockingtool

r H o l dt h e N o . 2 ( F r o n t )p i s t o nr i n g si n p r o p e rp o s i t i o n a, n d
insert piston into the No.2 (Front)cylinder.
o P u l l t h ec a m c h a i no u t o f N o . 2 ( F r o n t c) y l i n d e ra n d i n s t a l l
t h e c a m c h a i n g u i d e@ .

NOTE:
When mounting the cylinders, keep the camshaft drive
chains taut. The camshaft drive chain must not be caught
between cam drive chain sprocket and crankcase when
crankshaft is rotated.
Thereis a holder for the bottom end of the cam chain guide
cast in the crankcase. Be sure that the cam chain guide is
inserted properly.
 3-66
Etrlcilt|E

o Fit the dowel pins @ and the new cylinderhead gasket

to the cylinder.

A CAUTION
Use a new gasket to prevent gas leakage.

o Tightenthe No.2 (Front)cylinderheadbolts(long,1Omm)

diagonallyto the specifiedtorque,
o Tightenother cylinderheadnuts to the specifiedtorque.

NOTE:
The length of the bott @is 165 mm (6.5 in) and bolt @is
155 mm (6.1 in).
ptcyuno"r headbolt and nut:
( M 1 O ) :I n i t i a l2 5 N ' m ( 2 . 5 k g - m , 1 8 . O l b - f t )
Final 38 N'm {3.8 kg-m, 27.5 lb-ft)
(M8) : 25 N'm (2.5 kg-m, 18.0 lb-ft)
(M6) : 11 N'm (1.1 kg-m,8.0 lb-ft)

o l n s t a l lt h e N o . 1 ( R e a r c) y l i n d e ra n d c y l i n d e rh e a di n t h e
s a m em a n n e ro f N o . 2 ( F r o n t )c y l i n d e ra n d c y l i n d e rh e a d
installation.
NOTE:
When remounting the No. | (Rear)cylinder, install the water
hose @ and clamps.
3-67 EluGllUE

r T i g h t e nt h e c y l i n d e rh e a db o l t s( l o n g ,1 Om m ) d i a g o n a l l y
to the specifiedtorque.
o Tightenother cylinderheadnuts to the specifiedtorque.

NOTE:
The tength of the bott @is 165 mm (6.5 in) and bolt @is
155 mm (6.1 in).

ElCylina"r headbolts and nuts

( M 1 O ) :I n i t i a l2 5 N ' m ( 2 . 5 k g - m , 1 8 . O l b - f t )
Final 38 N'm {3.8 kg-m, 27.5 lb-ft)
(M8) : 25 N'm (2.5 kg-m, 18.0 lb-ft)

o Tightenthe water union bolts to the specifiedtorque.

o Tightenthe water h o s e c l a m p s c r e w s .
pW"t", u n i o nb o l t s : 1 O N ' m ( 1 . 0 k g - m , 7 . O l b - f t )

NOTE:
Apply grease to the new O-ring.
"A"
Srggooo-2b030: suzuKrsupERGREASE

o l n s t a l lt h e i n t a k e p i p e .

NOTE:
ApptVgreaseto the new O-ringQ.
"A"
fuggooo-2bo3o:suZUKtsupERGREAsE

o l n s t a l l t h e w a t e r p i p ea n d h o s e .

NOTE:
ApplV grease to the new O-ring.
"A"
fuggooo-2bo3o: sUZUKIsupERGREAsE
 EITIGil||E
3-68

CAMSHAFTTIMING
r Turn the crankshaft counterclockwisewith the box
wrench and align"T" line@on the generatorrotor with
the indexmark@on the generatorcover keepingthe cam-
shaft drive chain pulledupward.

CAUTION
lf crankshaftis turned without drawing the camshaft
drive chain upward, the chain will be caught between
crankcaseand cam chain drive sprocket.
( T , D . C .o f N o . 1 c y l i n d e r )

. A P P I YS U Z U K IM O L Y PASTEto the cam shaft journals

a n d e n g i n eo i l t o t h e c a m s h a f tj o u r n a lh o l d e r s .

6ggooo-2s14o: sUZUKtMoLYPAsrE
o Placeeach camshaftonto the c o r r e c tp o s i t i o n .( " R " i s
"F" is for No.2 (Front)
f o r N o . 1 ( R e a r )c y l i n d e ra n d
cylinder.)

e Alignthe arrow marks@on the front and rearcamshafts

so it is parallelwith the surface of the cylinderheads.
NOTE:
Arrow marks are located to forward.

N O . 1(REAR)CYLIT{DER
o Engagethe chainson the cam sprocketswith the locat-
i n g p i n h o l e s@ a s s h o w n i n t h e p h o t o g r a p h .
NOTE:
Do not rotate the generator rotor while doing this. When the
sprocket is not positioned correctly, turn the sprocket.
e Recheckthe positionof the "T" line@on the generator
r o t o r ,a r r o wm a r k@ o n t h e N o . 1 ( R e a r c) a m s h a f ta n d a r -
r o w m a r kO o n t h e N o . 2 ( f r o n t )c a m s h a f t .
N O . 2 ( F R O N TC
) YLINDER
3.69 EttlGlluE

lnstallthe lock washerso that it is coveringthe locating

pin.
A p p l y T H R E A DL O C KS U P E R" 1 3 O 3 " t o t h e b o l t s a n d
tighten them to the specifiedtorque.

[lC"- t o l t : 1 5 N . m ( 1 . 5 k g - m ,1 1 . 0 l b - f t )
c h a i ns p r o c k e b
"1gog"
ttiGif ggooo-32030:THREADLocK supER
r Bendup the washertongue positivelyto lock the bolts.

Camshaft

Pin

r R e m o v et h e c a m c h a i nt e n s i o n e rl o c k i n gt o o l s .

NOTE:
Click sound is heard when the cam chain tensioner is
released.
 ENGtlrlE3-70

o T u r n t h e c r a n k s h a fst o t h a t t h e N o . 1 ( R E A Re) n g i n ep o -
s i t i o ni s p o s i t i o n e da t T . D . C .

Arrow mark
Arrow mark

FRONT
.+

Aligningmark on crankshaft C A M S H A F TT I M I N G
Turn the crankshaftso that the rear
A l i g n i n gm a r k o n t h e d r i v e s p r o c k e t c y l i n d e ri s p o s i t i o n e da t T . D . C .
3-71EilGtrUE

o Thoroughlywipe off oil from the mating surfaces of

c y l i n d e rh e a d a n d c o v e r .
r I n s t a l tl h e t w o d o w e l p i n s @ t o t h e c y l i n d e rh e a ds i d e .
o U n i f o r m l ya p p l yS U Z U K IB O N D" 1 2 1 6 " 1 o t h e c y l i n d e r
head surfaces.
f i f i q 9 9 O O O - 3 1 1 6 0S: U Z U K IB O N D " 1 2 1 6 "

NOTE:
Do not apply SUZUKI BOND "1276" to the camshaft
journals.
o I n s t a l tl h e c a p s@ t o e a c h c y l i n d e rh e a d c o v e r .
. A p p l y g r e a s et o t h e O - r i n g@ .
"A"
,6rggooo-2b030:suzuKrsupERcREAsE
o I n s t a l tl h e p l a t e@ .
NOTE:
When tightening the cylinder head cover bolts, the piston
must be at top dead center on the compression stroke.

. L i g h t l yt i g h t e nt h e c y l i n d e rh e a dc o v e r b o l t sd i a g o n a l l y ,
andthen if everythingis satisfactory,tightensecurelywith
a t o r q u ew r e n c ht o t h e s p e c i f i e dt o r q u e .
ptCytino"r headcoverbolt:
( M 6 ) : 1 1 N ' m ( 1 . 1 k g - m ,8 . O l b - f t )
( M B ) :2 3 N ' m ( 2 . 3 k g - m , 1 6 . 5 l b - f t )

Checkand adjustthe valveclearance.(Referto page2-4,

-5 and -6 for procedures.)
 ElrlGlttlE3-72

H E A DB O L T
L O C A T I O NO F C Y L I N D E R

Front cylinder R e a rc y l i n d e r

L:165 L:155

L:165

L:165
155

L: 165

L: Length
Unit: mm

H E A DC O V E RB O L T
L O C A T I O NO F C Y L I N D E R

Front cylinder head cover Rearcylinderhead cover

L: 20
L:245 L:245

L: 2A ',|40
L:
L: 30
r . an*/i\
L:25 L ! v v v

L: 25
L: 25
*o *o
L:2
L: 30 L:'30*@ L..25
L: 140 L..20
L: 2Q L: 40
L: 50
L: 30
L:25
L: 55 L : 2 4 5 L: 55 L: 50
L: 3o "6 Before installingthe stud bolt,
"1216" to the
L: 55 a p p l yS U Z U K B
I OND
*/A thread of cylinderhead cover side.
* @ A p p l yS U Z U K B "1216" to the
I OND
L: Length Unit:mm thread of bolt.
*@ Allenbolt
3-73 ENGIIIE

. Apply greaseto the new O-ring@.

fuggooo-2bo3o:suZUKr "A"
supERGREASE
o I n s t a ltlh e w a t e ro u t l e tu n i o nt o t h e N o . 2 ( F r o n t c) y l i n d e r
head cover.

Installthe gasket@ and the breathercover@ to the No.1

(Rear)cylinderhead cover.

. A p p l y g r e a s et o t h e n e w O - r i n g s@ .

fu99ooo-25030: sUZUKT "A"

supERGREAsE
o l n s t a l lt h e v a l v e i n s p e c t i o nc a p s .

Installthe generatorcover plug and the timing inspection

plug.

o I n s t a l tl h e h e a d c o v e r c a p s @ .
 CONTENTS
F''EL SYSTEM ..., 4- 1
F'JEL PI'MP ,' 4- 2
DESCRIPTION 4- 2
F ']E L P U MP R E MOV A L...,,.,... ...,,.4- 3
FUEL P'IMP INSPECTION 4- 3
FIJELTANK AND FUEL VALVE "'''" 4- 4
FUEL VALVE MECHANISM 4. 4
F''EL TANK REMOVAL ..'"... ... 4- 4
FUELFILTERREMOVAL ...." 4- 5
INSPECTIONAND CLEANING.,....",,, 4- 5
o A R B U R E T OR.'.... ...."' 4- 6
CONSTRUCTION 4. 6
SPECIFICATIONS 4- 8
t.D. NO. LOCATTON . 4- I
DIAPHRAGM AND PISTON OPERATION 4-1O
SLOW SYSTEM 4-11
TRANSIENTENRICHMENTSYSTEM 4-11
MAIN SYSTEM 4-72
STARTERSYSTEM 4-13
FLOAT SYSTEM
R E M O V A L. " . . ' . . ' . . ' . . . .4 - 1 4
DtsAssEMBLY."......'. .....4-17
CARBURETORCLEANING ,". 4.21
|NSPECT|ON..... 4-27
NEEDLEVALVE INSPECTION...",' .....4.21
F'IEL LEVEL INSPECTION.""",. ... 4.22
FLOAT HEIGHTADJUSTMENT "....,... 4-23
THROTTLEPOSIflON SWITCH INSPECTION..'.;'..'.. .' 4-24
REASSEMBLYAND REMOUNTING ../.......... 4-24
BALANCE OF CARBTJRETORS . 4-28
LUBRICATION SYSTEM 4-3O
OIL PRESSURE 4-3O
OIL FILTER 4-30
OIL PUMP 4-30
OIL SUMP FILTER , 4.3O
ENGINELUBRICATIONSYSTEM CHART 4-31
4.1 FUELAIIIDTUBRICATIO]II
SYSTEM

FUELSYSTEM
As shown in the followingfigure,the fuel systemis composedof the fuel tank, fuel valve,fuel pump,
and carburetors.The fuel pump is operatedby an electro-magnetic force and its electricalenergy
is suppliedfrom the battery.The fuel sent underpressureby the fuel pumpflows into the float chamber
when the float of the carburetorhas droppedand the needlevalve is open. When the needlevalve
closes,the pressureof the fuel in the hose connectingthe carburetorand the fuel pump increases,
and when the set pressureis reached,the operationof the fuel pump is stoppedby the fuel pressure
to preventexcessivesupply.

F u e lt a n k

F u e lp u m p

Fuel valve

#
'
------rt-_----

t vl"
vl
_-\___-\ /tr,\
l.-.4 To carburetor
--=- v
lvl
- - \ ' /
\--..
 FUELAIilDLUBRICATIOIil
SYSTEM4.2

F U E LP U M P
DESCRIPTION
Starting Engine:
In orderto supplementfuel supply when startingthe engineby turningthe starterswitch ON, cur-
rent @ is sent directlyfrom the battery,thus operatingthe fuel pump.

After start:
The current@ generatedat coils No.2 flows to the fuel pump control circuit. The control circuit
receivesthis current@ and sends signal@ to the SCR,turning it ON. When the SCR turns ON,
current@ is sent from the battery through the fuel pump relay,thus operatingthe fuel pump.

Engine stop
l g n i t i o nc o i l
@
;-<r-o'lit"h
I
Starter
switch

Clutch O
?
Battery switch

Starter e*
control
unit

F u e lp u m p

to side-stand
switch

W I R EC O L O R
B / W : B l a c kw i t h W h i t e t r a c e r
Y/G : Yellow with Greentracer
B/Y : Black with Yellow tracer
O/W: Orangewith White tracer
 SYSTEM
4.3 FUELANDTUBBICATION

F U E LP U M PR E M O V A L
o R e m o v et h e r i g h t f r a m e c o v e r . ( R e f e rt o p a g e 6 - 1 . )
o Turn the fuel valve "OFF" positionand disconnectthe
fuel hoses (O and @) trom the fuel pump.
r Disconnectthe fuel pump lead wire couplerand remove
t h e f u e l p u m p m o u n t i n gb o l t s .
O: Outlet hose
@ : lnlet hose
o Removethe fuel pump.

Gasolineis highlyflammableand explosive.Keepheat,

spark and flame away.

F U E LP U M PI N S P E C T I O N
o Using the multi circuit tester, measurethe voltage be-
tween the leadwires in the followingtable.lf the voltage
checkedis incorrect,replacethe fuel pump.

@ Multicircuitset
ossoo-25o08:
Diodetest ( ++- )
ffipf""t"r knobindication:
NOTE:
Whenmaking above test, it is not necessarYto remove the
fuel pump.
( U n i t :V ) oiw
@ Probeof tester to:

q)
#
@
q)
I

+
0 , 9 4 -1 . 3 41 . 4 - 1 . 6 7

L
(L
(t ) 1 . 1 8 -1, 5 0 1 . 1 3 - 1 , 5 0

NOTE:
lf the tester read under 1.4V, replace the battery of multi
circuit tester when do not connecting the tester probes.
WIRECOLOR
O/W: Orangewith White tracer
B/Y : Black with Yellow tracer
Y/G : Yellow with Green tracer
B/W: Black with White tracer
 FUELA]IIDTUBRIGATIOITI
SYSTEM4.4

FUELTANK AND FUELVALVE

FUELVALVE MECHANISM
"OFF" " O N " a n d " R E S " .
A vafveis providedat the top of the fuel valve leverand can switch over to ,
"OFF" both holes close.
With the valve "ON" (normal),the main passageopens.With the valve ,

"ON" position "OFF" position

FUELTANK REMOVAL
. Removethe frame cover and seat. (Referto page 6-1.)
o Turn the fuel valve to "OFF" position.
. Removethe fuel valve mounting bolt.
o Disconnectthe fuel valve outlet hose O.

o Remove the fuel tank mounting bolt.

a Disconnectthe fuel tank drain hose @.

a Removethe fuel tank.

Gasolineis highlyflammableand explosive.Keepheat,

spark and flame away.
4.5 FUEIAI'IDTUBRICATIOltl
SYSTEM

FUELFILTERREMOVAL
. Removethe fuel filter by removingthe bolts.

Gasolineis highlyflammableand explosive.Keepheat,

spark and flame away.
Gasketsand O-ring must be replacedwith new ones
to prevent fuel leakage.

NOTE:
When installing the fuel valve and the filter, connect the fuel
hoses "R" to "RES" and "O" to "ON".

I N S P E C T I OA
NN D C L E A N I N G
lf the fuel filter is dirty with sedimentor rust, fuel will not
f l o w s m o o t h l ya n d l o s si n e n g i n ep o w e r m a y r e s u l t .C l e a n
the fuel filter with compressedair.
 FUELA]'IDTUBRICATIOIII
SYSTEM4.6

CARBURETOR
CONSTRUCTION
No.2 (FRONT)CARBURETOR

/'r

'\--t'
\3

>t ^
@ e
tl,
%

@ Throttle cable @ Vain let @ let needlestopper plate

@ Pilot air let @ lVainjet holder @ Spacer
@ ftoat chamber @ Pilot jet @ e-ring
@ Carburetorbody @ Starter plunger @ let needle
@ Float @ Vacuume inspectionscrew @ Washer
@ Float pin @ Coastingvalve @ Spring
@ N e e d l ev a l v e @ Fuel hose @ Pistonvalve
@ Valve seat @ Air vent hose @ Needlejet
@ Drain screw @ Top cap @ Pilot screw
@ Seal ring @ Pistonvalve spring @ Lever
4.7 FUEIAiIDIUBRICATIOIII
SYSTEM

No.1 (REAR)CARBURETOR

(ea

"gh,
Vs,
va
z.
@-+
@*
,@"^u

,', \
{-<
@x 7.4
A V E
Y'-J, q/

@ I 9-ror
q Q)-€ Y Y
@--b
\-_@

"f
O Needlejet @ Pilot let @ Air vent hose
@ Coastingvalve @ Vacuum inspectionscrew @ .tet needlestopper plate
Drain screw @ pllot air jet @ Spacer
@
@ Gasket @ Throttle stop screw @ e-ring
@ Float pin @ Float chamber @ let needle
@ ftoat @ Carburetorbody @ Washer
@ Needlevalve @ Pilot screw @ Spring
@ Valve seat @ Starter plunger @ Pistonvalve
@ M a i nl e t @ Top cap
@ Needlevalve @ Pistonvalve spring
seat stopper screw
 SYSTEM4.8
FUEI.AIID TUBRIGATIOIU

SPECIFICATION
SPECIFICATION
ITEM E- I
E - O 2 , O 4 ,71, 2 2 , 2 4 , 2 5 , 3 4
Carburetortype BS36SS BDS36SS BS365S BDS36SS
(Rear) (Front) (Rear) (Front)
Bore size 36 mm €- e +-

LD.No. 48E6 + 48E9 <_

ldler/min. 1 200+100 e 1 2ooj 188 e

r/min umln
Fuel level 7 . 3 +0 . 5 m m 1 5 . 0 + 0.5 m m 7 . 3 + 0 . 5 m m 1 5 . 0 +0 . 5 m n
O . 2 9 +O . O 2i n O . 5 9 + 0 . 0 2i n l 0 . 2 9 + 0 . 0 2 i n 0 . 5 9 + O . 0 2i n
Float height 2 7 . 7+ 1 . 0 m m 9 . 1 + 1 . O m m2 7 . 7+ 1 . Om m 9 . 1 + 1 . O m m
1. 0 9 + O . O 4i n ) 0 . 3 6 + 0 . 0 4 i n 1.09 + O.04 in) 0 . 3 6 + O . O 4i n
M a i ni e t (M.J.) #100 #90 #100 #90
Jet needle (J.N.) 5D27-3 5 C 2 9 - 3 5D27-3 5C29-2
N e e d l ei e t (N.J.) P-3 P-4 P-3 P-4
Throttle valve (Th.V.) # 1 1 5 e <* <-

P i l o ti e t (P.J.) #45 #40 <-

P i l o ts c r e w (P.S.) PRE-SET ( 1 5 l e PRE-SET(13/+ P R E - S E (T2 % PRE-SET(1 3/+

t u r n s b a c k ) turns back) turns back) t u r n s b a c k )
Throttle cable play O . 5 - 1. O m m +- <_
0.02-0.04 in

SPECIFICATION
ITEM
E-O3,28 E- 33
Carburetortype BS36SS BDS36SS BS36SS BDS36SS
(Rear) (Front) (Rear) (Front)
Bore size 36 mm e e +-

LD.No. 48E7 <_ 48EB

ldlerimin. 1200+ 100 +- +-
r/min
Fuel level 7 . 3 + 0 . 5 m m 1 5 . 0 + 0 . 5m m 7 . 3 + O . 5m m 1 5 . 0 +0 . 5 m m
O . 2 9 +O . O 2i n : O . 5 9 + O . Oi2n ) O . 2 9 + 0 . 0 2i n : O . 5 9 + 0 . 0 2i n )
F l o a th e i g h t 2 7 . 7 +1 . 0 m m 9 . 1 + 1 , O m m 2 7 . 7+ 1 . 0 m m 9 . 1 + 1 . 0 m m
( 1 . 0 9+ O . 0 4i n ) 0 . 3 6 + 0 . 0 4 i n l( 1. O g+ 0 . 0 4 i n ) 0 . 3 6 + O . O 4i n
M a i ni e t (M.J.) # IDD #9n # laU #9D
Jet needle (J.N.) 5D83 5C43 5D83 5C43
N e e d l ej e t (N.J.) P.3M P.LIM P-JM P-qM
T h r o t t l ev a l v e (Th.V.) # 115 <-

Pilotjet (P.J.) #L+5 #LTE #Ll5 #Lln

P i l o ts c r e w (P.S.) PRE.SET PRE-SET PRE-SET PRE.SET
Throttle cable play O . 5 - 1. O m m +- e
O.O2-0.04in)
4.9 FUEL
AIIDIUBRICATIOil
SYSTEM

SPECIFICATION
ITEM
E-37
Carburetortvpe BS3655 ( R e a r ) B D S 3 6 5 5( F r o n t )
Bore size 36 mm
LD.No. 48EC <-

ldler/min. 1 2 O O +1 O Or / m i n .
Fuel level 7 . 3 + O . 5m m 1 5 . O +O . 5m m
( O . 2 9+ O . 0 2 i n ) ( O . 5 9+ O , O 2i n )
Float height 2 7 . 7 +1 . 0 m m 9 . 1+ 1 . Om m
( 1. 0 9 + O . O 4i n ) ( O . 3 6 + 0 . 0 4i n )
M a i ni e t (M.J.) #100 #90
Jet needle (J.N.) 5D27-3 5C29-3
N e e d l ej e t (N.J.) P-3 P-4
T h r o t t l ev a l v e (Th.V.) # 115 +-

P i l o tj e t (P.J.) #45 #40-

Pilot screw (P.S.) P R E - S E T( ' l 7 e t u r n s b a c k ) P R E - S E T( 1 e l at u r n s b a c k )
Throttle cable play O . 5 - 1 . Om m
( 0 . 0 2 - O . O 4i n )

I.D. NO. LOCATION

E a c hc a r b u r e t ohr a s l . D . N u m b e r@ s t a m p e do n t h e c a r b u -
retor body accordingto its specifications.
 SYSTEM4.10
FUEIAI'IDIUBRICATION

DIAPHRAGMAND PISTONOPERATION
whose venturicrosssectionareais increasedor decreased
The carburetoris a variable-venturitype,
automaticallyby the piston valve e which moves accordingto the negativepressurepresenton
the downstreamside of the venturi@. Negativepressureis admittedinto the diaphragmchamber
@ through an orifice@ providedin the piston valve @ '

Risingnegativepressureovercomesthe spring@ force, causingthe piston valve @ to rise to in-

Thus,air velocityin the ventu-
creasethe sideareaand thus preventthe air velocityfrom increasing.
ri passageis kept relativelyconstantfor improvedfuel atomizationand for securingoptimum ratio
of fuel/airmixture.

+::= NEGATIVE
PRESSURE
4.11 FUEIANDTUBRIGATIOil
SYSTEM

SLOW SYSTEM
This systemsuppliesfuel duringengineoperationwith throttlevalve@ closedor slightopened.The
fuel from float chamber@ is meteredby pilot jet @ where it mixes with air comingin through pilot
a i r j e t s ( + 1 a n d # 2 1 @ . T h i s m i x t u r e ,r i c h w i t h f u e l , t h e n g o e s u p t h r o u g hp i l o t p a s s a g et o p i l o t
screw @. A part of the mixture is dischargedinto the main bore out of by-passports @. The re-
mainderis then meteredby pilot screw @ and sprayedout into the main borethroughpilot outlet@.

TRANSIENTENRICHMENT
SYSTEM
The transientenrichmentsystemis a devicewhich keepsfuel/airmixtureratioconstantin ordernot
to generateunstablecombustionwhen the throttlegrip is returnedsuddenlyduringhigh speeddriv-
ing. For normaloperation,joiningof the air from upper part of carburetorinlet side to pilot air pas-
sageobtainsproperfuel/airmixtureratio.But if the throttlevalveis suddenlyclosed,a largenegative
pressuregeneratedon cylinderside is appliedto a diaphragm.The valve @which interlockswith
the diaphragmclosesan air passage,thus, the pressureflows out to the pilot air passage.
This is system to keep the combustionconditionconstant by varyingthe fuel/airmixture ratio by
c o n t r o l i n ga i r f l o w i n t h e p i l o t c i r c u i t .

Pilot air jet-2

ting valve
@

-+_
Pilot screw @ )
r
P i l o ta i r j e t - 1 @

I
_=.€)

{9
____J
JI
Pilot jet I
:
?----
-\r-- AIR

@ F U E L / A I RM I X T U R E

€ FUEL
 SYSTEM4.12
FUEIA]'IOTUBBIGATION

MAIN SYSTEM
As throttlevalve@ is opened,enginespeedrises,and this increasesnegativepressurein the ventu-
r i @ . C o n s e q u e n t ltyh e p i s t o nv a l v e@ m o v e s u p w a r d .
Meanwhile,the fuel in float chamber@ is meteredby mainjet @ , and the meteredfuel entersnee-
d l e j e t @ , i n w h i c h i t m i x e sw i t h t h e a i r a d m i t t e dt h r o u g hm a i n a i r j e t @ t o f o r m a n e m u l s i o n '
The emulsifiedfuel then passesthroughthe clearancebetweenneedlejet @ and jet needle@ , and
i s d i s c h a r g e di n t o t h e v e n t u r i@ , i n w h i c h i t m e e t s m a i n a i r s t r e a mb e i n gd r a w n b y t h e e n g i n e '
Mixtureproportioningis accomplishedin needlejet @ ; the clearancethroughwhich the emulsified
f u e l m u s t f l o w i n l a r g eo r s m a l l ,d e p e n d i n gu l t i m a t e l yo n t h r o t t l e p o s i t i o n '

Mainair
jet @

<- AIR

@ F U E L / A I RM I X T U R E

FUEL
M a i nj e t @ -
4.I3 FUELAIIIDTUBRICATION
SYSTEM

STARTERSYSTEM
Pullingup the startershaft @ , fuel is drawn into the starter
c i r c u i tf r o m t h e f l o a t c h a m b e r@ .
Starterjet @ metersthis fuel, which then flows into starter
p i p e@ a n d m i x e sw i t h t h e a i r c o m i n gf r o m t h e f l o a t c h a m -
ber @ . The mixture, rich in fuel content, reachesstarter
p l u n g e r@ a n d m i x e sa g a i nw i t h t h e a i r c o m i n gt h r o u g ha
passageextendingfrom main bore.
The two successivemixingsof fuel with air are such that
properfuel/airmixturefor startingis producedwhen the mix-
ture is sprayedout through starteroutlet @ into the main
bore.

(::: arn
,4: FUEL/AlR
-<NLEU MIXTURE

- FUEL

FLOAT SYSTEM
Floats@ and needlevalve@ are associatedwith the same
m e c h a n i s ms, o t h a t , a s t h e f l o a t s@ m o v e u p a n d d o w n , /
r-- \ \
t h e n e e d l ev a l v e @ t o o m o v e sl i k e w i s e . r.
-'-\ _.:l
r""
W h e n f u e l l e v e li s u p i n f l o a t c h a m b e r@ , f l o a t s@ a r e u p \ /
\ , (-"1
,
a n d n e e d l ev a l v e@ r e m a i n sp u s h e du p a g a i n s tv a l v es e a t . ('t
U n d e rt h i s c o n d i t i o n n
, o f u e l e n t e r st h e f l o a t c h a m b e r@ . )
As the fuel levelfalls, floats O go down and needlevalve
rt P
\
I
To No.2
@ unseatsitself to admit fuel into the chamber@ . carburetor
l n t h i s m a n n e r ,n e e d l ev a l v e@ a d m i t sa n d s h u t s o f f f u e l
alternatelyto maintaina practicallyconstant fuel level in-
s i d et h e f l o a t c h a m b e r@ .

Needlevalve
@

<I FUEL
 SYSTEM4.I4
AI'IDTUBRICATION
FUET

REMOVAL
o R e m o v et h e s e a t . ( R e f e rt o p a g e 6 - 1 . )
o Removethe frame cover, left and right.
r Removethe fuel tank. (Referto page 4-4.)
o Removethe frame head cover, left and right.

o Removethe throttle cable connectormountingscrew.

. R e m o v et h e N o . 2 ( F r o n t )a i r c l e a n e rb o x m o u n t i n gb o l t s .

. Loosenthe carburetorclamp screw.

. R e m o v et h e N o . 2 ( F r o n t )a i r c l e a n e rb o x .

Separate t h e r i g h t h a n d l e b asr w i t c h a n d d i s c o n n e ctth e

t h r o t t l ec a b l e .
Separatethe throttlecableconnectorand disconnectthe
throttle cables.

o Remove the choke knob mounting bolt.

4.15 FUEL
AlllDtUBRlCATl0lrl
SYSTEM

o Remove the munual box.

r Remove the battery.

o Loosenthe clamp screw.

o R e m o v et h e N o . 1 ( R e a r a
) i r c l e a n e rb o x m o u n t i n gb o l t s
and move the air cleanerbox to the rear.

Removethe frame struct plate and fuel tank mounting

bracket.

r Disconnectthe fuel h o s eO f r o m t h e f u e l p u m p .

o Loosenthe carburetorelamp screws, left and right.

 FUEI.
AI{DI.UBRICATIO]U
SYSTEM4.16

o Disconnectthe coupler.
o D i s c o n n e c t h e b r e a t h e rh o s e f r o m t h e N o . 1 ( R e a r )
c y l i n d e rh e a d .

Removethe throttle returningcable @ from the No.2

(Front)carburetor.

R e m o v et h e N o . 1 a n d N o . 2 c a r b u r e t o r sa l o n gw i t h t h e
s y n c h r o n i z i ncga b l e ,t h r o t t l ec a b l e s ,a i r v e n t h o s e sa n d
fuel hose attachedto the carburetors.
4.17 FUET
AI'IDI.UBRICATION
SYSTEM

@ T h r o t t l ep u l l i n gc a b l e
ing cable @ Throttle returningcable
@Throttle

@ F u e lh o s e

@Adluster

@Adjuster
@Adluster
@Screw @ T h r o t t l e p u l l i n gc a b l e @ s y n 6 n r o n i z i n gc a b l e

@ Throttle returningcable

Adjuster

@Adluster

R i g h ts i d e o f N o . 1 c a r b u r e t o r
@Throttle stop screw

NOTE:
Do not turn the synchronizing cable adjuster @.
Once removing the synchronizing cable or a carburetor body, it is necessary to balance the two car-
buretors.

CAUTION
Do not turn the screw @of the No.2 (Front)carburetor.

DISASSEMBLY
B e f o r ed i s a s s e m b l yp,r e p a r ea c l e a na n d w e l l l i t w o r k p l a c e
wherecarburetorcomponentscan be laidout nearlyand will
not get lost. Study the servicemanualcarburetordiagram
and familiarizeyourselfwith componentlocationsand the
different fuel circuits and their routing through the car-
buretor.
 FUEIAlrlDtUBRlCATl0tU
SYSTEM4-18

. R e m o v et h e s t a r t e rp l u n g e ra s s e m b l i e@
s fromthe No.1
and No.2carburetors.

o Removethe fuel hoses @, air vent hoses @, throttle

r e t u r n i n gc a b l e@ a n d t h r o t t l ep u l l i n gc a b l e s@ .
CAUTION
Do not turn the screw @of the No.2 (Front)carburetor.

NOTE:
Once removing the synchronizing cable or carburetor body,
it is necessary to balance the two carburetors.

o Removethe carburetortop cap @.

@ OSSOO-O9OO3:
lmpact driver set

A CAUTION
Do not blow the carburetorbody with compressedair,
beforeremovingthe diaphragm.lt may causea damage
to the diaphragm.

. Removethe pistonvalvereturnspring@ and pistonvalve

w i t h d i a p h r a g m@ .

r Removethe jet needlefrom the piston valve by remov-

ing the screws.
@ Pistonvalve
@ Screw
@ let needlestopper plate . $[6'$
@
@
@
Spacer
e-ring
let needle
iYT
6 d @6
*-"*l*
| |
6
| |
t m
@-
@ Washer
@ Spring
 SYSTEM
AI'IDTUBRICATION
4.19 FUEI.

o Remove the float chamber body @.

@ lmpactdriverset
ossoo-09o03:
CAUTION
Gasketand O-ringmust be replacedwith new ones to
prevent fuel leakage.

. Removethe float @ with the needlevalve @ nV remain-

ing the float pin @.

CAUTION
Do not use a wire for cleaning the valve seat.

. Removethe following parts.

@ Valve seat
@ eitot iet
@ wain let
@ ruainjet holder
@ Needlejet securingbolt
@ N e e d l ej e t
@ Pilot air jet

A CAUTION
Do not use a wire for cleaning the passage and jets.
 FUEIAItlDTUBRICATIOI'I
SYSTEM4-20

o U s e a 1 1 8 " s i z e d r i l l b i t w i t h a d r i l l - s t o pt o r e m o v et h e
p i l o ts c r e wp l u g .S e t t h e d r i l l - s t o p6 m m f r o m t h e e n d o f
t h e b i t t o p r e v e n td r i l l i n gi n t o t h e p i l o t s c r e w . C a r e f u l l y
d r i l l t h r o u g ht h e p l u g . Drill-stop

Threada self-tapping sheetmetalscrewintothe plug.Pull

on the screw headwith pliersto removethe plug. Care-
f u l l y c l e a na n y m e t a l s h a v i n g sf r o m t h e a r e a .
( F o rE - 0 3 , 1 8 , 2 8 a n d 3 3 m o d e l s )

C AU T I ON
Replacethe plug with a new one.

Slowlyturn the pilotscrew @ in clockwiseand countthe

n u m b e ro f t u r n s u n t i l t h e s c r e w i s l i g h t l ys e a t e d .M a k e
a note of how many turns were made so the screw can
be reset correctlyafter cleaning.
Removethe pilot screw @ with the spring,washer and
O-ring.

Removethe coastingvalve@ and spring@ nV removing

the screws.

o Remove the throttle valve screws @, E - r i n g@ a n d p u l l

out throttle valve plate.

CAUTION
Thesetwo screws are locked by punchingthese ends.
Once removingthe screws, they will be damaged.
 SYSTEM
ANDIUBBICATIOIil
4.21 FUEL

CLEANING
CARBURETOR

Somecarburetorcleaningchemicals,especiallydip-type
soakingsolutions,are very corrosiveand must be han-
dled carefully. Always follow the chemical manufac-
turer's instructionson properuse, handlingand strage.

Cleanall jets with a spray-typecarburetorcleanerand

blow dry with compressedair,
Cleanall circuitsof the carburetorthoroughly- not just
the perceivedproblemarea.Cleanthe circuitsin the car-
buretorbody with a spray-typecleanerand allow each
circuitto soakif necessaryto loosendirt and varnish'Blow
the body dry with compressedair.
CAUTION
Do not use wire to cleanjets or passageways.Wire can
damagejets and passageways.lf the componentscan-
not be cleanedwith a spray cleanerit may be neces-
saryto use a dip-typecleaningsolutionand allow them
to soak.Always follow the chemicalmanufacturer'sin-
structionsfor proper use and cleaningof the carbure-
tor components.

the carburetorwith new sealsand gaskets.

r Reassemble

INSPECTION
C h e c kf o l l o w i n gi t e m s f o r a n y d a m a g eo r c l o g g i n g .
" Pilotjet * Starter jet * M a i n b l e e dp i p e h o l e
" M a i nj e t * O-rings It
Float
* M a i na i r j e t " Pistonvalve diaphragm * Throttle shaft oil seal
" Pilot air jet * Jet needle Pilot outlet and by-passhole
* Needlevalve * Needlejet * Coastingvalve
* Valve seat " N e e d l ej e t a i r b l e e d i n gh o l e

NEEDLEVALVE INSPECTION
lf foreignmatter is caught betweenthe valve seat and the
n e e d l e t, h e g a s o l i n ew i l l c o n t i n u ef l o w i n g a n d c a u s ei t t o
overflow. lf the seat and needleare worn beyondthe per-
m i s s i b l el i m i t s ,s i m i l a tr r o u b l ew i l l o c c u r .C o n v e r s e l yi f, t h e
needlesticks,the gasolinewill not flow into the float cham-
b e r .C l e a nt h e f l o a t c h a m b e ra n d f l o a t p a r t sw i t h g a s o l i n e '
l f t h e n e e d l ei s w o r n a s s h o w n i n t h e i l l u s t r a t i o nr,e p l a c e
it togetherwith a valve seat. Cleanthe fuel passageof the
CORRECT INCORRECT
m i x i n gc h a m b e rw i t h c o m p r e s s e da i r .
 FUEIANDTUBRICATIO]'I
SYSTEM4.22

FUELLEVELINSPECTION
o R e m o v et h e f r a m e c o v e r a n d s e a t . ( R e f e rt o p a g e 6 - 1 . )
o Removethe fuel tank. (Referto page 4-4.)
o Removethe enginesprocketcover and tool case @.

o Removethe box cover @

o R e m o v et h e P A I Rc o v e r @ . ( p o r E - 0 3 , 1 8 , 2 8 , 3 3 )

( F o rE - O 3 , 1 8 , 2 8 , 3 3 )
o Remove the box @.
r Disconnect the PAIR reed valve hoses @ and PAIR con-
trol valve vacuum hose @. (For E-O3, 18, 28, 33)

( F o rE - O 3 , 1
8,28,33)
r Removethe bracket@.
o Removethe PAIRsystem bracket@. (for E-03, 18, 28,
33)

( F o rE - 0 3 . 18 , 2 8 . 3 3 )
Disconnectthe fuel hose@ and connecta separatefuel
t a n k t o s u p p l yf u e l .
4.23 FUEtAI'IDTUBRIGATIO]II
SYSTEM

o Connectthe fuel levelgaugeto the one of two carbure-

t o r d r a i nn i p p l e s .

EE 09913-10730: Fuel level gauge

o KeeFthe motorcycleupright position.

NOTE:
When measuring the fuel level, inflate the tires.to the speci-
fied pressure and do not lift the tires off the ground.

r Loosenthe drain screw.

Gasolineis highlyflammableand explosive.Keepheat,

spark and flame away.
r Bleedthe air trappedin the fuel level gaugecompletely'
o Whilekeepingthe fuel levelgaugevertically,measurethe
fuel level@at the carburetorbody as shown in the right
illustrations.
N o . 1 ( R e a r )C a r b u r e t o r
NOTE:
Move the fuel levelgauge downward only when setting its
scale at the carburetor body.
lf moving the fuel level gauge upward, the fuel level@rises
from correct level.
F u e ll e v e l@ ( f u o . t l : 7 . 3 + 0 . 5 m m ( 0 . 2 9 + 0 . 0 2 i n )
( N o . 2 ) :1 5 . 0 + O . 5m m ( 0 . 5 9 + 0 . 0 2i n )

N o . 2 ( F r o n t )C a r b u r e t o r
e Adjustthe fuel level@as necessaryto bringthe fuel height ' .i.t,....
: l

@to the specifiedbelow. ;r,;ilillt:;ri; . . - l

, d3s,ui.l.
, . t "
'
iti;iii.iili:,[l -
FLOATHEIGHTADJUSTMENT
r To checkthe float height,invertthe carburetorbody, with
the float arm kept free, measurethe height@while float
arm is just in contactwith needlevalve by usingcalipers.
e Bendthe tongue@ of the float arm as necessaryto bring
the height @to the specifiedvalue.
Float height @ (tUo.1l: 27 .7 + 1 .O mm ( 1 .09 + O.O4in) No.1 (Rear)Carburetor
( N o . 2 ) 9: . 1 + 1 . 0 m m ( 0 . 3 6 + 0 . O 4i n )

@ verniercalipers
ossoo-2o101:

N.o.2(Front)Carburetor
 SYSTEM4-24
FUELANDTUBRICATION

THROTTLEPOSITIONSWITCH INSPECTION
(Exceptfor E-03, 28, 33 models)
r Inspectthe throttle positionswitch for continuitywith a Colar B
B
Position
tester.
ON
(Full-throttle) C
NOTE:
When making above test, it is not necessarY to start the OFF
engine. B: Black

R E A S S E M B LA
YN D R E M O U N T I N G
Reassemble in the reverseorder
and remountthe carburetors
of disassemblyand removal.Payattentionto the following
points:

THROTTLEVALVE
o Set eachthrottle valve in such a way that its top end @
meetsthe foremostby-pass@. This is accomplishedby
turningthe throttlestop screw and throttlevalvebalance
screw.
. Apply a smallquantityof THREADLOCK" 1342" to the
throttlevalvemountingscrewsandtightenit to the speci-
fiedtorque.

@ 99ooo-32obo:THEADLocK "1942"

CIlfhrottle valve mountingscrew: 1.0 N'm

(0.1 kg-m,0.7 lb-ft)

C AU T I ON
Face the stamped side of throttle valve to outside.

COASTINGVALVE
r W h e ni n s t a l l i n g t h e c o a s t i n gv a l v et o t h e b o d y ,a l i g nt h e
h o l e s@ .
o Tightenthe coastingvalvecovermountingscrewsto the
s p e c i f i e dt o r q u e .
(TlCoasting valve cover mounting screw:
2 . 0 N ' m ( O . 2k g - m , 1 . 5 l b - f t )

PILOTSCREW
o A f t e rc l e a n i n gr,e i n s t a l l t h p
e i l o ts c r e wt o t h e o r i g i n asl e t -
t i n g b y t u r n i n gt h e s c r e wi n u n t i li t l i g h t l ys e a t s ,a n dt h e n
b a c k i n gi t o u t t h e s a m en u m b e ro f t u r n s c o u n t e dd u r i n q
P l u g@
disassembly.
. I n s t a l nl e w p l u g@ O Vt a p p i n gi t i n t o p l a c ew i t h a p u n c h . Carburetor
body
( F o rE - 0 3 , 1 8 , 2 8 a n d 3 3 m o d e l s )

CAUTION
Replace the O-ring with a new one.
4.25 FUEI-AIUDTUBRICATION
SYSTEM

PILOTAIR JET
o Tightenthe pilot air jet to the specifiedtorque.

[ t e i t o t a i rj e t : 0 .7 N .m (0 .0 7ks-m,0 .5 lb- ft)

NEEDLEJET
o A l i g nt h e g r o o v e sO o f t h e n e e d l ej e t w i t h t h e p i n @ a n d
t h e n i n s t a l lt h e m a i n j e t .

Alignthe groovesO of the needlejet with the pin @ and

t h e n i n s t a l lt h e n e e d l ej e t s e c u r i n gb o l t .

PILOTJET, MAIN JET AND VALVE SEAT

. Tightenthe following parts to the specifiedtorque.

[ t e i l o t j e t @: 1 .0 N 'm (0 .1 ks-m.0 .7 lb- ft)

Pilotjet @: 0.8 N'm (0.08 kg-m, 0.6 lb-ft)
M a i nj e t @ : 1 . 8 N ' m ( 0 . 1 8 k g - m , 1 . 3 l b - f t )
Valve seat retainer@: 1.0 N'm (0.1 kg-m, 0.7 lb-ft)
Needtejet securingbolt @: 1.8 N'm
( 0 . 1 8 k g - m ,1 . 3 l b - f t )
 SYSTEM4-26
FUEIAI'|DtUBRlCATl0lu

FLOATCHAMBER
o Tightenthe float chamberbody mountingscrewsto the
s p e c i f i e dt o r q u e .

[lrlo"t chamberbody mouting screws @:

2.0 N'm (0.2 kg-m,1.4 lb-ft)

PISTON VALVE AND CARBURETORTOP CAP

o P l a c et h e t a b @ o f d i a p h r a g mt o t h e N o . 1 a n d N o ' 2 c a r -
buretors properly.
o Align the hole of diaphragm with the protrusion @of the
N o . 2 c a r b u r e t o rt o p c a p .
o T i g h t e n t h e t o p c a p s c r e w s t o t h e s p e c i f i e dt o r q u e .

0 top cap screw @: 3.5 N'm (O.35 kg-m, 2'5 lb-ft)

Top cap screw @: 2.O N'm (0.2 kg-rn, 1.4 lb-ft)

STARTERPLUNGER
o Tightenthe starterplungerholderto the specifiedtorque'

r o l d e r@ : 2 . 5 N ' m ( O . 2 5k g - m ,1 ' 8 l b - f t )
C I l S t " t t " t p l u n g eh
Starterplungerholder@: 4.0 N'm (0.4 kg-m, 3'O lb-ft)
NOTE:
Apply a small quantity of grease to the starter plunger O-ring'
suPER "A"
GREASE
fu99ooo-2s03o:suZUKt
C A U T I ON
Replacethe O-ringswith new ones.
4.21 FUELANDTUBRICATIOIII
SYSTEM

THROTTLECABLES
Pullingcables X:Y
o Equalizethe throttle pullingcables'innerlengthat the con-
nectorsideend by turningthe adjusterafter looseningthe
lock nuts.
. Tightenthe lock nuts.

Returningcable
r Adjust the throttle returninginner cable O to the play
s h o u l db e 1 - 2 m m { 0 . O 4 - 0 . 0 8 i n ) b y t u r n i n gt h e a d -
juster after looseningthe lock nut.
NOTE:
* Be careful not to twist the throttle cables
@ O.

CARBURETOR CLAMP
o Locatethe carburetorclamps,as shown in the illustrations.

4 A i r c l e a n e rs i d e

,\
E n g i n es i d e

j Jri-
A_r.}-
v\/
Engineside A i r c l e a n e rs i d e

o After all work is completed,mountthe carburetorson the

engineand the following adjustmentsare necessary.
* E n g i n ei d l e R P M . . , . P a g e2 - 9
* Throttle cable play . Page 2-9
 SYSTEM4.28
FUEIA]'IDIUBBICATIOI'I

BALANCEOF CARBURETORS

@ T h r o t t l e p u l l i n gc a b l e @ Throttle returningcable
O T h r o t t l e p u l l i n gc a b l e

@Fuel hose

@Adjuster

@Adluster

@Screw @Adjuster
@ S y n c h r o n i z i n gc a b l e
@Throttle pulling cable

@ Throttle returningcable
Adjuster

Adjuster

@Throttle stop screw

Right side of No'1 carburetor

NOTE:
Once removing the synchronizing cable @or carburetors,
it is necessary to balance the two carburetors.
This sectionexplainsthe balancingprocedurefor two car-
buretorsby using specialtool.

@! balancerset
ossr3-13121:Garburetor
(09913-131 4O: Adapter)
a R e m o v et h e f r a m ec o v e r sa n d s e a t . ( R e f e rt o p a g e6 - 1 . )
o Removethe fuel tank. (Referto page 4-4')
a Connecta separatefuel tank to the fuel pump and fuel
s h o u l db e s u p p l i e d .
Startup the engineand run it in idlingconditionfor warm-
ing up.
Stop the warm-up engine.
4.29 FUEIAIIIDTUBRICATIOIII
SYSTEM

CALIBRATINGEACH GAUGE(at idle speed)

o R e m o v et h e v a c u u mi n s p e c t i o ns c r e w f o r N o . 2 c a r b u r e -
tor and installthe adapterwith gasket.

o C o n n e c to n e o f t h e f o u r r u b b e rh o s e s o f t h e b a l a n c e r
gaugeto this adapter,and start up the engine,and keep
it runningat idle speed by turning throttle stop screw.

NOTE:
The idle speed is different amang the countries. (Refer to
pages 4-8 and -9.)

o T u r n t h e a i r s c r e w @ o f t h e g a u g es o t h a t t h e v a c u u m
a c t i n go n t h e t u b e o f t h a t h o s e w i l l b r i n gt h e s t e e lb a l l
@ i n t h e t u b e t o t h e c e n t e rl i n e @ .

After makingsure that the steel ball stays steady at the

centerline,disconnectthe hosefrom the adapterand con-
nectthe next hoseto the adapter.Turn air screwto bring
the othersteelball@ to the centerline.Now the balancer
h a s b e e nc a l i b r a t e d .

BALANCINGCARBURETORS (at idle speed)

o Removethe vacuuminspectionscrew @ from No.1 car-
buretorand installthe adapterwith gasket.
o C o n n e c te a c h c a l i b r a t e db a l a n c e rg a u g e h o s e t o t h e i r
respectiveadapters.
 SYSTEM4-30
FUELA]'IDTUBRICATIO]II

o S t a r t u p t h e e n g i n e ,a n d k e e p i t r u n n i n ga t i d l e s p e e d .
o Underthis condition,seeif the two steelballsstay equally
at the centerlevelline,as they should,to signifythat the
two carburetors are in balance:if not, loosenthe lock nut
andturn the synchronizing adjuster@and the throttlestop
screw @ to bring the steel ballsto the center level line
b y k e e p i n gt h e e n g i n er u n n i n ga t i d l e s p e e d .

NOTE:
lf turning the synchronizing adiuster, it is necessary to X-Y
separate the throttle cable connector and equalize the throt-
tle pulling cables' inner length at the connector.

SYSTEM
LUBRICATION
OIL PRESSURE
Referto page 2-2O.

OILFILTER
Referto page 2-8.

OIL PUMP
R e f e rt o p a g e3 - 4 6 .

O I L S U M PF I L T E R
l f t h e o i l s u m p f i l t e r i s d i r t y w i t h s e d i m e n to r r u s t , o i l w i l l
not flow smoothly.Cleanthe oil sumpfilterwith compressed
a i r . ( R e f e rt o p a g e 3 - 2 2 , - 2 3 a n d - 5 2 . )
4.31 FUETANDLUBRIGATIOIiI
SVSTEM

ENGINELUBRICATION
SYSTEMCHART

IlITAIG
GAMFAGE
I]ITIIG,ETHIUST l t , rtr, rtr, tt t
UATUES A]Il|SPRI]IGSl l t, l t t ,
) ) I

ARM
II{TIIGR|IGIGR
l T @
I
GAirslilflR.JounllAt |t@1
tl II{TAKE
RIICIGR
,r,
c ARTIISHAFT cHilil| I
I cnm
-r_____--_---r I nnm
sunrr I
T- i A
I

I GI]ISIIAFT
t. JI|UR]IAL j @
I , t +

1+'fu#T"'lffi
l l T ^u l"U]{DEB
WA!
I
CYLI]II|ER
HEAD I Prl
iTol{A1{0 -----T-----
I F!$T0NPtl{ | PlST0llPll{ | I
1t0.2GYHI|DER tl l
ln i,', [Tt l.f GYLlllDER ti t' r,, r t
I i^t
f ,
l ,
1t0.tG 1{0.2C0lrnotl
(lII.JET BIGETt0 0rr N0zztE I ot.lrr I BIGEl{I| oll ltozztE
STIRTER
GTUTCH
BEARIl{G
a
l-- J(|UR]IAL
[. CRAI{K R,CRAI{K
JIIURI{AT
r l
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MAIN GALLERY
i
OII JET
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,
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t,t,

OIL PAN:
 CONTENTS
cooLtNGsYsrEM """""" 5- 1
DESCRTPTTON """""""'5- 1
CONSTRUCTION 5- 2
COOLANT ........'..
ENGTNE "" 5- 4

NADIATOR AND WATER HOSES 5. 5

R E M O V A L. . - . . . ' . . . . 5- 5
....-...-'.
\ NS P E C T |ON 5- 6
INSTALLATION ,,, 5- 7

cooLING FAN ...... "' 5- 8

RE MOV A L......" " . 5- 8

INSPECTION
INSTALLATION 5- 9
COOLING FAN THERMO-SWITCH ... 5. 9

RE MOV A L....." ' 5- I

\ NS P E C T \ON ..." ...' 5- 10
INSTALLATION ..,. 5-1O

ENGINECOOLANT TEMPERATURE SWITCH .....'5.11

R E M O V A L. " . . . ' . . " "" 5-11

\NSPECTION """"' 5-11

INSTALLATION . 5-17

WATERPIIMP ....., 5-12

R E MOV A L....' 5- 12
INSPECTIONAND DISASSEMBLY ,,.. 5.74
REASSEMBLYAND INSTALLATION 5-15
5-t cooHtuGSYSTEM

COOLINGSYSTEM
DESCRIPTION
The engineis cooled by coolant set in forced recirculationthroughjackets formed in the cylinder
a n d h e a d ,a n d t h r o u g ht h e r a d i a t o r F
. o rt h e w a t e r p u m p ,a h i g h - c a p a c i tcye n t r i f u g apl u m p i s u s e d .
The radiatoris a tube-and-fintype made of aluminummaterial,which is characterized by lightness
in weight and g o o d h e a td i s s i p a t i o n .

The coolingfan, beinglocatedbehindthe radiator,is securedto the frame down tube by the bolts.
The fan drivemotoris automatically
controlledby the thermo-switch. This switch remainsopenwhen
oC
of enginecoolantis low, but it closesat about1Ob (221oFlof risingenginecoolant
the temperature
temperatureto set the fan in motion.

Reservoir

Radiator
 SYSTEM
Gooillrtc 5.2

CONSTRUCTION

@ Enginecoolant reservoirtank
@ Reservoirtank hose
@ Radiatorcap
@ Radiatorcover
@ Radiator
@ C o o l i n gf a n

@ Radiatormounting bolt
@ Coolingfan thermo-switch
@ Enginecoolant temperatureswitch
@ Coolingfan mounting bolt

f;
\

e )
\ /

s/
\ /

"{

re>

\
)

is//
!TEM N'm kg-m lb-ft
@ 6 0.6 4.5
@,o 12 1.2 8.5
@ 6 0.6 4.5
 SYSTEM
5.3 Co0LrrtIG

@ Water pump ass'y

@ Bearing
@ o-ring
@ oil seal
@ M e c h a n i c asl e a l
@ l m p e l l e rs h a f t
@ lmpeller
@ Water pump cover

@ lmpellersecuringbolt
@ Water pump cover screw
@ Water pump mounting bolt
@ Clamp

? e\

Kq

ITEM N'm kg-m tb-ft

@ 8 0.8 6.0
@,o 10 1.0 o.7
@ 2.3 o.23 1.65
 co0HitcSYSTEM
5.4

E N G I N EC O O L A N T
At the time of manufacture, the coolingsystemis filledwith
Anti-freeze
a 50 : 50 mixtureof distilledwater and ethyleneglycolanti- Freezingpoint
density
freeze.This 5O : 50 mixturewill providethe optimumcor- -310C (-24"F1
5Oo/o
rosionprotectionand excellentheat protection,and will pro-
55o/o -400c (-400F)
tect the coolingsystemfrom freezingat temperaturesabove
-310C (-24"F1. 60o/o -550C (-670F)
lf the motorcycleis to be exposedto temperaturesbelow ('F) ('c)
- 3 1 o C ( - 2 4 o F l , t h i s m i x i n gr a t i os h o u l db e i n c r e a s e d
up
32 0
1 4 .10
to 55% or 600/oaccordingto the figure.
€ ' 4 .20 \
A CAUTION E. .22 -30
* Use a high quality ethyleneglycol base anti-freeze, .E -40 -40 I
mixedwith distilledwater. Do not mix a alcoholbase
N
q)
I .se -50
I
tL
anti,freezeand different brands of anti-freeze.
-76 -60
* Do not put in more than 6O7oanti-freezeor lessthan a
t
-94 -70
50o/o.(Referto Right figure.)
* Do not use a radiator anti-leakadditive.
20 40 60 80 100
Density (%l
50% Enginecoolant includingreserve Fig' 1 Engine coolant density-freezing
point curve.
Anti-freeze 7 3 O m l ( 1 . 5 / 1 . 3U S / l m p .p t )
Water 7 3 O m l ( 1 . 5 / 1 . 3U S / l m p p. t)
("F) ("c)
302 1 5 0

284 1 4 0 1.5 or
'6
266 r 3 0 o.s3
.g 248 120
3 23o r 1 0 o (,B
212 1 0 0

D e n s i t y( % )

Fig. 2 Engine coolant density-boiling

point curve.

* You can be injuredby scaldingfluid or steam if you open the radiatorcap when
the engineis hot. After the enginecools,wrap a thick cloth aroundcap and care-
fully removethe cap by turning it a quarterturn to allow pressureto escapeand
then turn the cap all the way off.
* The engine must be cool before servicing the cooling system.
* The coolant is harmful;
. lf it comes in contact with skin or eyes, flush with water.
. lf swallow it accidentally,induce vomiting and call physician immediately.
. Keep it away from children.
5-5Cooulrlc
SYSTEM

RADIATORAND WATER HOSES

REMOVAL
o Removethe left frame cover.
o Removethe seat and the fuel tank.
( R e f e rt o p a g e s6 - 1 a n d 4 - 4 . )
. Removethe frame head cover.

o P l a c ea p a n b e l o w t h e e n g i n e .
I Removethe radiatorcap @ and disconnectthe water hose
@ from the radiator,then drain engine coolant.

Do not open the radiatorcap when the engineis hot,

as you may be injuredby escaplnghot liquid or vapor.
Coolantmay be harmful if swallowed or if it comes
in contact with skin or eyes. lf coolant gets into the
eyesor in contact with the skin, flush thoroughlywith
plenty of water. lf swallowed, induce vomitting and
call physician immediately!

o Disconnect the water hose @ from the front cylinder head,

Disconnectthe reservoirtank hose @ from the conduc-

tion caseand removethe conductioncasemountingbolt.

Disconnectthe enginecoolanttemperatureswitch lead

wire coupler.
Removethe radiatormounting bolts.
 SYSTEM
cooUI'tG 5.6

o Disconnectthe coolingfan thermo-switchleadwire cou-

pler and removethe radiator.

INSPECTION
COOLINGSYSTEMINSPECTION
Beforeremovingthe radiatorand drainingthe enginecoolant,
inspectthe coolingsystem for tightness.
o Removethe seat and the fuel tank. (Referto pages6-1
and 4-4.1

. Removethe frame head cover.

o Removethe radiatorcap and connect the tester to the
filler.
o G i v e a p r e s s u r eo f a b o u t 1 2 0 k P a ( 1 . 2 k g / c m z ,1 7 p s i )
and seeif the systemholdsthis pressurefor 1Oseconds.
l f t h e p r e s s u r es h o u l df a l l d u r i n gt h i s 1 O - s e c o nidn t e r v a l ,
it meansthat thereis a leakingpointin the system'In such
a case,inspectthe entiresystemand replacethe leaking
componentor part.

* Do not removethe radiatorcap when the engineis hot'

* When removingthe radiatorcap tester, put a rag on
the filler to prevent spouting of engine coolant.

CAUTION
Do not exceedthe radiatorcap releasepressure,or the
radiator can be damaged.

RADIATORCAP INSPECTION
Test the radiatorcap for releasepressureby usingthe radi-
ator tester in the following manner:
o Fit the radiatorcap to the tester,as shown, and buildup
pressureslowly by operatingthe tester. Make sure that
t h e p r e s s u rbeu i l d - u spt o p sa t 1 1 0 + 1 5 k P a( 1 . 1 + 0 . 1 5
k g / c m z ,1 5 . 6 + 2 . 1 p s i ) a n d t h a t , w i t h t h e t e s t e r h e l d
standstill,the cap is capableof that pressurefor at least
10 seconds.Replacethe cap if it is found not to satisfy
either of these two requirements. Radiatorcap tester R a d i a t o rc a p

Radiatorcap valve
releasepressure:1 10 + 15 kPa
( 1 . 1+ O . 1 5 k g / c m 2 ,1 5 . 6+ 2 . 1 p s i )
5.7 COOTIITG
SVSTEM

RADIATORINSPEGTION AND CLEANING

Roaddirt or trash stuck to the fins must be removed.Use
of compressedair is recommendedfor this cleaning.Cor-
rugatedfins bent down or dentedcan be repairedby straight-
ening them with the blade of a small screwdriver.

WATER HOSES
Any water hose found in a crackedconditionor flattened
must be replaced.Any leakagefrom the connectingsection
should be correctedby propertightening.

INSTALLATION
The radiatoris to be installedin the reverseorder of the
removalprocedure.Pay attentionto t h e f o l l o w i n gp o i n t s :

RADIATORMOUNTINGBOLTAND CLAMP
r Tightenthe radiatormountingbolts @ and clamps@ to
the specifiedtorque.

S n"Oi"tor mountingbolt O: 6 N'm (O.6 kg-m, 4.5 lb-ft)

G f a m p@ : 2 . 3 N ' m { 0 . 2 3 k g - m , 1 . 6 5 l b - f t )

. Be sureto routethe radiatorhoses.(Referto page8-18.)

o After installingthe radiator,be sureto add enginecoolant:
r e f e rt o p a g e 2 - 1 0 a n d - 1 1 f o r r e f i l l i n gi n f o r m a t i o n .
 cooutltcSYSTEM
5-8

COOLINGFAN
REMOVAL
o Removethe coolingfan mounting bolt.
o D i s c o n n e ctth e c o o l i n gf a n l e a d w i r e c o u p l e re .

. R e m o v et h e e n g i n em o u n t i n gb o l t @ .
. Removethe right frame down tube.

e Removethe radiatormounting bolts.

Move the radiatorforward and then removethe cooling

fa n .
5-9 G00tll'lcSYSTEM

INSPECTION
Test'thecoolingfan drivemotorfor loadcurrentwith an am-
meter connectedas shown in the illustration.
The voltmeteris for makingsurethat the batteryapplies12 Fan motor
volts to the motor. With the motor with electricmotor fan
Battery
r u n n i n ga t f u l l s p e e d ,t h e a m m e t e rs h o u l db e i n d i c a t i n gn o t
more than 5 amperes.
lf the fan motor does not turn, replacethe motor assembly
with a new one.
NOTE:
When making this test, it is not necessary to remove the
cooling fan.

INSTALLATION
The coolingfan is to be installedln the reverseorderof their
removalprocedure.Pay attentionto the following point:
o Tightenthe enginemountingbolts,framemountingbolts,
radiatormountingbolts and coolingfan mountingbolts
to the specifiedtorque.
p enginemountingbolt @: 88 N'm (8.8 kg-m, 63.5 lb-ft)
Framemountingbolt @: 5O N'm (5.0 kg-m, 36.0 lb-ft)
Framemountingbolt @: 25 N'm (2.5 kg-m, 18.0 lb-ft)
Radiatormountingbolt @: 6 N'm (0.6 kg-m, 4.5 lb-ft)
Coolingfan mountingbolt @: 6 N'm (0.6 kg-m, 4.5 lb-ftl

C O O L I N GFAN THERMO.SWITCH
REMOVAL
o Removethe r a d i a t o r .( R e f e rt o p a g e s5 - 5 a n d - 6 . )
o Removethe coolingfan thermo-switch@.
 5-10
cooililGSYSTEM

INSPECTION
The thermo-switchmust be checkedfor its temperature-
i n i t i a t e dc l o s i n ga c t i o na t t h e s p e c i f i c a t i ovna l u eo f 1 O 5 o C
( 2 2 1 o F lb y t e s t i n gi t a t t h e b e n c ha s s h o w n i n t h e f i g u r e '
Connectthe thermo-switchto a circuittester and placeit
i n t h e o i l c o n t a i n e di n a p a n , w h i c h i s p l a c e do n a s t o v e ;
heat the oil to raise its temperatureslowly, and read the
c o l u m nt h e r m o m e t e w r hen the switch closes.
Thermo-switchspecification
O F F- O N A p p r o x .1O 5o C ( 2 2 1 o F l
ON --+ OFF A p p r o x .1 O 0 o Cl 2 1 2 0 F l

A C AU T I ON
Do not allow the switch to touch the parl, or false read-
ing will result.

INSTALLATION
. A p p l y g r e a s et o t h e O - r i n g '
"A"
supERGREAsE
fuggooo-2so3o:sUZUKt
o Tighten the cooling fan thermo-switch to the specified
torque.

[t cooling fan thermo-switch:12 N'm

(1.2 kg-m,8.5 lb-ft)

A CAUTION
Take special care when handling the thermo-switch.
It may cause damage if it gets a sharp impact.
Replacethe O-ringwith a new one.

o Tightenthe radiatormountingboltse and clamps@ to

t h e s p e c i f i e dt o r q u b .

S R"ai"tor rnountingbolt O: 6 N'm (0.6 kg-m, 4.5 lb-ft)

C l a m p@ : 2 . 3 N ' m ( 0 . 2 3 k g - m , 1 . 6 5 l b - f t )
o A f t e r i n s t a l l i n tgh e c o o l i n gf a n t h e r m o - s w i t c hb, e s u r et o
a d d e n g i n ec o o l a n t .( R e f e tr o p a g e2 - 1 Oa n d - 1 1 . )
5.11CooL|]ilG
SYSTEM

ENGINECOOLANTTEMPERATURE
SWITCH
REMOVAL
o Removethe radiator.(Referto pages 5-5 and -6)
o Removethe enginecoolant temperatureswitch @.

INSPECTION
. Inspectthe enginecoolanttemperatureswitch in the same
mannerof the coolingfan thermo-switchinspection.
Enginecoolant temperatureswitch
OFF' ON A p p r o x .1 2 0 " C ( 2 4 B " F l
ON --+ OFF A p p r o x .1 1 3 " C ( 2 3 5 . 4 ' F )

CAUTION
Do not allow the switch to touch the pan, or false read-
ing will result.

INSTALLATION
. A p p l y g r e a s et o t h e O - r i n g .

fuggooo-2bo3o: sUZUKT "A"

supERGREASE
r Tighten the engine coolant temperatureswitch to the
specifiedtorque.

[t engine coolant temperatureswitch:

1 2 N . m ( 1 . 2 k g - m ,8 . 5 l b - f t )
A CAUTION
Take specialcare when handlingthe engine coolant
temperatureswitch. lt may cause damage if it gets a
sharp impact.
Replacethe O-ringwith a new one.
. T i g h t e nt h e r a d i a t o rm o u n t i n gb o l t sO a n d c l a m p s@ t o
the specifiedtorque.

S n"Oi"tor mountingbolt @: 6 N.m (0.6 kg-m, 4.5 lb-ftl

C l a m p@ : 2 . 3 N ' m ( 0 . 2 3 k g - m , 1 . 6 5 l b - f t )

After installingthe enginecoolanttemperatureswitch, be

s u r et o a d d e n g i n ec o o l a n t .( R e f e tr o p a g e2 - 1 0 a n d - 1 1 . )
 5-12
SYSTEM
co0ulllG

WATER PUMP
REMOVAL
o Removethe seat and fuel tank. (Referto pages6-1 and
4-4.1
o Removethe frame head cover.
o Drain enginecoolant. (Referto p a g e2 - 1 0 . )
o Drainengineoil. (Referto page 2 - 8 . 1

o Removethe gearshiftarm O.
r Removethe swingarmpivot cover@ and enginesprock-
et cover @.

a Removethe left front footrest bracket@.

a Removethe rear c y l i n d e re x h a u s tp i p e @ .

e Remove the water pipe @.

5-r3 C0oUIilG
SYSTEM

R e m o v et h e w a t e r p u m p i n l e tp i p e@ w i t h t h e h o s ea n d
the water outlet hose @.
Removethe water pump ass'y @.

. Removethe water pump cover.

Removethe impellersecuringbolt, washerand gasketby

h o l d i n gt h e i m p e l l e rs h a f t w i t h a w a t e r p u m p p l i e r s .
R e m o v et h e i m p e l l e @ r .

r Removethe m e c h a n i c asl e a l r i n g @ .

o Remove t h e i m p e l l e rs h a f t .
 5-14
co0ultcSYSTEM

AND DISASSEMBLY
INSPECTION
WATER PUMP BEARING
T u r nt h e i n n e rr a c ea n d c h e c kt h e b e a r i n gp l a y .l f a b n o r m a l
noiseoccursor any sign of stickinessis noted, replacethe
bearingwith a new one.

MECHANICALSEAL
V i s u a l l yi n s p e c t h e m e c h a n i c asle a lf o r d a m a g e ,w i t h p a r -
ticular attention given to the sealing face. Replacethe
mechanicalseal that shows indicationsof leakage.Also
replacethe oil seal if necessary.

DISASSEMBLY
o D r a w o u t t h e b e a r i n g sb y u s i n gt h e s p e c i a tl o o l s .

@! o s s + 1 -5 0 1 1 1B re mo ver
: e a ri n g

A CAUTION
The removedbearingsmust be replacedwith new ones.

NOTE:
lf no abnormal noise, bearing removal is not necessarY.
o Driveout the mechanicalsealwith oil sealby usinga suita-
b l e s i z eb o x w r e n c h a n d s o o n .

A C AU T I ON
The removed mechanicalseal and oil seal must be
replacedwith new ones.

NOTE:
lf no water or oil leakage, mechanical seal and oil seal
removal is not necessary.
5.15C00U[{G
SYSTEM

REASSEMBLY
AND INSTALLATIOIU
Reassemble and remountthe water pumpin the reverseord-
er of removaland disassembly.Payattentionto the follow-
ing points:
. A p p l y g r e a s et o t h e o i l s e a l l i p b e f o r ei n s t a l l i n g .

fuggooo-2so3o:suZUKr "A"
supERGREAsE
. Pressthe new oil seal into the stuffing box with a suita-
b l e s i z e s o c k e tw r e n c h a n d s o o n .
o Pressthe new mechanicalsealinto the stuffing box with
t h e s p e c i a l t o o la, s u i t a b l es i z es o c k e tw r e n c ha n d s o o n .
NOTE:
When installing the mechanical seal, apply SUZUKI BOND
"12O78" to its outer surface.
"
f,td666666666666666EEEEEEEEEEEEEEEEl
991 04-31 140: suZUKt BoND 12078"

@ Oggz 4-84521: Bearinginstaller

r Pressthe new bearingsintothe stuffingbox with the spe-

c i a l t o o l , a s u i t a b l es i z e s o c k e tw r e n c h a n d s o o n .

@ oggz 4-84521: Bearinginstaller

. Replacethe mechanical sealringand water sealwith new

o n e s w h e n r e a s s e m b l i ntgh e w a t e r p u m p .

NOTE:
" Apply SUZUKI SUPER GREASE "A" to the O-rings.
"A"
,6rggooo-2b030: suzuKrsupERGREASE
" The mechanicalsealring must be assembled with marked
face @ of the ring toward the impeller.
 c0oliltlcsYsrEM5-16

. Tightenthe impellersecuringboltto the specifiedtorque,

$ lmpellersecuringbolt: I N'm (0.8 kg-m, 6.0 lb-ft)

NOTE:
The seallip side @ faces impeller.
o Replace the O-rings@ with new ones.

|.:|.,|
.'::r.l
''.:..:
,'..:.

r Tightenthe water pump cover screws to the specified

torque.

[tW"t", p u m pc o v e rs c r e w : 1 0 N ' m ( 1 . Ok g - m , 7 . Ol b - f t ]

NOTE:
"A" to the O-ring.
ApplV SUZUKI SUPER GREASE
"A"
fu99ooo-2s030:suZUKr
supERcREAsE

o I n s t a l tl h e w a t e r p u m p a n d t i g h t e ni t s m o u n t i n gb o l t t o
t h e s p e c i f i e dt o r q u e .
NOTE:
* Apply SUZUKI SUPERGREASE "A" to the water pump
O-ring.
" Ser the water pump shaft to the oil pump shaft as shown
in the illustration. (Refer to page 5-17.)
" Refer to page 8-18 for the radiator hose routing.

[tW"t". p u m pm o u n t i n gb o l t : 1 ON ' m ( 1 . Ok g - m ,7 . 0 l b - f t )
"A"
supERGREAsE
fuggooo-2so3o:suZUKr
5-17Co0Hlt|G
SYSTEM

M e c h a n i c asl e a l
rE!!!l

lmpeller fu Bearing

Oil pump

Water pump

r Tightenthe exhaustpipe bolt and the left front footrest

bracket bolt to the specifiedtorque.

[te*n"u"t pipebolt: 25 N.m (2.5 kg-m, 18.0 lb-ft]

Front footrest bracketbolt: 39 N'm (3.9 kg-m, 28.0 lb-ft)

o After installingthe water pump and hoses,be sureto add

e n g i n ec o o l a n t .( R e f e tr o p a g e 2 - 1 Oa n d - 1 1 . )
 CONTENTS
EXTERIORPARTS .,,. 6- 1
R E M O V A L. . . . . " . . . . . . . . . . . . . .6. .- I
RE MOU N T T N G ................ 6- 1
FRONT WHEEL . 6. 2
RE MOV A L....'...." 6- 2
INSPECTIONAND DISASSEMBLY.,,..,,.... ,.. 6- 3
REASSEMBLYAND REMOUNTING 6- 4
FRONTBRAKE 6-11
BRAKEPAD REPLACEMENT............ . 6-12
BRAKEFLUIDREPLACEMENT....".,... 6-12
CALIPERREMOVALAND DISASSEMBLY.....,.. 6.13
CALIPERINSPECTION ,, 6-14
CALIPERREASSEMBLYAND REMOUNTING 6.14
BRAKE DISC INSPECTION 6.15
MASTERCYLINDERREMOVALAND DISASSEMBLY..........,.....6-15
MASTERCYLTNDEn |NSnECTTON........... .... 6-16
MASTER CYLINDER REASSEMBLY AND REMOUNTING 6.17
FRONT FORK .... 6- 18
RE MOV A LA N D D IE A S SEM BLY ....,....... ......6- 18
INSPECTION 6-21
REASSEMBLYAND REMOUNTING 6.21
STEERING 6-26
REMOVALAND DISASSEMBLY.,,.,,....,. ..,,.. 6-26
|NSPECT|ONAND DTSASSEMBLY........... ... 6-28
REASSEMBLYAND REMOUNTING 6.29
STEERINGTENSIONADJUSTMENT ,....,..,,, 6.30
REAR WHEELAND BRAKE .... 6-31
REMOVALAND DISASSEMBLY,,..,,.. 6-31
INSPECTIONAND DISASSEMBLY..,..,..... .,. 6-34
REASSEMBLYAND BEMOUNTING .,.. 6-35
REAR BRAKE PEDAL .... 6-37
REAR SUSPENSIONAND SWINGARM 6-39
REMOVAL..".'..'.. 6-39
INSPECTION AND DISASSEMBLY,...,......
REASSEMBLYAND REMOUNTING .. 6.42
FINAL INSPECTIONAND ADJIJSTMENT .......,. 6-43
6-t GHASS|S

EXTERIORPARTS
REMOVAL
FRAMECOVER
. Removethe left and right bolts.
r Removethe framecover by extractingthe hookedparts,
left and right.

*: hooked part

STEERING HEAD GOVER

r Removethe left and right bolts.
. Removethe steeringheadcover by extractingthe hooked
part, left and right.

*': hooked part

SEAT
o Removethe seat by using the ignition key.

. Removethe rear seat by removingthe bolts.

REMOUNTING
. Remountthe framecoversand seatsin the reverseorder
of removal.
 GHASSIS
6.2

FRONTWHEEL

@ Front axle spacer

@ Front brake disc
@ Bearing
@ Front wheel
@ Speacer
@ Bearing
@ Speedometergearbox

@ Brakedisc bolt
@ Front axle
@ Rxte pinch bolt

g
ITEM N'm kg-m lb-ft
@ 23 2.3 16.5
@ 65 6.5 47.O
o 23 2.3 23.O

REMOVAL
. Removethe front brake calipermounting bolts O.
r Loosenthe axle pinch bolt @.
r Loosenthe front axle @.
o Raisethe front wheel off the ground with a jack.
. Removethe front axle and the front wheel.

A CAUTION .|{.o
Do not operatethe brake lever while dismountingthe ffi\
front wheel.
w
NOTE:
After removing the front wheel, fit the caliper temporarily
to the original position.
6.3 CHASSTS

. Removethe brakedisc from the front wheel.

INSPECTION
AND DISASSEMBLY
SPEEDOMETER GEARBOX
Inspectthe lip of dust seal and the drive lugs for damage.

TIRE
R e f e rt o p a g e2 - 1 5 .

FRONTWHEEL
Make sure that the wheel runout checkedas shown does
not exceedthe servicelimit.An excessiverunoutis usually
due to worn or loosenwheel bearings.lf bearingreplace-
ment fails to reducethe runout, replacethe wheel.

ServiceLimit (Axial and Radial):2.0 mm (0.08 in)

WHEELBEARINGS
Inspectthe play of the wheel bearingsby fingerwhile they
are in the wheel. Rotatethe inner race by fingerto inspect
for abnormalnoise and smooth rotation.
Replacethe bearingin the followingprocedureif thereis any-
thing unusual.

a Insertthe adaptorinto the wheel bearing.

a After insertingthe wedgebarfrom the oppositeside,lock
the wedge bar in the slit of the adaptor.
Driveout the wheel bearingby knockingthe wedge bar.

@! oss+l-so11I:Bearing
remover
A CAUTION
The removed bearingsshould be replaced with new
ones.
 GHASS|S
6-4

FRONTAXLE
U s i n ga d i a l g a u g e ,c h e c kt h e f r o n t a x l e f o r r u n o u t .
lf the runout exceedsthe limit, replacethe front axle.

Diatsause(1/1oomm)
@b oggo0-2o6oo:
09900-20701: Magneticstand
O99OO-21304:V-block set (10O mm)
S e r v i c eL i m i t : 0 . 2 5 m m ( 0 . 0 1 0 i n )

R E A S S E M B LA
YN D R E M O U N T I N G
Reassemble and remountthe front wheel in the reverseorder
of removaland disassembly.Payattentionto the following
points:

WHEELBEARING
. A p p l y S U Z U K IS U P E RG R E A S E" A " t o t h e b e a r i n g sb e -
fore installing.
"A"
Srggoo0-2b030:suzuKrsupERGREAsE
r I n s t a ltlh e w h e e lb e a r i n g sa s f o l l o w sb y u s i n gt h e s p e c i a l
tools.
@b ogg+1-34513:Bearing/Steering
raceinstall

A CAUTION
Firstinstallthe left wheel bearing,then installthe right
wheel bearing.Referto following illustrationfor details.
The sealed cover on the bearing must face to the
outside.

LeitH nrgnl LeftH Right

Spacer
Left bearing
{New part)
Use old part

Bearing
installer

Useold part R i g h tb e a r i n g
(Newpart)

Clearance
6-5 CHASSTS

BRAKEDISC
r Make sure that the brake disc is clean and free of any
g r e a s ym a t t e r .A p p l y T H R E A DL O C KS U P E R" 1 3 6 O " t o
the disc mounting bolts and tighten them to the speci-
fied torque.

@ ggooo-92130:THREADLocK supER"1960"
ptSrate disc bolt: 23 N.m (2.3 kg-m, 16.5 tb-ft)

SPEEDOMETER GEARBOX
o Beforeinstallingthe speedometer gearbox,applySUZUKI
SUPERGREASE " A" to its gear
and dustseallip,and align
the drivelugs@ to the recesses@ of the wheel hub and
attachthe speedometergearboxto the wheel hub.
"A"
6nggooo-2503o:suzuKrsupERGREAsE

o T o u c h t h e s t o p p e r @ othe
n speedometergearboxto the
lug @ on the left front fork,

FRONTAXLE
o Tightenthe front axle@ to the specifiedtorqueand then
moving the motorcycleup and down 4 or 5 times.
o Tightenthe front axlepinch bolt @ to the specifiedtorque.
ptfront axle:65 N.m (6.5 kg-m,47.0 lb-ft)
Front axle pinch bolt: 23 N.m (2.3 kg-m, 16.5 lb-ft)
o Tightenthe brakecalipermountingbolts@ to the speci-
fiedtorque.
plerate calipermountingbott:39 N.m
(3.9 kg-m, 28.0 lb-ft)
 c]tAssrs6-6

TIREAND WHEEL
TIREREMOVAL
The most criticalfactor of a tubelesstire is the seal betweenthe wheel rim and the tire bead. Be-
causeof this, we recommendusing a tire changerwhich is also more efficientthan tire levers.
For tire removal,the following tools are required.

:
@

ffi

r/7
a sA
@
z @

@ @ @

@
o
@
@
@
@
Tire changerstand
Operationarm
Tire lever
Center shaft
@ Bead pushingroller
@ n i m g u i d er o l l e r
@ Bead breaker
@ nim protector
@ Core remover
@ Air pressuregauge
@ tire lubricant

o Removethe valve core from the valve stem, and deflate

the tire completely.

NOTE: 5\
Mark the tire with chalk to note the position @ of the tire \-s
on the rim and rotational direction @ of the tire.

=
6-7 CHASSTS

o Placethe centershaft @ to the wheel,and fix the wheel

with the rim holder@.

e Attach the operationarm @ to the center shaft.

o Attach the beadbreaker@ to the operationarm, and dis-

mount the bead from the rim. Turn the wheel over and
dismountthe other bead from the rim.

o I n s t a l lt h e r i m g u i d er o l l e r@ .
r Installthe rim protector@, and raisethe bead with the
tire lever@.

o Set the tire lever againstthe operationarm, and rotate

the leveraroundthe rim. Repeatthis procedureto remove
the other bead from the rim.
 6.8
GHASSTS

INSPECTION
WHEEL
Wipe off any rubbersubstanceor rust from the wheel, and
inspectthe wheel rim. lf any one of the following items is
observed,replaceit with a new wheel.
* A distortionor crack.
* Any scratchesor flaws in the bead seatingarea.
* Wheelrunout(Axial& Radial)of morethan 2.0 mm (0.08
in),

TIRE
Thoroughlyinspectthe removedtire, and if any one of the followingitemsis observed,do not repair
t h e t i r e . R e p l a c ew i t h a n e w o n e .
* A p u n c t u r eo r a s p l i t w h o s e t o t a l l e n g t ho r d i a m e t e re x c e e d s6 . 0 m m ( 0 . 2 4 i n ) .
* A scratch or split at the side wall.
" Treaddepthlessthan 1.6 mm (O.OO in) in the front tire and lessthan 2.Omm (0.08 in) in the reartire.

@ O99OO-208O5:Tire depth gauge

* Plyseparation,
* Tread separation.
* Tread wear is extraordinarily deformedor distributedaroundthe tire.
* Scratchesat the bead.
* Cord is cut.
* Damagefrom skidding(flat spots).
* A b n o r m a l i t yi n t h e i n n e rl i n e r .

NOTE:
When repairing a flat tire, follow the repair instructions and use only recommended repairingmaterials.

VALVE INSPECTION
lnspectthe valveafterthe tire is removedfrom the rim, and
replacewith a new valve if the seal rubberhas any splits
or scratches.

Inspectthe removedvalve core and replacewith the new

o n e i f t h e s e a l i s a b n o r m a l l yd e f o r m e do r w o r n .

Seal
6.9 CHASSTS

VALVE INSTALLATION
Any dust or rust aroundthe valve holemust be cleanedoff .
Then installthe valve in the rim.

NOTE:
To properly install the valve into the valve hole, apply a spe-
cial tire lubricant or neutral soapy liquid to the valve.

A CAUTION
Be careful not to damage the lip of valve.

Valve

TIREINSTALLATION
. Apply a specialtire lubricantor neutralsoapyliquidto the
tire bead.

A CAUTION
Never apply grease,oil or gasolineto the tire bead.

r When installingthe tire, makecertainthat the directional

arrow facesthe directionof wheel rotationand alignthe
balancingmark of the tire with the valve as shown.

. Set the bead pushingroller@.

. Rotatethe operationarm aroundthe rim to mount the bead
completely,Do the bottom beadfirst, then the upperbead.
o Removethe wheel from the tire changer,and installthe
valve core in the valve stem. 4
NOTE:
Before installing the valve core, inspect the core.
L@
 0HASSTS
6-10

o Bouncethe tire severaltimeswhile rotating.This makes

the tire beadexpandoutwards,and thus makesinflation
easier.
NOTE:
Before inflating, confirm that the balance mark lines up with
the valve stem.
I
o Pump up the tire with air.

Do not inflate the tire to more than 4OO kPa (4.0

kg/cm2, 56 psi). The tire could burst with sufficient
force to causesevereinjury. Never stand dlrectly over
the tire while inflating it.

NOTE:
Check the "rim line" cast on the tire side walls. lt must be
1"'-''""\
equidistant from the wheel rim all the way around. lf the
6;:ot
distance between the rim line and wheel rim varies, this in-
dicates that the bead is not properly seated. lf this is so,
deflate the tire completely, and unseat the bead for both
srdes. Coat the bead with lubricant, and try again.

o After tire is properlyseatedto the wheel rim, adjustthe

air-pressure to the recommendedpressure.Correctthe
wheel balanceif necessary.

* Do not run a repairedtire more than 50 km/h (30

mph) within 24 hours after tire repairing,since the
patch may not be completely cured.
* Do not exceed 130 km/h (8O mph) with a repaired
tire.

TIREPRESSURE
] O L D I N F L A T I O N S O L OR I D I N G D U A LR I D I N G
T I R EP R E S S U R EkPa <g/cmz psl kPa kg/cm2 p s i
FRONT 200 2 . O O 2 9 200 2 . O O 2 9
REAR 2 2 5 2 . 2 5 33 225 2.25 33
6-1t CHASSTS

FRONTBRAKE

@ Diaphragm
@ Dust boot
@ Circlip
@ Piston
@ Primarycup
@ Returnspring
@ Piston seal
@ Piston
@ Dust seal
@ Brakepad
@ Ctip
@ Pad mounting pin
Brakehose
ql @

@ Front master cylinder

mounting bolt
\)i @ Brakehose union bolt
@ Calipermounting bolt
@ Caliperair bleedervalve

u
ITEM N'm kg-m lb-ft
@ 10 1.0 7.O
@ 23 2.3 16.5
o 39 ? q 28.O
o 7.5 0.75 5.5

EWUre
* This brakesystem is filled with a ethylene glycol-basedDOT 4 brakefluid. Do not use or mix
different types of fluid such as silicone-basedor petroleum-based.
* Do not use any brake fluid taken from old, used or unsealedcontainers.Never reuse brake
fluid left over from the last servicing or stored for long periods.
* When storing the brake fluid, seal the container completelyand keep away from
children.
* When replenishingbrake fluid, take care not to get dust into fluid.
* When washing brake components, use fresh brake fluid. Never use cleaning
solvent.
* A contaminatedbrakedisc or brakepad reducesbrakingperformance.Discard
contaminated
pads and clean the disc with high quality brake cleaneror neutral detergent.

I A CAUTIONI
Handlebrakefluid with care:the fluid reactschemicallywith paint, plastics,rubbermaterialsetc.
 CHASS|S
6-12

BRAKEPAD REPLACEMENT
. Removethe calipermountingbolts.
o Removethe brakepads by removingthe clip @ and pad
m o u n t i n gp i n @ .

CAUTION
:;.fu]
x Do not operatethe brakelever while dismountingthe
pads.
* Replacethe brake pad as a set, otherwise braking
w
performancewill be adverselyaffected.

. Remounthe new pads.

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.

BRAKEFLUIDREPLACEMENT
r Placethe motorcycleon a levelsurfaceand keepthe han-
dlebarsstraight.
. Removethe mastercylinderreservoircap and diaphragm.
o S u c k u p t h e o l d b r a k ef l u i d a s m u c h a s p o s s i b l e .
r Fill the reservoirwith fresh brakefluid.

o Attach a pipeto the caliperair bleedervalve, and insert

the free end of hose into a receptacle.
. Loosenthe bleedervalve and pump the brakeleveruntil
no more old brakefluid flows out of the bleedervalve.
o Closethe caliperair bleedervalve,and disconnecta clear
hose.Fillthe reservoirwith fresh brakefluid to the upper
end of the inspectionwindow. (;
I

- Specificationand Glassification:DOT 4
le'Fl

C AU T I O N
&'
Bfeedair in the brakefluid circuit. (Referto page 2-14.1
6.13CHASSTS

CALIPERREMOVALAND DISASSEMBLY
o Removethe brakehosefrom the caliperby removingthe
union bolt @ and catch the brake fluid in a suitable
receptacle.
. Removethe brakecaliperby removingthe calipermount-
ing bolts @.

CAUTION
Neverreusethe brakefluid left over from previousser-
vicing and stored for long periods.

BrakeflUid, if it leaks, will interfere with safe running

and discolor painted surfaces. Check the brake hose
and hose joints for cracks and fluid leakage.

r R e m o v et h e p a d s . ( R e f e rt o p a g e 6 - 1 2 . 1
o Removethe caliperholder@.
o Removethe spring.

o Placea rag over the pistonsto prevent its popping

and push out the pistonswith an air gun.

A CAUTION
Do not use high pressureair to preventpiston damage.

. Removethe dust sealsand piston seals.

A CAUTION
Do not reusethe dust sealsand piston sealsto prevent
fluid leakage.

O O
 GHASS|S
6.14

CALIPERINSPECTION
CALIPER
lnspectthe calipercylinderwall for nicks,scratchesor other
damage.

PISTON
Inspect the piston surface for any scratches or other
damage.

CALIPERREASSEMBLY
AND REMOUNTING
Reassemble the caliperin the reverseorderof removaland
disassembly.Pay attentionto the following points:
o Wash the caliperboresand pistonswith specifiedbrake
fluid. Particularly
wash the dust sealgroovesand piston
seal grooves.

@ Specificationand Classification:DOT 4
CAUTION
* Wash the calipercomponentswith fresh brakefluid
before reassembly.
x Do not wipe the brake fluid off after washing the
components.
* When washing the components, use the specified
brakefluid. Neveruse different types of fluid or clean-
ing solvent such as gasoline,kerosineor the others.
* Replacethe piston seals and dust seals with new
oneswhen reassembly.Applythe brakefluid to both
sealswhen installingthem.
. A p p l y S U Z U K IS I L I C O N E
G R E A S Et o t h e c a l i p e ra x l e s .
,6t 99ooo-2b10o:
suZUKrsrLrcoNE
GREASE

o Tighten each bolt to the specifiedtorque.

plCaliper mountingbolt @: 39 N.m (3.9 kg-m,28.Otb-ft)

Brakehose union bolt @: 23 N.m (2.3 kg-m, 16.5 lb-ft) i

NOTE:
Before remounting the caliper, push the piston allthe way
into the caliper.

A CAUTION
Bleedair from the system after reassemblingthe caliper.
(Referto page 2-14.1
6.15GHASSTS

BRAKEDISC INSPECTION
o Removethe front wheel. (Referto page 6-2.)

Visuallycheck the brakedisc for damageor cracks.

Measurethe thicknesswith a micrometer.
Replace the disc if the thicknessis lessthan the servicelimit
o r i f d a m a g ei s f o u n d .
Service Limit
F r o n td i s c : 4 . 0 m m ( 0 . 1 6 i n l

@! osso0-2020s: (o-25 mm)

Micrometer
M e a s u r et h e r u n o u tw i t h a d i a l g a u g e .
Replacethe disc if the runout exceedsthe servicelimit.

Service Limit
F r o n td i s c : O . 3 Om m ( O . 0 1 2i n )

Diatsauge(1/1oomm)
@! ossoo-20606:
09900-20701: Magneticstand

. R e m o v et h e d i s c . ( R e f e rt o p a g e 6 - 3 . )
o I n s t a l tl h e d i s c . ( R e f e rt o p a g e 6 - 5 . )

MASTERCYLINDERREMOVALAND
DISASSEMBLY
o Disconnectthe front brakelightswitch leadwires and re-
move the rear-viewmirror.

o Place a rag underneaththe union bolt on the master

cylinderto catch any spilleddropsof brakefluid. Remove
the union bolt and disconnectthe brake hose.

A CAUTION
lmmediatelyand completelywipe off any brake fluid
contactingany part of the motorcycle.The fluid reacts
chemicallywith paint, plasticsand rulbbermaterials,etc.
and will damage them severely.
 GHASS|S
6.16

. Removethe mastercylinderassembly.

a Removethe brake lever@ and brake light switch @ .

a R e m o v et h e r e s e r v o i cr a p a n d d i a p h r a g m .
a D r a i nb r a k ef l u i d .

o Pull the dust boot out and remove the circlip.

snapringptiers
@! ossoo-oo1o8:

o Removethe piston,secondarycup, primarycup and return

spring.

@ S e c o n d a r yc u p
@ Piston
@ Primarycup
@ Returnspring

MASTERCYLINDERINSPECTION
Inspectthe mastercylinderborefor any scratchesor other
damage.
Inspect the piston surface for any scratches or other
damage.
I n s p e c t h e p r i m a r yc u p , s e c o n d a r yc u p a n d d u s t s e a lf o r
wear or damage.
6-17CHASSTS

MASTERCYLINDER
REASSEMBLY
AND
REMOUNTING
Reassemblethe master cylinder in the reverseorder of
removaland disassembly.Pay attention to the following
points:

A CAUTION
x Wash the master cylinder components with fresh
brakefluid beforereassembly.Neveruse cleaningsol-
vent or gasolineto wash them.
* Do not wipe the components with a rag.
" Apply brakefluid to the cylinderboreand allthe com-
ponent to be inserted into the bore.

@ Specificationand Classification:DOT 4
. When remountingthe mastercylinderon the handlebars,
alignthe mastercylinderholder'smatingsurfaceO with
punchedmark @ on the handlebarsand tighten the up-
per mounting bolt first as shown.

[t Frontmastercylinder
m o u n t i n gb o l t : 1 O N . m ( 1 . 0 k g - m , 7 . 0 l b - f t )

A CAUTION Master cylinder

Bleed air from the system after reassemblingmaster Handlebars

cylinder.{Referto page 2-14.1

Clearance
 6-18
GHASS|S

FRONTFORK

O o-ring
@ outer tube
@ Oil seal retainer
@ Oil seal
@ oil seal stopper ring
@ Dust seal
@ R u b b e rc u s h i o n
@-{o\ @ Damper/innertube

o-Q
v @ Front fork cap bolt
@ Lock nut
@ Front axle pinch bolt

6>--f\
5,^ rX
e )
e-fi
@-@

"--@ ITEM N'm kg-m lb-ft

@--@ @ 23 2.3 16 . 5
@ 40 4.O 29.O
o 23 2.3 16 . 5

REMOVALAND DISASSEMBLY
r Removethe front wheel. (Referto page 6-2.)
r Removethe front fender by removingthe four bolts.
6-r9 CHASSTS

. R e m o v et h e b r a k eh o s e f r o m t h e h o s e g u i d e@ .
. Removethe fenderbracewith fork lower coversby remov-
i n g t h e m o u n t i n gb o l t s .

A CAUTION
Hang the brake caliperfrom the motorcycle frame by
using a string and so on, taking care not to bend the
brake hose.

o L o o s e nt h e f r o n t f o r k u p p e ra n d l o w e r c l a m p b o l t s a n d
t h e t u r n s i g n a ll i g h t c l a m p b o l t s .
r Removethe front forks.

NOTE:
Slightly loosen the front fork cap bolt to facilitate later dis-
assembly.

o Separatethe front fork cap bolt @ and outer tube @ by

l o o s e n i n gt h e c a p b o l t . @
t

o L o o s e nt h e l o c k n u t @ .
o R e m o v et h e c a p b o l t @ . l o c k n u t a n d r u b b e r c u s h i o n@ .

i :

..;
'

o T u r n t h e f o r k u p s i d ed o w n a n d d r a i nf o r k o i l .
o H o l dt h e f o r k u p s i d ed o w n f o r a f e w m i n u t e st o d r a i no i l .

NOTE:
When draining fork oil, pull the outer tube out very slowly
from the damper/inner tube.
 GHASSTS
6-20

o Strokethe damperseveraltimes to let out fork oil from

the damper.

. Removethe dust seal @ from the outer tube.

o Removethe oil seal stopper ring @.

o Remove the oil seal with the special tool.

@! ossr3-soj21:oit seatremover
A CAUTION
The removed oil seal should be replacedwith a new
one.

. Removethe oil seal retainer@.

ffi
W '].., n ,
'r,lSi,ii:i,::
'.,lilril,i.,
6.21CHASSTS

INSPECTION
DAMPER/INNER TUBE
Measurethe height@ tor fork spring set lengthas shown
in the photo. lf it is shorterthan the serviceIimit, replace
the damper/inner tube with a new one may be damagedthe
fork spring.
S e r v i c eL i m i t@ : 1 5 6 m m ( 6 . 1 i n )

I n s p e c t h e d a m p e r / i n n etru b e f o r w e a r o r d a m a g e .

A CAUTION
Do not attempt to disassembJe
the damper/innertube.
It is unserviceable.

OUTERTUBE
I n s p e c t h e o u t e rt u b e f o r w e a r o r d a m a g e .

R E A S S E M B LA
YN D R E M O U N T I N G
Reassemble and remountthe front fork in the reverseorder
of removaland disassembly.Pay-attention to the following
pointsr

OIL SEAL
o Installthe new oil sealto the outer tube with the special
tool after installingthe oil seal retainer.

@b ogg't g-7o122: oit seatinstaler

r l n s t a l lt h e o i l s e a ls t o p p e rr i n g @ .

A CAUTION tu
Make sure that the oil sealstopper ring fitted securely.

. A p p l y g r e a s et o t h e l i p o f o i l s e a l .
"A"
Snggooo-25030: suzuKrsupERGREAsE
 GHASS|S
6.22

o I n s t a l lt h e d u s t s e a l .
a I n s t a l l t h e o u t e r t u b e t o t h e d a m p e r i i n n e rt u b e .

A CAUTION
Be carefulnot to damagethe lip of oil sealwhen install-
ing the outer tube.

e:Dust seal
@ : Oil seal stopperring
@:Oil seal
(L\-
Oil seal retainer

F O R KO I L
o Pourspecifiedfork oil into the front fork and adjustfork
oil level as follows.
Fork oil type: Fork oil + 15
Giil ggoo0-99044-1bG:
suZUKtFoRKotl # 1b
Capacity(eachleg): 838 ml 128.3129.5US/lmp oz)

o Preparethe outertube holderring @with cardboardetc.

as shown in the illustration.
. Set the holderring @ between the outer tube and axle
b r a c k e ta s s h o w n i n t h e i l l u s t r a t i o n .
r Holdthe front fork vertical,and pourspecifiedoil into the
d a m p e r@ a p p r o x .8 O Om l .

1 7 7m m
(7.0in)
6.23CHASSTS

o Removethe holder ring.

o Installthe lock nut O and cap bolt @ to the damperrod
and tighten the lock nut.
Oil level
o Tightenthe cap bolt to the outer tube. (after 1 5th
o Compressand reboundthe front fork slowly about 1Sth strokes)
strokes at vertical position.
o Keepthe front fork at 5 minutes at verticalpositions. Oil level
(after 5 minutes)

e Setthe holderring@after removingthe cap bolt and lock

nut.
o R a i s et h e o u t e rt u b e 5 0 m m ( 2 . 0 i n ) f r o m t h e u p p e rs u r -
face of the holderring @to fill fork oil to the oil chamber
o,
o KeeFthe outer tube above positionuntil no longercon-
t a i n sa i r b u b b l e s .
NOTE:
Do not raise the outer tube over 7Omm to protect oil leak-
age from the hole @ of damper.
o Lowerthe outer tube slowly to touch the holderring @.
 GHASSTS
6.24

Pourspecifiedfork oil intothe damper@to the uppersur-

face of the outer tube.
R e r a i s et h e o u t e rt u b e s l o w l y 5 0 m m ( 2 . 0 i n ) f r o m t h e
u p p e rs u r f a c eo f t h e h o l d e rr i n g @ .
a Lower the outer tube slowly to the holder ring @.
a Keepthe outer tube above positionat 5 minutes.

. S e t t h e h o l d e rr i n g @ .
o Hold the front fork verticaland adjust the fork oil level
w i t h t h e s p e c i a tl o o l .

@! os9+3-74111:Forkoit tevetgauge
Oil level
Oil level: 149 mm (5.9 in) 149mm
( 5 . 9i n )
6.25 CHASSTS

a C l e a nt h e t h r e a do f d a m p e rw i t h a n a i r g u n .
a W h e n i n s t a l l i n gt h e r u b b e rc u s h i o n@ , f a c e t h e t a p a r e d
portion@of the cushionto the bottom.
a Installthe lock nut @ to the lowest positionof thread.
a Tighten the cap bolt @ with finger.

. Tighten the lock nut to the specifiedtorque.

p loct nut: 4O N.m {4.O kg-m, 29.0 lb-ft)

FRONTFORKREMOUNTING
. Align the top surface@ of the inner tube with top sur-
face @ of the steeringstem upper bracket.

. T i g h t e ne a c h b o l t t o t h e s p e c i f i e dt o r q u e .

S front fork cap bolt @: 23 N.m (2.3 kg-m, 16.5 lb-ft)

Upper clamp bolt @: 23 N ' m ( 2 . 3 k g - m , 1 6 . 5 l b - f t )
Lower clamp bolt @: 33 N'm (3.3 kg-m, 24.0 lb-ft)

I n s t a l lt h e f r o n t f e n d e rb r a c ea n d t i g h t e nt h e m o u n t i n g
b o l t sw i t h f i n g e r .
I n s t a l lt h e f r o n t w h e e l . ( R e f e rt o p a g e 6 - 5 . )
S w i n g t h e m o t o r c y c l eu p a n d d o w n s e v e r a tl i m e s .
Tighten the front fender brace mounting bolts.
 GHASSTS
6.26

STEERING
@ Handlebars
@ Steeringstem head
Steeringstem nut
@
@ Dust seal 9-e
@ Steeringstem
upper bearing o
@ Steeringstem
@ Steeringstem
lower bearing

Steeringstem head nut

J
Handlebarmounting nut
Front fork upper clamp bolt
Front fork lower clamp bolt
ffi-o
1\v,,t1
r__tr----(+)

@--_; \=r'
\=r'
g=-; e-_-@

ITEM N'm kg-m lb-ft

@ 90 9.0 65.0
@ 54 5.4 39.0
o 23 2.3 16.5
@ 33 3.3 24.O

REMOVALAND DISASSEMBLY
o Removethe front wheel. (Referto page 6-2.)
o R e m o v et h e f r o n t f o r k . ( R e f e rt o p a g e 6 - 1 9 . )
o Removethe headlightmountingscrews.
e R e m o v et h e h e a d l i g h bt y d i s c o n n e c t i ntgh e l e a d w i r e s .

. R e m o v et h e h e a d l i g h h
t o u s i n gw i t h h o u s i n gb r a c k e t .
6-27 CHASSTS

o Remove the clutch cable from the clutch lever.

. Remove the left handlebar switch from the handlebars.

Removethe brake hose @ from the steeringstem by

r e m o v i n gt h e u n i o n b o l t @ .
a R e m o v et h e m a s t e rc y l i n d e r .( R e f e rt o p a g e 6 - 1 6 . )
a R e m o v et h e r i g h t h a n d l e b asr w i t c h a n d t h r o t t l ec a b l e s .

. R e m o v et h e h a n d l e b a rbs y r e m o v i n gt h e m o u n t i n gn u t s ,

e Removethe indicatorlight lower cover.

o R e m o v et h e s p e e d o m e t ear s s e m b l y .

Removethe steeringstem head by removingthe steer-

i n g s t e m h e a dn u t .

'l\
*,'.,
 GHASSTS
6-28

o Remove the steering stem nut by usingthe specialtool,

then remove the steering s t e m .

@! oss+o-14911:Steeringstem nut wrench

NOTE:
Hold the steering stem by hand to prevent it from falling.

INSPECTION
AND DISASSEMBLY
Inspectthe removedparts for the following abnormalities.
" Handlebarsdistortion
* R a c ew e a r a n d b r i n e l l i n g
" B e a r i n gw e a r o r d a m a g e
* A b n o r m a ln o i s eo f b e a r i n g
" Distortionof steeringstem

o Removethe steeringstem upper bearing.

. Removethe steeringstem lower bearingby using the

chisel.

A CAUTION
The removed bearingshould be replacedwith a new
one.

o Driveout the steeringstem bearingraces,upperand low-

er, by usingthe specialtool and appropriatesteel pipe.

@! oss+1-s4g11:Bearingouterraceremover
6.29 CHASSTS

REASSEMBLY
AND REMOUNTING
Reassemble and remountthe steeringstem in the reverse
orderof removaland disassembly.Pay attentionto the fol-
lowing points:

OUTERRACES
. Pressin the upperand lower outer racesby usingthe spe-
c i a lt o o l .

@b ogg+1-34513:steeringraceinstailer
BEARING
o Pressin the lower bearingby using the specialtool.

@b Oggo1-74g1o:Steeringbearinginstailer

. ApplySUZUKISUPERGREASE" A" to the upperand low-

er bearingsbefore remountingthe steeringstem.
,,A,,
,6rggooo-2503o: suzuKrsupERGREASE

STEM NUT
. Tightenthe steeringstem nut to the specifiedtorque.

6b ogg+o-14g11:steeringsternnut wrench
[D Steerlngstem nut: 45 N.m (4.b kg-m, 32.S lb-fr)

o Turn the steeringstem about five or six times to the left

and right so that the taper roller bearingwill be seated
1 1 4 - 1 1 2t u r n
properly. Fl
o T u r n b a c kt h e s t e m n u t b y 1 1 4 - 1 1 2 t u r n .
Then retightenvery lightlyso that no play can be defect-
ed in the stem.
.@-
NOTE: \
This adjustment will vary from motorcycle to motorcycle.
 6-30
GHASSIS

. T i g h t e nt h e s t e e r i n gh e a d n u t a n d h a n d l e b a m
r ounting
nuts to the specifiedtorque,

U Steeringstem headnut: 9O N.m (9.O kg-m, 65.0 lb-ft)

Handlebarmountingnut: 54 N.m (5.4 kg-m, 39.0 lb-ft)

NOTE:
Before tighten the steering stem head nut, install the front
fork temporarily.

r Tightenthe front fork upperand lower clampbolts.(Refer

t o p a g e6 - 2 5 . )
. Apply greaseto the throttle grip.
"A"
,6rggooo-25030:suzuKrsupERGREAsE
o A d j u s t t h e t h r o t t l ec a b l e p l a y . ( R e f e rt o p a g e 2 - 9 . )
o I n s t a l tl h e f r o n t w h e e l . ( R e f e rt o p a g e 6 - 5 . )

STEERING
T E N S I O NA D J U S T M E N T
o Checkthe steeringmovementafter reassembleand re-
m o u n tt h e a l l p a r t s .
r l f p l a y i s f o u n d , a d j u s ti t i n f o l l o w i n gp r o c e d u r e .
1)First,loosenthe front fork upperclampboltsand steer-
ing stem headnut, and then adjustthe steeringstem
n u t b y l o o s e n i n go r t i g h t e n i n gi t .
2)Tightenthe steeringstem headnut and clamp boltsto
the specifiedtorque and re-check.
6-3r CHASSTS

REARWHEELAND BRAKE

g
I
l - -
f@t
6 , o
> l @ r
YdX^b; @ Rearaxle

'w#
@ S p a c e r( L H )
@ Rearsprocket

-Y/1n,u)@
@ Dust seal
@ Bearing
@ Retainer
@ Sprocketmountingdrum
@ W h e e td a m p e r
@ B e a r i n g( L H )
@ Spacer
g B e a r i n g( R H )

ITEM N'm kg-m lb-ft @

I @
@
@
Brakepanel
Brakecamshaft
@ Brakecam lever
@ 65 6.5 47.O @ Brakeshoe
@ 10 1.0 7.O
@ Rearaxle nut
o 25 2.5 18.0 @ Rear brake cam lever bolt
Reartorque link nut
o 50 5.O 36.O
@
@ Rearsprocket nut

REMOVAL
. R e m o v et h e r e a rt o r q u el i n k n u t a n d b o l t @ .
o Removethe rear brake adjuster@ and brake cable.
. R e m o v et h e c o t t e r p i n . ( F o rC a n a d aa n d U . S . A . )
o L o o s e nt h e r e a r a x l e n u t @ .
 cHASSTS
6.32

o Remove the chain case.

a Supportthe motorcyclewith a jack.

a Removethe axle nut and rear axle.
a Removethe rear wheel by disengagingthe drive chain.

o Removethe rearb r a k ea s s e m b l yf r o m t h e w h e e l .

o Remove the rear brake cam lever O and spring@.

o Removethe washer@ and O-ring@.

6-33CHASSTS

. Removethe brake shoes.

. Removethe rearsprocketmountingdrum from the wheel.

NOTE:
Slightly loosen the rear sprocket mounting nuts to facilitate
later disassembly before separate the mounting drum.

e Removethe drum retainer@.

o Removethe rear sprocket@.

r Removethe spacer@ and dust seal @.

A CAUTION
The removeddust seal should be replacedwith a new
one.

o Removethe wheel dampers,

 6-34
GHASS|S

AND DISASSEMBLY
INSPECTION
TIRE ...... R e f e rt o p a g e 6 - 3 .
REARWHEEL .. Refer to page 6-3.
WHEELBEARING Referto page 6-3.

REARAXLE
U s i n ga d i a l g a u g e ,c h e c kt h e r e a r a x l e f o r r u n o u t .
lf the runout exceedsthe limit, replacethe rear axle.
ServiceLimit: 0.25 mm (O.O1Oin)
Dialsauge(1/'loomm)
@! ossoo-2o6o6:
O99OO-2O7Ol: Magneticstand
09900-21304: V-block set (100 mml

WHEELDAMPER
I n s p e c t h e w h e e l d a m p e r sf o r w e a r a n d d a m a g e .

SPROCKET
Inspectthe sprocketteeth for wear. lf they are worn as
shown, replacethe sprocketsand drive chain as a set.

Normal wear Excessivewear

REARSPROCKET MOUNTINGDRUM BEARING

lnspectthe play of the bearingby finger while it is in the
mountingdrum. Rotatethe inner race by finger to inspect
for abnormalnoise and smooth rotation,
R e p l a c et h e b e a r i n gi f t h e r e i s a n y t h i n gu n u s u a l .
6.35CHASSTS

BRAKESHOE
Checkthe brakeshoe for the thicknessof the brakeshoe
l i n i n g .l f t h e b r a k es h o e l i n i n gi s w o r n d o w n t o t h e l i m i t ,
replacethe brakeshoe.

S e r v i c eL i m i t : 1 . 5 m m ( 0 . 0 5 6 i n )

@ ossoo-2o102:Verniercalipers

A CAUTION
Replacethe brake shoe with a set, otherwise braking
performancewill be adverselyaffected.

BRAKEDRUM
Measurethe brakedrum l.D.to determinethe extentof wear
and, if the limit is exceededby the wear noted, replacethe
d r u m .T h e v a l u eo f t h i s l i m i t i s i n d i c a t e di n s i d et h e d r u m .
S e r v i c el i m i t : 1 8 0 . 7 m m ( 7 . 1 1 i n )

I n s p e c t h e d r u m L D . f o r s c r a t c hm a r k s .l f t h e l . D . s u r f a c e
is scratchedor otherwise roughened,smoothen it with
sandpaper.

R E A S S E M B LA
YN D R E M O U N T I N G
Reassemble and remountthe rearwheel in the reverseord-
er of removaland disassembly.Payattentionto the follow-
ing points.

WHEELBEARING
. A p p l y S U Z U K IS U P E RG R E A S E" A " t o t h e b e a r i n gb e -
fore installing.
"A"
Srggooo-25030: suzuKrsupERGREAsE
o I n s t a l lt h e w h e e l b e a r i n gb y u s i n gt h e s p e c i a lt o o l .

A CAUTION
Firstinstallthe wheel bearingfor right side (Brakedrum
side).

@ race installer
ogg+1-34513: Bearing/Steering
 GHASS|S
6.36

Left ft c) Risht LeTr \.-r -2 Fitgnt

B e a r i n g( R ) Bearing(L) Bearing(R)

REARSPROCKETMOUNTINGDRUM BEARING
. I n s t a l tl h e n e w b e a r i n gw i t h t h e s p e c i a tl o o l .

@ OSSf3-75520: Bearinginstaller
NOTE:
Apply grease to the bearing and dust seal lip before install-
ing to the rear sprocket mounting drum.

fuggooo-zso3o:suZUKr "A"
supERGREAsE

o Tightenthe rear sprocketnuts to the specifiedtorque.

P n""t sprocketnut: 5O N'm (5.0 kg-m, 36.0 lb-ft)

. A p p l y S U Z U K IS U P E RG R E A S E" A " t o t h e b r a k ec a m -
shaft and camshaftsurface.

fu99ooo-2s030:suZUKr "A"
supERGREASE

Be careful not to apply too much greaseto the brake

camshaft.
6.37CHASSTS

o Installthe brake cam lever and tighten the bolt to the

specification.
p n"", brakecamleverbolt: 10 N.m(1.0 kg-m,7.0 lb-ft)

. Tightenthe reartorquelink nut @ to the specifiedtorque.

[ln""r torquelink nut: 25 N'm (2.5 kg-m,18.0 lb-ft)

r Installthe rearaxle and tighenthe rearaxle nut @ to the
specifiedtorque.

$ Rearaxle nut: 65 N.m (6.5 kg-m, 47.0 lb-ft)

r I n s t a l lt h e n e w c o t t e r p i n . ( F o rC a n a d aa n d U . S . A . )

REARBRAKEPEDAL
REMOVALAND REASSEMBLY
r Removethe right swingarm pivot cover.

. Removethe rear brakecable adjuster@.

. Removethe rear brakecable from the brake panel.
 6-38
GHASSIS

Removethe rearbrakelightswitch cable@ and innerwire

@.
R e m o v et h e b r a k ec a b l ec l a m p@ .

o Removethe cable clamp @.

r Remove the brake pedal with front footrest.

Removethe rear brake r o d l i n k @ , r e a r b r a k ec a b l e@ ,

rear brake light switch c a b l e@ a n d b r a k ep e d a l@ .

REMOUNTING AND REASSEMBLY

Reassemble and remountthe rearbrakepedalin the reverse
orderof removaland disassembly,pay attentionto the fol-
l o w i n gs t e p s .
. A p p l y S U Z U K IS U P E RG R E A S E" A " t o t h e b r a k ep e d a l
oivot and brake rod link.
"A"
,6rggoo0-2b030: suzuKtsupERGREAsE
CAUTION
Always install a new cotter pin.

o Tightenthe front footrest bolts to the specifiedtorque'

p front footrest bolt: 39 N'm (3.9 kg-m, 28.0 lb-ft)

After installingthe rearbrakepedal,adjustthe brakeca-

b l e p l a y . ( R e f e rt o p a g e 2 - 1 4 . 1
Make sure that the brake system operatescorrectly.
6-39CHASSIS

REARSUSPENSION
AND SWINGARM

o&o

v
@--^ I
\4 I
%),
wo

m-F_@

@-u

@___@sQ ,@.
\t/sx
\ \
\\
| \ia
R e a rt o r q u e l i n k t -
R e a rs h o c k a b s o r b e r @
R e a rs w i n g a r m
C h a i na d j u s t e r
@ Chain buffer ITEM N'm kg-m lb-ft
@ C h a i nc a s e
@ S w i n g a r mp i v o t s h a f t @ 100 10.0 72.5
@ 23 2.3 16 . 5
R e a rs w i n g a r mp i v o t n u t
R e a rs h o c k a b s o r b e rb o l t
R e a rs h o c k a b s o r b e rn u t
o 50 5.0 36.0
R e a rt o r q u e l i n k n u t @ 35 3.5 25.5

REMOVAL
r R e m o v et h e r e a rw h e e l . ( R e f e tr o p a g e6 - 3 1 . )
o R e m o v et h e r e a rs h o c k a b s o r b e rl o w e r m o u n t i n gn u t s .
 6.40
GHASS|S

. Removethe left and right swingarm pivot covers.

o Removethe reartorquelink by removingthe nut and bolt.

r Removethe swingarm pivot shaft nut.

. Removethe swingarmby removingthe swingarmpivot
shaft.

o Removethe rear shock absorbers.

6.41CHASSTS

AND DISASSEMBLY
INSPECTION
SWINGARMPIVOTBEARINGS
Inspectthe swingarmpivot bearingsfor wear whilethey are
in the frame. Rotatethe spacerby hand to inspectfor ab-
normalnoiseand smooth rotation.Replacethe bearingsif
there is anything unusual. Also replace the spacer if
necessary.
o Removethe left and right spacers.
o Removethe swingarmbearingsfrom the frame with the
s p e c i a tl o o l s .
stidinsshaft
@! ossso-3o102:
09923-7 451O: Bearingpuller
CAUTION
The removed bearingsshould be replacedwith new
ones.

. Removethe center spacer,

SHOCKABSORBER l

Inspectthe shock absorberbody for damageand oil leak-

age. lf any defectsare found, replacethe shock absorber
with new one.

CAUTION
Do not attempt to disassemblethe rear shock absorb-
er unit. lt is unserviceable.

SWINGARMPIVOT SHAFT
Usinga dialgauge,checkthe pivot shaft runoutand replace
it if the runout exceedsthe limit.

Diatgause(1/1oomm)
@! ossoo-2o6o6:
09900-20701: Magneticstand
O 9 9 O O - 2 1 3 0 4V: - b l o c k( 1 0 0 m m )

ServiceLimit: 0.30 mm (0.O12 in)

SWINGARM
I n s p e c t h e s w i n g a r mf o r d a m a g e .
 GHASSTS
6-42

CHAIN BUFFER
Inspectthe chain buffer for damage.

REASSEMBLY
AND REMOUNTING
Reassemble and remountthe swingarmand rearshock ab-
sorbersin the reverseorderof removaland disassembly,and
also carry out the following steps:
SWINGARMBEARING
o Pressthe bearingsinto the frame with the specialtool.

@! OSS+1-34513:Bearing/Steering
raceinstaller

NOTE:
When reinstalling the bearing, stamped mark of bearing is
positioned outside.
. A p p l y S U Z U K IS U P E RG R E A S E" A " t o t h e b e a r i n g s .
"A"
fu99ooo-2b030:suZUKr
supERGREAsE

REARSWINGARMPIVOTNUT
. Tighten the rear swingarm pivot nut to the specified
torque.

S n"ar swingarmpivot nut: 100 N'm

(10.0 kg-m,72.5lb-ttl

REARSHOCKABSORBERBOLTAND NUT
o Tightenthe shockabsorbermountingbolt and nut to the
specifiedtorque.
p 2 3 N 'm (2 .3 kg -m,16.5 lb- ft)
e o n ( U p p e r):
Nut (Lower):50 N'm (5.0 kg-m, 36.0 lb-ftl
6.43 CHASSTS

REARAXLE AND TOROUELINK NUT

o Tightenthe reartorque link nuts and rearaxle nut to the
specifiedtorque.

[l n"", torquelink nut (front]:35 N.m (3.5 kg-m, 2S.Stb-ft]

(rear):25 N'm (2.5 kg-m,18.Olb-ft)
Rearaxle nut: 65 N'm {6.5 kg-m, 47.0 lb-ft}

FINAL INSPECTION
AND ADJUSTMENT
After installingthe rearsuspentionand rearwheel,the fol-
lowing adjustmentsare requiredbeforedrivingmotorcycle.
D R | V EC H A I N . . . . . . . R e f e rt o p a g e 2 - 1 2 .
REARBRAKE ... Referto page 2-14.
T|RE FRESSURE Referto page 2-15.

SUSPENSION SETTING
Adjust the spring pre-loadas follows.
* The set position"5" providesthe stiffestspringpre-load.
* The set position" 1" providesthe softestspringpre-load.

STD spring position:"3"

NOTE:
Make sure that both spring position should be equalized.
 CONTENTS
CAUTIONS IN SERVICING .".. 7- 1
LOCATION OF ELECTRICALCOMPONENTS ,","... 7. 3
CHARGINGSYSTEM ,.... 7- 5
DESCRIPTTON 7- 5
TROUBLESHOOTING """""" 7- 7
.'..'.'.."
\N S P E C T T ON """' 7- I
STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK
SYSTEM 7-1O
STARTER SYSTEM DESCRIPTION
SIDE-STAND/IGNITION INTERLOCK SYSTEM DESCRIPTION .... 7-1 O
TROUBLESHOOTING 7.12
STARTER MOTOR REMOVAL AND DISASSEMBLY "..' 7.13
STARTERMOTOR INSPECTION ...."' 7.13
STARTER MOTOR NEASSEMBLY ......"... .,.. 7-14
STARTERRELAY INSPECTION ..,,, 7-15
STABTER CONTROL RELAY INSPECTION .. 7-16
SIDE-STAND/IGNITION INTERLOCK SYSTEM PART
|N 9 P E C T |ON .........'. 7- 17
tcNITtoN SYSTEM 7-19
DESCRTPTTON ...... 7-19
TROUBLESHOOTING 7-20
INSPECTION ."""'7-21
SPEEDOMETERAND INSTBUMENT PANEL ... 7-25
REMOVALAND DISASSEMBLY...",...... 7-25
INSPECTION ..........' 7-26
LAMP9 7-27
HEADL\GHT"""""" 7-27
TAIL/BRAKE LIGHT .. 7.28
TURN SIGNAL LIGHT .,' 7-29
RELAY..'......... 7-29
S WT T C H E S ..' ...7- 3O
BATTEBy ..'."...7-31
SPECIFICATIONS
\NITLALCHARGING """"""" 7-31
S E R V \C T N'..........
G """ 7- 32
RECHARGING OPERATION 7.33
7.1 ETECTBICAI
SYSTEM

CAUTIONSIN SERVICING
CONNECTOR
r When connectinga connector,be sureto push it in untill
a click is felt.
o Inspectthe connectorfor corrosion,contaminationand
breakagein its cover.

COUPLER
o With a lock type coupler,be sure to releasethe lock be-
fore disconnecting it and pushit in fully till the lock works
when connectingit.
. When disconnecting the coupler,be sureto holdthe cou-
pler itself and do not pull the lead wires.
o Inspecteach terminalon the couplerfor being loose or
bent.
r Inspecteach terminalfor corrosionand contamination.

CLAMP
r Clampthe wire harnessat such positionsas indicatedin
" W I R E H A R N E S SR O U T I N G "( R e f e r p a g e s CORRECT INCORRECT
to 8 - 1 Oa n d
11 . ) .
o Bend the clamp properly so that the wire harness is
clampedsecurely.
o ln clampingthe wire harness,use care not to allow it to
h a n gd o w n .
o Do not use wire or any other substitutefor the bandtype
clamp.
FUSE
r When a fuse blows, always investigatethe cause,cor-
rect it and then replacethe fuse.
o Do not use a fuse of a different capacity.
r Do not use wire or any other substitutefor the fuse.

SEMI.CONDUCTOR
EOUIPPEDPART
o Be carefulnot to drop the part with a semi-conductorbuilt lNcoRRECr I
in such as a ignitor unit.
o When inspectingthis part, follow inspectioninstruction
,/3 I
strictly.Neglectingproperproceduremay causedamage
to this part.
\KI
Y'
 SYSTEM7-2
ELECTRICAL

BATTERY
CONNECTING
o When disconnectingterminalsfrom the battery for dis-
assemblyor servicing,be sure to disconnectthe nega-
tive ( e ) terminalfirst.
o When connectingterminalsto the battery,be sureto con-
nect the positive(@ ) terminalfirst.
o lf the terminalis found corroded,removethe battery,pour
warm water over it and clean with a wire brush,
. Upon completionof connection,apply greaselightly.
o Put a cover over the positive(@ ) terminal,

WIRINGPROCEDURE
. Routethe wire harnessproperlyaccordingto "WIRE HAR-
N E S SR O U T I N G "( R e f e tr o p a g e s8 - 1 Oa n d 1 1 . ) .

USINGMULTI CIRCUITTESTER
o Be sure to use positive( @ ) and negative( O ) probes
of the testerproperly.Theirfalseuse may causedamage
in the tester.
o lf the currentvaluesare not known, start measuringin
t h e h i g h e rr a n g e .
o Taking a measurementwhere voltage is appliedin the
resistancerangemay causedamagein the tester.When
measuringresistance, checkto makesurethat no voltage Multi circuit tester
i s a p p l i e dt h e r e .
o After usingthe tester,turn the switch to the OFFposition.

CAUTION
Beforeusing the multi circuit tester, read the instruc-
tion manual.
7.3 ETECTRIGAT
SYSTEM

LOCATIONOF ELECTRICAL
COMPONENTS

(1) Battery o l g n i t i o nc o i l ( N o . 1 )
@ Side-stand/ignition interlockdiode @ Generator
@ Fuse box @ S i g n a lg e n e r a t o r
@ M a i n ef u s e @ Neutralswitch
( 11 ) Side-standswitch
t?/ Starter relay
\9/ Startercontrol relay
 ELECTRICAI. 7.4
SYSTEM

. :r:!!
..,iiti

..:: ^:r;il:r '

@ I n d i c a t o lri g h t d i o d e @ interlockrelay
Side-stand/ignition
@ l g n i t i o nc o i l ( N o . 2 ) @ Coolingfan thermo-switch
@ lgnitionswitch @ Oil pressureswitch
@ Water temp. switch (t) ier
Regulator/rectif
(1 6 ) Startermotor lgnitor
@
@ T u r n s i g n a lr e l a y @ Rear brake switch
 SYSTEM
7.5 ETEGTRICAT

CHARGINGSYSTEM
DESCRIPTION
The circuitof the chargingsystem is indicatedin the figure,which is composedof an AC generator,
regulator/rectifierunit and battery.
The AC current generated from the AC generatoris rectifiedby the rectifierand is turned into DC
current,then it chargesthe battery.

Regulator/rectif
ier lg. switch
AC generator

FUNCTIONOF REGULATOR
While the enginer/min is low and the generatedvoltageof the AC generatoris lower than the ad-
justedvoltageof Regulator, the regulatordoesnot function.However,the generatedcurrentcharges
the battery directlyat this time.

ier
Regulator/rectif
lg. switch
I

I
I
I
L
 ETECTRICAT
SYSTEM7.6

When the enginer/min becomeshigher,the generatedvoltageof the AC generatoralso becomes

higherand the voltage betweenthe battery terminalsbecomeshigh accordingly.When it reaches
the adjustedvoltageof the LC., (lntegratedCircuit)and it is turned "ON", a signalwill be sent to
the SCR (Thyristor)gate probe and the SCR will be turned "ON".
Then,the SCRbecomesconductivein the directionfrom point @to point @. nt this time, the cur-
rentgeneratedfrom the AC generatorgetsthroughthe SCRwithout chargingthe batteryand returns
to AC generatoragain.At the end of this state, sincethe AC currentgeneratedfrom AC generator
flows to point @, the reversecurrenttends to flow to SCR.Then, the circuit of SCRturns to the
OFFmodeand beginsto chargethe batteryagain.Thus theserepetitionsmaintainchargingvoltage
and currentto the battery constant and protect it from overcharging,

Regulator/rectif
ier
AC generator
7-7 EIECTRICAI
SYSTEM

TROUBLESHOOTING

Battery runs down quickly.

Check accessorieswhich excessively

In sta IIed ------------J> o Removeaccessories
waste electricpower.

Not installed

Leak---------------- . Short circuit of wire harness

a Loose or disconnectedwires
a Faulty battery
No leak

Correct -------------> . Faulty battery

a A b n o r m a ld r i v i n gc o n d i t i o n

Incorrect

No continuity ----------->o Faultygeneratorcoils or discon-

nected lead wires
Correct

lncorrect ---------l-' FaultyAC generator

Correct

In correct --------------->
o Faulty regu lator/rectifier

Correct

Incorrect--------------->
o Short circuit of wire harness
o Poor contact of couplers
Correct
+ o Faulty battery

Batteryovercharge I . Faulty regulator/rectifier

o Faulty battery
o Poor contact of generatorlead wire coupler
 SYSTEM7-8
ETECTBICAI.

INSPECTION
BATTERYLEAK CURRENTINSPECTION
e Removethe seat and battery cover.
o Turn the ignitionswitch to the OFF position.
o Disconnectthe battery Q lead wire.
o Connectthe multi circuittester betweentfre O terminal
and Q lead wire of the battery.
Notethat leakageis indicatedif the tester readsover 1mA. *- ,S

Multicircuittesterset
GD oggoo-25o08:
Batteryleak current: Under 1mA
Current( = , 2OmA)
tEUtester knobindication:

A CAUTTON
Red lead
* Becausethe leak current might be large, turn the
tester to high range first when connecting an
ammeter.
* Do not turn the ignition switch to the ON position
when measuringcurrent.

When leakageis found, look for the part where the tester
r e a du n d e r 1 m A t h r o u g ht h e c o u p l e r sa n d c o n n e c t o r sa r e
removedone by one.

CHARGINGOUTPUTINSPECTION
o Removethe seat and battery cover.
. S t a r t t h ee n g i n ea n d k e e pi t r u n n i n ga t 5 O O Or / m i n .w i t h
l i g h t i n gs w i t c h t u r n e dO N a n d d i m m e rs w i t c h t u r n e dH l
position.
Measurethe DC voltagebetweenthe batteryterminals@
and O with a multi circuittester. lf the tester readsunder
13 . 5 V o r o v e r 15 . 0 V , i n s p e c t h e g e n e r a t o cr o i l a n d r e g u -
lator/rectif ier.

NOTE:
When making this test, be sure that the battery is fully-
charged condition.

@ oSso0-25008:Mutti circuittester set

Chargingoutput
Standard1: 3.5-15.0 at 5 O00 r/rnin.

ffipf""t"r knob indication:Voltage( = )

7.9 ETECTRICAT
SYSTEM

GENERATOR COIL CONTINUITYINSPECTION

. Removethe left frame cover. (Referto page 6-1.)
r Disconnectthe generatorcoupler.
Usinga multi circuittester, inspectthe continuitybetween
the three lead wires.
Also check that the stator core is insulated.
lf there is no continuity,replacethe statorwith a new one.
@ ossoo-2s008:Multicircuittesterset
t$$f"rt"r knob indication:Continiutytest ( .l)) )
NOTE:
Whenmaking above test, it is not necessary to remove the
AC generator.

GENERATOR NO-LOADPERFORMANCE INSPECTION

o Start the engineand keep it runningat 5 OOOr/min.

Usinga multi circuittester, measurethe voltage between

the three lead wires.
lf the testerreadsunderthe specifiedvalue,replacethe AC
generatorwith a new one.

@! ossoo-25008: Multi circuit tester set

Generatorno-load performance:
More than 75V at 5 OOOr/min
(When engine is coldl
Voltage(-)
ffipf""t"r knobindication:
/'T\:-fl5I
i,*r"Jr"--]J=j
REGULATOR/RECTIFIER INSPECTION
\.!7+v-+
o Removethe right frame cover. (Referto page 6-1.)
o Disconnectthe regulator/rectifier
couplers.
Usinga multi circuit tester, measurethe voltage between
the lead wires in the following table. .---.-BM
lf voltageis incorrect,replacethe regulator/rectifier. r"t
@! ossoo-25008:Multicircuittesterset Lgf'
ffiUTester knob indication:Diodetest (.*Gl Yz
Unit:
D Probeof tester to:
R Yr Yz Ys B/W
R o.4-o.6 o.4-0.6 o.4-o.6 0.5-o.7
Yr | 1.4- 1.5 1 . 4 - 1 . 5 1 . 4 - 1 . 5 o.4-o.6
Yz 11.4-1.5 1.4-1.5 1 . 4 - 1 . 5 0.4-o.6
Ys 1 1 . 4 - 1 . 5 1 . 4 - 1 . 5 1. 4 - 1 . 5 0.4-o.6
B/W 11.4-1.5 1.4-1.5 1.4-1.5 1.4-1.5
Y: Yellow, R: Red, BAIV:Black with White tracer

NOTE:
lf the testerread under 1.4V, replacethe battery of multi
circuit tester when do not connecting the tester probes.
 SYSTEM7-10
ETECTRICAI

INTERLOCK
STARTERSYSTEM AND SIDE.STAND/IGNITION
SYSTEM
STARTERSYSTEM DESCRIPTION
The startersystem is shown in the diagrambelow: namely,the startermotor, starterrelay,starter
controlrelay,clutch leverpositionswitch, starterbutton,enginestop switch, side-standrelay,side-
stand switch, neutralswitch, lG switch and battery.
Depressingthe starterswitch (on the right handlebarswitch box) energizesthe relay,causingthe
contact points to close which connectsthe starter motor to the battery.The motor draws about
8O amperesto start the engine.

tt"o
reverpositionswitch 5*?:;

I
I
I
I
I
I
t

Starter
Starter button
control
relay

INTERLOCKSYSTEMDESCRIPTION
SIDE.STAND/IGNITION
interlocksystem is to preventstartingthe motorcyclewith the side-stand
This side-stand/ignition
left down. The systemis operatedby an electriccircuitprovidedbetweenthe batteryand ignitioncoil.

Side-stand Enginestop
l g n i t i o ns w i t c h reray switch
T o i g n i t o ra n d
i g n i t i o nc o i l
Startermotor Starter
button
Neutral
indicator
Clutch lever
light positionswitch

WIRECOLOR
R : Red B/W : Black with White tracer Y/B : Yellow with Blacktracer
G : Green O/B : Orange with Black tracer Y/G : Yellow with Green tracer
Bl : Blue O/W: Orangewith White tracer
7.I1 ETEGTBICAT
SYSTEM

The.circuitconsistsof relay,lamp,diodeand switchesand decidesto livethe ignitioncoil depending

on the positionof the TRANSMISSIONand SIDE-STAND with the neutraland side-standswitches
working mutually.
The ignitioncoil lives only in two situationsas follows.
"DOWN (OFF)"
1 . T r a n s m i s s i o n":N E U T R A L( O N ) " S i d e - s t a n d :
The currentflow @turns "ON" the relay and the ignitioncoil lives even the side-standis kept
d o w n . T h i s i s o r w a r m i n gu p t h e e n g i n e .

SIDE-STAND
IGNITION
SW. R E L A Y" O N ' '

IGNITION
BATTERY
cor L

NEUTRAL
LAMP

DIODE

NEUTRAL
SW. "ON" SW.
SIDE.STAND
SIDE.STAND
, , D O W NP O S I T I O N ' '

2 . S i d e - s t a n d":U P - R I G H T( O N ) "
" O N " t h e r e l a ya n d t h e i g n i t i o nc o i l l i v e s .T h e e n g i n ec a n b e e a s i l y
T h e c u r r e n tf l o w @ t u r n s
startedat any transmissionposition.

SIDE-STAND
IGNITION
SW. R E L A Y" O N "

IGNITION
BATTERY
cor L

SIDE-STANDSW.
NEUTRAL ,,UP.RIGHT
SW. "OFF" POSITION"
 ETECTBICAI. 7.12
SYSTEM

TROUBLESHOOTING

Starter motor will not run.

The transmissionis in neutral. Check whether to run the

Turn on the ignitionswitch with startermotor when connectthe
the enginestop switch in "RUN" CIicks starter motor terminal to the
position. battery@ terminaldirectly.
Check whether to hear the click (Do not use thin wire, because
noisefrom the starterrelaywhen a large amount of current
the starter button is pushed. flows.)

Run Not run

No click t i
o Faultystarter motor
t
o Faultystarter relay
o Loosenor disconnectedstarter
motor lead wire
Measurethe starterrelayvoltage
at the starterrelayconnectors(be- r Faulty ignition switch
Not voltage-----------D
tween Y/B @ and B/W O) *hen o Faultyenginestop switch
the starter button is pushed. o Faultyneutralswitch
o Faultydiode
o Faultyside-standrelay
r Faultystarter button
Voltage measured
o Faultyclutch lever position
switch
r Faultystartercontrol relay
o Poor contact of connector
. Open circuit in wiring harness
Checkthe starter relay.
( R e f e rt o p a g e 7 - 1 5 . ) Incorrect------------> r Faulty starter relay

Correct
r Poor contact of the starter relay

Startermotor runs when the transmissionis in neutral,but does not run with the transmissionin
any positionexcept neutral,with the side-standup position.

lncorrect ---------------->
r Faulty side-stand switch

Correct
. Open circuit in wiring harness
r Poor contact of connector

Enginedoes not turn | . Faulty starter clutch

though starter motor runs.
7-13 ELECTRICAI.
SYSTEM

STARTERMOTOR REMOVALAND
DISASSEMBLY
o Disconnectthe starter motor lead wire.
r Removethe starter motor.

o Disassemble
the startermotoras shown in the illustration'

@
@
@
%@ @
@
@
@ (

O O-ring
@ H o u s i n ge n d ( i n s i d e )
@ Starter motor case
@ Washer set
@ Armature
@ Shim seat
@ Brush holder
@ Brush spring
@ Housingend (outside)

STARTERMOTOR INSPECTION
CARBONBRUSH
lnspectthe brushedfor abnormalwear, crack or smooth-
n e s si n t h e b r u s h h o l d e r .
l f t h e b r u s hh a s f a i l e d ,r e p l a c et h e b r u s h s u b assy.
tr
tJ
 SYSTEM7-14
ETECTRICAT

COMMUTATOR
I n s p e c t h e c o m m u t a t o rf o r d i s c o l o r a t i o na, b n o r m aw
l ear
o r u n d e r c u@ t .
lf the commutatoris abnormally worn, replacethe armature'
is
Whensurface descolored, polish it with #4OOsandpaper
and clean it with dry cloth.
lf thereis no undercut,scrapeout the insulator@ with saw
blade.

ARMATURECOIL INSPECTION
Checkfor continuity between each segment'
Checkfor continuitybetweeneachsegmentand the arma-
ture shaft.
lf there is no continuitybetweenthe segmentsor there is
continuitybetweenthe segmentsand shaft, replacethe ar-
m a t u r ew i t h a n e w o n e .

OIL SEAL INSPECTION

C h e c kt h e s e a l l i p f o r d a m a g eo r l e a k a g e .
l f a n y d a m a g ei s f o u n d , r e p l a c et h e h o u s i n ge n d .

STARTERMOTOR REASSEMBLY ,il':

Reassemble the startermotor in the reverseorderof disas-

sembly. Pay attentionto the following points:

CAUTION
Replace the O-ring with a new one to prevent oil leak-
age and moisture.

. A p p l y S U Z U K IS U P E RG R E A S E" A " t o t h e l i p o f t h e o i l
seal.
"A"
GREAsE
suPER
fu99ooo-2s030:sUZUKt
. Apply a smallquantityof MOLY PASTEto the armature
shaft.

fu99ooo-2s140:suZUKlMoLYPAsrE

tu
7-I5 EIECTBIGAL
SYSTEM

. Appfy a smallquantityof THREADLOCK" 1342" to the

startermotor housingbolts.

t't#l 99ggo-32obo:THREADLocK
"1942"

.d
@

STARTERRELAYINSPECTION
o Removethe seat and left f ramecover. (Referto page6- 1.)
o Disconnectthe batteryQ lead wire.
. Disconnectthe starterrelayleadwire coupler@ and re-
lay cover @.
. Disconnectthe startermotor lead w t r e and battery lead
wire at the starter relay.
o Removethe starter relay.

A p p l y 1 2 v o l t st o @ a n d@ t e r m i n a l si,n s p e c t h e c o n t i n u i t y
betweenthe terminals,positiveand negative.
lf the starterrelayis in soundcondition,continuityis found.

@f ossoo-25o08: Multi circuittester set

( .t)) )
ffi$t"ster knob indication:Continuitytest
A CAUTION
Do not apply a battery voltage more than 5 seconds
to the starter relay as it may overheat and cause
damageto the relay coil.

To starter motor e @ To battery

r Checkthe coilfor "open", "ground" and ohmicresistance.

The coilis in goodconditionif the resistanceis as follows,

@! osso0-25008: Multi circuittester set

Starter relay resistance
S t a n d a r d3
: -50
 ETECTRIGAI.
SYSTEM7-I6

STARTERCONTROLRELAYINSPECTION
o Removethe left frame cover. (Referto page 6-1.)
o Remove the starter control relay and disconnectthe
coupler.

Usinga multi circuittester, measurethe voltagebetween

t h e t e r m i n a l si n t h e f o l l o w i n gt a b l e .
Unit:V
@ Probeof tester to:
ii
P

g b
yut

LL] o

@! oSSOo-25008:Multi circuittester set

LEUt"*t"r knob indication:Diodetest ({G}
NOTE:
lf the tester read under 1.4V, replace the battery of multi
circuit tester when do not connecting the tester probes.
 SYSTEM
7.17 ETECTBICAT

SYSTEM
INTERLOCK
SIDE.STAND/IGNITION
PART INSPECTION
lf the interlocksystemdoesnot operateproperly,checkeach
component.lf any abnormalityis found, replacethe com-
ponent with a new one.

DIODE
The diode @ is locatedunder the battery cover.
o Removethe seat and battery cover.
o Disconnectthe diode.

Usinga multi circuit,tester, measurethe voltagebetween

the terminalsin the following table.
Unit:V
@ Probeof tester to:
ii
P

R b
F6
d g
rF
/-;\
\ro

@! ossoO-2soo8: Multicircuittesterset
(-iGl
ffip f""t"r knobindication:Diodetest
NOTE:
lf the tester read under 1.4V, replace the battery of multi
circuit tester when do not connecting the tester probes.

NEUTRALSWITCH
The neutralswitch lead wire coupleris locatedbehindthe
left frame cover.
. Removethe left frame cover. (Referto page 6-1.)
o Disconnectthe neutralswitch lead wire and check the
continuitybetweenBlueand Groundwith the transmis-
sionin "NEUTRAL",
Blue Ground
ON r\
(Neutral)
OFF
(Exceptneutral)
 ETEGTRICAI 7.I8
SYSTEM

SIDE-STANDSWITCH
The side-standswitch lead wire coupleris locatedbehind
the left frame cover.
r Removethe left frame cover. (Referto page 6-1.)
o Disconnectthe side-standswitch lead wire couplerand
checkthe continuitybetweenGreenand BlackMhite lead
wires.

@! osso0-25008: Multi circuittester set

Diodetest (-{G}
ffip f"rt"r knobindication:
Green Black/White
(@ Probe) (Q Probe)

ON
0.4-0.6 v
(UP-rightposition)
OFF
1 . 4 - 1 . 5V
(Down position)

NOTE:
lf the tester read under 1.4V, replace the battery of multi
circuit tester when do not connecting the tester probes.

SIDE-STAND/IGNITION INTERLOCKRELAY
The side-standiignition interlockrelayis locatedbehindthe
right frame cover.
o R e m o v et h e r i g h t f r a m e c o v e r . ( R e f e rt o p a g e 6 - 1 . )
o Removethe side-stand/ignition interlockrelay.

First,checkthe insulationbetweenO and @ terminalswith

tester. Then apply 12 volts to @ and @ terminals,
@ to @ and e to @, and check the continuity between
O and@.
lf there is no continuity,replaceit with a new one.
7-Ig ELECTRICAL
SYSTEM

IGNITIONSYSTEM
DESCRIPTION
The fully transistorizedignitionsystem consistsof the signalgenerator,ignitor,ignitioncoils, and
spark plugs.The signalgeneratorcomprisesthe rotor tip and signalcoil.
The rotortip is mountedat the rotor.The signalcoil is mountedat the generatorcover.The induced
signalin the signalgeneratoris sent to wave-formarrangementcircuit,and CPUreceivesthis signal
and calculates the bestignitiontimingfrom the signalof ceramicvibratorand data storedin the ROM,
The CPU outputs signalto the transistorof the l.G. coil output circuit which is connectedto the
primarywindingsof the ignitioncoil which is turned OFFand ON accordingly,thus it inducesthe
secondarycurrenton the ignitioncoil secondarywindingsand producethe sparkbetweensparkplug
gaps'

l g ni t i o n
o/wgl
Generatorrotor
put circuit
Sparkplug /$r;"
R
CPU

Oc. ["'{+F'J g'E* { ,,""

fR
tsonr

f Battery
i fi2v
-f loAh)
B/W I
,2 *
WIRECOLOR
G : Green R :Red B/Y : Black with Yellow tracer
Bl : Blue O/W: Orangewith White tracer B / W : B l a c kw i t h W h i t e t r a c e r
W: White O/Y : Orangewith Yellow tracer R/W: Red with White tracer
O : Orange O/B : Orangewith Black tracer

NOTE:
The ignition cut-off circuit is not incorporated in this ignitor unit.
 SYSTEM7.20
ELECTBICAT

TROUBLESHOOTING

No spark or poor spark Checkthat the transmissionis in neutralpositionand

the enginestop switch is in the RUNposition.Inspect
that the fuse is not blown and batteryis fully-charged
conditionbeforethe diagnosis.

Checkthe ignitionsystem couplers --_>

Looseness o Poor connectionof couplers
for poor connection.

Correct

lnspect the battery voltage between

inputleadwires (O/Yand B/W) at the ig- lncorrect --------->. Faulty ignitionswitch
"ON"
nitor unit with the ignitionswitch a Brokenwire harnessor poor
position. connectionof relatedcircuit
couplers
Correct

Inspectthe ignitioncoil primarypeakvol-

t a g e . ( R e f e rt o p a g e 7 - 2 1 . 1
NOTE: This inspection method is ap- Correct
plicable using only for Multicircuit tester
and peak volt adaptor.
Correct Incorrect

lncorrect I
V
o Faultyspark plug
V
o Poor connectionof
s p a r kp l u g c a p .
I n s p e c t h e i g n i t i o nc o i l . Incorrect# o Faulty ignitioncoil
( R e f e rt o p a g e 7 - 2 2 . 1

Correct

lnspectthe signalgeneratorpeakvoltage
and its resistance.(Referto gage 7-23
and -24.1
NOTE: The signal generator peak vol-
tage inspection is applicable using only Incorrect---------->.
Faulty signal generator
for Multi circuit tester and peak volt
adaptor.

Correct
o Faulty ignitor unit
o Poor connectionof ignition
couplers.
7.2I ELECTRICAT
SYSTEM

INSPECTION
IGNITIONCOIL PRIMARYPEAK VOLTAGE
o Removethe fuel tank. (Referto page 4-4.)
o Removethe two spark plug caps.
o Connectnew two sparkplugsto the eachsparkplugcap
a n d g r o u n dt h e m .
NOTE:
Be sure that all couplers and spark plugs are connected
properly and the battery used is in fully-charged condition.

Inspectthe No.1 ignitioncoil primarypeak voltage in the

f o l l o w i n gp r o c e d u r e .
o Connectthe multi circuittester with peak voltageadap-
tor as follow.
N o . 1 i g n i t i o nc o i l : W h i t e t e r m i n a l - G r o u n d
(@ Probe) (Q Probe)

NOTE:
Do not disconnect the ignition coil primary wire.

@! ossoo-25o08:Multicircuittesterset
CAUTION
When usingthe multi circuittester and peak volt adap-
tor, follow the instruction manual.
o Shift the transmissioninto the neutraland turn ignition
switch "ON".
Crankthe enginea few secondswith starter motor by
depressing starterbutton and then checkthe ignitioncoil
primarypeak voltage.
Repeatthe aboveinspectiona few times and measurethe
highestignitioncoil primarypeak voltage.

tEUtester knob indication:Voltage( = )

lgnition coil primary peak voltage: More than 210 V

Do not touch the tester probesand spark plugs to pre-

vent an electric shock while testing.
 SYSTEM7.22
ETECTRICAT

Inspectthe No.2 ignitioncoil primary peak voltage in the

s a m e m a n n e ro f N o . 1 i g n i t i o nc o i l i n s p e c t i o n .
N o . 2 i g n i t i o nc o i l : B / Y t e r m i n a l - G r o u n d
(@ Probe) (Q Probe)
B/Y: Black with Yellow tracer
NOTE:
Do not disconnect the ignition coil primary wire.

ffipf"rt"r knob indication:Voltage( = )

lgnition coil primary peak voltage: More than 205 V
lf they are lowerthan the specifiedvalues,inspectthe igni-
tion coil, signalgeneratorand ignitor.(Referto page7-2O'l

IGNITIONCOIL (Checkingwith Electro Tester)

o Removethe fuel tank. (Referto page 4-4.)
. Removethe ignitioncoils.

NOTE:
Make sure that the three-needle sparking distance of elec-
tro tester r.ssef at I mm (O.3 in).

. With the tester,test the ignitioncoil for sparkingperfor-

mance.The test connectionis as indicated.
lf no sparkingor orangecolorsparkingoccuresin the above
conditions,it may be causedby defectivecoil.
tester
@! ossoo-2a108:Etectro
Spark performance:Over 8 mm (0.3 in)

Do not touch the wire clips to prevent an electric shock

when testing.
CAUTION
8mm
When using the electro tester, follow the instruction ;"F".-eK
manual. / l l
SPark ll

IGNITIONCOIL RESISTANCE
o An ohm metermay be used,insteadof the electrotester'
In eithercase,the ignitioncoil is to be checkedfor con-
tinuity in both primaryand secondarywindings' Exact
ohmic readingsare not necessary,but, if the windings
are in soundcondition,their continuitywill be notedwith
these approximateohmic values.
7.23ETECTBICAI.
SYSTEM

lgnitioncoil resistance
Primary:2*60 (@ tap-O tap)
Secondary: 15-30 kO (Plugcap-@ tap)

SIGNALGENERATOR (Checkingwith Multi GircuitTester)

o Disconnectthe ignitorleadwire coupler@ from the igni-
tor unit.
NOTE:
Be sure that allcouplers are connected properly and the bat'
tery used is in fully-charged condition.

Inspectthe signalgeneratorpeak voltage between Green

a n d B l u el e a d w i r e s o n t h e i g n i t o rc o u p l e r . Signal Ignitor
generator c o u p l e r
o Connectthe multi circuittesterwith peakvolt adaptoras coupler
follow.
G r e e n1 @P r o b e ) - B l u e( Q P r o b e )
Peakvolt
@! ossoo-2soo8:Mutticircuittesterset Signal
generator adaptor

A CAUTION
When using multi circuit tester and peak volt adaptor,
follow the instruction manual.

. Shift the transmissioninto the neutraland turn ignition

"ON".
switch
Crankthe enginea few secondswith starter motor by
depressingstarterbutton and then checkthe signalgener-
ator peak voltage.
Repeatthe abovetest procedurea few times and meas-
ure the highestsignalgeneratorp e a k v o l t a g e .

ffipf"*t"r knob indication:Vottage( = )

Signal generator peak voltage:
More than 1.5V (Green-Blue)
lf the peak voltagemeasuredon the ignitor lead wire cou-
pler is lower than the specifiedvalue, check the peak vol-
tage on the signalgeneratorleadwire couplerin the following
procedure.
 ETECTRICAL
SYSTEM7-24

o R e m o v et h e l e f t f r a m e c o v e r . ( R e f e rt o p a g e 6 - 1 . )
o Disconnectthe signalgeneratorleadwire couplerand con-
nect the multi circuit tester with peak volt adaptor.
Green (@ Probe)-Blue (Q Probe)
r Measurethe signalgeneratorpeak voltage in the same
mannerof measuringon the signal generatorlead wire
coupler.

ffif Testerknob indication:Voltage( = )

Signal generatorpeak voltage: Signal
More than 1.5V (Green-Blue) generator
coupler
lf the peak voltageon the signalgeneratorlead wire cou-
p l e ri s n o r m a lb u t o n t h e i g n i t o rl e a dw i r e c o u p l e ri s a b n o r -
m a l , t h e w i r e h a r n e s sm u s t b e r e p l a c e d l.f t h e b o t h p e a k
voltageis abnormal,the signalgeneratormust be replaced
and recheck.

SIGNALGENERATOR RESISTANCE
e Removethe left f ramecoverand disconnectthe leadwire Signal
generator
coupler.
o Measurethe resistancebetweenlead wires and ground.
is not specifiedvalue,the signalcoilmust
lf the resistance
be replaced.

Signalcoil resistance:170-2800 (Green-Blue) Signal

ooO {Green-Ground) generator

NOTE:
Refer to page 3-45 for signal generator replacing.

SPARK PLUG
Refer to page 2-7.
7-25 ETECTRICAT
SYSTEM

SPEEDOMETER
AND INSTRUMENT
PANEL
REMOVALAND DISASSEMBLY
. Flemovethe fuel tank. (Referto page 4-4.)
o Disconnectthe speedometerlead wire coupler.
r Disconnectthe speedometercable.
o Removethe indicatorlight lower cover.
. Removethe speedometerassemblyby removingthe nuts.

-g
 SYSTEM7-26
ELECTRICAT

INSPECTION
Checkthe continuity between lead wires in the diagram.
lf the continuitymeasuredis incorrect,replacethe respec-
tive parts.
NOTE:
When making this test, it is not necessary to remove the
speedometer.

ITEM @ Probe of Q Probe of

tester to: tester to:
1 )T E M P o/G B/G
(2) HIGH BEAM B/W
(3) olL o/G G/Y
(4) METERILLUMI Gr B/W
( 5 )N E U T R A L o/G BI/B
(6) TURN B Ls
WIRE GOLOR
B : Black
Gr : Gray
Lg : Light green
Y : Yellow
B/G : Black with Greentracer
B/W: Black with White tracer
B l / B : B l u ew i t h B l a c kt r a c e r
G / Y : G r e e nw i t h Y e l l o wt r a c e r
O/G : Orangewith Greentracer
7.27 ETECTRICAT
SYSTEM

LAMPS
HEADLIGHT

N
{rrNu

Headlightbulb: 12V 6O/55W

Positionlight bulb: 12V 4W (Except for E-03,24,28,33l-
NOTE:
Adjust the headlight, both vertical and horizontal, after reassembling.

BULBREPLACEMENT
o Removethe headlightby removingthe two screws.
. Disconnectthe lead wire coupler@.
o R e m o v et h e h e a d l i g h b
t ulb.
o Reassemblethe headlightbulb in the reverseorder of
removal.
CAUTION
lf you touch the bulb with your barehands,cleanit with
a cloth moistenedwith alcohol or soapy water to pre-
vent early failure.
 SYSTEM7.28
ETECTRICAT

TAIL/BRAKELIGHT

Tail/brakelight bulb: 12V 5121W

BULBREPLACEMENT
. R e m o v et h e c a p e .
r Removethe bulb socket @.
o R e m o v et h e t a i l / b r a k el i g h t b u l b .
. Reassemble the tail/brakelight bulb in the reverseorder
of r e m o v a l .
CAUTION
lf you touch the bulb with your barehands,cleanit with
a cloth moistenedwith alcoholor soapy water to pre-
vent early failure.
7.29 ETECTBICAL
SYSTEM

T U R N S I G N A LL I G H T

n.(
rR\\
\v/-
))J
d"
Turn signallight bulb: 12V 5121W{ForE-03,28,33)
12V 21W (Forothers)

A CAUTION
lf you touch the bulb with your bare hands, clean it with
a cloth moistenedwith alcohol or soapy water to pre-
vent early failure.

RELAY
STARTERRELAY
The starter relay is locatedbehindthe left frame cover.
( R e f e rt o p a g e s7 - 3 a n d 7 - 1 5 f o r d e t a i l s . )

INTERLOCKRELAY
SIDE.STAND/IGNITION
interlockrelayis locatedbehindthe
The side-stand/ignition
rightframecover. (Refer
to pages7-4 and 7-18f or details')

TURN SIGNALRELAY
The turn signalrelayis locatedbehindthe rightframecover,
lf the turn signallight does not light, inspectthe bulb, turn
signalswitch and circuit connection.
lf the bulb,turn signalswitch and circuitconnectionchecked
are correct,the turn signalrelay may be faulty, replaceit
with a new one.
NOTE:
Be sure that the battery used is in fully-charged condition'
 EI.ECTBICAI 7.30
SYSTEM

SWITCHES
lnspecteach switch for continuitywith the tester. lf any abnormalityis found, replacethe respec-
tive switch assemblieswith new ones.
IGNITIONSWITCH STARTERBUTTON
---------..-
For E-24 Color
------\ Position------....-. o/w Y/G
Color
Positidn------..- R o o/Y G r Br a

OFF PUSH
ON r --o r --o HORNBUTTON
------..-
For others Color
-----=\ Pos't'oi----...-
B/BI B/W
Color
Positioi-----.- R o o/Y G r Br a

PUSH a)
OFF
ON r o- -c FRONTBRAKESWITCH
P G --o \---\ Color
B/R B
Positidi------.-
LIGHTINGSWITCH
For E-03,24,28,33 OFF
-------\
Color ON o- C
Positioi-*---...- o/Bl Gr o/R Y/W
REARBRAKESWITCH
ON G- ---o o- {
-------\
Color
Positioi------..- o W/B
For others
------\ OFF
Color
Positidi------- o/Bl Gr o/R Y/W ON
OFF OIL PRESSURE SWITCH
-------\
S o- -{ Color
G/Y Ground
ON o- ---o o- { Position-------
E n g i n ei s
DIMMERSWITCH stopped
------.\
Color E n g i n ei s
Positioi------..- Y/W W Y
running
HI o- --{
LO o- --o NOTE:
Before inspecting the oil pressure switch, check
TURN SIGNALSWITCH
-----.-\ if the engine oil level is enough.
Color
Positioi-------..- Lg Lbl B WIRECOLOR
L r -o B : Black Lbl: Light blue R : Red
Br: Brown Lg : Light green Y : Yellow
PUSH
Gr: Gray O : Orange W: White
R o- { B/Bl : Black with Blue tracer
PASSINGLIGHTSWITCH B/W: Black with White tracer
B/R : Black with Red tracer
Color
Position-' o/R Y BiBl : Black with Blue tracer
G/Y : Green with Yellow tracer
a
O/B : Orangewith Black tracer
PUSH o- r) O/Bl: Orange with Blue tracer
O/R : Orangewith Red tracer
ENGINESTOPSWITCH
OiWr Orange with White tracer
Color
Positiori o/B o/w O/Y : Orangewith Yellow tracer
W/B: White with Black tracer
OFF Y/G : Yellow with Green tracer
RUN o- -€ Y/W: Yellow with White tracel
7.3T ETEGTRICAT
SYSTEM

BATTERY
SPECIFICATIONS Upper
breather
Type ddsignation FTX12-BS erminal
Cathode Safety valve
Capacity 1 2 V , 3 6 k C ( 1 0A h ) / 1 0 H R plates
Separator
Standardelectrolyte ( fi b e r g l a s s
1 . 3 2 Oa t 2 0 o C ( 6 8 o F ) plate)
S.G,
Anode Dlates

INITIALCHARGING
Fillingelectrolyte
o Removethe aluminumtape @ sealingthe battery elec-
trolyte filler holes.

o Removethe caps @ .

NOTE:
* After filling the electrolyte completely, use the removed
cap @ as the sealed caps of battery-filler holes.
x Do not remove or pierce the sealed areas of the elec-
@
trolyte container.

r Insertthe nozzlesof the electrolytecontainerinto the bat-

f i l l e rh o l e s ,h o l d i n gt h e c o n t a i n efri r m l y
t e r y ' se l e c t r o l y t e
so that it does not fall. Take precautionnot to allow any
of the fluidto spill.

Makesureair bubblesarecomingup each electrolytecon-

tainer,and leavein this positionfor about more than 20
minutes. "o

)
a)
-o
o.
 SYSTEM7-32
ETECTBICAL

NOTE:
lf 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 confirmingthat the electrolytehas enteredthe bat-

tery completely,removethe electrolytecontainersfrom
the battery.Wait for around 20 minutes'
lnsertthe caps into the filler holes,pressingin firmly so
that the top of the capsdo not protrudeabovethe upper Insert the caps firmlY.

surfaceof the battery'stop cover.

A CAUTION
* Never use anything except the specified battery.
* once installthe caps to the battery; do not remove
the caps.

CORRECT INCORRECT

o Using multi circuittester, measurethe battery voltage'

T h e t e s t e rs h o u l di n d i c a t em o r et h a n 1 2 . 5 - 1 2 . 6 V ( D C )
as shown in the Fig, lf the batteryvoltageis lower than
the specification,chargethe batterywith a battery charg-
e r . ( R e f e rt o t h e r e c h a r g i n go p e r a t i o n , )

NOTE:
tnitial charging for a new battery is recommended if two
4 6 8 1 0 ( M i n u t e s )
years have elapsed since the date of manufacture. Time

SERVICING
Visuallyinspectthe surfaceof the batterycontainer'lf any
signs of crackingor electrolyteleakagefrom the sides of
the batteryhave occurred,replacethe battery with a new
one. lf the batteryterminalsarefound to be coatedwith rust
or an acidic white powdery substance,then this can be
cleanedaway with sandpaper.
 SYSTEM
7.33 EIECTRICAI.

OPERATION
RECHARGING Charging period
o Usingthe multi circuittester, checkthe batteryvoltage. Stop charging
lf the voltagereadingis lessthan the 12,0V (DC),recharge
the battery with a battery charger.

CAUTION
When rechargingthe battery, remove the battery from
the motorcycle. 0 3 0 4 0 5 0 6 0
Time (Minutes)
NOTE:
Do not remove the caps on the battery top while recharging. (v) 0 0- 4 0 0 c )
14
time: 5A for one hour or 1 .ZAfor 5 to 1Ohours
Recharging
13

CAUTION 12

Be careful not to permit the charging current to exceed 11

5A at any time. 10

r After recharging,wait for morethan 30 minutesand check

Battery chargedcondition
the battery voltagewith a multi circuit tester.
o ff the batteryvoltageis lessthan the 12.5V, rechargethe
battery again.
o lf batteryvoltageis still less than 12.5V, after recharg-
ing, replacethe battery with a new one.
o When the motorcycleis not usedfor a long period,check
the battery every 1 month to prevent the battery dis-
charge.
 CONTENTS
.....1...".."
T ROU B L E S H OOT T N G ."....8- 1

ENGTNE ......"..'8- 1
'.'..'.
oA R B U R E T OR ..... 8- 4

RADIATOR.."'.' 8- 4
CHASS|S 8- 5
BRAKES.'.."-.'.-...: .8- 6
ELECTRICAL..-...... . . . . . . . . .8. - 7

BATTERY 8- 8
WIRING DIAGRAM 8- 9
WIRE HARNESS. CABLE AND HOSE NOUTING 8-1O
WIRE HARNESS ROUTING 8-1O
CABLE BOUTING 8.13
FUEL SYSTEM HOSE ROUTING 8-14
COOLINGSYSTEM HOSE ROUTING 8-16
PAIR (AIR SUPPLY)SYSTEM HOSE ROUTING 8-7 7
FRONT BRAKE HOSE ROIJTING .. 8-18

SPECIALTOOLS....'. ..; ... ..'.. 8- I I

T TGH T E N INTGOR A U E ...";".....' . "....8- 21

SERV|CEDATA ...... 8-24

8-1 SERVICING
ITUFOBMATIOII

TROUBLESHOOTING
ENGINE
Complaint Symptom and possiblecauses Remedy

Enginewill not start, Compressiontoo low

or is hard to start. 1. Out of adjustmentvalve clearance. Adjust.
2. Worn valve guidesor poor seatingof valves. Repairor replace.
3. Mistimingvalves. Adjust.
4. Excessivelyworn piston rings. Replace.
5. Worn-down cylinderbores. Replaceor rebore.
6. Too slowly starter motor cranks. See electricalsection.
7. Poor seatingof spark plugs. Retighten.
Plugs not sparking
1 . F o u l e ds p a r kp l u g s . Clean.
2 . W e t s p a r kp l u g s . Cleanand dry.
3. Defectiveignitioncoil. Replace.
4. Open or short in high-tensioncords. Replace.
5. Defectivesignalcoil or ignitor unit. Replace.
No fuel reachingthe carburetors
1. Cloggedor defectivefuel valve. Cleanor replace.
2. Defectivefuel pump. Replace.
3. Defectivecarburetorneedlevalve. Replace.
4. Cloggedfuel hose or fuel valve strainer. Cleanor replace.
5. Defectivesignalcoil, ignitioncoil and ignitor. Replace.

Enginestalls easily. 1 . Fouledspark plugs. Clean.

2 . Defectivesignalcoil or ignitorunit. Replace.
3 . Cloggedfuel hose. Clean.
4 . Cloggedjets in carburetors. Clean.
5 . Out of adjustmentvalve clearance. Adjust.
6 . Defectivefuel pump. Replace.

Noisy engine. Excessive valve chatter

1. Too large valve clearance. Adjust.
2. Weakenedor brokenvalve springs. Replace.
3. Worn down rocker arm or rockerarm shaft. Replace.
4. Worn and burnt camshaftjournal. Replace.
Noise seems to come from Piston
1. Worn down pistonsor cylinders. Replace.
2. Fouledwith carboncombustionchambers. Clean.
3. Worn piston pins or piston pin bore. Replace.
4. Worn piston rings or ring grooves. Replace.
Noise seems to come from timing chain
1. Stretchedchain. Replace.
2. Worn sprockets. Replace.
3. Not working tension adjuster. Repairor replace.
Noise seems to come from clutch
1. Worn splinesof countershaftor hub. Replace.
2. Worn teeth of clutch plates. Replace.
3. Distortedclutch plates,driven and drive. Replace.
4. Worn clutch releasebearing. Replace.
5. Weakenedclutch dampers. Replacethe primary
drivengear.
 SERVICI]'IG
INFOBMATIOil
8.2

Complaint Symptom and possiblecauses Remedy

Noisy engine. Noise seems to come from crankshaft

1. Due to wear rattlingbearings. Replace.
2. Worn and burnt big-endbearings. Replace.
3. Worn and burnt journalbe6rings. Replace.
4. Too largethrust clearance. Replacethrust bearing.
Noise seems to come from transmission
1 . W o r n o r r u b b i n gg e a r s . Replace.
2. Worn splines. Replace.
3. Worn or rubbingprimarygears. Replace.
4. Worn bearings. Replace.
Noise seems to come from water pump
1. Too much play on pump shaft bearing. Replace.
2. Worn or damagedimpellershaft. Replace.
3. Worn or damagedmechanicalseal. Replace.
4. Touchespump case and impeller. Replace.

Slipping clutch. 1. Out of adjustmentor loss of play clutch control. Adjust.

2. Weakenedclutch springs. Replace
3. Worn or distortedpressureplate. Replace
4. Distortedclutch plates.drivenand drive. Replace

Dragging clutch. 1 Out of adjustmentor too much play clutch control. Adjust.
2 Some clutch springsweakenedwhile others are not. Replace.
3 Distortedpressureplate or clutch plate. Replace.

Transmissionwill 1 Brokengearshiftcam. Replace

not shift. 2 Distortedgearshift forks. Replace
3 Worn gearshiftpawl. Repla'ce

Transmissionwill 1 Brokenreturnspringon shift shaft. Replace.

not shift back. 2 Rubbingor stickly shift shaft. Repairor replace.
3 Distortedor worn gearshiftforks. Replace.

Transmissionjumps 1. Worn shiftinggearson driveshaftor countershaft. R e p l a c e

out of gear. 2. Distorted or worn gearshiftforks. Replace
3. Weakenedstopperspringon gearshiftstopper. Replace

Engineidles poorly. 1. Out of adjustmentvalve clearance. Adjust.

2. Poor seatingof valves. Replaceor repair.
3. Defectivevalve guides. Replace.
4. Worn down rocker arm or rockerarm shaft. Replace.
5. Too wide spark plug gaps. Adjust or replace.
6. Defectiveignitioncoil. Replace.
7. Defectivesignalcoil or ignitorunit. Replace.
8. Out of adjustmentin carburetorsfloat-chamber Adjust.
fuel level.
9. Cloggedjets or imbalanceof carburetors. Cleanor adjust.
10. Defectivefuel pump or ignitorunit. Replace.
8.3 SERVtCtilG
iluFoRMATtolt

Complaint Symptom and possiblecauses Remedy

Engineruns poorly 1. Weakenedvalve springs. Replace.
in high speed range. 2. Worn camshafts. Replace.
3. Valve timing out of adjustment. Adjust.
4. Too narrow spark plug gaps. Adjust.
5. lgnitionnot advancedsufficientlydue to poorly Replaceignitorunit.
working timing advancecircuit.
6. Defectiveignitioncoil. Replace.
7. Defectivesignalcoil or ignitorunit. Replace.
8. Too low float-chamberfuel level. Adjust.
9. Cloggedair cleanerelement. Clean.
10. Cloggedfuel hose, resultingin inadequatefuel Cleanand prime.
supplyto carburetors.
1 1. Defectivefuel pump or ignitorunit. Replace.
Dirty or heavy 1 . T o o m u c h e n g i n eo i l i n t h e e n g i n e . Check with inspection
exhaust smoke. window drain out
excessoil.
2. Worn piston rings or cylinders. Replace.
3. Worn valve guides. Replace.
4. Scoredor scuffed cylinderwalls. Reboreor replace.
5. Worn valves stems. Replace.
6. Defectivestem seal. Replace.
7. Worn oil ring side rails. Replace.

Enginelacks power. 1. Loss of valve clearance. Adjust.

2. Weakenedvalve springs. Replace.
3. Out of adjustmentvalve timing. Adjust.
4. Worn piston rings or cylinders, Replace.
5. Poor seatingof valves. Repair.
6 . F o u l e ds p a r kp l u g . Cleanor replace.
7. Incorrectspark plug. Adjust or replace.
8. Cloggedjets in carburetors. Clean.
9. Out of adjustmentfloat-chamberfuel l e v e l . Adjust.
10. Cloggedair cleanerelement. Clean.
1 1. Loosecarburetorbalancingadjuster. Retightenand balance
the carburetor.
1 2 . S u c k i n ga i r f r o m i n t a k ep i p e . Retightenor replace.
1 3 . T o o m u c h e n g i n eo i l . Drainout excessoil.
14. Defectivefuel pump or ignitorunit. Replace.
15. Defectivesignalcoil, ignitorunit and ignitioncoil. Replace.
Engine overheats. 1. Heavy carbondepositon piston crowns. Clean.
2 . N o t e n o u g ho i l i n t h e e n g i n e . Add oil.
3. Defectiveoil pump or cloggedoil circuit. R e p l a c eo r c l e a n .
4. Too low in float chambersfuel level. Adjust.
5. Suckingair from intake pipes. Retightenor replace.
6. Use incorrectengineoil. Change.
7. Defectivecoolingsystem. See radiatorsection.
 SEBVICING
llllFORMATl0f'l
8-4

CARBURETOR
Complaint Symptom and possiblecauses Remedy
Trouble with staning. 1. Cloggedstarterjet. Clean.
2. Cloggedstarter pipe. Clean.
3. Air leakingfrom a joint between starter body and Check starter body and
carburetor. carburetorfor tightness,
adjustand replace
gasket.
4. Air leakingfrom carburetor'sjoint or vacuum Check and adjust.
gaugejoint.
5 . Not operationproperlystarterplunger. Check and adjust.
ldling or low-speed 1. Cloggedor loose pilot jet, pilot air jet. C h e c ka n d c l e a n .
trouble. 2. Air leakingfrom carburetor'sjoint, vacuum gauge Check and adjust.
joint, or starter.
3. Cloggedpilot outlet or bypass. Check and clean.
4. Not fully closedstarter plunger. Check and adjust.
Medium-orhigh 1. Clogged main jet or main air jet. C h e c ka n d c l e a n .
speed trouble. 2. Clogged needle jet. Check and clean.
3. Not operating properly throttle valve. Check throttle valve
for operation.
4 . C l o g g e df u e l f i l t e r . Check and clean.
5. Carburetor balancing adjuster loose. Retightenand balance
the carburetor.
Overflow and fuel 1. Worn or damagedneedlevalve. Replace.
level fluctuations. 2. Brokenspringin needlevalve. Replace.
3. Not working properlyfloat. Check and adjust.
4. Foreignmatter has adheredto needlevalve. Clean.
5. Too high or low fuel level. Adjust float height.
6. Defectivefuel pump or ignitorunit. Replace.
7. Cloggedcarburetorair vent pipe. Clean.
8. Defectivesignalcoil, ignitorunit and ignitioncoil. Replace.

RADIATOR
Complaint Symptom and possiblecauses Remedy
Engineoverheats. 1. Not enoughenginecoolant. Add enginecoolant.
2. Cloggedwith dirt or trashesradiatorcore. Clean.
3. Faultycoolingfan. Repairor replace.
4. Defectivecoolingfan thermo-switch. Replace.
5. Cloggedwater passage. Clean.
6. Air trappedin the coolingcircuit. Bleedout air.
7. Defectivewater pump. Replace.
8. Use incorrectenginecoolant. Replace.
Engineovercools. 1. Defectivecoolingfan thermo-switch. Replace.
2. Extremelycold weather. Put on the radiator
cover.
8-5 SERVICING
IITIFORMATION

CHASSIS
Complaint Symptom and possiblecauses Remedy

Heavy steering. 1. Overtightenedsteeringstem nut. Adjust.

2. Brokenbearingin steeringstem. Replace.
3. Distorted steeringstem. Replace.
4. Not enough pressurein tires. Adjust.

Wobbly handlebars. 1. Loss of balancebetween right and left front forks. Replace.
2. Distortedfront fork. Repairor replace.
3. Distortedfront axle or crookedtire. Replace.
4. Loosesteeringstem nut. Adjust.
5. Worn or incorrecttire or wrong tire pressure. Adjust or replace.

Wobby front wheel. 1. Distortedwheel rim. Replace.

2. Worn front wheel bearings. Replace.
3. Defectiveor incorrecttire. Replace.
4. Looseaxle or axle pinch bolt Retighten.
5. lncorrectfront fork oil level. Adjust.

Front suspension 1 Weakenedsprings. Replace.

too soft. 2 Not enoughfork oil. Replenish.
3 Wrong weight fork oil. Replace.

Front suspension 1 .Too viscousfork oil. Replace.

too stiff. 2 . Too much fork oil. Drainexcessoil.
3 . Front axle bent. Replace.
Noisy front 1. Not enough fork oil. Replenish.
suspension. 2. Loose bolts on suspension. Retighten.

Wobbly rear wheel. 1. Distortedwheel rim. Replace.

2. Worn rear wheel bearingor swingarmbearings. Replace.
3. Defectiveor incorrecttire. Replace.
4. Worn swingarmand rear shock absorber. Replace.
5. Loosenuts or bolts on rear suspensions. Retighten,

Rear suspension 1 . W e a k e n e ds h o c k a b s o r b e sr p r i n g . Replace.

too soft. 2. lmproperlyset rear suspensionadjuster. Adjust.
3. Leakageoil of shock absorber. Replace.

Rearsuspension 1. lmproperlyset rear suspensionadjuster. Adjust.

too stiff. 2. Bent shock absorbershaft. Replace
3. Bent swingarm. Replace
4. Worn swingarm bearings. Replace

Noisy rear 1. Loosenuts or bolts on rear suspension. Retighten.

suspension. 2. Worn swingarm bearings. Replace.
 iluF0BMATtoil
SERV|C|NG 8-6

BRAKES
Complaint Symptom and possiblecauses Remedy

lnsufficient brake 1. Leakageof brakefluid from hydraulicsystem. Repairor replace.

power. 2. Worn pads/shoe. Replace.
3. Oil adhesionof engagingsurfaceof pads/shoe. Cleandisc and pads.
4. Worn disc/drum. Replace.
5. Air in hydraulicsystem. Bleedair.
6. Not enoughbrakefluid in the reservoir. Replenish.
7. Too much play on brake pedal. Adjust.

Brakesqueaking. I Carbon adhesion on pad/shoe surface. Repairsurface with

sandpaper.
2 Tilted pad. Modify pad fitting or
replace.
3 Damagedwheel bearing. Replace.
Loosen front-wheel axle or rear-wheel axle. Tighten to specified
torque.
5 Worn pads. Replace.
6 Foreign material in brake fluid. Replace brake fluid.
7 Clogged return port of master cylinder. D i s a s s e m b l ea n d c l e a n
master cylinder.

Excessivebrake 1 Air in hydraulicsystem. Bleed air.

lever stroke. 2 lnsufficientbrakefluid. R e p l e n i s hf l u i d t o s p e -
cified level; bleed air.
3 lmproperquality of brakefluid. Replacewith correct
f luid.

Leakage of brake 1. Insufficienttighteningof connectionjoints. Tightento specified

fluid. torque.
2 . C r a c k e dh o s e . Replace.
3. Worn piston and/orcup. Replacepiston and/or
cup.
8-7 SERVICII'IG
lNFORMATl0l'l

ELECTRICAL
Complaint Symptom and possiblecauses Remedy

No sparkingor poor 1. Defectiveignitioncoil. Replace

sparking. 2. Defectivespark plugs. Replace
3. Defectivesignalcoil or ignitorunit. Replace

Spark plug soon 1 . M i x t u r et o o r i c h . Adjust carburetors.

becomefouled with 2. ldling speedset too high. Adjust carburetors.
carbon. 3. Incorrectgasoline. Change.
4. Dirty elementin air cleaner. Clean.
5. Too cold spark plugs. Replacewith hot type
plugs.

Spark plugs become 1 . W o r n p i s t o nr i n g s . Replace

fouled too soon. 2. Worn piston or cylinders. Replace
3. Excessiveclearanceof valve stems in valve Replace
guides.
4. Worn stem oil seal. Replace

Spark plug electrod- 1 . T o o h o t s p a r kp l u g s . Replacewith cold type

es overheator burn. plugs.
2. Overheatedthe engine. Tuneup.
3. Loosespark plugs. Retighten.
4. Too lean mixture. Adjust carburetors.

Generatordoes not 1. Open or short lead wires, or loose lead Repairor replace or
charge. connections. retighten.
2. Shorted,groundedor open generatorcoils. Replace.
3. Shorted or pancturedregulator/rectifiers. Replace.

Generatordoes 1. Lead wires tend to get shortedor open-circuited Repairor retighten.

charge, but charging or looselyconnectedat terminals.
rate is below the 2. Groundedor open-circuited stator coils or Replace.
specification. generator.
3. Defectiveregulator/rectifier. Replace.
4. Defective cell plates in the battery. Replacethe battery.

Generator 1. Internalshort-circuitin the battery. Replacethe battery.

overcharges. 2. Damagedor defectiveresistorelementin the Replace.
regulator/rectifier.
3. Poorlygroundedregulator/rectifier. Cleanand tighten
groundconnection.

Unstablecharging. 1. Lead wire insulationfrayed due to vibration, Repairor replace.

resultingin intermittentshorting.
2. Internallyshortedgenerator. Replace.
3. Defective regulator/rectifier. Replace.

Starter button is not 1. Run down battery. Repairor replace.

effective. 2. Defective switch contacts. Replace.
3. Not seatingproperlybrusheson commutatorin Repairor replace.
starter motor.
4. Defective starter relay/starterinterlock switch. Replace.
 r1'lFoRMATtoltI
SERVICTNG 8.8

BATTERY
Complaint Symptom and possiblecauses Remedy
"Sulfation", Replacethe battery.
acidic 1. Crackedbattery case.
white powdery sub- 2. Battery has been left in a run-down condition for Replacethe battery.
stance or spots on a l o n gt i m e .
surfacesof cell
plates.

Battery runs down 1. Not correctthe chargingsystem. Checkthe generator,

quickly. regulator/rectif
ier
and circuit connections
and make necessary
adjustmentsto obtain
specifiedcharging
operation.
Cell plateshave lost much of their active Replacethe battery,
materialas a result of overcharging. and correctthe charg-
ing system.
3 A short-circuitconditionexists within the battery. Replacethe battery.
4 Too low battery voltage. Rechargethe battery
fully.
5 Too old battery. Replacethe battery.
Battery "sulfation" 1. Too low or too high chargingrate. Replace the battery.
(When not in use batteriesshould be checked at
least once a month to avoid sulfation.)
2. Lett unused the battery for too long in cold Replace the battery, if
climate. badly sulfated.

Battery discharges Dirty containertop and sides. Clean.

too rapidly.
 IilFOBMATION
8-9 SERVICIIIG

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 INFORMATION
SEBVICING 8.Ill

WIRE HARNESS.CABLEAND HOSEROUTING

W I R EH A R N E S SR O U T I N G

Clamp Clamp
Clamp W i r i n gh a r n e s s
W i r i n gh a r n e s s
narness

Corrugatedtube

Clamp

C o r r u g a t e dt u b e

C a r b u r e t o cr a b l e
W i r i n gh a r n e s s
B a t t e r y@ t e r m i n a l
Clamp
Starter r e l a y

F r o n tt u r n s i g n a l
lisht (R & L)
Clamp
Clamp
W i r i n gh a r n e s s

H a n d l e b asr w i t c h ( R & L )

Headlight H a n d l e b asr w i t c h ( R & L ) P a s st h r o u g ht h e l e a d

housing wires between the brace
a n d r e a rf e n d e r .
Clamp
S i d e - s t a n ds w i t c h Clamp
Neutral switch T a i l / B r a k el i q h t
Generator R e a rt u r n s i g n a l
light (L)

Horn

Fanmotorswitch
Clamp

Generator
N e u t r a ls w i t c h
Radiator Clamp

Pass through the Side-stand switch

S i d e - s t a n ds w i t c h
side-standswitch Neutral switch
Clamp lead wire inside the
f rame. Clamp
8.11 SERVIGING
ITIIFORMATION

H a n d l e b asr w i t c h ( R )
B r a k eh o s e H a n d l e b asr w i t c h ( L )

Brakehose

Front turn signal light lead wire

Clamp
W i r i n gh a r n e s s
Fan motor switch
Engine coolant temp. switch

No.2 cylinder

lgnition coil
I I
L_2 FOrWarO

Clamp

lgnition coil

P a s st h r o u g ht h e
s t a r t e rm o t o r l e a d
w i r e b e t w e e nt h e
carburetoa r nd
air cleaner.

Starter motor
B r a k es w i t c h
cable

W i r i n oh a r n e s s
G r o u n dw i r e
Starter motor
R e a rb r a k e l i q h t s w i t c h
R e g u l a t o r / r e c t iife r
O i l p r e s s u r es w i t c h
 SERVICING
INFORMATION
8-12

S t a r t e rm o t o r l e a d w i r e

Oil pressureswitch
lead wire

Generator
lead wire N e u t r a ls w i t c h
l e a dw i r e

G r o u n dw i r e

Clamp

N \ J \ J
v --_--\

O i l p r e s s u r es w i t c h
l e a dw i r e

Clamp
8-13 SERVtCiltTG
tilFoRMATtoN

CABLEROUTING

Throttle cable (pull)

Choke cable
Throttle cable (return)
Clutch cable

Brake hose Throttle cable

Passthrough the throttle cables
behind the brake hose.

W i r i n gh a r n e s s
Throttle cables

Throttle cable (pull)

\ / - Throttle cable (pull)
Throttlecable(return) C a b l eg u i d e
T h r o t t l ec a b l e ( r e t u r n )

Throttle cables
Clutch cable
C h o k ec a b l e
W i r i n gh a r n e s s
Throttle cable
Clamp

C l u t c hc a b l e

Choke cable

Rear brake cable

Rear brake switch cable

Rear brake switch cable cap

S t a r t e rm o t o r l e a d w i r e A i r c l e a n e rd r a i n h o s e

Clamp

Rear brake cable

 SERVICING
I]'IFORMATION
8.I4

FUELSYSTEMHOSEROUTING

Fuel tank water drain hose

Fuel hose

Pass through the fuel Fuel valve

tank water drain hose
under the fuel hoses.

Fuel pump hose

Fueltank water drain hose

_1_
F u e lt a n k w a t e r d r a i n
I
8-l 5 SERVtCttUG
tl'tF0RMAT|0II

T h r o t t l ec a b l e F u e lp u m p n o s e
C h o k ec a b l e (return)
Air vent F u e lh o s e S y n c h r o n i z i n/ n F u e l o u m o
nose Wiring \ cable
harness

Air vent hose

Fuel Breather
W i r i n g h a r n e s s/ hose nose
Choke
T h r o t t l ec a b l e cable
Throttlecable (return)
(pull)

RH

t \

w /1\ outlet tube clamp

tn,"t" PiPeclamP
Air cleaner
(No.2)
-Wr,
fi

LH Carburetor
(No.2) lntake pipe O u t l e tt u b e
cramp clamp
--> RH
- l
ffi
Breather
hose -r) {;
\-/ \r-,/
{ t r r
tt-/

>/
'/'
/tT'
F u e lh o s e
(forfuel pump
to carburetor
Choke cable t
N o . 1)
F u e lh o s e lgnitor-
(for fuel tank to fuel valve)
/_
F u e lv a l v e Air cleaner
d r a i nh o s e
r G e n e r a t o rl e a d w i r e
o N e u t r a ls w i t c h l e a d w i r e
Fuel hose . Side-standswitch--'---
(for fuel valve
lead wire L---,.---
to fuel pump)

. G r o u n dw i r e
. R e g u l a t o r / r e c t i f ileera d w i r e
o l g n i t o rl e a d w i r e
 SERVIGIII|G
IIIIFORMATION
8.16

C O O L I N GS Y S T E MH O S ER O U T I N G

Clamp

R e s e r v o itra n k

W a t e rt e m p .
switch

Clamp
Clamp
Radi
White mark cap

Reservoir tank
inlet hose

--fre/
Yellow mark

fl
Radiator C o o l i n gf a n t h e r m o - s w i t c h

I
ClamP

Cylinderhead joint hose

C y l i n d e jro i n t h o s e

Drain
hose Clamp
F a c et h e h e a do f s c r e w
to the left side.

Mark
position Radiator hose
 ITIIFORMATION
8.17 SERVICING

PAIR IAIR SUPPLY)SYSTEMHOSEROUTING

0)

:
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E z
i

E.

o
o

:
-
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.: z
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 8.18
INFORMATIOIII
SERVICII'IG

FRONTBRAKEHOSEROUTING

Passthrough the brake hose

into the holeof lower bracket.

Pass through the brake hose

in front of the throttle cables.

Fix the brake hose grommet

to the lower bracket.

Brake hose
(
F i x t h e b r a k eh o s e g r o m m e t
t o t h e h o s eg u i d e .

After touching the brake hose

u n i o nt o t h e s t o p p e r .t i g h t e nt h e
union bolt to the specifiedtorque.
8-rI SERVTCil\|G
IIF0RMATToN

SPECIALTOOLS

O99OO-20101 or o9900-20202
o9900-06107 09900-o6108 o9900-09003 09900-20102 Micrometer
Snapring pliers Snapring pliers lmpact driverset Verniercalipers (25-50 mm)

09900-20204 o9900-20205 o9900-20602

Micrometer Micrometer o9900-20508 Dialgauge 09900-20605
(75-100mml (0-25 mm) Gylindergaugeset ( 1 / 1 0 0 0m m , 1 m m ) Dial calipers

o9900-20606 o9900-20803
Dial gauge o9900-20701 09900-20806 o9900-20805 09900-21304
(1/10Omm, 10 mml Magnetic stand Thicknessgauge Tire depthgauge V-block(10Omml

09900-22403 o9900-25008
09900-22302 Smallbore gauge Multi circuit 09900-28106 o9913-10730
Plastigauge (18-35mm) tester set Electrotester Fuellevelgauge

o 9 9 13 - 13 12 1 0 9 9 13 - 7 5 5 2 0
Carburetorbalancer 0 9 9 13 - 5 0 12 1 09913-70122 09913-85210 o9914-245'tO
set Oil seal remover Bearinginstaller Bearinginstaller T-handle

0 9 9 15 - 6 3 2 10 0 9 9 15 - 7 4 5 3 1
09915-40610 Compressiongauge o 9 9 1 5 - 6 4 5 10 0 9 9 15 - 7 4 5 1 0 Oil pressure gauge
Oil filter wrench adapter Compressiongauge Oil pressure gauge adaptor
 8-20
lNF0BMAT|0t'l
SERVlClltlG

0991 5-77330 o 9 9 16 - 1 4 5 10 o 9 9 16 - 14 9 10 0991 6-24480

Meter {for high Valve spring Valve spring com- 0 9 9 1 6 - 2 11 1 0 Solid pilot
pressurel compressor pressor attachment Valve seat cutter set (N-140-5.5)

Valve seat cutter o9916-34550 0991 6-34580 o9916-44910

head o991 6-34541 Valve guide reamer Valve guide reamel Valve guide remover/
S e ep a g e3 - 3 1 . Reamerhandle (5.5 mml ( 1 O . 8m m ) installer

09918-53810
0991 6-44920 0991 6-8451 1 0 9 9 17 - 10 4 1 0 09917-47910 Chain tensioner
Attachment Tweezers Valve adjuster driver Vacuum pump gauge locking tool

3120
09920-1 o9920-53740
Crankcase separating Clutch sleeve hub 09923-73210 09923-74510 o9924-a4521
tool holder Bearingpuller Bearingpuller Bearinginstallerset

0 9 9 3 0 - 10 1 4 1 09930-14530 o9930-30102 09930-34970 09930-40113

Socket wrench Universdl joint Sliding shaft Rotor remover Rotorholder

\b\\-
0 9 9 4 0 - 1 4 9 11 0 9 9 4 1 - 5 4 9 11 o9941-74910
Steering stem 09941-34513 0 9 9 4 1 - 5 0 11 1 Bearing outer race Steering bearing
wrench Steering race installer Bearing remover remover installer
8.2t SERV|CilllG
tilFoRMATt0il

09943-7411 1
Fork oil level gauge

NOTE:
When order the special tool, please confirm whether it is available or not.

TIGHTENING
TOROUE
ENGINE
ITEM N.m kg-m lb-ft
Cylinder head cover bolt M6 11 1.1 8.0
M8 23 2.3 16 . 5
C y l i n d e rh e a d b o l t a n d n u t M10 38 3.8 27.5
M8 25 2.5 18.0
M6 11 1.1 LO
Primarydrive qear bolt 95 9.5 68.5
Clutch sleevehub nut 95 9.5 68.5
Rockerarm shaft 28 2.8 20.o
C a m c h a i nt e n s i o n e rb o l t 10 1.0 7.O
C a m c h a i ng u i d es e t b o l t 10 1.0 7.O
Cam chain sprocket bolt 15 1.5 11 . O
Valve adjusterlock nut 15 1.5 11 . 0
Crankcasebolt 22 2.2 16.0
Generatorcover hole plug 15 1.5 11 . 0
T , D . C .I n s p e c t i o np l u g 23 2.3 16.5
O i l d r a i np l u g 21 2.1 15.0
Oil pumpbolt I 0.8 6.0
O i l p r e s s u r er e g u l a t o r 28 2.8 20.0
E n g i n em o u n t i n gb o l t 88 8.8 63.5
Generatorrotor bolt 160 16.0 11 5 . 5
Enginemounting bracket bolt 50 5.O 36.0
Framemounting bolt M10 50 5.0 36.0
M8 25 2.5 18.0
Conrodnut 51 5.1 37.O
E x h a u s tp i p e c l a m p b o l t 25 2.5 18.0
Starterclutch securingbolt 26 2.6 18.5
Gearshiftarm stopper 19 1.9 14.O
C l u t c hs p r i n gm o u n t i n gb o l t 10 1.0 7.O
Water union bolt 10 1.0 7.O
Muffler mounting bolt 25 2.5 18.O
Clutch cover bolt 11 1.1 LO
 rNF0RMATloil
sERVtCilrG 8-22

ITEM N.m kg-m lb-ft

Gearshiftcam stopper bolt 10 1.O 7.O
Gearshiftcam stopperplate bolt 10 1.0 7.O
Oil pressureswitch 14 1.4 10.o
Oil nozzleretainerbolt 10 1.0 7.O
Oil sump filter cover bolt 10 1.0 7.O
Bearingretainerscrew 8 0,8 6.0
Enginesprocketnut 115 11 . 5 83.0
Generatorstator set bolt 10 1.0 7.O
Generatorstator clamp bolt 10 1,0 7.O
Signalgeneratorstator set bolt 4.5 0.45 3.5
Startermotor mountingbolt 10 1.0 7.O

E N G I N EC O O L I N G
ITEM N.m kg-m lb-ft
Radiatormountingbolt 6 o.6 4.5
Coolingfan thermo-switch 12 1.2 8.5
Enginecoolanttemperatureswitch 12 1.2 8.5
Water pump mountingbolt 10 1,0 7.O
Water pump cover bolt 10 1.0 7.O
l m p e l l e rs e c u r i n gb o l t 8 o.8 6.O
C o o l i n gf a n m o u n t i n gb o l t 6 0.6 4.5

CHASSIS
ITEM N.m kg-m lb-ft
Steeringstem head nut 90 9.0 65.0
Front fork cap bolt 23 2.3 16.5
F r o n tf o r k l o w e r c l a m p b o l t 33 3.3 24.O
H a n d l e b am r o u n t i n gn u t 54 5.4 39.O
Front fork upper clamp bolt 23 2.3 16.5
Front fork cap lock nut 40 4.O 29.O
Front axle 65 6.5 47.O
Front axle pinch bolt 23 2.3 16.5
Front mastercylindermounting bolt 10 1.0 7.O
Brakehose union bolt 23 2.3 16.5
Calipermountingbolt 39 3.9 28.O
C a l i p e ra i r b l e e d e rv a l v e 7.5 o.75 5.5
Brakedisc plate bolt 23 2.3 16.5
Rearshock absorberfitting bolt (upper) 23 2.3 16.5
nut (lower) 50 5.0 36.0
Rearaxle nut 65 6.5 47.O
Rearbrake cam lever bolt 10 1.0 7.O
Reartorque link nut (front) 35 3.5 25.5
(rear) 25 2.5 18.0
Rearswingarm pivot nut 100 10.0 72.5
Front footrest bolt 39 3.9 28.O
8.23 SERVTCII|G
ttUFoRMATt0trl

TIGHTENINGTOROUECHART
Forbther bolts and nuts listed previously,refer to this chart:

Bolt Diameter Conventionalor "4" markedbolt "7" marked bolt

@(mm) N'm kg-m lb-ft N'm kg-m lb-ft
4 1.5 0 . 15 1.0 2.3 o.23 1.5
5 3 0.3 2.O 4.5 0.45 3.0
6 5.5 0.55 4.O 10 1.O 7.O
I 13 1.3 9.5 23 2.3 16.5
10 29 2.9 21.O 50 5.0 36.0
12 45 4.5 32.5 85 8.5 61.5
14 65 6.5 47.O 135 13 . 5 97.5
16 105 10.5 76.O 210 21.O 152.O
18 160 16.O 115.5 240 24.O 173.5

T-
@
-!_

Conventionalbolt " 4" marked bolt "7" marked bolt

 8-24
ttllFoRMATlolu
SERV|C|NG

SERVICEDATA
VALVE+ GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
V a l v ed i a m . 30
tN. ( 1. 1 8 )
26
EX. (1.O2)
Valve clearance
lN. & EX. o.o8-0.13
(when cold) (o.003-o.oo5)
Valve guide to valve stem o.o10-0.037
clearance
tN. (o.oo04-o.oo15)
EX.
o.o30-0.057
(o.oo12-o.oo22\
Valve stem deflection o.35
l N .& EX. (0.014)
Valveguide l.D. 5.500- 5.512
l N . & EX. (0.2165-O.2170l,
V a l v es t e m O . D . 5.475- 5.490
tN. (0.2156-0.2161)
5.455-5.470
EX. @.2148-O.2154\
Valve stem runout
IN.& EX.
o.o5
( 0.00 2)
Valve head thickness 0.5
IN.& EX. (0,02)
Valve stem end length 3.1
IN.& EX. Q.121
Valve seat width 0 . 9 - 1. 1
IN.& EX. (0.035-0.043)
Valve head radialrunout o.03
I N .& E X , (o.oo1)
Valve springfree length 38.3
INNER (1.51)
40.1
OUTER (1.58)
Valve springtension 6 . 5 1- 7 . 4 9 k s
INNER ( 14 . 3 5 - 16 . 5 1l b s )
a t l e n q t h3 2 . 5m m ( 1 . 2 8i n )
1 2 . O 9 -1 3 . 9 1k s
OUTER ( 2 6 . 6 5 - 3 0 . 6 7l b s )
at length36.0 mm 11.42in\

CAMSHAFT+ CYLINDERHEAD U n i t :m m ( i n )
ITEM STANDARD LIMIT
Camheight 35.950-35.998 35.660
tN. (1.4154-1.41721 ( 1. 4 0 3 9 )
E - 1I
36.920-36.968 36,620
EX. ( 1. 4 5 3 5 - 1 . 4 5 5 4 1 (1.4417l,
35.954-36.002 35.660
tN. ( 1 . 4 1 5 5 -1 . 4 1 7 4 l . (1.4039)
Others
36.919-36.967 36.620
EX. (1,4535-1.45541 (1.4417l,
C a m s h a f jto u r n a lo i l c l e a r a n c e 0.032-0.066 0 . 15 0
(0.0013-0.0026) +0.0059)
8.25 SEBVICING
INFORMATION

ITEM STANDARD LIMIT

C a m s h a f tj o u r n a lh o l d e rL D . No,1 Left side 20.012-20.O25
N o . 2 R i g h ts i d e (0,7879-O.78841
N o . 1 R i g h ts i d e 25.012-25.O25
No.2 Left side (0.9847-0.9852)
C a m s h a f jt o u r n a lO . D . No.1 Left side 1 9 . 9 5 9 -1 9 . 9 8 0
N o . 2 R i g h ts i d e (0.7858-0.7866)
N o . 1 R i g h ts i d e 24.959-24.980
No.2 Left side (o.9826-0.9835)
Camshaftrunout o.10
(0.004)
R o c k e ra r m l . D . 1 2 . 0 0 0 -1 2 . O 1 8
t N .& E X . 1o.4724- O.47311
R o c k e ra r m s h a f t O . D . 1 1 . 9 6 6 - 11 . 9 8 4
t N .& E X . Q . 4 7 1 1- O . 4 7 1 8 1
C y l i n d e rh e a d d i s t o r t i o n o.o5
(o.002)
Cylinderhead cover distortion o.o5
( 0.002)

+ PISTON+ PISTONRING
CYLINDER U n i t :m m ( i n )
ITEM STANDARD LIMIT
Compressionpressure 1 5OOkPa 1 1 O Ok P a
/15 kg/cm,\ /11 kg/cm2\
\ 213 psi / \ 156osi /
Compressionpressure 200 kPa
difference /2 kg/cm' \
\ 28psi /
Pistonto cylinderclearance 0.o45-0.055 o.120
(0.0018-o.oo22l (o.oo47)
C y l i n d e rb o r e 83.OOO-83.015 83.085
r c . 2 6 7-73 . 2 6 8 3 ) 8.27111
P i s t o nd i a m . 82.950*82.965 82.880
- 3.2663)
|.3.2657 (3.2630)
at 15 mm (0.6in) fromthe skirtend.
Vleasure
C y l i n d e rd i s t o r t i o n o.o5
( 0.002)
Pistonring free end gap ^ 10.5 8.40
1st A p p r o x .( 0 . 4 1 3 ) (0.s31)
9.44
2nd R Approx.
rJ.l&r lo.372l
Pistonring end gap 0.20-0.35 o.50
1st (o.oo8-o.o14l (0.020)
0.20-0.35 0.50
2nd (o.oo8-0.014) ( 0.020)
Pistonring to groove 0 . 18 0
clearance 1st (0.0071)
2nd
0 . 15 0
(0.0059)
 sEBVrCrilG
lI'IF0RMAT|0N
8-26

ITEM STANDARD LIMIT

Pistonring groovewidth 1 . 0 1- 1 . 0 3
1st (o.0398-0.0406)
1. 2 1 - 1 . 2 3
2nd
lo.o476-o.04841
2.51-2.53
oir (o.0988-0.0996)
Pistonring thickness 0.970-0.990
1st (0.0382-0.0390)
1 . 1 7 0 -1 . 1 9 0
2nd (0.0461-0.0469)
Pistonp i n b o r e 20.oo2-20.008 20.o30
Q.7875-O.7877l, (o.7886)
P i s t o np i n O . D . 19.996-20.OOO 19.980
1o.7827-0.7874\ (o.7866)

CONROD+ CRANKSHAFT U n i t :m m ( i n )
ITEM STANDARD LIMIT
C o n r o ds m a l le n d l . D . 20.o10-20.018 20.o40
Q.7878-0.7881) (0.7890)
Conrodbig end side clearance o.10-o.20 0.30
(0.004-0.008) (0.012)
Conrod big end width 2 1. 9 5 - 2 2 . O O
(0.864-0.866)
C r a n kp i n w i d t h 22.10-22.15
( 0.870- 0.872],
C o n r o db i g e n d o i l c l e a r a n c e o.o24-o.o42 0.080
(o.ooo9-0.0017) (0.0031)
C r a n kp i n O . D . 40.982- 41.000
(1.61351 - .6142l'
C r a n k s h a fjto u r n a lo i l 0.020-0.050 0.080
clearance ( o.ooo8- 0.0020) {o.oo31)
C r a n k s h a fjto u r n a lO . D . 47.965-47.980
( 1. 8 8 8 4 - 1 . 8 8 9 0 )
C r a n k s h a fjto u r n a lb e a r i n gl . D . 48.OOO-48.015
( 1. 8 8 9 8 - 1 . 8 9 0 4 )
Crankshaftthrust bearing 1.925-2.175
thickness (0.0758-0.0856)
Crankshaftthrust clearance o.o5-o.10
(0.002-0.004)
Crankshaftrunout o.05
(o.oo2)

OILPUMP
ITEM STANDARD LIMIT
Oil pump reductionratio 1 . 3 6 4 ( 8 3 1 4 4x 3 4 1 4 7 1
O i l p r e s s u r e( a t 6 0 o C , 1 4 0 o F ) A b o v e 4 5 0 k P a ( 4 . 5 k g / c m 2 ,6 4 p s i )
B e l o w 7 5 O k P a ( 7 . 5 k g / c m z ,1 0 7 p s i )
a t 3 O O Or i m i n .
8.27SERVTC|IUG
iluF0RMAT|0lll

CLUTCH Unit:mm (in)

ITEM STANDARD LIMIT
C l u t c hc a b l ep l a y 10- 15
(0.4-0.6)
Drive plate thickness 2.92-3.O8 2.62
No.1 ( 0 . 115 - 0 . 1 2 1 1 , (0.103)
3.42-3.58 3.12
No.2 (0.135-0.141l, (0.123)
Drive plate claw width 15.9-16.0 15 . 1
(0.626-0.630) (0.594)
Driven plate distortion o.10
(0.o04)
Clutch springfree length 24.6
No.1 (o.97)

No.2 23.3
(o.92)

RADIATOR+ FAN
ITEM STANDARD LIMIT
Radiatorcap valve release 1 1 0 + 1 5k P a
pressure ( 1. 1 + O . 15 k g / c m z ,1 5 . 6+ 2 . 1 p s i )
Coolingfan thermo-switch ON A p p r o x .1 O 5 o C( 2 2 1 o F l
operatingtemperature
OFF A p p r o x ,I O O o C( 2 1 2 " F \
Enginecoolanttemperature ON A p p r o x .1 2 O o C( 2 4 8 " F 1
switch operatingtemperature
OFF A p p r o x .1 1 3 o C ( 2 3 5 o F )

TRANSMISSION Unit: mm (in) Except ratio

ITEM STANDARD LIMIT
Primarvreductionratio 1 . 8 8 6 83t44r,
Finalreductionratio 3 . 2 0 0 48t15l'
Gear ratios Low 2 . 4 6 1 32t131
2nd 1 . 5 7 8 30/19)
3rd 1 . 2 0 0 24t201,
4th 0 . 9 5 6 22t231'
Top 0.800 20t251
Shift fork to groove clearance o.10-0.30 0.50
( 0.004- 0.o121, ( 0.o20)
Shift fork groove width 5.50- 5.60
( o . 2 1 7- O . 2 2 0 1
Shift fork thickness 5.30- 5.40
(o,209-0.2131
Drive chain Type DtD 50VA2
Links 1 1 6 l i n k s ,E N D L E S S
2O-pitch 319.4
length t12.61
D r i v ec h a i ns l a c k 15-25
(0.6- 1.0)
Gearshiftlever height 50
(2.O1
 SERVICING
INFORMATIOIU
8.28

GARBURETOR
SPECIFICATION
ITEM
E-03
Carburetortvoe M I K U N8 I 53655(No.1) M I K U N IB D S 3 6 S S( N o . 2 )
Bore size 36 mm <_

l . D .N o . 48E7 <_

ldlerimin. +
1 2 O O 1 O Or / m i n . e

Fuel level 7 . 3 +0 . 5 m m 1 5 . 0 +0 . 5 m m
( 0 , 2 9+ 0 . 0 2 i n ) ( 0 . 5 9+ O . O 2i n )
Float height 2 7 . 7+ 1 . 0 m m 9.1+1.Omm
( 1 . 0 9+ O . 0 4i n ) ( 0 . 3 6+ O . O 4i n )
M a i nj e t (M.J.) # tna #9D
Jet needle (J.N.) 5D83 5C43
N e e d l ej e t (N.J.) F.3M P-LTM
Throttle valve (Th.V.) # 115 e

Pilot iet (P.J.) #Ll5 #Llu

P i l o ts c r e w (P.S.) (PRE-SET) (PRE-SET)
Throttle cable play O . 5 - 1 . 0m m (--
(O.02-0.04 in)

CARBURETOR
SPECIFICATION
ITEM
E- 33
Carburetoitvoe MIKUN8 I 53655(No.1) M I K U N IB D S 3 6 S S( N o , 2 )
Bore size 36 mm -
l . D ,N o . 48EB <-

ldler/min. +
1 2 O O 1 O 0r i m i n . <-

Fuel level 7 . 3 +0 . 5 m m 15 . 0+ 0 . 5 m m
( 0 . 2 9+ O . O 2i n ) ( 0 . 5 9+ 0 . 0 2 i n )
F l o a th e i g h t 2 7 . 7+ 1 . 0 m m 9 . 1+ 1 . Om m
( 1. O gt O . 0 4 i n ) ( 0 . 3 6+ O . O 4i n )
Main iet (M.J # t]n #90
Jet needle (J.N 5D83 5C43
N e e d l ei e t (N.J P-fM P-LTM
Throttle valve (Th.V # 11 5 <_

Pilotjet (P.J #L+5 #LID

P i l o ts c r e w (P.S (PRE.SET) (PRE-SET)
Throttle cable play 0 . 5 - 1 . 0m m <_
(0.O2-0.04 in)
 lltlF0RMATlO
8-29 SERVICIITIG lll

ELECTRICAL Unit:mm (in)

ITEM SPECIFICATION NOTE
l g n i t i o nt i m i n g 5 o B . T . D . Cb
. e l o w 1 5 O Or / m i n .
Firingorder 1.2
S p a r kp l u g
Type
0.8-0.9
Gap (0,031-0.035)
Spark performance Over8 (0.3) at 1 atm.
S i g n a lc o i l r e s i s t a n c e 170-280 0 G-BI
lgnitioncoil resistance Primary 2-6 A @ p-Q tap
t a
15-30 kO P l g qc a p -
Secondary (D tap
Generatorcoil resistance Charging o . 2 - 1 . 50 Y-Y
Generator no-load voltage
(When engine cold) M o r e t h a n 7 5 V ( A C ) a t 5 O O Or / m i n .
GeneratorMax. output 2 5 O W a t 5 O 0 Or / m i n .
Regulatedvoltage 1 3 . 5 - 1 5 . 5 V a t 5 O O Or / m i n .
Starterrelay resistance 3-6 0
Battery Tvpe desiqnation FTX12-BS
Capacity 1 2 V 3 6 k C( 1 o A h ) / 1 0 H R
Standard
1 . 3 2 a ' t2 O o C( 6 8 o F )
e l e c t r o l y t eS . G .
Fusesize H e a d l i g h {t H D 1 5A
(LO) 1 5A
Signal 1 5A
lgnition 1 0A
Tail 1 0A
Main 30A

WATTAGE Unit:W
SPECIFICATION
ITEM
E-03,28,33 E-24 The others
Headlight HI 60 e e

LO 55 e +-

Parkinq liqht 4
Tail/Brake liqht 5121 e <_

T u r n s i g n a ll i g h t Front 5121 +- 21
Rear 21 e

Speedometer liqht 1.7 <_ <_

W a t e r t e m p . i n d i c a t o rl i q h t 1.7 <_ <_

T u r n s i q n a li n d i c a t o rl i q h t 3.4 <_ +-

H i s h b e a mi n d i c a t o rl i q h t 1.7 (- <-

N e u t r a li n d i c a t o rI i q h t 3.4 e <_

Oil pressureindicatorlight 1.7 {- <-

 SEBVICII'IG
lllF0RMAT|0N
8.30

BRAKE+ WHEEL Unit:mm (in)

ITEM STANDARD LIMIT
Rearbrake pedalfree travel 20-30
( o . 8 *1 . 2 )
R e a rb r a k ep e d a lh e i g h t 60
(2.4)
B r a k el i n i n gt h i c k n e s s 1.5
Rear (0.o6)
B r a k ed r u m l . D . 180.7
Rear ( 7. 1 1 1
B r a k ed i s c t h i c k n e s s 4.5+O.2 4.O
Front ( 0 . 1 8+ 0 . 0 1 ) (0.16)
Brakedisc runout 0.30
Q.O12l
M a s t e r c y l i n d e rb o r e 12.700-12.743
Front (o.5000-0.5017)
M a s t e r c y l i n d e rp i s t o n d i a m . 1 2 . 6 5 7- 1 2 . 6 8 4
Front (o.4983-O.4993)
B r a k ec a l i p e rc y l i n d e rb o r e 30.230-30.306
Front ( 1 . 1 9 0 21- . 1 9 3 1 )
B r a k ec a l i p e rp i s t o nd i a m . 30.150-30.200
Front ( 1. 1 8 7 0 -1. 1 8 9 0 )
Wheel r i m r u n o u t 2.O
Axial (0.08)
Radial
2.O
(o.08)
Wheel axle runout o.25
Front (o.010)
Rear 0.25
(0.010)
Wheel rim size Front J16xMT3.OO
Rear J 1 s M / Cx M T 3 . 5 0
Tire size Front 1 3 0 / 9 0 - 1 66 7 H
Rear 1 5 0 / 9 0 - 1 5M t C 7 4 H
Tire tread depth 1.6
Front (0.06)
Rear 2.O
(0.08)

SUSPENSION Unit:mm (in)

ITEM STANDARD LIMIT NOTE
Front fork stroke 140
(5.5)
Front fork damper free length 156
(6.1)
Front fork oil level 154
(Atoutertube177mmup position) (6.1)
Rearwheel travel 102
( 4.0)
S w i n g a r mp i v o t s h a f t r u n o u t 0.3
(o.01)
 I]IIFORMATIOIII
8.31SERVICII'IG

TIREPRESSURE
N O R M A LR I D I N G
C O L DI N F L A T I O N S O L OR I D I N G D U A LR I D I N G
T I R EP R E S S U R E kPa (q/cm2 p s l kPa kgicmz psl
FRONT 200 2 . O O 2 9 200 2 . O O 2 9
REAR 225 2 . 2 5 3 3 225 2 . 2 5 33

FUEL+OIL+COOLANT
ITEM SPECIFICATION NOTE
Fueltype U s e o n l y u n l e a d e dg a s o l i n eo f a t l e a s t 8 7
p u m p o c t a n e ( R+ M) o r 9 1 o c t a n e o r
higher rated by th6 researchmethod.
GisolinecontainingMTBE(MethylTertiary U . S . A .m o d e l
B u t y l E t h e r ) ,l e s s t h a n 1 0 % e t h a n o l ,o r
less than 5% methanol with appropriate
cosolvents and corrosion inhibitor is
permissible
Use only unleadedgasolineof at least 87
p u m p o c t a n e( t ; t m e t h o d )o r 9 1 o c t a n e C a n a d a m o d e l
br hiqher rated bl the ResearchMethod.
G a s o l i n eu s e ds h o u l db e g r a d e d8 5 - 9 5 o c -
t a n e o r h i g h e r . A n u n l e a d e dg a s o l i n ei s Other models
recommended.
Fueltank includingreserve 1 3 . OL
8 . 4 1 2 . 9 U S / l m pg a l )
l."*"t" 3.0L
US/lmpgal)
( O.8/O.7
E n q i n eo i l t y p e S A E 1 O W / 4 OA , PI SF or SG
E n g i n eo i l c a p a c i t y 1 700 ml
Change ( 1 . 8 / 1 . 5U S / l m pq t )
2 100 ml
Filterchange ( 2 . 2 1 1 . 8U S / l m pq t )
2 500 ml
Overhaul 1 2 . 6 1 2 . 2U S i l m pq t )
Front fork oil type F o r ko i l + 1 5
Front fork oil capacity 838 ml
( e a c hl e g ) ( 2 8 . 3 1 2 9 . 5U S / l m Pozl
Brakefluid type DOT4
Coolantcapacity 1 460 ml
( 1 , 5 / 1 . 3U S / l m pq t )
EMISSION CONTROL CARBURETORCOMPONENTS .... 9- 1
EVAPORATIVEEMISSIONCONTROLSYSTEM .......,,.....9- 2
CANISTER.HOSEROUTING ,... 9- 3
EVAPORATIVEEMISSION CONTROLSYSTEM INSPECTION...,.... 9- 3
PAIR (AIR SUPPLY)SYSTEM DIAGRAM .....,,. 9- 4
PAIR (AIR SUPPLY)SYSTEMHOSEROUTING .,.,..,.,....,9- 5
PAIR (AIR SUPPLY) SYSTEM INSPECTION ..... 9- 6
9.1 EMtSSt0til INFoRMATIoN
CotUTRot

COMPONENTS
EMISSIONCONTROLCARBURETOR
VZSOOmotorcyclesareequippedwith precision,manufacturedcarburetorsfor emissionlevelcontrol.
Thesecarburetorsrequirespecialmixture control componentsand other precisionadjustmentsto
f u n c t i o np r o p e r l y .

Thereare severalcarburetormixturecontrolcomponentsin each carburetorassembly'Three(3) of

thesecomponentsare machinedto much closertolerancesthan standardmachinedcarburetorjets.
J E T , P I L O TJ E T - m u s t n o t b e r e p l a c e db y s t a n -
T . h e s teh r e e( 3 ) p a r t i c u l ajre t s - M A I N J E T , N E E D L E
dardjets. To aid in identifyingthese three (3) jets a differentdesignof letter and numberare used.
lf replacementof these close tolerancejets becomesnecessary,be sure to replacethem with the
same type close tolerancejets marked as in the examplesshown below.

T h e j e t n e e d l ei s a l s oo f s p e c i a lm a n u f a c t u r eO . n l y o n e c l i p p o s i t i o ni s p r o v i d e do n t h e j e t n e e d l e .
lf replacementbecomesnecessarythe jet needlemay only be replacedwith an equivalentperform
i n g r e p l a c e m e nct o m p o n e n t S . u z u k ir e c o m m e n d st h a t G e n u i n eS u z u k iP a r t sb e u t i l i z e dw h e n e v e r
p o s s i b l ef o r t h e b e s t p o s s i b l ep e r f o r m a n c ea n d d u r a b i l i t y .

ConventionalFiguresUsed
on StandardToleranceJet
Components
12 3 4 5 6 7 I 9 0
1 5 E ,7 E g n
EmissionType Figures
U s e do n C l o s eT o l e r a n c e
Jet Components
I e f
VZSOOare as follows.
The carburetorspecificationsfor the emission-controlled

Carburetor Main Needle Jet Pilot Pilot

l . D ,N o . Jet Jet Needle Jet Screw

48EB
(California PRE-SET
# l n ] ( N o . 1 ) F - J M ( N o . 1 ) 5 D 8 3( N o . 1 ) # 9 5 ( N o . 1 ) DO NOT
m o d e lo n l y ) *1El No.2l P - L I M( N o . 2 ) 5 C 4 3 ( N o . 2 ) + t i O ( N o . 2 ) ADJUST
48E7

Adjusting,interferringwith, improperreplacement, or resettingof any of the carburetorcomponents

may adverselyaffect carburetor performance and cause the motorcycleto exceedthe exhaustemission
level limits. lf unableto effect repairs,contact the distributorsrepresentative for further technical
informationand assistance.
 EMtSSloil
coilTR0t|IrtF0RMATtoN
9-2

EVAPORATIVE EMISSIONCONTROLSYSTEM
(Californiamodel only)

Fuel filler pipe

F u e l - v a p osr e p a r a t o r

v_- - -l

';::s'-'--

<::------r FUEL
<-_ HC VAPOR

+-- FRESA
HI R
9-3 EMlSSl0lrl
CONTR0L
llrlF0RMATl0ltl

GANISTERHOSEROUTING(Galiforniamodel only)

Fuel-vaporseparator

To No.2 carburetor

To No.1
carburetor

Canister
Purgehose

EVAPORATIVEEMISSION CONTROL
SYSTEMINSPECTION
(Californiamodel only)
o Removethe frame covers and fuel tank. (Referto page
4-4.1

HOSESAND PIPES
I n s p e c t h e h o s e sa n d p i p e sf o r w e a r o r d a m a g e .
I n s p e c t h a t t h e h o s e sa n d p i p e sa r e s e c u r e l yc o n n e c t e d .

CANISTER
lnspectthe canisterfor damageof the body.
 EMtssloil
C0tuTRot
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9-4

PAIR(AIR SUPPLYISYSTEMDIAGRAM

V a c u u mh o s e

N o . 1c y l i n d e r
head

-- F R E S HA I R

<---------- E X H A U S TG A S
9-5 EMlSSlOlrl
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PAIR (AIR SUPPLY}SYSTEMHOSEROUTING

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 CorilTRoL
EM|SS|0N 9-6
|NF0BMAT|0I'I

PAIR (AIR SUPPLY}SYSTEMINSPECTION

(Californiamodel only)
r Removethe PAIRcover. (Referto page 3-3.)

HOSESAND PIPES
I n s p e c tt h e h o s e sa n d p i p e sf o r w e a r o r d a m a g e .
l n s p e c tt h a t t h e h o s e sa n d p i p e sa r e s e c u r e l yc o n n e c t e d .
PAIR CONTROLVALVE
lnspectthe PAIR control valve for damageof the body.

PAIR CLEANER
I n s p e c tt h e P A I Rc l e a n e rf o r d a m a g eo f t h e b o d y .
REEDVALVE OF PAIR CONTROLVALVE
o Remove the PAIR control valve.
o Remove the both reed valves @.

Inspect the reed valves.

l f t h e c a r b o n d e p o s i t i s f o u n d i n t h e r e e d v a l v e , r e p l a c et h e
PAIR control valve with a new one.

PAIR CONTROLVALVE
o Removethe PAIRcontrol valve.
Blow the air inlet port of the controlvalve as shown in the
lf airdoesnot flow out, replacethe controlvlave
illustration.
with a new one.

C o n n e c t h e v a c u u mp u m p t o t h e v a c c u mp o r t o f t h e c o n -
t r o l v a l v ea s s h o w n i n t h e i l l u s t r a t i o nA. p p l yn e g a t i v ep r e s .
sureslowlyto the controlvalveand blow the abovemanner.
lf air doesnot becomeflow out within the specification, the
c o n t r o lv a l v e i s n o r m a lc o n d i t i o n .
lf the controlvalve does not function within the specifica-
tion, replacethe control valve with a new one.
Negativepressurerange: 36-60 kPa (27O-450 mmHg)

@ ossr 7-47910:vacuumpumpgauge

CAUTION
Use a handoperatedvacuum pump to preventthe con-
trol valve damage.
This section describes service data, service specifications and servicing procedures
which differ from those of the VZSOOV('97-model).

NOTE:
o The specifications and service data are the same as those of the V-MODEL.
o please refer to the section 1 through I for details which are not given in this
section.

CONTENTS

sPEctFtcATIoNs """ 10- 1

"""' 10- 2
SERVICEDATA
BELAY ...".,,.... ' 10-12
SIGNAL/SIDE-STAND
TTTRN
"' 10-13
WtRtNe DIAGRAM
wtRE HARNESSROUTTNG 10-16
 r0.1 vz800wr98-M0DEr)

SPECIFICATIONS
D I M E N S I O N SA N D D R Y M A S S
O v e r a l ll e n g t h 2 4 0 5m m ( 9 a . 7i n ). . . . E. -17
, 18,22,25
2 3 6 5m m ( 9 3 . 1i n ) . . . . O
. thers
O v e r a l lw i d t h 7 5 0m m ( 2 9 . 5i n )
O v e r a l lh e i g h t 1 1 1 0m m ( 4 3 . 7i n )
Wheelbase 1 6 4 5 m m ( 6 4 . 8i n )
G r o u n dc l e a r a n c e 1 3 5m m ( 5 . 3i n )
S e a th e i g h t .. 7 0 0 m m ( 2 7 . 6i n )
Dry mass 207 kg (4s6 lbs)
ENGINE
Type.. . F o u r - s t r o k e ,w a t e r - c o o l e d ,O H C , 4 5 - d e g r e e ,V - t w in
Numberof cylinders
B o r e. . . 8 3 . 0m m ( 3 . 2 6 8i n )
Stroke. 74.4mm (2.929in\
Displacement 8 0 5c m 3( 4 9 . 1c u . i n )
C o m p r e s s i o nr a t i o
'10.0: 1
Carburetor,
front . . MIKUNIBDS36
rear... M I K U N8I 5 3 6
Air cleaner Non-woven fabric element
Startersystem Electric
L u b r i c a t i o ns y s t e m Wet sump
ldlespeed 1 1 5 0 - 1 3 0 0 r / m i n . . . . .E - 1 8
1 1 0 0 - 13 0 0r / m i n. . . . O
. thers
TRANSMISSION
C lu t c h Wet multi-plate type
Transmission. . 5-speedconstantmesh
Gearshiftpattern 1 - d o w n4, - u p
P r i m a r yr e d u c t i o n 1 . 8 8 6( 8 3 / 4 4 )
Secondaryreduction 3 . 2 0 0( 4 8 / 1 5 )
G e a r r a t i o s ,L o w 2.461l32l13l
2 n d. . . . .. 1 . 5 7 (83 0 / 1 9 )
3rd.... .. 1.200(241201
4th 0.956Q2/23\
T o p. . . . .. 0 . 8 0 0( 2 0 / 2 5 )
D r i v e c h a .i n
... D | D S O V M1, 1 6 l i n k s

cHASSTS
F r o n ts u s p e n s i o n I n v e r t e d t e l e s c o p i c ,c o i l s p r i n g , o i l d a m p e d
R e a rs u s p e n s i o n Swingarm type, coil spring, oil damped, spring pre-loads-way adjustable
S t e e r i na
gn g l e 40'(right & left)
Caster J3-

T u r n i n gr a d i u s 3 . 1m ( 1 0 . 2
ft)
Front brake .. Disk brake
R e a rb r a k e . . Drum brake
Front tire size . . . 1 3 0 / 9 0 -1 6 6 7 H , t u b e l e s s
R e a rt i r e s i z e . . . . 150/90-15 M / C 7 4 H ,t u b e l e s s
F r o n tf o r k s t r o k e . i 4 0 m m ( 5 . 5i n )
R e a rw h e e l t r a v e l . . 1 0 2 m m ( 4 . 0i n )

ELECTRICAL
l g n i t i o nt y p e E l e c t r o n i ci g n i t i o n ( T r a n s i s t o r i z e d )
lgnition timing . 5 " B . T . D . C .b e l o w 1 5 0 0 r / m i n
S p a r kp l u g N G KD P R B E Ao- gr D E N S OX 2 4 E P R - U 9
B a t t e r V. . 1 2 V3 6 . 0k C( 1 0A h ) / 1 0 H R
Generator Three-phase A.C.generator
Fuse... 31l15l15l15l11l10A
H e a dl i gh t 12V60/55W
P a r k i n go r c i t y l i g h t . . . .. . - 0 20, 4 ,1 7, 1 8 , 2 2 , 2 5 , 3 4p,- 3 7
1 2 V4 W . . . . E
Brakelight/Taillight.... 12V2115W
F r o n tt u r n s i g n a l l i g h t 12V5121W.....E-03,28,33
12V21W.....Others
R e a rt u r n s i g n a l l i g h t 12V21W
S p e e d o m e t e rl i g h t . . 12V1.7W
T u r n s i g n ai ln d i c a t o r l i g h t . . . .. 12V3.4W
N e u t r a li n d i c a t o rl i g h t . 1 2 V3 . 4 W
H i g h b e a m i n d i c a t o lri g h t . . . .. 1 2 V1 . 7 W
C o o l a n tt e m p e r a t u r ec h e c k l i g h t 12V1.7W
O i l p r e s s u r ei n d i c a t o rl i g h t 1 2 V1 . 7 W
CAPACITIES
F u e lt a n k , i n c l u d i n gr e s e r v e 1 3 , 0L ( 3 . 4 / 2 .U
9 S / l m pg a l )
reserve. 3.0L (0.8/0.7 US/lmpgal)
E n g i n eo i l , w i t h o u tf i l t e rc h a n g e 1 7 0 0m l ( 1 . 8 / 1 .U5 s / l m pq t )
with filterchange. 2 100ml \2.211.8 Us/lmpqt)
Overhaul 2 500ml 12.612.2 US/lmpqt)
Frontfork oil leachl"g) . . . 845ml (28.6/29.6 Us/lmpoz)
Coolant 1 4 6 0m l ( 1 . 4 / 1 .U2 s / l m pq t )
 10-2
vz800wrg8-M0DEU

SERVICEDATA
VALVE+ GUIDE U n i t :m m ( i n )
ITEM STANDARD LIMIT
Valvediam. 30
tN. ( 1. 18 )
EX.
26
(1.O21
Valve clearance 0,08-0.13
(when cold) t N .& E X . (o.oo3-0.005)
Valve guide to valve stem 0.010-0.037
crearance tN. (o.ooo4-0.0015)
EX.
o.o30-0.057
(o.oo12-o.oo22\
Valve stem deflection 0.35
I N .& E X . (0.014)
V a l v eg u i d el . D . 5.500-5.512
I N .& E X . (0.2165-0.2170\
Valvestem O.D. 5.475- 5.490
lN. ( 0 . 2 15 6 - O . 2 1 6 1 l /
5.455-5.470
EX. (0.2148-0.2154\
Valve stem runout
t N .& E X .
0.05
(o.oo2)
Valve headthickness
t N .& E X .
0.5
(0.02)
Valve stem end lenqth 3.1
t N .& E X . (0,12)
Valve seat width 0 . 9 - 1. 1
t N .& E X . (0.035-0.043)
V a l v e h e a d r a d i a lr u n o u t
t N .& E X .
0.03
(0.001)
V a l v e s p r i n gf r e e l e n g t h
INNER
38.3
(1.51)
40.1
OUTER ( 1, 5 8 )
Valve spring tension 6 . 5 1- 7 . 4 9 k s
INNER ( 1 4 . 3 5 -1 6 . 5 1l b s )
a t l e n s t h3 2 . 5m m ( 1 . 2 8i n )
1 2 . 0 9 - 1 3 . 9 1k g
OUTER (26.65-30.67lbs)
a t l e n g t h3 6 . 0 m m ( 1 . 4 2 i n )

CAMSHAFT+ CYLINDERHEAD U n i t :m m ( i n )
ITEM STANDARD LIMIT
Cam height 35.950-35.998 35.660
tN. ( 1. 4 1 5 4 - 1. 4 1 7 2 ' t (1.4039)
E-18
EX.
36,920- 36.968 36.620
( 1 . 4 5 3 s -1 . 4 5 5 4 1 11.4417)
tN.
3 5 . 9 5 4 -3 6 . 0 0 2 35,660
( 1 . 4 1 5 51- . 4 1 7 4 l ' ( 1. 4 0 3 9 )
Others
EX.
3 6 . 9 19 - 3 6 . 9 6 7 36.620
( 1, 4 5 3 5 - 1. 4 5 5 4 ) (1.44171
r0-3vz800wr98.M0DEt)

ITEM STANDARD LIMIT

C a m s h a f tj o u r n a l o i l c l e a r a n c e 0.032-0.066 0 . 15 0
(o.oo13-0.0026) ( 0.0059)
C a m s h a f tj o u r n a l h o l d e r l . D . No.1 Leftside 24.O12-20.O25
N o . 2 R i g h ts i d e ( 0.7879- 0.78841
N o . 1 R i g h ts i d e 25.O12-25.O25
No.2 Left side (0.9847-0.9852)
C a m s h a f tj o u r n a l O . D . No.1 Leftside 1 9 . 9 5 9 -1 9 . 9 8 0
N o . 2 R i g h ts i d e (0.7858-0.7866)
N o . 1 R i g h ts i d e 24.959-24.980
No.2 Leftside (0.9826-0.9835)
C a m s h a f rt u n o u t 0.10
( 0.oo4)
R o c k e ra r m l . D . 1 2 . 0 0 0 -1 2 . 0 1 8
t N .& E X . Q.4724-O.47311
R o c k e ra r m s h a f t O . D . 11 . 9 6 6 -11 . 9 8 4
t N .& E X . Q . 4 7 1 1- O . 4 7 1 8 1 '
C v l i n d e rh e a d d i s t o r t i o n 0.05
(0.002)
Cylinderhead cover distortion 0.05
{ 0.002)

+ PISTON+ PISTONRING
CYLINDER U n i t :m m ( i n )
ITEM STANDARD LIMIT
C o m p r e s s i opnr e s s u r e 1 500 kPa 1 1 O Ok P a
/15 kg/cm' \ 1 1 1k g / c m 2 1
\ 213 psi I \ 156osi I
C o m p r e s s i opnr e s s u r e 200 kPa
difference i2 kg/cm2i
\ 28psi t
P i s t o n t o c y l i n d e rc l e a r a n c e 0.045-0.055 o.120
(0.0018-o.oo22) (o.oo47)
C y l i n d e rb o r e 83.000-83.015 83.085
(3.2677-3.2683) 8.2711l,
P i s t o nd i a m . 82.950-82.965 82,880
(3.2657-3.2663) (3.2630)
at 15 mm (0.6in) fromthe skirtend.
Measure
C y l i n d e dr i s t o r t i o n o.o5
( 0.002)
P i s t o nr i n g f r e e e n d g a p ^ 10,5 8.40
1st A P P r o x '( 0 , 4 1 3 ) (0.331)
9.44
2nd R Approx.
rJ.LSur (o.3721
P i s t o nr i n g e n d g a p 0.20-0.35 0.50
1st (0.008-0.014) ( 0.020)
0,20-0.35 0.50
2nd (0.008-0.014) (0.020)
Pistonring to groove clearance 0 . 18 0
1st (0.0071)
0 . 15 0
2nd ( o.oo59)
 vz800wr98.M0DEr)
10-4

ITEM STANDARD LIMIT

Piston ring groove width 1 , 0 1- 1 . 0 3
1st (0.0398-0.0406)
1.21-1.23
2nd ( 0.0476- 0.0484)
2.51-2.53
oil (0.0988-0.0996)
Pistonring thickness
1st
0.970-0.990
(0,0382-0.0390)
1 . 1 7 0 -1 . 1 9 0
2nd (0.0461-0.0469)
Piston oin bore 20.oo2-20.008 20.030
(0.7875-0.7877l, ( 0.7886)
P i s t o np i n O . D . 19.996-20.OOO 19.980
p.7827 -O.78741 (o.7866)

+ CRANKSHAFT
CONROD U n i t :m m ( i n )
ITEM STANDARD LIMIT
C o n r o ds m a l l e n d l . D . 20.010-20.018 20.o40
(0.7878-0.7881) ( 0.7890)
Conrodbig end side clearance 0.10-0.20 0.30
( o.004- 0.008) (0,012)
Conrodbig end width 21.95-22.OO
(0.864-0.866)
Crankpin width 22.10*22.15
( o.870- 0.872l,
Conrodbig end oil clearance o.o24-o.o42 0.08 0
(0.0009-o.oo17) (0.0031)
C r a n kp i n O . D . 40.982- 41.000
(1.6135-1.6142l.
C r a n k s h a f tj o u r n a l o i l c l e a r a n c e 0.020-0.050 0.080
( o.ooo8- 0.0020) (0.0031)
C r a n k s h a f tj o u r n a l O . D . 47.965-47.980
( 1 . 8 8 8 4 -1 . 8 8 9 0 )
C r a n k s h a fj to u r n a lb e a r i n gl . D . 48.000-48.015
( 1. 8 8 9 8 - 1. 8 9 0 4 )
C r a n k s h a f tt h r u s t b e a r i n g 1 . 9 2 5* 2 . 1 7 5
thickness (0.0758-0.0856)
C r a n k s h a f tt h r u s t c l e a r a n c e 0.05-0.10
( o.oo2- 0.004)
C r a n k s h a f tr u n o u t 0.05
(0.002)

OILPUMP
ITEM STANDARD LIMIT
O i l p u m p r e d u c t i o nr a t i o 1 . 3 6 4 ( 8 3 1 4 4x 3 4 1 4 7 1
O i l p r e s s u r (ea t 6 0 o C , 1 4 0 o F ) Above 450 kPa (4.5 kg/cmz,64 psi)
B e l o w 7 5 0 k P a ( 7 . 5 k g / c m z ,1 0 7 p s i )
at 3 0OOr/min.
 ('98-M0DE[)
10-5VZ800W

CLUTCH U n i t :m m ( i n )
ITEM STANDARD LIMIT
Clutch cableplay 10-15
(0.4-0.6)
Drive olatethickness 2.92-3.08 2.62
No.1 ( 0 . 115 - 0 . 12 1) (0.103)
3.42-3.58 3.12
No.2 (0.1 3 5 - 0 . 1 4 1) t0.123)
Drive plate claw width 1 5 . 9 -1 6 . 0 15.1
(0.626-0.630) (0.s94)
Driven olate distortion o.10
(0.004)
C l u t c h s p r i n gf r e e l e n g t h 24.6
No.1 (0.97)

No,2 23.3
(0.e2)

RADIATOR+ FAN
ITEM STANDARD LIMIT
Radiatorcap valve release 1 1 0 + 1 5k P a
pressure ( 1 . 1 + 0 . 1 5k g / c m 21, 5 . 6 + 2 . 1p s i )
Cooling fan thermo-switch ON A p p r o x .1 O 5 o C1 2 2 1 o F l
operating temperature
OFF A p p r o x .1 0 O o C( 2 1 2 0 F l
E n g i n ec o o l a n t t e m p e r a t u r e ON A p p r o x .1 2 0 o C( 2 4 8 " F 1
switch operating temperature
OFF A p p r o x ,1 1 3 o C( 2 3 5 ' F )

TRANSMISSION Unit: mm (in) Exceptratio

ITEM STANDARD LIMIT
Primarvreductionratio 1.886 {€3t44
Final reduction ratio 3 . 2 0 0( 4 8 / 1 5 )
Gear ratios Low 2.461 t32t13l
2nd 1 . 5 7 8( 3 0 / 1 9
3rd 1 200 124t20
4th 0 . 9 5 6( 2 2 1 2 3
Top 0.800 ( 20125
Shift fork to groove clearance 0.10-0.30 0.50
(0.004-o.o12l (0.020)
Shift fork groove width 5.50-5.60
Q . 2 1 7- O . 2 2 0 1
Shift fork thickness 5.30- 5.40
(0.209-0.213)
D r i v ec h a i n Type DtD 5OVA2
'l
Links 1 6 l i n k s ,E N D L E S S
20-pitch 319.4
length { 12 , 6 )
Drive chain slack 15-25
(0.6-1.0)
G e a r s h i f tl e v e r h e i g h t 50
(2.O1
 vz800w r0.6
r98.M0DEL)

CARBURETOR
SPECIFICATION
ITEM
E-O2,O4 17, , 2 2 , 2 4 , 2 5 , 3 4
Carburetortvpe M I K U N 8I 5 3 6 5 5 ( N o . 1 ) MIKUNB I D S 3 6 S S( N o . 2 )
Boresize 36 mm {-
l . D .N o . 48E6
ldle r/min. 1 2 O O +1 0 0 r / m i n ,
Fuellevel 7 . 3 + 0 . 5m m 1 5 . 0 +0 . 5 m m
Q.29+0.02 i n ) ( 0 . 5 9+ O . O 2i n )
Float height 2 7 . 7+ 1 . 0 m m 9.1+1.0mm
( 1. 0 9+ 0 . 0 4 i n ) ( 0 . 3 6 + 0 . 0 4i n )
Mainjet (M.J.) #100 #90
Jet needle (J.N.) 5D27-3 5C29-3
N e e d l ej e t (N.J.) P-3 P-4
T h r o t t l ev a l v e (Th.V.) # 115 e

P i l o tj e t (P.J.) #45 #40

Pilotscrew (P.S.) (PRE-SET) 1sleturns back (PRE-SET) 1slaturns back
Throttle cable play 0 . 5 - 1 . 0m m 4-
(0.02-0.04 in)

CARBURETOR
SPECIFICATION
ITEM
E-03,28
Carburetortvpe M I K U N 8I 5 3 6 S 5( N o . 1 ) M I K U N IB D S 3 6 S S( N o . 2 )
Boresize 36 mm e

l.D.No. 48E7
+-
l d l er / m i n . 1 2 O O +1 0 0 r / m i n .
Fuel level 7 . 3 +0 . 5 m m 15 . 0+ 0 . 5 m m
Q . 2 9 + O . O 2i n ) ( 0 . 5 9+ 0 . 0 2 i n )
Floatheight 2 7 . 7+ 1 . 0 m m 9 . 1+ 1 . 0 m m
( 1. O g+ 0 . 0 4 i n ) ( 0 . 3 6 + 0 . 0 4i n )
Mainiet (M.J.) # l1D #gn
Jet needle (J.N.) 5D83 5C43
N e e d l ei e t (N.J.) P-JM P-L]M
Throttlevalve (Th.V.) # 1 1 5
P i l o ti e t (P.J.) #Ll5 #Ll0
Pilotscrew (P.S.) PRE-SET PRE-SET
Throttle cable play 0 . 5 - 1 . 0m m e
(0.02-0.04 in)
t0.7 vz800w('98-M0DEL)

CARBURETOR
SPECIFICATION
ITEM
E- 8
Carburetortype M I K U N 8I 5 3 6 5 5 ( N o . 1 ) M I K U N IB D S 3 6 S S( N o . 2 )
Boresize 36 mm e

l . D .N o . 48E9 (-
ldle r/min. 1 200-_t5ooo
r/min.
F u e ll e v e l 7 . 3 + 0 . 5m m 1 5 . 0 +0 . 5 m m
( 0 . 2 9+ 0 . 0 2 i n ) ( 0 . 5 9+ 0 . 0 2 i n )
Float height 2 7 . 7+ 1 . 0 m m 9.1+1.Omm
( 1. 0 9+ 0 . 0 4 i n ) ( 0 . 3 6+ 0 . 0 4 i n )
M a i ni e t (M.J.) # 100 #90
Jet needle (J,N.) 5D27-3 5C29-2
N e e d l ei e t (N.J.) P-3 P-4
Throttlevalve (Th.V.) # 115 e

Pilotiet (P.J.) #40

Pilotscrew (P.S.) (PRE-SET) 27+ turns back (PRE-SET)
13lcturns back
Throttle cable play 0 . 5 - 1 . 0m m e
(0.02-0.04 in)

CARBURETOR
SPECIFICATION
ITEM
E-33
Carburetortype M I K U N 8I 5 3 6 5 5 ( N o . 1 ) MIKUNB I D S 3 6 S S( N o . 2 )
Boresize 36 mm
l . D .N o . 48EB
l d l er / m i n . 1 2 O O +1 O Or / m i n , <-.

Fuellevel 7 . 3 +0 . 5 m m 1 5 . 0 + 0 . 5m m
( 0 . 2 9+ 0 . 0 2 i n ) ( 0 . 5 9+ 0 . 0 2 i n )
Float height 2 7 . 7+ 1 . 0 m m 9.1+1.Omm
( 1. 0 9+ 0 . 0 4 i n ) ( 0 . 3 6+ 0 . 0 4 i n )
Main iet (M.J # tEU #gD
Jet needle (J N 5D83 5C43
N e e d l ei e t (N.J P- 1 M P-L]M
Throttlevalve (Th.V # 115 <-

P i l o tj e t (P.J #15 #L+D

P i l o ts c r e w (P.S (PRE-SET) (PRE-SET)
Throttle cable play 0 . 5 - 1 . 0m m {-
(0.02-0.04 in)
 ('98-M0DEL)
vz800w 10-8

CARBURETOR
SPECIFICATION
ITEM
P-37
Carburetortvpe M I K U N 8I 5 3 6 5 5 ( N o . 1 ) MIKUNB I D S 3 6 S S( N o . 2 )
Boresize 36 mm e

LD,No. 48EC <-

ldle r/min. 1 2OO+1OOr/min. e

Fuellevel 7 . 3 +0 . 5 m m +
15 . 0 O . 5 m m
( 0 . 2 9+ O . O 2i n ) ( 0 . 5 9 + 0 . 0 2i n )
Floatheight 2 7 . 7+ 1 . 0 m m 9 . 1+ 1 . 0 m m
( 1. 0 9+ O . O 4i n ) ( 0 . 3 6+ O . O 4i n )
M a i ni e t (M.J.) # 100 #90
Jet needle (J.N.) 5D27-3 5C29-3
N e e d l ei e t (N.J.) P-3 P-4
T h r o t t l ev a l v e (Th.V.) # 115
P i l o tj e t (P.J.) #45 #40
Pilotscrew (P.S.) tPRE-SET) 1sleturns back (PRE-SET) 13l+turns back
Throttle cable play 0 . 5 - 1 . 0m m
(0.02-0.04 in)
r0-9vz800wr98-M0DEt)

ELECTRICAL U n i t :m m ( i n )
ITEM SPECIFICATION NOTE
l g n i t i o nt i m i n g 5 o B . T . D . Ca. t 2 O O 0r / m i n .
F i r i n go r d e r 1.2
Sparkplug N . G . K .D : PRSEA-9
Type D E N S OX : 24EPR-Ug
0.8-0.9
Gap (0.031-0.035)
Spark oerformance O v e r I ( 0 . 3 )a t 1 a t m .
Signalcoil resistance 1 7 0 - 2 8 00 G- B I
lgnitioncoil resistance Primary 2-6 {t @ tap-Q tap
15-30 k0 Plup cap-
Secondary
tD tap
G e n e r a t o rc o i l r e s i s t a n c e Charging o . 2 - 1 . 50
Generator no-load voltage
( W h e n e n g i n ec o l d ) M o r e t h a n 7 5 V ( A C )a t 5 O 0 Or / m i n .
G e n e r a t o rM a x . o u t p u t 25OW at 5 O0Or/min.
Flegulatedvoltage 13.5-15.5V at 5 000 r/min.
Starterrelayresistance 3-6 0
Battery Type designation FTX12-BS
Capacity 12 V 3 6 k C ( 1 o A h ) / 1 0 H R
Standard
1 . 3 2a t 2 0 " C ( 6 8 ' F )
e l e c t r o l y t eS . G .
F u s es i z e H e a d l i g h t( H D 1 5A
(LO) 1 5A
Signal 1 5A
lgnition 10A
Tail 10A
Main 30A

WATTAGE Unit:W
SPECIFICATION
ITEM
E-O3,28,33 E-24 The others
Headlight HI 60 e

LO 55 e e

P a r k i n ql i q h t 4
B r a k el i q h t / T a i l l i q h t 21t5
T u r n s i g n a ll i g h t Front 21t5 +- 21
Rear 21
Speedometerliqht 1.7 e

W a t e rt e m p . i n d i c a t o lri g h t 1.7
T u r n s i q n a li n d i c a t o lri g h t 3.4
H i q h b e a mi n d i c a t o lri q h t 1.7
Neutral indicator liqht 3.4 e

O i l p r e s s u r ei n d i c a t o rl i g h t 1.7 e- e
 ('g8.MoDEu
vz800w 10-,|0

BRAKE+ WHEEL U n i t :m m ( i n )
ITEM STANDARD LIMIT
Rearbrakeoedalfree travel 20-30
( 0 . 8 -1 . 2 )
Rearbrake pedalheight 60
(2.41
B r a k el i n i n gt h i c k n e s s 1.5
Rear (0.06)
B r a k ed r u m l . D . 180.7
Rear (7.11)
B r a k ed i s c t h i c k n e s s 4 . 5 +4 . 2 4.0
Front ( 0 . 18 + 0 . 0 1 ) (0.16)
B r a k ed i s c r u n o u t 0.30
(0.012)
M a s t e r c y l i n d e rb o r e 12.700- 12.743
Front (0.5000-0.5017)
M a s t e r c y l i n d e rp i s t o n d i a m . 1 2 . 6 5 7- 1 2 . 6 8 4
Front (0.4983-0.4993)
B r a k e c a l i p e rc y l i n d e r b o r e 30.230-30.306
Front (1.1902-1.1931)
B r a k ec a l i p e rp i s t o nd i a m . 30.150-30.200
Front (1.1870-1.1890)
W h e e lr i m r u n o u t 2.O
Axial ( 0.08)
2.O
Radial ( 0.o8)
Wheel axle runout o.25
Front (0.010)
0.25
Rear (0.010)
W h e e lr i m s i z e Front J16xMT3.00
Rear J 1 s M / Cx M T 3 . 5 0
T i r es i z e Front 1 3 0 / 9 0 - 1 66 7 H
Rear 1 5 0 / 9 0 - 1 5M I C 7 4 H
Tire tread depth 1.6
Front (0.06)
2.O
Rear ( 0.08 )

SUSPENSION U n i t :m m ( i n )
ITEM STANDARD LIMIT NOTE
Front fork stroke 140
(5.5)
Frontfork damperfree length 156
(6.1)
Front fork oil level 154
(At outertube 177 mm up position) (6.1)
R e a rw h e e lt r a v e l 102
(4.O)
Swingarm pivot shaft runout 0.3
(0.01)
r0.11vz800wr98-M0DEr)

TIREPRESSURE
N O R M A LR I D I N G
C O L DI N F L A T I O N S O L OR I D I N G D U A LR I D I N G
T I R EP R E S S U R E kPa (g/cm2 osi
kPa <o/cm2 osi
FRONT 200 2 . O O 2 9 200 2 . O O 2 9
REAR 225 2.25 33 225 2.25 33

FUEL+OIL+COOLANT
ITEM SPECIFICATION NOTE
Fueltype Use only unleadedgasolineof at least 87
pump octane (* ; *) or 91 octane or
higherrated by thd researchmethod.
GasolinecontainingMTBE(MethylTertiary U . S . A .
B u t y l E t h e r ) ,l e s s t h a n 1 O % e t h a n o l ,o r
less than 5% methanolwith appropriate
cosolventsand corrosion inhibitor is
permissible.
U s e o n l y u n l e a d e dg a s o l i n eo f a t l e a s t 8 7
pump octane( B+14method)or 91 octane C a n a d a m o d e l
or hiqherrated bV the ResearchMethod'
Gasolineused shouldbe graded85-95 oc-
t a n e o r h i g h e r .A n u n l e a d e dg a s o l i n ei s Other models
recommended.
F u e lt a n k i n c l u d i n gr e s e r v e 1 3 . 0L
( 3 . 4 1 2 .U
9S/lmpgal)
|."*r* 3.0 L
l O . 8 l O . 7U S / l m Pg a l )
E n qn e o i l t y p e S A E 1 O W 1 4 OA, P I S F o r S G
E n g i n eo i l c a p a c i t y 1 7OOml
Change ( 1 . 8 / 1 , 5U S / l m pq t )
2 1 O Om l
F i l t e rc h a n g e
1 2 . 2 1 1 .U 8 S / l m pq t )
2 5OOml
Overhaul ( 2 . 6 1 2 . 2U S i l m pq t )
Front fork oil type F o r ko i l + 1 5
Front fork oil capacity 838 ml
( e a c hl e g ) ( 2 8 . 3 1 2 9 . 5U S / l m Po z )
B r a k ef l u i d t v p e DOT 4
C o o l a n tc a p a c i t y 1 460 ml
( 1 . 5 / 1 . 3U S / l m pq t )
 uz800w('98-M0DE[)
10-12

TURN SIGNAL/SIDE.STAND
RELAY
T h e t u r n s i g n a l r e l a y i s c o r p o r a t e dw i t h t h e s i d e - s t a n d
r e l a ya n d d i o d e t o f o r m t h e o n e c o m p o n e n tp a r t w h i c h i s
c a l l e dt h e t u r n s i g n a l / s i d e - s t a nr edl a y .
It is locatedbehind the left frame cover.
o Removethe left frame cover.
. R e m o v et h e t u r n s i g n a l / s i d e - s t a nr edl a y .

TURN SIGNALRELAYINSPECTION
B e f o r er e m o v i n gt h e t u r n s i g n a l / s i d e - s t a n r edl a y ,c h e c kt h e
o p e r a t i o no f t h e t u r n s i g n a ll i g h t .
l f t h e t u r n s i g n a ll i g h t d o e s n o t l i g h t ,i n s p e c t h e b u l b ,t u r n
s i g n a ls w i t c ha n d c i r c u i tc o n n e c t i o n .
lf the bulb, turn signal switch and circuit connection
c h e c k e da r e a l l r i g h t ,t h e t u r n s i g n a lr e l a y m a y b e f a u l t y ,
r e p l a c et u r n s i g n a l / s i d e - s t a nr edl a yw i t h a n e w o n e .
NOTE:
Be sure that the battery used is in fully-charged condition.

SIDE-STANDRELAYINSPECTION
F i r s tc h e c kt h e i n s u l a t i o nb e t w e e n@ a n d @ t e r m i n a l sw i t h
testerT . h e n a p p l y 1 2 v o l t s t o @ a n d @ t e r m i n a l sO , to @
a n d O t o @ , a n d c h e c kt h e c o n t i n u i t yb e t w e e n@ a n d @ .
lf there is no continuity,replaceturn signal/side-stand relay
with a new one.

DIODEINSPECTION
Using a multi circuittester,measurethe voltage between
t h e t e r m i n a l si n t h e f o l l o w i n gt a b l e .
U n i t :V
@ Probeof testerto:
F
v x

o o
L P
o- gl
ri\
\t/
E J
@! osso0-2s008:
Mutti circuittester set
{exceptfor European market)
ffip Testerknob indication:Diodetest (-f* )
NOTE:
lf the tester read under 7.4V replace the battery of multi
circuit tester when do not connecting the tester probes.
10-13VZ800W
r98-M0DEr)

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 vz800w 10-14
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 (' g8-M0DEt)
10.15VZ800W

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 ('98-M0DEI)
vz800w t0-,|6

WIRE HARNESSROUTING

Clamp
Clamp harness
W i r i n gh a r n e s s
Wiring harness

C a r b u r e t ocr a b l e W i r i n gn a r n e s s
Battery @ terminal
Clamp
Starter relay

Front turn signal

light (R & L)
Clamp
Clamp
Wiring harness
Speedometer
H a n d l e b a rs w i t c h ( R & L )
Clamp

Headlight H a n d l e b a rs w i t c h ( R & L ) S i d e - s t a n ds w i t c h Passthrough the lead

housing Oil oressureswitch wires between the brace

^*[
,r Side-stand s w
N e u t r a ls w i t c h
i
Clamp
t ch
Generator

Tail/Brake
and rear fender.

Clamp

Generator R e a rt u r n s i g n a l
l i g h t( L )

Speedometer
cable
Horn

Fan motor switch

Clamp

Generator
N e u t r a ls w i t c h
Radiator Clamp

Passthrough the S i d e - s t a n ds w i t c h
S i d e - s t a n ds w i t c h side-standswitch Neutralswitch
Clamp l e a d w i r e i n s i d et h e
frame. Clamp
t0-17vz800w('98-M0DEI)

Clamp
H a n d l e b a rs w i t c h ( R )
H a n d l e b a rs w i t c h ( L )

B r a k eh o s e

Front turn signal light lead wire

W i r i n gh a r n e s s
Fan motor switch
Enginecoolant temp. switch

{|;;"

4 Forward

Fuel pump
Rear brake light switch
lgnition coil

P a s st h r o u g ht h e
starter motor lead
wire between the
c a r b u r e t o ar n d
air cleaner.

S t a r t e rm o t o r
e switch
Clamp W i r i n qh a r n e s s
G r o u n dw i r e
Starter motor
R e a rb r a k el i g h t s w i t c h
Starter motor
R e g u l a t o r / r e c t iife r
R e a rb r a k ec a b l e
O i l o r e s s u r es w i t c h
Oil oressureswitch
This sectiondescribes service data, seruice specificationsand seruicingprocedures which
differ from those of the VZ800W ('99-modd).

NOTE:
'00,
. Any differencesbetween the VZB17W('98-model)and VZB00(Y/K1/K2/K3 (99,
'01, '02, '\S-models) in specificationsand seruice data are indicated with an asterisk
mark (").
. Pleaserefer to the sections1 through 10 for details which are not given in this section.

SPEC\F\CAT\ONS 11- 1
SERVICE DATA ...11- 2
ENG//NE .....,......
\DLERPM (IDLEADJUSTMENT) 11-12
EXHAUSTPIPE ANDMUFFLER .....,.11.12
ENGINESIDEBOX SET-IJP
EVAPORATIVE EMISSIONCONTROLSYSTEM
(Californiamodel only) ".."11'14

X/Y.MODELS E-02,03, 04, 17, 18, 22, 24, 25, 28, 33, 34, P-37
Kl/K2IKS.MODELS E-02,03, 04, 17, 18, 22, 24, 25, 28, 33, 34
11-1

SPECIFICATIONS
DIMENSIONSAND DRY MASS
length....
Overall 2 4 0 5m m ( 9 a . 7i n ). . . . E
. -17,18,22,25
2 365 mm (93.1in) .....Others
Overallwidth 750 mm (29.5in)
Overall height 1 1 1 0 m m ( 4 3 . 7i n )
1 645 mm (64.8in)
1 3 5 m m ( 5 . 3i n )
700 mm (27.6 in)
207 kg (456 lbs)

Four-stroke,water-cooled,OHC, 45-degree,V-twin
N u m b e ro f c y | i n d e r s . . . . . . . . . . . . . . . . . . . . .
83.0 mm (3.268in)
Stroke ., 74.4mm (2.929in)
Displacement 805 cms(49.1cu' in)
Compressionratio
iront...
Carburetor, MIKUNIBDS36SS
MIKUNIB53655
fabricelement
Non-woven
Starter system
L u b r i c a t i osny s t e m. . . . . . . . . . . . . . wet sump
1 1 5 0- 1 3 0 0 r / m i n. . . . .E - 1 8
1 100- 1 300 r/min.....Others

TRANSMISSION
Clutch Wet multi-platetype
Transmission s-speed constant mesh
G e a r s h i fpt a t t e r n. . . . . . . . . . . . . . . 1-down,4-up
Primary reduction 1.886(83/44)
Secondary reduction 3.200 (48/15)
Gear ratios, Low .............. 2.461 (3213)
2 n d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.578 (30/19)
3rd 1.2O0(24/20)
0.e56 (22t23)
T o p. . . . . . . . . . . . . . . . . . . . . . 0.800 (20125)
Drivechain D | D 5 o V M 1, 1 6 l i n k s

CHASSIS
Frontsuspension Invertedtelescopic,coil spring,oil damped
Rearsuspension Swingarmtype, coil spring,oil dampad,springpre-loads-wayadjustable
Steeringangle 40'(right & left)
35'
146 mm (5.7 in)
3 . 1 m ( 1 0 . 2f t )
Disc brake
Rearbrake Drum brake
130/90-1667H, tubeless
150/90-15 MIC 7 4H, tubeless
1 4 0 m m ( 5 . 5i n )
1 0 2 m m ( 4 . 0i n )

ELECTRICAL
type......
lgnition Electronicignition (Transistorized)
5'B.T.D.C.below 1 500 r/min
NGK DPRBEA-9or DENSOX24EPR-U9
1 2 V3 6 . 0k c ( 1 0 A h y l o H R
Three-phaseA.C.generator
30/1sn 5/15^ 0/10A
12V 60/55W
12V 4W .....E-Oz,04, 17, 18, 22, 25, 34, P-37
.........
Brakelight/Taillight 12V 21/5W
Frontturn signallight ...., 12V 5121W.....E-03,28, 33
12V 21W..... Others
Rearturn signallight ..... 12V 21W
S p e e d o m e t el irg h t. . . . . . . . . . . . . . . . . . . 1 2 V1 7 W
T u r ns i g n a li n d i c a t ol ri g h t . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 V3 . 4 W
Neutralindicatorlight.................... ......'...'.12V3.4W
High beam indicatorlight 12V 1.7W
Coolanttemperaturechecklight... . . . . . . . . . . '1 2 V 1 . 7 W
O i l p r e s s u r ei n d i c a t olri g h t . . . . . . . . . . . . . . . . . . . . .".. 12V1.7W

CAPACITIES
F u e lt a n k ,i n c l u d i n rge s e r v e. . . . . . . . . . . . . . . . US/lmpgal)
13.0L (3.4/2.9
US/lmpgal)
3.0L (0.8/0.7
Engineoil, withoutfilterchange 1 700ml(1.8/1.5 US/lmpqt)
with filterchange .8 Us/lmpqt)
2 100ml (2.2/1
overnaul 2 500ml (2.6/2.2Us/lmpqt)
Frontfork oil (each leg) 845ml (28.6/29.6
US/lmpoz)
C o o l a n t. . . . . . . . . . . . . 1 460ml (1.4/1.2Us/lmpqt)
 11-2

SERVICEDATA
VALVE+ GUIDE (in)
Unit:mm
ITEM STANDARD LIMIT
Valvediam. 30
tN. ( 1. 1 8 )
26
EX, (1.02)
Valveclearance 0 . 0 8- 0 . 1 3
I N .& E X . (0.003- 0.005)
(whencold)
Valveguide to valve stem tN. 0.010- 0.037
clearance (0.0004- 0.0015)
0.030- 0.057
EX. (0.0012- o.oo22)
Valvestem deflection 0.35
IN.& EX. (0.014)
ValveguideLD. 5.500- 5.512
I N .& E X . (0.2165- 0.2170)
ValvestemO.D. 5.475- 5.490
tN. (0.2156- 0.2161)
5.455- 5.470
EX. (0.2148- 0.2154)
Valvestemrunout 0.05
IN.& EX. (0.002)
Valvehead thickness 0.5
IN.& EX, (0.02)
Valvestem end length 3.1
I N .& E X . (0.12)
Valveseat width 0 . 9- 1 . 1
I N ,& E X . (0.035- 0.043)
Valvehead radialrunout 0.03
I N .& E X . (0.001)
Valvespringfree length 38.3
INNER ( 1. 5 1 )
40.1
OUTER (1.58)
Valvespringtension 6.51- 7.49 k9
INNER ( 1 4 , 3 5- 1 6 . 5 1l b s )
at length32.5mm (1.28in)
1 2 . 0 9- 1 3 . 9 1k g
OUTER (26.65- 30.67 lbs)
at length36.0mm (.a2in)

CAMSHAFT+ CYLINDERHEAD (in)

Unit:mm
ITEM STANDARD LIMIT
Cam height 35.950- 35.998 35.660
tN. (1.4154- 1.4172) (1.403e)
E-18
36.920- 36.968 36.620
EX. (1.4535- 1.4554) (1.4417)
35.954- 36.002 35.660
lN. ( 1 . 4 1 5-51 . 4 1 7 4 ) (1.403e)
Others
36.919- 36.967 36.620
EX. (1.4535- 1.4554) (1.4417)
11-3

ITEM STANDARD LIMIT

Camshaftjournaloil clearance 0.032- 0.066 0.150
(0.0013- 0.0026) (0.005e)
Camshaftjournalholderl.D. No.1Left side 2A.012-20.025
No.2Rightside - 0.7884)
(0.7879
No.1Left side 25.O12- 25.025
No.2 Riqhtside (0.9847- 0.9852)
CamshaftjournalO.D. No.1Left side 1 9 . 9 5 9- 1 9 . 9 8 0
No.2Rightside (0.7858- 0.7866)
No.1Left side 24.959-24.980
No.2Riqhtside (0.e826- 0.e835)
runout
Camshaft 0.10
(0.004)
Rockerarml.D. 1 2 . 0 0-0 1 2 . 0 1 8
I N .& E X . (0.4724 - 0.4731)
Rockerarm shaft O.D. 1 1 . 9 6 -6 1 1 . 9 8 4
I N .& E X , (0.4711- 0.4718)
Cylinderhead distortion 0.05
(0.002)
Cylinderhead coverdistortion 0.05
(0.002)

CYLINDER+ PISTON+ PISTONRING U n i t : m m( i n )

ITEM STANDARD LIMIT
Campressionpressure 1 500 kPa 1 100 kPa
(';'\S';Ji') ('i#';Ji')
pressure difference
Campression 200 kPa
('#!"J1.,)
Pistonto cylinderclearance 0.045- 0.055 0 . 12 0
(o.oo18- 0.0022) (0.0047)
Cylinderbore 83.000- 83.015 83.085
(3.2677- 3.2683) (3.2711)
Pistondiam. 82.950- 82.965 82.880
(3.2657- 3.2663) (3.2630)
at 15 mm (0.6in)fromtheskirtend.
Measure
distortion
Cylinder 0.05
(0.002)
8.40
Pistonringfree end gap
1st Approx.
rJ?ft1 (0.331)
^ 11.8 9.44
2nd R APProx. (0.372)
(0.465)
Pistonringend gap 0.20- 0.35 0.50
1st (0.008- 0.014) (0.020)
0.20- 0.35 0.50
2nd (0.008- 0.014) (0.020)
Pistonringto grooveclearance 0.180
1st (0.0071)
0 . 15 0
2nd (0.0059)
 11-4

ITEM STANDARD LIMIT

Pistonring groovewidth
1st 1 . 0 1- 1 . 0 3
(0.03e8 - 0.0406)
1 . 2 1- 1.23
2nd (o.0476- 0.0484)
2.51- 2.53
oil (0.0988- 0.0966)
Pistonring thickness 0.970- 0.990
1st (0.0382- 0.0390)
1.170 - 1.190
2nd (0.0461- 0.0469)
Pistonoin bore 20.002- 20.008 20.030
(0.7875- 0.7877) (0.7886)
Pistonpin O.D. 19.996- 20.000 19.980
(0.7827- 0.7874) (0.7866)

CONROD+ CRANKSHAFT U n i t : m m( i n )
ITEM STANDARD LIMIT
Conrodsmallend l.D. 2 0 . 0 1 -0 2 0 . 0 1 8 20.040
(0.7878 - 0.7881) (0.78e0)
Conrodbig end side clearance 0 . 1 0- 0 . 2 0 0.30
(0.004- 0.008) (0.012)
Conrodbig end width 21.95- 22.00
(0.864- 0.866)
Crankpin width 2 2 . 1 0- 22.15
(0.870- 0.872)
Conrodbig end oilclearance 0.024- 0.042 0.080
(0.0009- 0.0017) (0.0031)
CrankpinO.D. 40.982- 4'1.000
(1.6135- 1.6142)
Crankshaftjournaloil clearance 0.020- 0.050 0.080
(0.0008- 0.0020) (0.0031)
CrankshaftiournalO.D. 47.965- 47.980
(1.8884 - 1.8890)
Crankshaftjournalbearingl.D. 48.000- 48.015
(1.8898- 1.8904)
thrustbearinq
Crankshaft 1 . 9 2 5- 2.175
thickness (0.0758- 0.0856)
thrustclearance
Crankshaft 0 . 0 5- 0 . 1 0
(0.002- 0.004)
runout
Crankshaft 0.05
(0.002)

OILPUMP
ITEM STANDARD LIMIT
Oilpumpreduction ratio 1.364(83144x 34147)
Oil pressure
(at 60'C,140'F) Above 450 kPa (4.5 kg/cm', 64 psi)
Below750 kPa (7.5 kglcm2,107psi)
at 3 000 r/min.
11-5

CLUTCH (in)
Unit:mm
ITEM STANDARD LIMIT
Clutchcable play 10-15
(0.4- 0.6)
Driveolatethickness 2.92-3.08 2.62
No.1
( 0 . 1 5- 0 . 1 2 1 ) (0.103)
3.42- 3.58 3.12
No.2 ( 0 . 1 3-5 0 . 1 4 1 ) (0.123)
Drive plate claw width 1 5 . 9- 1 6 . 0 15.1
(0.626- 0.630) (0.5e4)
Drivenplatedistortion 0.10
(0.004)
Clutchspringfree length 24.6
No.1 (0.e7)
23.3
No.2 (0.92)

RADIATOR+ FAN
ITEM STANDARD LIMIT
Radiatorcap valve release 110t15kPa
Dressure ( 1 . 1t 0 . 1 5k g / c m 21, 5 . 6t 2 . 1 P s i )
Coolingfan thermo-switch ON Approx.105"C(221"F)
operatingtemperature OFF Approx.100'C (212"F)
Enginecoolanttemperature ON Approx.120"C (248"F)
temperature
switchoperatinq OFF Approx.113'C (235'F)

TRANSMISSION Unit:mm (in)Exceptratio

ITEM STANDARD LIMIT
ratio
Primaryreduction 1.886(83/44)
Finalreductionratio 3.200(48i15)
Gearratios Low 2.461(32113)
2nd 1.578(30/1e)
3rd 1.200 (24120)
4th 0.e56(22t23)
Top 0.800 (20125)
Shift fork to grooveclearance 0 . 1 0- 0 . 3 0 0.50
(0.004 - 0.012) (0.020)
Shift fork groovewidth 5.50- 5.60
(a.217- 0.220)
Shiftfork thickness 5.30- 5.40
(0.20e- 0.213)
Drivechain Type DIDsOVA,
Links 1 1 6l i n k s E
, NDLESS
20-pitch 319.4
lenqth (12.6)
Drivechainslack 15-25
(0.6- 1.0)
Gearshiftleverheight 50
e.a)
 11-6

CARBURETOR
SPECIFICATION
ITEM
E-02,04,17,22,24,25,34
Carburetor
type I 53655(No.1)
M I K U N8 MIKUNIBDS36SS(No.2)
Boresize 36 mm <_
LD. No. -48EE <--
ldler/min. 1 200 t 100 r/min. <-
Fuel level 7.3 + 0.5 mm +
1 5 . 0 0 . 5m m
(0.29* 0.02in) (0.59t 0.02in)
Floatheight 2 7 . 7x . 1 . 0m m 9 . 1t 1 . 0m m
( 1 . 0 9t 0 . 0 4i n ) (0,36t 0.04in)
Mainiet (M.J.) #100 #90
Jet needle (J.N.) 5D27-3 5C29-3
Needlejet (N.J.) P-3 P-4
Throttlevalve (Th.V.) # 11 5 <_
Pilotjet (P.J.) #45 #40
Pilotscrew (PS.) .PRE-SET(11lz turns back)
Throttlecableplay -
2.0 4.0 mm €-
(0.08- 0.16in)

CARBURETOR
SPECIFICATION
ITEM
E-28
Carburetor
type I 53655(No.1)
MIKUN8 (No.2)
MIKUNIBDSsGSS
Boresize 36 mm <_
LD. No. -48FF <_
ldlerimin. 1 200+ 100r/min. <_
Fuel level 7 . 3+ 0 . 5m m 1 5 . 0t 0 . 5 m m
(0.29r 0.02in) (0.59r 0.02 in)
Floatheight 2 7 . 7+ 1 . 0m m 9 . 1t 1 . 0m m
( 1 . 0 9t 0 . 0 4i n ) (0.36t 0.04in)
Mainjet (M.J.) #t u u #gu
Jet needle (J.N.) 5D83 5C43
Needlejet (N.J.) P- 3M P_L]M
Throttlevalve ffh.V.) # 11 5 (-
Pilotjet (P.J.) # 115 # Ltu
Pilotscrew (P.S.) "PRE-SET (1%turnsback)
Throttlecable play 2.0- 4.0mm (-
( 0 . 0 8- 0 . 1 6i n )
11-7

CARBURETOR
SPECIFICATION
ITEM E- 8
type
Carburetor I 53655(No.1)
MIKUN8 I D S 3 6 S S( N o , 2 )
MIKUNB
Boresize 36 mm <_
-48EJ <_
l.D. No.
ldle r/min. 1 200 lluofr/min. <_
Fuel level 7.3 + 0.5 mm 1 5 . 0t 0 . 5 m m
(0.29t 0.02in) (0.59t 0.02in)
Floatheight 2 7 . 7* . 1. 0 m m 9 . 1t 1 . 0m m
('1.09 t 0.04in) (0.36+ 0.04in)
Mainjet (M J.) #100 #90
Jet needle (J N ) 5D27-3 5C29-2
Needlejet (N.J.) P-3 P-4
Throttlevalve (Th.V.) # 11 5
Pilotjet (P.J.) #40
.PRE-SET (2 turnsback) .PRE-SET(17+turns back)
Pilotscrew (P.S.)
Throttlecable play -
2.0 4.0mm
( 0 . 0 8- 0 . 1 6i n )

CARBURETOR
SPECIFICATION
ITEM E-33
type
Carburetor I 53655(No.1)
MIKUN8 MIKUNIBDS36SS(No.2)
Boresize 36 mm <_-
-48EG (-
LD. No.
ldler/min. 1 200t 100r/min. (-
Fuel level 7 . 3+ 0 . 5m m 1 5 . 0t 0 . 5 m m
(0.29t 0.02 in) (0.59t 0.02in)
Floatheight 2 7 . 7x . 1 . 0m m 9 . 1r 1 . 0m m
( 1 . 0 9* 0 . 0 4i n ) (0.36t 0.04in)
Mainjet (M.J.) #tuu #gu
Jet needle (J.N.) 5D83 5C43
Needlejet (N.J.) P_ ]M P _ L ]M
Throttlevalve (Th.V.) # 11 5 f-

Pilotjet (P.J.) # Ll5 # Llu

Pilotscrew (P.S.) PRE-SET (-
Throttlecableplay 2.0- 4.0mm <_
( 0 . 0 8- 0 . 1 6i n )
 11-8

CARBURETOR
SPECIFICATION
ITEM
E-03
Carburetor
type M I K U N8I 3 3 6 5 5( N o . 1 ) MIKUNIBDS36SS(No.2)
Boresize 36 mm <_
LD. No. *48EF <-
ldle r/min. 1 200+ 100r/min. C-

Fuellevel 7 . 3+ 0 . 5m m 1 5 . 0+ 0 . 5 m m
(0.29t 0.02in) (0.59r 0.02 in)
Floatheight 2 7 . 7x . 1 . 0m m 9 . 1r 1 . 0m m
( 1 , 0 9+ 0 , 0 4i n ) (0.36* 0.04in)
Mainjet (M.J.) #tuu #gD
Jet needle (J.N.) 5D83 5C43
Needlejet (N.J.) P_JM P-LTM
Throttlevalve ffh.V.) # 11 5 <_
Pilotjet (PJ ) # 115 # Llu
Pilotscrew (P.S.) PRE-SET <-
Throttlecable play 2 , 0- 4 . 0m m <_
( 0 . 0 8- 0 . 1 6i n )

CARBURETOR
SPECIFICATION
ITEM
P-37
Carburetor
type MIKUNI8S3655 (No.1) MIKUNIBDS36SS(No.2)
Boresize 36 mm <_

LD. No. "48EH (-

ldle r/min. 1 200+ 100r/min. (-
Fuel level 7 . 3+ 0 . 5m m 1 5 . 0r 0 . 5m m
(0.29r 0.02 in) (0.59t 0.02in)
Floatheight 2 7 . 7+ 1 . 0m m 9 . 1r 1 . 0m m
( 1 . 0 9t 0 . 0 4i n ) (0.36t 0.04in)
Mainjet (M.J.) .#105 .#95
Jet needle (J.N.) *5D105-3 .5C29-5
Needlejet (N.J.) P-3 *P-7
Throttlevalve (Th.V.) # 11 5 <_
Pilotjet (P.J.) *#50 *#47.5
Pilotscrew (P.S.) .PRE-SET(11lz turnsback) (1%turnsback)
PRE-SET
Throttlecableplay -
2.0 4.0mm <_
( 0 . 0 8- 0 , 1 6i n )
11-9

ELECTRICAL Unit:mm (in)

ITEM SPECIFICATION NOTE
lgnitiontiming at 2 000r/min.
5" B.T.D.C.
Firinoorder 1'2
Sparkplug NGK:DPRSEA-9
Type DENSO: X24EPR-Ug
0.8- 0.9
Gap (0.031- 0.035)
Spark pedormance Over8 (0.3)at 1 atm.
Sionalcoilresistance 170- 280 O G_BI
lgnitioncoil resistance Primary 2-6 0 @tap-Otap
Plugcap -
Secondary 15 -30 kO
@ tap
coilresistance
Generator Charqinq 0 . 2- 1 . 5O
Generatorno-loadvoltage
More than 75V (AC) at 5 000 r/min.
(whenenginecold)
Max.output
Generator 250Wat 5 000rimin.
Regulatedvoltage 13.5- 15.5Vat 5 000 rimin.
Starterrelayresistance 3-6fl
Battery Typedesignation FTX12.BS
Capacity 12V36kC (10Ah)/10HR
Standard 1.32at 20'C (68"F)
electrolyteS.G
Fusesize Headlight(Hl) 15A
(Lo) 15A
Signal 15A
lgnition 10A
Tail 10A
Main 30A

WATTAGE Unit:W
SPECIFICATION
ITEM E-03,28,33 E-24 The others
Headlight HI 60 €- <-

LO 55 <_ <_

ParkingIight 4
Brakelight/Taillight 21t5 (- <_
Turnsignallight Front 21t5 <_ 21
Rear 21 <--. <_

Speedometerlight 1.7 (- <_

Watertemp.indicatorlight 1.7 €- <_

3.4 (-- (-
Turnsiqnalindicatorliqht
1.7 <_ (-
High beam indicatorlight
Neutralindicatorliqht 3.4 <_ <-
(- <_
Oilpressure light
indicator 1.7
 11,10

BRAKE+ WHEEL U n i t : m m( i n )
ITEM STANDARD LIMIT
Rear brake pedalfree travel 20-30
( 0 . 8- 1 . 2 )
Rear brakepedalheight 60
(2.4)
Brakeliningthickness 1.5
Rear
(0.06)
BrakedrumLD. 180.7
Rear (7.11\
Brakedisc thickness 4 . 5x . 0 . 2 4.0
Front ( 0 . 1 8t 0 . 0 1 ) (0.16)
Brakedisc runout 0.30
(0.012)
Mastercylinderbore
Front 12.700- 12.743
(0.5000- 0.5017)
Mastercylinderpistondiam. 12.657- 12.684
Front
(0.4e83- 0.4e93)
Brakecalipercylinderbore 30.230- 30.306
Front (1.1902-1.1931)
Brakecaliperpistondiam. 30.150 - 30.200
Front
( 1 . 1 8 7 01- . 1 8 9 0 )
Wheelrimrunout 2.4
Axial
(0.08)
Radial
2.0
(0.08)
Wheelaxlerunout 0.25
Front (0.010)

Rear 0.25
(0.010)
Wheelrimsize Front J16 x MT3.00
Rear J1sM/Cx MT3.50
Tiresize Front 130/90-16
67H
Rear 150/90-15
MlC74H
Tire tread depth 1.6
Front (0.06)

Rear 2.0
(0.08)

SUSPENSION U n i t : m m( i n )
ITEM STANDARD LIMIT NOTE
Frontforkstroke 140
(5.5)
Frontfork damperfree length 156
(6.1)
Frontfork oil level 154
(At outertube 177 mm up position) (6.1)
Rear wheel travel 102
(4.0)
pivotshaftrunout
Swingarm 0.3
(0.01)
11-11

TIRE PRESSURE
NORMALRIDING
COLD INFLATION S O L OR I D I N G DUALRIDING
TIRE PRESSURE
kPa kg/cm2 psi kPa kglcm2 psl
FRONT 200 2.OO 29 200 2.OO 29
REAR 225 2.25 .t.t 225 2.25 33

FUEL+OlL+COOLANT
ITEM SPECIFICATION NOTE
Fueltype Use only unleadedgasolineof at least87 pump oc-
tane (lje) or 91 octaneor higherrated by the re-
search riethod. GasolinecontainingMTBE (Methyl E-03,28,33
TertiaryButyl Ether),less than 10% ethanol,or less
than 5% methanol with appropriatecosolventsand
corrosioninhibitoris permissible.
Gasolineusedshouldbe graded91 octaneor higher. Other models
An unleadedgasolineis recommended.
reserve
Fueltankincluding 1 3 . 0L
(3.412.9US/lmpgal)
reserve 3.0L
(0.8i0.7US/lmpgal)
Engineoiltype SAE 10W40, API SF or SG
Engineoilcapacity 1 700 ml
Change (1.8/1.5US/lmpqt)
2 1 0 0m l
Filterchange US/lmpqt)
(2.211.8
2 500ml
Overhaul US/lmpqt)
(2.612.2
Frontfork oil type Forkoil #15
Frontfork oil capacity 838 ml
(eachleg) (28.3129.5
US/lmpoz)
Brakefluidtype DOT4
Coolantcapacity 1 460 ml
(1.5/1.3US/lmpqt)
 11-12

ENGINEIDLERPM(IDLEADJUSTMENT)
NOTE:
The engineidling speed should be adjustedwhen the engine is
hot.

. Removethe seat.
. Connecta tachometer.
. Startup the engineand set its speedat idlespeedby turning
throttlestopscrewe.

E n g i n ei d l e s p e e d : 12 0 0 1 t ! ! r l r n i n . . . . . f oE
r -l8
12OO+ 100 r/min .....for others

EXHAUSTPIPEAND MUFFLER

Gasket

Applyexhaustgas sealer.(PERMATEX
1372)
p z st t ' m
(,?:.iB:[)

$ zs trt'm
1 2.5 kg-m
\ 1 8 . 0t b - f t

Gasket

plzs tit.m
(,';LiB.il)

S z st t . m
('';Lifl:il)
11-13

SIDEBOXSET.UP
ENGINE

C\I
.i
z

c)
6

o
z

= .J)

o
T

=d
x

o
a
 11-14

EVAPORATIVE EMISSIONCONTROLSYSTEM
(Californiamodel only)

Fuelfillerpipe

Fuel-vaporseparator

Carburetorsurge
controlvalve

';';rE

h Fuel

<- HC vapor
11.15

EMISSIONCONTROLSYSTEMHOSEROURING
EVAPORATIVE

The vacuumand carburetorsurgehose(Carburetorsurgecontrolvalve- 3way)

mustbe passedunderthe wiringharnessandthe fuelhose.

Carburetorsurge hose Throttlecable Fuelpumphose

(Carburetorsurge (return)
valve - 3way) Synchronizing Fuelpump
Fuel Wiring \cable
narness

Carburetorsurge
control

Fuel Breather
Wiringharness hose hose
Choke cable trrroK
Throttle cable
(return) cable
Throttlecable
(pull) Air ventpipe

RH
\
tf-.' Outlettube clamp
Air ventpipe
4"\<
+r rottlecable

A pipe
Air cleaner
(No.2)
A + T Intake clamp
W \ Air,ventpipe
LH Outlettube
Intakepipe cramp
Carburetor nlamn
No.2) *RH
LH- ,1*
fiITIJ
Breather /'1\
{+f
v

Fuelhose
(forfuel tank to fuel valve)
,A
Fuelvalve Air cleaner
drainhose
. Generatorleadwire : /
. Neutralswitchleadwire ier
Regulator/rectif
Fuelhose
(forfuel valve . Side-standswitch
to fuelpump) leadwire

. Groundwire
. Regulator/rectifier
leadwire
. lgnitorleadwire
 11-16

- ]
[FrameNumber= JS1VS53A-X2101115

Fueltank

^-,h,,.^+^, \
vat uur gLvr
,,/\
surgenose / \

\>j\\.l:L.l--....-
I -:-.-.-:--
1--\..r
Air vent oioe Il \...\. Canistersurgepipe
Vaiuumhose-'-:--
Carburetorsurge
controlvalve
Purgehose

To No.1
Carburetor

Surgehose

Purgehose

-"-\'

vrqr i rP
11-17

- ]
[FrameNumber= JS1VS53A-X2102685

Fuel-vaporseDarator

__-.._1._\.._i
Carburetorsurqe .. \
- Alr \\
controlValve VenIPlPe
Canistersurgepipe

To No.1
Carburetor

Surgehose

-----'-"n"-
//'- ClamP

ToCarburetor
surgecontrol
VAIVE
 11-18

EVAPORATIVEEMISSION
CONTROLSYSTEMINSPECTION
. Removethe framecoversand the fuel tank.

HOSES
lnspectthe hosesand pipesfor wear or damage.
lnspectthe hosesand pipesfor connection.
CANISTER
Inspectthe canisterfor damageof the body.

CARBURETOR SURGECONTROLVALVE
. Removethe carburetorsurgecontrolvalve.
. Connectthe vacuumpumpto the vacuumport as shown.
. Applythe specifiednegativepressureto the carburetorsurge
controlvalve.
. The specifiednegativepressuremust be maintained.
. Replacethe carburetorsurgecontrolvalveif negativepres-
sure is not maintained.

EM ttegativepressure=2.7 kPa (20 mm Hg)

@ vacuumpumpgauge
09912-47010:
A CAUTION
Use a hand operatedvacuum pump to preventthe con-
trol valve damage.
11-19

. Whileapplyingthe specifiednegativepressureto the carbu-

retorsurgecontrolvalvevacuumport, blow air throughthe
openair port.
. Air shuldflow throughthe carburetorsurgecntrolvalveand
out the air vent port @.
. Replacethe carburetor surgecontrolvalveif air does notflow
out the air ventport @.

. Plugthe air ventport@.

. Whileapplyingthe specifiednegativepressureto the carbu-
retorsurgecontrolvalvevacuumport, blow air throughthe
openair port.
. Air shouldnot flowthroughthe carburetorsurgecontrolvalve
and out the canisterport@
. Replacethe carburetorsurgecontrolvalve if air leakesout
the canisterport @.

. Removethe vacuumpumpand blowair throughthe air vent

port @.
. Air shouldflowthroughthe carburetersurgecontrolvalveand
port
out the canister O.
. Replacethe carburetor surgecontrolvalveif air doesnotflow
port
out the canister O.

. Plugthe canisterport@.
. Air shouldnot flowthroughthe carburetor
surgecontrolvalve
and out the openair port.
. Replacethe carburetorsurgecontrolvalveif air leak out the
openair port.
 12-1
vz800K4('04-M0DEL)

This chapterdescribesservice data, service specificationsand servicingprocedureswhich dif-

fer from those of the VZB00K3('03-MODEL).
NOTE:
. Any differencesbetween the VZ800KS('1?-model)and VZ800K4('14-model)in specifica-
tions and seruicedata are indicated with an asteriskmark (.).
* Pleaserefer to the chapter 1 through 11 for details which are not given in this chapter.

SPECIFICATIONS 12- 2
SERVICEDATA .12. 3
PERIODICMAINTENANCECHART . 12-12
WIRINGDIAGRAM 12-13
12-2 VZ800K4('04-M0DEL)

SPECIFICATIONS
D I M E N S I O N SA N D D R Y M A S S
Overall length 2 365mm (93.1in)
Overall width 750mm (29.5in)
n,,^,^II L^i^hr 1 1 1 0m m ( 4 3 . 7i n )
vvttEEtudDE,...... 1 645 mm (64.8in)
Groundclearance..................... 135mm (5.3in)
Seatheight...... 700 mm (27"6in)
D r ym a s s . . . . . . . . . 207 kg (456lbs)

ENGINE
T y p e . . . . . . . . . . ". Four-stroke,liquid-cooled, V-twin
OHC,45-degree,
Numberof cylinders z
B o r e. . . . . . . . . . . . . . . . 83.0mm (3.268in)
Stroke.............. 74.4mm (2.929in)
ni^^t^^^6^h+
805cmo(49.1cu. in)
Compression ratio................. 1 0 . 01
:
Carburetor,front................. MIKUNIBD536
re4r.................. MIKUNI8536
A i rc l e a n e r . . . . . . . Non-woven fabricelement
Startersystem. Electric
Lubrication system............. Wetsump
ttl^ ^6^^n
'1200 r 100 r/min

DRIVETRAIN
C l u t c .h. . . . . . . . . . . . . Wet multi-plate
type
Transmission 5-speedconstantmesh
uEdtSt Itt uartcr r l ..,.......,., 1-down,4-up
Primaryreduction.......... 1.886(83/44)
Gearratios, Low.................. 2.461(32113)
2 n d. . . . . . . . . . . . . . . . . . 1.578(30/1e)
3rd................... 1.2OO(24/20)
4 1 h. . . . . . . . . . . . . . . . . . . 0.e56(22/23)
Top................... o.8oo(20/2s)
Finalreductionratio............,..... 3.200(48/15)
Drivechain DID50VM,116 links

CHASSIS
F r o nst u s p e n s i o n . . . . . . . . . . . . . . . . . . . . . . . Invertedtelescopic, coilspring,oil damped
R e a rs u s o e n s i o. .n. . . . . . . . . . . . . . . . . . . . Swingarmtype,coilspring,oil damped
Frontforkstroke............... 140mm (5.5in)
Rearwheeltravel............... 102mm (4.0in)
Caster............. 35"
Trai1.................. 146mm (5.7in)
S t e e r i nagn g l e . . . . . . . . . . . . , . . . 40" (right& left)
Turningradius 3 . 1m ( 1 0 . 2f t )
Frontbrake....... Diskbrake
Rearbrake Drumbrake
Fronttiresize.................. 130/90-16 M/C67H,tubeless or 130/90-1667H,tubeless
R e a rt i r es i z e . . . . . . . . . . . . . , . . . . 150/90-15 MlC74H,tubeless or 150/90-1574H,tubeless

ELECTRICAL
lgnition type...... Electronic ignition(Transisto rized)
lgnition timing... 5" B.T.D.C. at 1 200 rpm
S p a r kp | u 9 . . . . . . . NGKDPRBEA-9 or DENSOX24EPR-U9
Battery............. 12V36.0kc (10Ah)/1oHR
Three-phase A.C.generator
Mainfuse 30A
Fuse................ 10/10/10/10110A
Head1i9ht...................:.............. 12V60/55W(H4)
............,......
Brakelight/Taillight 12V 21/5W
Frontturnsignal1ight........ 1 2 V2 11 5 W . . . . . . . . . . . . . . . . . . .E. -. .0. 3. .2,. 8
. ,3 3
' 1 2 V2 1W . . . . . . . . . . . . . . . . . . . . .P. .-.3. 7 .....
RearturnsignalIight....... 12V21W
Speedometer 1i9h1.................. 12V1.7W
Highbeamindicator light................. 12V1.7W
Turnsignalindicator
light................. 12V3.4W
light...............
Neutralindicator 12V3.4W
Coolant temperaturewarning1ight.................. 12V1.7W
Oilpressurewarninglight................. 12V1.7W

CAPACITIES
Fueltank including reserve............. 13.oL (3.412.9 US/lmpgal)
reserve............ 3.0 L (0.8/0.7US/lmpgal)
Engineoil oil change 1 700ml (1.8/1.5US/lmpqt)
withfilterchan9e............. 2100 ml (2.2/1.8 Us/lmpqt)
Overhaul 2 500 ml (2.6/2.2US/lmpqt)
Coolant............ 1 . 5L ( 1 . 6 / 1 .U
3S/lmpqt)
 12-3
vz800K4('04'M0DEL)

SERVICEDATA
VALVE+ GUIDE U n i t :m m ( i n )
ITEM STANDARD LIMIT
Valve diam. 30
tN. ( 1. 1 8 )
EX. 26
(1.02)
Valveclearance 0 . 0 8- 0 . 1 3
(whencold) I N .& E X . (o.oo3- 0.005)
Valveguideto valvestem 0 . 0 1 0- 0 . 0 3 7
tN. (0.0004 - 0.0015)
clearance
0.030- 0.057
EX. (0.0012- 0.0022)
Valvestemdeflection 0.35
I N .& E X . (0.014)
Valveguide l.D. 5 . 5 0 0- 5 . 5 1 2
I N .& E X . ( 0 . 2 1 6 -5 0 . 2 1 7 0 )
ValvestemO,D. tN. 5.475- 5.490
( 0 . 2 1 5-6 0 . 2 1 6 1 )
5.455- 5.470
EX. (0.2148- 0.2154)
Valvestemrunout 0.05
I N .& E X . (0.002)
Valve head thickness 0.5
I N .& E X . (0.02)
Valvestemend length 3.1
I N .& E X . (0.12)
Valveseatwidth 0 . 9- 1 . 1
I N .& E X . (0.35- 0.043)
Valveheadradialrunout 0.03
I N .& E X . (0.001)
Valvespringfree length 38.3
INNER ( 1. 5 1 )
40.1
OUTER (1.58)
Valvespringtension 6.51- 7.49k1t
INNER ( 1 4 . 3 5 - 1 6 . 5l 1
bs)
a t l e n g t h3 2 . 5m m ( 1 . 2 8i n )
1 2 . 0 9- 1 3 . 9 1k o f
OUTER (26.65- 30.67lti's)
at length36.0mm (1.42in)
12-4 VZ800K4('04-M0DEL)

+ CYLINDERFIEAD
CAMSHAFT Unit:mm (in)
ITEM STANDARD LIMIT
Camheight tN. 35.954- 36.002 35.660
( 1 . 4 1 5 -51 . 4 1 7 4 ) (1.403e)
3 6 . 9 1 9- 3 6 . 9 6 7 36.620
EX. (1.4535- 1.4554) (1.4417)
iournaloil clearance
Camshaft 0.032- 0.066 0.150
(0.0013- 0.0026) (0.0059)
journalholderl.D.
Camshaft No.1Leftside 20.012- 20.025
No.2Rightside (0.787e - 0.7884)
No.1Leftside 25.A12- 25.025
N o . 2R i g h ts i d e (0.e847- 0.9852)
journalO.D.
Camshaft No.1Leftside 1 9 . 9 5 9- 1 9 . 9 8 0
No.2Rightside (0.7858- 0.7866)
No.1 Left side 24.959 - 24.980
No.2 Right side (0.e826- 0.e835)
Camshaftrunout 0.10
(0.004)
Rockerarm l.D. 1 2 . 0 0 -0 1 2 . 0 1 8
I N .& E X . (0.4724- 0.4731)
Rockerarm shaftO.D. 1 1 . 9 6-6 1 1 . 9 8 4
I N .& E X . ( o . 4 7 1 -1 0 . 4 7 1 8 )
headdistortion
Cylinder 0.05
(0.002)
Cylinderheadcoverdistortion 0.05
(0.002)

+ PISTON+ PISTONRING
CYLINDER U n i t :m m ( i n )
ITEM STANDARD LIMIT
pressure
Campression 1 500 kPa 1 1 0 0k P a
( 1 5k g / c m ' , 2 1 p
3si) (11 kg/cm', 156psi)
pressure difference
Campression 200 kPa
(2kglcm",28 psi)
Pistonto cylinderclearance 0.045- 0.055 0j20
( 0 . 0 0 1 -8 0 . 0 0 2 2 ) (0.0047)
Cylinder
bore 8 3 . 0 0 0- 8 3 . 0 1 5 83.085
(3.2677- 3.2683) (3.2711)
Pistondiam. 82.950- 82.965 82.880
(3.2657- 3.2663) (3.2630)
Measureat 15 mm (0.6in)fromthe skirtend.
Cylinder
distortion 0.05
(0.002)
Pistonringfree end gap 8.40
1st A p p r o x1. 0 . 5( 0 . 4 1 3 ) (0,331)
9.44
2nd R A p p r o x1. 1 . 8( 0 . 4 6 5 ) (o.372)
Pistonringend gap 0.20- 0.35 0.50
1st ( 0 . 0 0 8- 0.014) (0.020)
0 . 2 0- 0.35 0.50
2nd ( 0 . 0 0 8- 0.014) (o.o2o)
Pistonringto grooveclearance 0.180
1st (0.0071)
0.150
2nd (o.oo5e)
 vz800K4('04-M0DEL)
12-5

ITEM STANDARD LIMIT

Pistonringgroovewidth 1. 0 1- 1 . 0 3
1st (0.0398- o.0406)
1 . 2 1- 1 . 2 3
2nd (o.0476- 0.0484)
2 . 5 1- 2 . 5 3
oil (0.0988- 0.0e66)
Pistonringthickness 1st 0.970- 0.990
(0.0382- 0.0390)
1 . 1 7 -0 1 . 1 9 0
2nd (0.0461- 0.0469)
Pistonpin bore 20.002- 20.008 23.030
(0.7875- 0.7877) (0.7886)
Pistonoin O.D. 1 9 . 9 9 6- 2 0 . 0 0 0 19.980
(0.7827- 0.7874) (0.7866)

CONROD+ CRANKSHAFT U n i t :m m ( i n )
ITEM STANDARD LIMIT
C o n r o ds m a l l e n dl . D . 2 0 . 0 ' 1-0 2 0 . 0 1 8 20.040
(0.7878- 0.7881) (0.78e0)
Conrodbig endsideclearance 0 . 1 0- 0 . 2 0 0.30
(0.004- 0.008) (0.012)
Conrodbig endwidth 2 1 . 9 5- 2 2 . 0 0
(0.864- 0.866)
Crankoinwidth 2 2 . 1 0- 2 2 . 1 5
(0.870- 0.872)
Conrodbigend oilclearance 0.024- o.o42 0.080
- 0.0017)
( 0.0009 (0.0031)
CrankpinO.D. 40.982- 41.000
( 1 ^ 6 1 3- 51 . 6 1 4 2 )
journaloil clearance
Crankshaft 0.020- 0.050 0.080
(0.0008- 0.0020) (0.0031)
journalO.D.
Crankshaft 47.965 - 47.980
( 1 . 8 8 8 4- 1 . 8 8 e 0 )
journalbearingl. D.
Crankshaft 4 8 . 0 0 0- 4 8 . 0 1 5
( 1 . B B 9-B1 . 8 9 0 4 )
thrustbearingthickness
Crankshaft 1 . 9 2 5- 2 . 1 7 5
(0.0758- 0.0856)
thrustclearance
Crankshaft 0 . 0 5- 0 . 1 0
(0.002- 0.004)
runout
Crankshaft 0.05
(0.002)

OILPUMP
ITEM STANDARD LIMIT
Oil pumpreductionratio 1.364(83144x 34/47)
(at60 "C, 140'F)
Oil pressure Above450 kPa (4.5kg/cm',64 psi)
Below750 kPa (7.5kg/cm',107psi)
at 3 000 r/min
12.6 VZS0oK4('04-M0DEL)

CLUTCH U n i t :m m ( i n )
ITEM STANDARD LIMIT
Clutchcableplay 10-15
( 0 . 4- 0 . 6 )
Driveolatethickness 2 . 9 2- 3 . 0 8 2.62
N o .1 ( 0 . 11 5- 0 . 1 2 1 ) (0.103)
3.42- 3.58 3.12
N o .2 ( 0 . 1 3 5- 0 . 1 4 1 ) (0.123)
Driveolateclawwidth 1 5 . 9- 1 6 . 0 15.1
(0.626- 0.630) (0.594)
Drivenplatedistortion 0.10
(0.004)
Clutchspringfreelength 24.6
N o .1 (0.e7)
23.3
No.2 (0.e2)

RADIATOR+ FAN
ITEM STANDARD LIMIT
Radiatorcap valverelease 1 1 0t 1 5 k P a
pressure ( 1. 1 * 0 . 1 5 k g / c m 21, 5 . 6* 2 . 1 p s i )
Coolingfan thermo-switch ON Approx.105'C (221"F)
operatingtemperature OFF Approx.100'C (212'F)
switch
Enginecoolanttemperature ON Approx.120"C (248'F)
operating
temperature OFF A p p r o x1. 1 3 ' C ( 2 3 5 ' F )

TRANSMISSION Unit:mm (in) Exceptratio

ITEM STANDARD LIMIT
Primaryreductionratio 1.886(83i44)
Finalreductionratio 3.200(48/15)
Gearratios Low 2.461(32113)
2nd 1.578(30/1e)
3rd 1.200(24120)
4th 0.956(22123)
Top 0.800(20t25)
Shiftforkto grooveclearance 0 . 1 0- 0 . 3 0 0.50
( 0 . 0 0 4- 0 . 0 1 2 ) (0.020)
Shiftforkgroovewidth 5 . 5 0- 5 . 6 0
( 0 . 2 1 7- 0 . 2 2 O )
Shiftforkthickness 5.30- 5.40
( 0 . 2 0 9- 0 . 2 1 3 )
Drivechain Type D I Ds O V M
Links 1 1 6 l i n k sE, N D L E S S
20-pitch 319.4
lenqth (12,6)
Drivechainslack 15-25
( 0 . 6- 1 . 0 )
Gearshiftleverheight 50
(2.0)
 vz800K4('04-M0DEL)
12-7

CARBURETOR
SPECIFICATION
ITEM
E-03
Carburetor type M I K U N8I S 3 6 5 5( N o .1 ) M I K U N8I 5 3 6 5 S( N o . 2 )
Boresize 36 mm e-
l . D .N o . 48EF <_

ldle r/min 1 200 * 100 r/min

Fuellevel 7 . 3 t 0 . 5m m 1 5 . 0t 0 . 5m m
(0.29r 0.02in) (0.59* 0.02in)
Floatheight 27.7+1.0mm 9 . 1t 1 . 0m m
( 1 . 0 9t 0 . 0 4i n ) (0.36t 0.04in)
Main jet (M.J.) #lDn #90
Jet needle (J.N.) 5D83 5C43
Needlejet (N.J.) P_ 1M F-LI M
Throttlevalve (Th.V.) # 11 5 <-
Pilotjet (P.J.) #115 #qD
Pilotscrew (P.S) PRE-SET <--
Throttlecableplay 2 . 0- 4 . 0m m (-
( 0 . 0 8- 0 . 1 6i n )

CARBURETOR
SPECIFICATION
ITEM
E-28
Carburetor type M I K U N8I 5 3 6 5 S( N o .1 ) ( N o .2 )
M I K U NBI D S 3 6 S S
Boresize 36 mm +-
l . D .N o . 48FF e-
ldler/min 1 200 * 100 r/min <_
Fuellevel 7 . 3 r 0 . 5m m 1 5 . 0+ 0 . 5m m
(0.29t 0.02in) (0.59t 0.02in)
Float height 2 7 . 7x . 1. 0 m m 9 . 1 t 1 . 0m m
( 1 . 0 9t 0 . 0 4i n ) (0.36t 0.04 in)
Mainjet (M.J.) #luu #gu
Jet needle (J.N.) 5D83 5C43
Needlejet (N.J.) P_ 1M P_L] M
Throttlevalve (Th.V.) #115 <--
Pilotjet (P.J.) #Ll5 #Llu
Pilotscrew (P.S.) PRE-SET(1 and 1/2turnsback) <_
Throttlecable play 2 . 0- 4 . 0 m m (-
( 0 . 0 8- 0 . 1 6i n )
12-8 VZ8o0K4('04-M0DEL)

CARBURETOR
SPECIFICATION
ITEM
E-33
Carburetortype M I K U N8I S 3 6 5 5( N o .1 ) M I K U NB (No.2)
I DS36SS
Boresize 36 mm €-
LD.No. 48EG (-
ldler/min 1 200 t 100r/min (-
Fuellevel 7 . 3 + 0 . 5m m 1 5 . 0r 0 . 5m m
(0.29* 0.02in) ( 0 . 5 9r 0 . 0 2i n )
Floatheight 2 7 . 7+ 1 . 0m m 9 . 1t 1 . 0m m
( 1 . 0 9= 0 . 0 4i n ) ( 0 . 3 6t 0 . 0 4i n )
Mainjet (M.J.) #tuu #gD
Jet needle (J.N.) 5DB3 5C43
Needlejet (N.J.) P. JM F - L TM
Throttlevalve (Th.V.) # 11 5 <-
Pilotjet (P.J.) #Ll5 # Llu
Pilotscrew (P.S.) PRE-SET <-

Throttlecableplay 2 . 0- 4 . 0 m m <_
( 0 . 0 8- 0 . 1 6i n )

CARBURETOR
SPECIFICATION
ITEM
P-37
Carburetor type I 5 3 6 5 S( N o .1 )
M I K U NB (No.2)
M I K U NBI D S 3 6 S S
Boresize 36 mm <_
l . D .N o . 48EK (-
ldlerimin 1 200 + 100r/min <_
Fuellevel 7.3 + 0.5 mm 1 5 . 0t 0 . 5m m
(0.29 r 0.02 in) ( 0 . 5 9t 0 . 0 2i n )
Floatheight 2 7 . 7x . 1. 0 m m 9 . 1* 1 . 0m m
( 1 . 0 9* 0 . 0 4i n ) ( 0 . 3 6t 0 . 0 4i n )
Mainjet (M.J.) # 10 5 #95
Jet needle (J.N.) 5D105-3 5C29-4
Needlejet (N.J.) P-3 P-7
Throttlevalve (Th.V.) # 11 5 <-
Pilotjet (P.J.) #70 #42.5
Pilotscrew (P.S.) PRE-SET(2 and1/2turnsback) PRE-SET(2 and3/8 turnsback)
Throttlecableplay 2 . 0- 4 . 0 m m <--
( 0 . 0 8- 0 . 1 6i n )
 vz800K4('04.M0DEL)
12-9

ELECTRICAL U n i t :m m ( i n )
ITEM SPECIFICATION NOTE
Firingorder 1.2
Sparkplug Type NGK:DPR8EA-9
D E N S OX: 2 4 E P R - U g
Gap 0 . 8- 0 . 9
(0.031- 0.035)
Sparkperformance OverB (0.3)at 1 atm.
Signalcoilresistance 170 - 280 f) G_BI
lgnitioncoil resistance Primary 2-6A @tap-Otap
Plug cap -
Secondary 15-30kO
O taP
Generatorcoil resistance Chanqinq 0 . 2 - 1 . 5f )
Generatorno-loadvoltage
(whenenginecold) Morethan 75 V (AC)at 5 000 r/min
Generator Max.output 250Wat 5 000 r/min
Regulated voltage 13.5- 15.5V at 5 000 r/min
Starterrelayresistance 3-6f2
Battery Type FTX12-BS
designation
Capacity 1 2 V3 6 k C( 1 0 A h ) / 1 0 H R
Standard 1.32at 20 "C (68"F)
S.G.
electrolvte
Fusesize (Ht) *10A
Headlight
(Lo) 10A
Signal 10A
lgnition 104
Tail 10A
Main 30A

WATTAGE Unit:W
SPECIFICATION
ITEM
E-03,28, 33 P37
Headlight HI 60 (-
LO 55 <_
Brake light/Taillight 21t5 <_
Turnsignallight Front 21t5 21
Rear 21 <-
Speedometer light 1.7 (-
Watertemp.warninglight 1.7 (-
Turnsignalindicatorlight 3.4 (-
Highbeamindicator light 1.7 (-
Neutralindicatorlight 3.4 <_
.1 7
Oil pressure
warninglight <_
BRAKE+ WHEEL U n i t :m m ( i n )
ITEM STANDARD LIMIT
Rearbrakepedal
freetravel 20-30
( 0 . 8- 1 . 2 )
Rearbrakepedalheight 60
(2.4)
Brakeliningthickness 1.5
Rear (0.06)
Brakedruml. D. 180.7
Rear ( 7 . 11 )
Brakediscthickness 4 . 5x . 0 . 2 4.O
Front ( 0 , 1 8t 0 . 0 1 ) (0.16)
Brakedisc runout 0.30
(0.012)
Mastercylinderbore 12.700- 12.743
Front ( o . 5 o o -o 0 . 5 0 1 7 )
Mastercylinderpistondiam. 12.657- 12.684
Front (0.4983- 0.4993)
Brakecalipercylinderbore 30.230- 30.306
Front (1.1902-1.1e31)
Brakecaliperpistondiam. 3 0 . 1 5 0- 3 0 . 2 0 0
Front ( 1 . 1 8 7-0 1 . 1 8 9 0 )
Wheelrim runout 2.0
Axial (0.08)
2.O
Radial (0.08)
Wheelaxlerunout 0.25
Front (0.010)
0.25
Rear (0.010)
Wheelrimsize Front J 1 6 x M T 3 . 0 0J, 1 6 M / Cx M T 3 . 0 0
Rear J1sMiCx MT3.50
Tiresize Front 130/90-16 67H,130/90-16 M/C67H
Rear 150/90-1 5 74H,150/90-1 5 MIC74H
Tiretreaddepth 1.6
Front (0.06)
2.O
Rear (0.08)

SUSPENSION Unit:mm (in)

ITEM STANDARD LIMIT NOTE
Frontfork stroke 140
(5.5)
Frontforkdamperfree length 156
(6.1)
Frontforkoil level 154
(Atoutertube 177 mm up position) (6.1)
Rearwheeltravel 102
(4.0)
Swingarmpivotshaftrunout 0.3
(0.01)
 vz800K4('04-M0DEL)
12-11

TIREPRESSURE
N O R M A LR I D I N G
COLDINFLATION S O L OR I D I N G D U A LR I D I N G
T I R EP R E S S U R E
kPa kg/cm' psl kPa kg/cm' psl
FRONT 200 2.00 29 200 2.00 29
REAR 225 2.25 33 225 2.25 33

FUEL+OlL+COOLANT
ITEM SPECIFICATION NOTE
Fueltype Use only unleadedgasolineof at least87 pump
octane(R/2 + Ml2) or 91 octaneor higherratedby
the researchmethod.
GasolinecontainingMTBE (MethylTertiaryButyl E - 0 3 , 2 83, 3
Ether),less than 10 % ethanol,or less than 5 %
methanolwith appropriatecosolventsand corro-
sioninhibitoris oermissible.
Gasolineused should be graded91 octane or
The others
higher.An unleadedgasolineis recommended.
Fueltankincludingreserve 1 3 . 0L
(3.4/2.9US/lmpgal)
reserve 3 . 0L
(0.8/0.7US/lmpgal)
Engineoil type SAE 10W-40,API SF or SG
Engineoil capacity Change 1 7 0 0m l
( 1 . 8 / 1 .U
5 S / l m pq t )
Filterchange 2 1 0 0m l
(2.211.8 US/lmpqt)
Overhaul 2 5 0 0m l
(2.612.2 US/lmpqt)
Frontforkoil type F o r ko i l# 1 5
Frontforkoil capacity B3BmI
(eachleg) (28.3129.5 US/lmpoz)
Brakefluidtvpe DOT4
Coolantcapacity 1 500 ml
(1.6/1.U 3 S / l m pq t )
 CHART
MAINTENANCE
PERTODIC
lnterval km 1 000 6 000 12000 1 80 0 0 24 000
miles 600 4 000 7 500 1 10 0 0 1 50 0 0
Item months 2 12 24 36 48
Air cleaner R
Sparkplugs R R
Tappetclearance
E n g i n eo i l R R R R R
E n q i n eo i l f i l t e r R R
Fuelhose I
Replaceevery4 years.
Engineidlespeed I I
Throttlevalvesynchronization I
I I
(E-33only)
Evaporativeemissioncontrolsystem I I
(E-33only) Replacevaporhoseevery4 years.
PAIR(airsupply)system(E-33only) I
Throttlecableplay I I I
Clutchhose I I I
Replaceevery4 years.
Clutchfluid I I
Replaceevery2 years.
Radiatorhoses I I
Enginecoolant Replaceevery2 years.
Drivechain I I
Cleanand lubricateevery1 000 km (600miles).
Brakes I
Brakehoses I
Replaceevery4 years.
I
Brakefluid I

Replaceevery2 years.
Tire I
Steering I I
Frontforks I I
Rearsuspension I I
Exhaustpipeboltand nut T T T
Chassisboltand nuts T T T T T

NOTE:
l=lnspectand adjust,clean,lubricateor replaceas necessary'
R=Replace
T=Tighten
WIRINGDIAGRAM
iE$g$$3FEEEiF$
F , ^

@ :\ee/
F

=ffi
z IT : i ;t sl
I T t

IT
Ei,ffi..,f
T::::ffi
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