SUZUKI

---~----------- --·-·--·-

SERVICE MANUAL
 FOREWORD GROUP INDEX
This manual contains an introductory description
on SUZUKI DR650SE and procedures for its in-
spection/service and overhaul of its main com-
ponents.
GENERAL INFORMATION
Other information considered as generally known
is not included.
Read GENERAL INFORMATION section to PERIODIC MAINTENANCE
familiarize yourself with outline of the vehicle and
MAINTENANCE and other sections to use as a
guide for proper inspection and service.
This manual will help you know the vehicle bet- ENGINE
ter so that you can assure your customers of your
optimum and quick service.
* This manual has been prepared on the ba-
FUEL AND LUBRICATION
sis of the latest specification at the time SYSTEM
of publication.
If modification has been made since then,
difference may exist between the content CHASSIS
of this manual and the actual vehicle.
* Illustrations in this manual are used to
show the basic principles of operation and
work procedures.
ELECTRICAL SYSTEM
They may not represent the actual vehi-
cle exactly in detail.
* This manual is intended for those who SERVICING INFORMATION
have enough knowledge and skills for ser-
vicing SUZUKI vehicles. Without such
knowledge and skills, you should not at- EMISSION CONTROL
tempt servicing by relying on this manu-
INFORMATION
al only.
Instead, please contact your nearby
authorized SUZUKI motorcycle dealer. DR650SEVIW/X/Y
('97/'98/'99/'00-MODEL)
IMPORTANT
All street-legal Suzuki motorcycles with engine
displacement of 50cc or greater are subject to
Environmental Protection agency emission regul-
lations. These regulations set specific standards
for exhaust emission output levels as well as par-
DR650SEK1 ('01-MODEL)
'------------------~
SUZUKI MOTOR CORPORATION
m
ticular servicing requirements. This manual in-
Motorcycle Service Department
cludes specific information required to properly
inspect and service DR650SE in accordance with
all EPA regulations. It is strongly recommended
that the chapter on Emission Control, Periodic
Servicing and Carburetion be thoroughly
reviewed before any type of service work is per-
formed.
Further information concerning the EPA emission
regulations and U.S. Suzuki's emission control
program can be found in the U.S. SUZUKI EMIS-
SION CONTROL PROGRAM MANUAL/SERVICE
BULLETIN.
HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE
LOOKING FOR:
1. The text of this manual is divided into sections.
2. As the title of these sections are listed on the previ-
ous page as GROUP INDEX, select the section where
what you are looking for belong.
3. Holding the manual as shown at the right will allow
you to find the first page of the section easily.
4. On the first page of each section, its contents are
listed. Find the item and page you need.

COMPONENT PARTS AND WORK TO BE DONE

Under the name of each system or unit, its exploded view is provided with work instruction and
other service information such as the tightening torque, lubricating points and locking agent points .

Example: Front wheel

©
5 G) 0 -ring
@ Housing end (inside)
@ Washer set
© 0-ring (2 pcs )
® Starter motor case
@ Armature
(J) Washer set
@ Brush holder
® Brush spring
@ Housing end (outside)
SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary
for servicing and meaning associated with them respectively.

SYMBOL DEFINITION SYMBOL DEFINITION

•G
Torque control required. Apply THREAD LOCK SUPER

~ Data beside it indicates

specified torque.
"1303".
(99000-32030)
Apply oil. Use engine oil unless Use fork oil.

~ otherwise specified. (99000-99044-1 OG )

Apply SUZUKI SUPER GREASE

I
Apply or use brake fluid.

~ ''A''.
(99000-25030)
Apply SUZUKI SILICONE GREASE. Measure in voltage range.

~ (99000-25100)
~
Apply SUZUKI MOLY PASTE. Measure in resistance range.

~ (99000-25140)
~
Apply SUZUKI BOND "1207B". Measure in current range.
'41201e] (99104-31140)
~

•
Apply THREAD LOCK "1342" . Use special tool.
(99000-32050) 1fooh
Apply THREAD LOCK SUPER
-t113s§J "1360".
(99000-321 30)
 GENERAL INFORMATION

~ -- - -- - - - - CONTENTS - -- -- - -- --
WARNING/CAUTION/NOTE ······· ·· ··· ·························· ·· ····· ····· ······· · 1- 1
GENERAL PRECAUTIONS · · · · · · · · · · · · · · · · · · · · · · · · · · ·· ·· · · · ·· ·· ·· · ·· ·· · · · ·· ·· · ·· ·· · · · · 1- 1
SUZUKI DR650SET ('96-MODEL) · · · · · · · · · · · · · .. · ·· ·· · · · ·· ·· · · · ·.. · · ·· ·· · · · ·· · · · · 1- 3
SERIAL NUMBER LOCATION · · · · · · · ·· · · · · · · · · · · · · ·· ·· ·· · · · ·· ·· · · · ·· ·· · ·· ·· · · · ·· · · · · 1- 3
FUEL AND OIL RECOMMENDATION ·· · · · · · ·· · · · ·· ·· · · · ·· ·· ·· · ·· ·· · · · ·· ·· · · · ·· ·· 1- 3
FUEL ······························································· ····· ···· ········ ······ ·· 1- 3
ENGINE OIL · ·· ·· · ·· ·· · ·· ·· · · · ·· ·· · · · · · · · · · · · · · · · · · · · · · · · · · · ·· ·· · ·· ·· ·· ·· · ·· ·· · ·· ·· ·· · · · ·· 1- 4
BRAKE FLUID ·· · ·· ·· · · · ·· · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · ·· ·· · · · · · ·· ·· ·· · ·· · · · ·· ·· · ·· ·· 1- 4
FRONT FORK OIL · ·· · ·· ·· · · · · · ·· · · · ·· · · · · · · · · · · · · · · · · · · · · · ·· ·· · · · ·· ·· ·· · ·· · · · · · ·· · · · · · 1- 4
BREAK-IN PROCEDURES····· ··· ·· ··· ·················· ·· ·· ················ ··········· 1- 4
INFORMATION LABELS · · ·· · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · · · ·· ·· · ·· ·· ·· · · · ·· ·· · ·· ·· ·· · 1- 5
SPECIF/CA T/ONS ·· · · · ·· ·· · · · ·· · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · · · ·· ·· · · · ·· ·· · · · ·· ·· · ·· ·· ·· · 1- 7
COUNTRY OR AREA · · ·· ·· · ·· · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · ·· ·· · · · ·· ·· ·· · ·· ·· · · · ·· ·· · 1- 9
1-1 GENERAL INFORMATION

WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the
symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special atten-
tion to the messages highlighted by these signal words.

A WARNING
Indicates a potential hazard that could result in death or injury.

I A.CAUTION I
Indicates a potential hazard that could result in vehicle damage.

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

Please note, however, that the warnings and cautions contained in this manual cannot possibly cover
all potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to
the WARNINGS and CAUTIONS stated, you must use good judgement and basic mechanical safety
principles. If you are unsure about how to perform a particular service operation, ask a more ex-
perienced mechanic for advice.

GENERAL PRECAUTIONS
A WARNING
• Proper service and repair procedures are important for the safety of the service mechanic
and the safety and reliability of the vehicle.
• When 2 or more persons work together, pay attention to the safety of each other.
• When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors.
• When working with toxic or flammable materials, make sure that the area you work in is well-
ventilated and that you follow all of the material manufacturer's instructions.
• Never use gasoline as a cleaning solvent.
• To avoid getting burned, do not touch the engine, engine oil or exhaust system during or for
a while after engine operation.
• After servicing fuel, oil , exhaust or brake systems, check all lines and fittings related to the
system for leaks.
 GENERAL INFORMATION 1-2

I A CAUTION I
• If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their
equivalent.
• When removing parts that are to be reused, keep them arranged in an orderly manner so that
they may be reinstalled in the proper order and orientation.
• Be sure to use special tools when instructed.
• Make sure that all parts used in reassembly are clean, and also lubricated when specified.
• When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the specified
type.
• When removing the battery, disconnect the negative cable first and then the positive cable .
When reconnecting the battery, connect the positive cable first and then the negative cable,
and replace the terminal cover on the positive terminal.
• When performing service to electrical parts, if the service procedures not require use of bat-
tery power, disconnect the negative cable the battery.
• Tighten cylinder head and case bolts and nuts, beginning with larger diameter and ending
with smaller diameter, from inside to outside diagonally, to the specified tightening torque.
• Whenever you remove oil seals, gaskets, packing, 0-rings, locking washers, cotter pins, cir-
clips, and certain other parts as specified, be sure to replace them with new ones. Also, be-
fore installing these new parts, be sure to remove any left over material from the mating
surfaces.
• Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larg-
er than required to slip the circlip over the shaft. After installing a circlip, always ensure that
it is completely seated in its groove and securely fitted .
• Do not use self-locking nuts a few times over.
• Use a torque wrench to tighten fastners to the torque values when specified. Wipe off grease
or oil if a thread is smeared with them .
• After reassembly, check parts for tightness and operation.

• To protect environment, do not unlawfully dispose of used motor oil and other fluids: batter-
ies, and tires.
• To protect Earth's natural resouces, properly dispose of used vehicles and parts.
1-3 GENERAL INFORMATION

SUZUKI DR650SET ('96-MODEL)

RIGHT SIDE LEFT SIDE

* Difference between photographs and actual motorcycles depends on the markets.

SERIAL NUMBER LOCATION

The frame serial number or V.I.N . (Vehicle Identification Number) CD is stamped on the right side
of the steering head pipe. The engine serial number 0 is located on the left side of the crankcase.
These numbers are required especially for registering the machine and ordering spare parts.

FUEL AND OIL RECOMMENDATION

FUEL (For U.S.A. model}
1. Use only unleaded gasoline of at least 87 pump octane ( R; M) method or 91 octane or higher
rated by the research method.
2. Suzuki recommends that customers use alcohol free, unleaded gasoline whenever possible.
3. Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted.
4. Use of blended gasoline/alcohol fuel is permitted , provided that the fuel contains not more than
10% ethanol. Gasoline/ alcohol fuel may contain up to 5% methanol if appropriate cosolvents and
corrosion inhibitors are present in it.
5. If the performance of the vehicle is unsatisfactory while using blended gasoline/ alcohol fuel, you
should switch to alcohol-free unleaded gasoline.
6. Failure to follow these guideline could possibly void applicable warranty coverage. Check with
your fuel supplier to make sure that the fuel you intend to use meets the requirements listed above.

FU EL (For Canadian model)

Use only unleaded gasoline of at least 87 pump octane ( R ~ M) m ethod or 91 octane or higher rated
by the researc h method.

FUEL (For the other models)

Gasoline used should be graded 85- 95 octane (Research Method) or higher. An unleaded gasoline
type is recommended.
 GENERAL INFORMATION 1-4

ENGINE OIL (For U.S.A. model)

SUZUKI recommends the use of SUZUKI PERFORMANCE
4 MOTOR OIL or an oil which is rated SE, SF or SG under
the API (American Petroleum Institute) classification system. MULTIGRADE
. .
The viscosity rating is SAE 1 OW/ 40. If an SAE 1 OW/ 40 mo- f • • •

10W 30
tor oil is not available, select an alternate according to the
right chart. 0
c -30 -20 - 10 o 10 20 Jo 40
TEMP.
Of -22 -4 14 32 60 68 86 104
ENGINE OIL (For the other models)
Make sure that the engine oil you use comes under API clas-
sification of SE, SF or SG and that its viscosity rating is SAE
1OW/40. If an SAE 1OW/40 motor oil is not available, select
an alternate according to the right chart.
BRAKE FLUID
Specification and classification: DOT 4

A WARNING
Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufac-
turer, do not use or mix different types of fluid such as silicone-based and petroleum-based fluid
for refilling the system, otherwise serious damage will result.
Do not use any brake fluid taken from old or used or unsealed containers.
Never re-use brake fluid left over from a previous servicing, which has been stored for a long
period .

FRONT FORK OIL

Use fork oil # 10

BREAK-IN PROCEDURES
During manufacture only the best possible materials are used and all machined parts are finished
to a very high standard but it is still necessary to allow the moving parts to " BREAK-IN" before sub-
jecting the engine to maximum stresses. The future performance and reliability of the engine de-
pends on the care and restraint exercised during its early life. The general rules are as follows.

• Keep to these break-in procedures :

Initial 800 km ( 500 miles): Less than 1 /2 throttle

Up to 1 600 km ( 1 000 miles): Less than 3/4 throttle

• Upon reaching an odometer reading of 1 600 km ( 1 000 miles) you can subject the motorcycle
to full throttle operation.
• Do not maintain constant engine speed for an extended time period during any portion of the break-
in. Try to vary the throttle position.
1-5 GENERAL INFORMATION

INFORMATION LABELS

I.D. plate Safety label

(For E-03, 28, 33) (For E-28)
Brake approval label (For E-02, 21, 22, 34, 53)

Regulation
approval label
(For European
markets)

LH VIEW RH VIEW
Manufacturer
plate
(For European
markets)

Engine starting label Starter motor

Engine idle
speed label

Right knuckle cover

Warning safety label

 GENERAL INFORMATION 1-6

Fuel tank
Fuel tank

Vacuum hose
~ ' > . - - - - routing diagram
label (For E-33)

1.D. label

LH VIEW RH VIEW

Seat
Rear fender

Ti re air pressure label

LH VIEW
Manual notice
label Swingarm pivot
Swingarm
1-7 GENERAL INFORMATION

SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length .. .... .. ......... . .. ... ....... ... .... ...... . . 2 345 mm (92 .3 in) ..... E18, 2 2
2 325 mm (91 . 5 in) .... . E18, 2 2 (Low seat)
2 255 mm (88.8 in) ..... Others
2 235 mm (88 .0 in) .... . Others (Low seat)
Overall w idth ..... .. .... ...... ... . ........... . .......... .. 865 mm (34. 1 in)
Overall height .. . .... . ........ ........... .... ....... ....... 1 205 mm (4 7.4 in)
1 165 mm (45 .9 in) ..... (Low seat)
Wheelbase .. .... . .......... .... . .... . ......... . ........... . 1 490 mm (58. 7 in)
1 475 mm (58.1 in) .. .. . (Low seat)
Ground clearance...... ...... ......... ... .. .............. 265 mm (10.4 in)
225 mm ( 8.9 in) .... . (Low seat)
Seat height ... .......... .. .............. ... .. .. ...... .. .. .. 885 mm (34.8 in)
845 mm (33 in) ..... (Low seat)
Dry mass .. .......... ... .. ................ .. ... ... .... ... ... 14 7 kg (324 lbs)

ENGINE
Type .... .... ............... ................... ... ... ......... Four-stroke , air-cooled, with SACS, OHC
Valve clearance (IN) .. .... .. .. ...... .. ......... .. .. .... . 0.08 - 0.13 mm (0 .003 - 0.005 in)
(EX) .... .. .... .. ........... .. .......... 0.17 - 0.22 mm (0 .007 - 0.009 in)
Number of cylinders ...... .. ..... . ............ .. ........ 1
Bore .. ... .. ... . .. .. ........ . ............ ................... ... 100 mm (3.937 in)
Stroke.................... . .... .. ...... .. .......... .. ........ 82 mm (3.228 in)
Piston displacement ... ..... . ........... ................ 644 cm 3 (39.3 cu. in)
Compression ratio ..... .. .... .... .................. ...... 9.5 : 1
Carburetor .. ......... . .......... .. .... .. ... ... . .......... .. BST40, single
Air c leaner ... .. ....... ........... .. .... .. ..... .... .. . .... .. Polyurethane foam elem ent
Starter system .... .. ..... ..... .... .... .. .... .. .... . ..... . Electric
Lubrication system . .... .. ..... .... .. .. ........ .......... Wet sump

TRANSMISSION
Clutch ................. .. ... ... ...... .. .. .... ....... .. . .. ....
Wet multi-plate type
Transmission ............ .. ............... . ................ 5-speed constant m esh
Gearshift pattern .... ................... .. ........ .. ..... 1-down, 4-up
Primary reduction ratio ............ ... .......... ....... 2 . 178 (61 / 28)
Gear ratios, Low ....... ... . ...... . ...... . ...... . .. .. .....
2.416 (29/ 12)
2nd ..... . ................................... 1 .625 (26/16)
3rd ........... .. ............................. 1 .238 (26/ 21)
4th .......... .... .... .. ..... .. ...............1 .000 (21 / 21)
Top .......... .... ..... .. .. ... .... .. .........
0.826 (19/ 23)
Final reduction ratio ................... . .. .............. 2.800 (42/ 15) ..... E03, 28,33
2.733 (41 / 15) .. ... Others
Drive chain .. ........ ..................... .......... ... .. .. D1D525 V9, 110 links
 GENERAL INFORMATION 1-8

CHASSIS
Front suspension ....... .... . ......... ................... Telescopic, coil spring, oil damped
Rear suspension .................. ....................... Link type, coil spring, gas/oil damped,
spring pre-load fully adjustable, compression
damping force adjustable
Front fork stroke ...... . .. ...... .......... ........... . ... 260 mm ( 10. 2 in)
220 mm ( 8. 7 in) ... .. (Low seat)
Rear wheel travel . .. . ...... ... .... ....... ............... 260 mm ( 10. 2 in)
220 mm ( 8. 7 in) .... . (Low seat)
Steering angle ..... . ............ .. ........... ............. 43°
Caster ...... .... .................. .. . ............. ... ........ 28 ° 30'
Trail .................... .... ... ....... ........................ 111 mm (4.37 in)
Turning radius ...... ....... ...... .. ............ ........... 2.5 m (8.2 ft)
Front brake .. ..... .... .. ...... ............ .. ...... . .... .... Disc brake
Rear brake . .............. .... . ...... .. .................. ... Disc brake
Front tire size ..... ..... .. ... . ...... . .. ...... ..... . .. ...... 90/ 90-21 54S, tube type
Rear tire size ............ ........... .... .......... ......... 120/ 90-1 7 64S, tube type

ELECTRICAL
Ignition type ............... . ......... .. ....... . ..... ...... Electronic ignition (CDI)
Ignition timing .................. . .................. .... ... 10° B.T.D .C. at 1 500 rpm
Spark plug ... .... ... ......... ..... ...... .. ... .... .. .... .... NGK CR1 OE or NIPPONDENSO U31 ESR-N
Battery .. ............ .......... .............................. 12V 28.8 kC (8 Ah) / 10 HR
Generator .... . ..... .. ... ...... . .... . .... ... .... . ...... ..... Three-phase A.C. generator
Fuse ...... . . .... . ..... . ... .................. .. ............... 30/ 10/ 1 0A
Headlight .. .... ...... . .............. . ...... . ............... . 1 2V 60/55W
Parking or city light ... . .... . .. ......... ... ........... ... 1 2V 4W ... .. except E03, 24, 28, 33
Turn signal light ... . ........ ... ....... ......... . ...... ... 1 2V 21 W
Tail /brake light ................ . ........... .. ..... . ....... 12V 5/ 21 W
License plate light . ................ . ...... . ....... ...... . 12V 5W
Speedometer light ............ . ........... ... ........... . 1 2V 3W
Neutral indicator light ....... . .. .... . .... ... .. .. ...... .. 1 2V 2W
High beam indicator light.. .. ..... . ............. .. .... 1 2V 2W
Turn signal indicator light ... . ............. . ...... . ... 1 2V 2W

CAPACITIES
Fuel tank, including reserve ......... .. ..... . ..... .. . 12.0 L (3.2/ 2.6 US/ Imp gal) .. ... E33
13.0 L (3.4/ 2 .9 US/Imp gal) . .... Others
reserve ... .... .. ...... . ........ . .. .... . .. .. .... 3.0 L (0.8/ 0. 7 US/Imp gal)
Engine oil, oil change ... ...... . ... ..... ..... ... ... ... . . 2 300 ml (2.4/ 2.0 US/Imp qt)
with filter change .. ............... . .. .... 2 400 ml (2 . 5/ 2. 1 US/Imp qt)
overhaul . ............. . .. ...... .. ............ 2 600 ml (2.7/ 2.3 US/Imp qt)
Front fork oil (each leg).......... .. ..... . ....... .. .... 565 ml (19.1 / 19.9 US/Imp oz)
563 ml ( 19.0/ 19.8 US/Imp oz) . .... (Low seat)
1-9 GENERAL INFORMATION

COUNTRY OR AREA
The series of symbols on the left stand for the countries or area on the right.

SYMBOL COUNTRY or AREA

E-02 U.K.
E-03 U.S.A.
E-04 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-28 Canada
E-33 California (U.S.A.)
E-34 Italy
E-37 Brazil
E-39 Austria
E-53 Spain

E-1 5 and 16 countries are included in E-1 7.)

E-21 and 53 countries are included in E-34.
(
E-39 country is included in E- 18.
 PERIODIC MAINTENANCE

~ - - -- - - - -- CONTENTS - - -- - - - - - - - ,
PERIODIC MAINTENANCE SCHEDULE · ·· · .. ·· · · · ·· ·· · ·· ·· ·· · · · ·· ·· · · · ·· · · · · · .. 2- 1
PERIODIC MAINTENANCE CHART························· ················· ·· 2- 1
LUBRICATION POINTS ··· ······················ ··· ····· ················· ........... 2- 2
MAINTENANCE AND TUNE-UP PROCEDURES · ·· ·· · · · ·· ·· ·.. · · ·· · · · ·· ·· · · · 2- 3
VAL VE CLEARANCE · ·· ·· · · · · .. · · · .. · · · .. · · · · · · ·· · · · ·· ·· · · · ·· ·· · · · ·· ·· ·· · ·· ·· · · · ·· ·· · 2- 3
SPARK PLUGS · · · · ·· · · · · · ·· · · · ·· · · · · · · · · · · · · · · · · · ·· ·· · ·· ·· ·· · ·· ·· ·· · ·· ·· ·· · ·· ·· · · · · · · · · 2- 4
AIR CLEANER ELEMENT · · · · · · · · · · · · · · · · · · · · · ·· ·· · · · ·· ·· · ·· ·· ·· · · · ·· ·· · · · ·· ·· · .. · · · 2- 5
CARBURETOR ·· ·· · ·· · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · ·· ·· · · · ·· ·· · · · ·· ·· · · · ·· ·· ·· · ·· ·· · · · ·· · 2- 6
FUEL LINE · · · ·· · ·· ·· · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·· ·· · ·· ·· ·· · · · ·· ·· · · · ·· ·· · · · ·· · · · ·· · 2- 7
FUEL VAL VE STRAINER · · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · ·· ·· · · · ·· · · · ·· ·· · · · ·· · · · · · · 2- 7
CLUTCH························ ········ ·· ····· ······················· ············ ····· ···· 2- 7
ENGINE OIL AND OIL FILTER · · · · · · · · · · · · · · · · · ·· ·· · · · ·· ·· ·· · ·· ·· · · · ·· · · · ·· ·· · · · · 2- 8
DRIVE CHAIN··········· ·· ········· ································ ·············· ······· 2- 9
BRAKES ·· · ·· ·· · ·· · · · ·· ·· · ·· ·· · ·· ·· · · · ·· · · · · · · · · · · · · · · · · · · · ·· ·· · · · ·· ·· · · · ·· · · · · · ·· · · · ·· · · · · 2-10
TIRES····· ······················· ········ ····················· ··· ······ ··············· ...... 2-12
SPARK ARRESTER · · · · ·· · · · .. · · .... · · · · · · · · · · · · · · · · · · ·· ·· · · · ·· ·· ·· · ·· ·· · · · ·· ·· · ·· ·· · · 2-13
STEERING · · ·· ·· · ·· · · · ·· · · · ·· · · · ·.. · · · · .. · · .. · · · · · · · · · · · · · · · ·· ·· · ·· · · ·· · ·· ·· ·· · ·· ·· · · · ·· ·· 2-13
FRONT FORKS ··········· ······························································ 2 - 14
REAR SUSPENSION······· ································· ··· ····· ··············· ··· 2-14
EXHAUST PIPE AND MUFFLER BOLTS ..................................... 2-14

CHASSIS BOLTS AND NUTS · · · · · · · · · · · · · · · ·· · · · · · ·.. · ·· · · .. · ·· ·· .. · ·· · ·· ·· ·· · · · 2-15

COMPRESSION PRESSURE CHECK .. · · · .. · · ·.. · · · · · .. · ·· ·· .... · ·· · ·· ·· · · · ·· · · · ·· 2-17
OIL PRESSURE CHECK ·· · · · ·· · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · ·· ·· · ·· ·· ·· · ·· ·· · · · ·· ·· · · · 2-18
2-1 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

IMPORT ANT: The periodic maintenance intervals and service requirements have been established
in accordance with EPA regulations. Following these instructions will ensure that the motorcycle
will not exceed emission standards and it will also ensure the reliability and performance of the
motorcycle.
The chart below lists the recommended intervals for all the required periodic service w ork necessary
to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms
of kilometer, miles and time for your convenience.
NOTE:
More frequent servicing may be performed on motorcycles that are used under severe conditions.

PERIODIC MAINTENANCE CHART

INTERVAL: km 1 000 6 000 12 000 18 000 24 000
THIS INTERVAL SHOULD BE JUDGED miles 600 4 000 7 500 11 000 15 000
BY ODOMETER READING OR
MONTHS WHICHEVER COMES FIRST months 2 12 24 36 48
Valve clearance I - I - I
Spark plugs - I R I R
Air cleaner element Clean every 3 000 km (2 000 miles) .
Carburetor idle rpm I I I I I
Fuel line I I I I I
(EVAP hose ... California model only) Replace every 4 years .
Fuel valve strainer - - C - C
Clutch I I I I I
Engine oil R R R R R
Engine oil filter R - R - R
I I I I I
Drive chain
Clean and lubricate every 1 000 km (600 miles).
Brakes I I I I I
- I I I I
Brake hose
Replace every 4 years.
- I I I I
Brake fluid
Change every 2 y ears.
Tires - I I I I
Clean every 6 000 km (4 000 miles).
Spark arrester (For Canada and U .S.A.)
Steering I - I - I
Front forks - - I - I
Rear suspension - - I - I
Exhaust pipe and muffler bolts T - T - T
Chassis bolts and nuts T T T T T

NOTE: I: Inspection and adjust, clean, lubricate or replace as necessary.

R: Replace T: Tighten C: Clean
 PERIODIC MAINTENANCE 2-2

LUBRICATION POINTS
Proper lubrication is important for smooth operation and long life of each working part of the
motorcycle.
Major lubrication points are indicated below.

1§1 Clutch lever holder - - - - - .

and clutch cable

~ Side-stand pivot [i' Drive chain

and spring hook

1§1 Throttle cable- -~ ~-- [11Brake lever holder

~ Brake pedal pivot

NOTE:
* Lubricate exposed parts which are subject to rust, with a rust preventative spray whenever the
motorcycle has been operated under wet or rainy conditions. If the spray is unavailable, use either
motor oil or grease.
* Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.
2-3 PERIODIC MAINTENANCE

MAINTENANCE AND TUNE-UP PROCEDURES

This section describes the servicing procedures for each item
of the Periodic Maintenance requirements .

VALVE CLEARANCE
Inspect Initially at 1 000 km (600 miles, 2 months) and
Every 12 000 km (7 500 miles, 24 months) thereafter.

The valve clearance specification is different for intake and

exhaust valves.
Valve clearance adjustment must be checked and adjust-
ed, 1) at the time of periodic inspection, 2) when the valve
mechanism is serviced, and 3) when the camshaft is dis-
turbed by removing it for servicing.

Valve clearance (when cold):

IN.: 0.08-0.13 mm (0.003-0.005 in)
EX.: 0.17-0.22 mm (0 .007-0.009 in)

NOTE:
Valve clearance is to be checked when the engine is cold.
Both intake and exhaust valves must be checked and ad-
justed when the piston is at Top-Dead-Center (TDC) on
the compression stroke.
• Remove the frame covers, seat and fuel tank.
• Remove the spark plug and valve inspection caps, intake
and exhaust.
• Remove the valve timing inspection plug and magneto
cover cap.
• Turn the crankshaft counterclockwise with the box
wrench to set the piston at T .D.C. on the compression
stroke. (Turn the crankshaft until the "T" line CD on the
magneto rotor is aligned with the center of hole on the
magneto cover .)
• Insert the thickness gauge into the clearance between the
valve stem end and the adjusting screw on the rocker arm .

~ 09900-20803: Thickness gauge

09917-14910: Valve clearance adjusting driver

• If clearance is out of the specification, bring it into the

specified range.
• Securely tighten the lock nut after adjustment is com-
pleted.

IA CAUTION I
Both right and left valve clearances, should be as closely
set as possible.

• Reinstall the spark plug, valve inspection caps, valve tim-

ing inspection plug and magneto cover cap.
 PERIODIC MAINTENANCE 2-4

SPARK PLUGS
Inspect Every 6 000 km (4 000 miles, 12 months) and
Replace Every 12 000 km (7 500 miles, 24 months).

• Remove the spark plugs.

ditJ 09930-10121: Spark plug socket wrench set

---- NGK
ND
Standard
CR10E
U31 ESR-N
Hot type
CR9E
U27ESR-N

CARBON DEPOSIT
Check to see the carbon deposit on the plug.
If the carbon is deposited, remove it with a spark plug cleaner
machine or carefully using a tool with a pointed end.

SPARK PLUG GAP

Measure the plug gap with a thickness gauge if it is correct.
If not, adjust it to the following gap.

Standard
Spark plug gap 0.7 - 0 .8 mm
(0.028 - 0.031 in)

ditJ 09900-20803: Thickness gauge

ELECTRODE'S CONDITION
Check to see the worn or burnt condition of the electrodes.
If it is extremely worn or burnt, replace the plug. And also

1 ! 0.7 - 0 .8 mm
~
replace the plug if it has a broken insulator, damaged thread,
(0.028 - 0.031 in)
etc.

I A CAUTION I
Confirm the thread size and reach when replacing the
plug. If the reach is too short, carbon will be deposited
on the screw portion of the plug hole and engine
damage may result.
2-5 PERIODIC MAINTENANCE

AIR CLEANER ELEMENT

I Clean Every 3 000 km (2 000 miles).

If the air cleaner is clogged with dust, intake resistance will

be increased with a resultant decrease in power output and
an increase in fuel consumption.
Check and clean the element in the following manner.
• Remove the left frame cover.
• Remove the air cleaner case cover by removing screws G).
• Remove the air cleaner element by removing its support
screw @.
• Remove the polyurethane foam element @ from the ele-
ment frame @ .
• Fill a washing pan of a proper size with non-flammable
cleaning solvent. Immerse the element in the cleaning sol-
vent and wash it clean.
• Squeeze the cleaning solvent out of the washed element
by pressing it between the palms of both hands.
• Immerse the element in motor oil, and squeeze the oil out
of the element leaving it slightly wet with oil.
NOTE:
Do not twist or wring the element because it will tear or the
individual cells of the element will be damaged.

I A CAUTION I
Inspect the element carefully for rips, torn seams, etc.
If any damage is noted, replace the element.

• Reinstall the cleaned or new cleaner element in the reverse

order of removal.

·
• When installing the air cleaner element in the cleaner case,
Non-flammable ~ J
make sure that the "UP" mark comes upward. cleaning solvent u.i0 ~
I A CAUTION I ~
e I~
- ..
If driving under dusty conditions, clean the air cleaner
element more frequently. The surest way to acceler- ~•-
~ • @) SAE
ate engine wear is to use the engine without the ele-
ment or to use a ruptured element. Make sure that the
~ I k 1 0 W/40
c:::::::,;OIL
air cleaner is in good condition at all times. Life of the
engine depends largely on this component!

NOTE:
When you clean the air cleaner element, drain water from
the air cleaner drain hose by removing the drain plug.
 PERIODIC MAINTENANCE 2-6

CARBURETOR
Inspect Initially at 1 000 km (600 miles, 2 months) and
Every 6 000 km (4 000 miles, 12 months) thereafter.

THROTTLE CABLE ADJUSTMENT

A twin throttle cable system is used in this motorcycle. Ca-
ble G) is for pulling and c able 0 is for returning. To adjust
the cable play, adjust the returning cable first and then ad-
just the pulling cable .
Returning cable play
The returning cable should be adjusted to have a thread
length@of 3 - 4 mm (0 .12 - 0 .16 in) as shown in the Fig.
If the adjustment is necessary, adjust the thread length in
the following way:
• Loosen the lock nuts @.
• Move the adjuster @) to obtain the thread length @ of 3 - 4
mm (0.12-0.16 in).
• Tighten the lock nuts @ securely.

Pulling cable play

The pulling cable should be adjusted to have a cable play
® of 0 . 5 - 1.0 mm (0.02 - 0.04 in) as shown in the Fig . If
the adjustment is necessary, adjust the cable play in the fol-
lowing way:
• Turn the handlebar all the way to the left .
• Loosen the lock nuts (@ , @ ).
• Turn the adjuster (!) or move the adjuster @ to obtain the
cable play @of 0.5 - 1.0 mm (0 .02-0.04 in).
• Tighten the lock nuts (@ , @) securely .

A WARNING
After the adjustment is completed, check that handle-
bar movement does not raise the engine idle speed and
that the throttle grip returns smoothly and automat-
ically.

IDLE RPM ADJUSTMENT

NOTE:
Make this adjustment when the engine is warm.
• Connect a tachometer .
mil 09900-26006: Tachometer
• Start up the engine and set its speed at anywhere between
1 400 and 1 600 r/min by turning the throttle stop screw G).
• Turn in or out the pilot screw within 1 / 2 turn from the
standard setting, and set it when the engine speed is at
the highest possible level. Engine idle speed:
• After previous adjustment, recheck the idling speed and 1 500 ± 50 r/min ... for Switzerland
adjust to between 1 400 and 1 600 r/ min with throttle 1 500 ± 100 r/min ... for the Others
stop screw if necessary .
2-7 PERIODIC MAINTENANCE

FUEL LINE (EVAP HOSE ... California model only)

Inspect Initially at 1 000 km (600 miles, 2 months) and

Every 6 000 km (4 000 miles, 12 months) thereafter.
Replace Every 4 years.

FUEL VALVE STRAINER

Clean Every 12 000 km (7 500 miles, 24 months).

Refer to page 4-2 for removal procedure.

CLUTCH
Inspect Initially at 1 000 km (600 miles, 2 months) and
Every 6 000 km (4 000 miles, 12 months) thereafter.

• Loosen the lock nut G) and turn the clutch cable adjuster
@ fully in.
• Loosen the lock nut @ and turn the clutch cable adjuster
@ to provide the specified clutch lever play @ .
Clutch lever play@: 10-15 mm (0.4-0.6 in)

• Tighten the lock nuts (G) and @) while holding the ad-
justers (@ and @ ) in positions.

NOTE:
Minor adjustment can be made by the adjuster @ after
loosening the lock nut G). At the same intervals, lubricate
the clutch cable with motor oil
 PERIODIC MAINTENANCE 2-8

ENGINE OIL AND OIL FILTER

(ENGINE OIL)
Replace (Change) Initially at 1 000 km (600 miles, 2
months) and Every 6 000 km (4 000 miles, 12 months)
thereafter.

(OIL FILTER)
Replace Initially at 1 000 km (600 miles, 2 months) and
Every 12 000 km (7 500 miles, 24 months) thereafter.

Oil should be changed while the engine is warm. Oil filter

replacement at the above intervals should be don e together
with engine oil change.
• Keep the motorcycle upright, supported by ja ck or woo-
den block.
• Place an oil pan below the engine and remove the engine
oil drain plug G) and oil fill er cap @ to drain engine oil.
• Remove the oil filter cap by removing the three bolts @.
• Remove the oil filter @) and install the new one .
• Install the oil filter cap and tighten the bolts@ securely.
NOTE:
Before installing the oil filter and oil filter cap, check to be
sure that the spring ® and new 0-rings (@ and (!)) are in-
stalled correctly and apply engine oil lightly to the new 0-
ring @.

• Tighten the oil drain plug G) securely, and pour fresh oil
through the oil filler. The engine will hold about 2 300
ml of oil. Use an API classification of SE, SF or SG oil with
SAE 1 OW/40 viscosity.

(!] Drain plug: 24 N·m (2.4 kg-m, 17.5 lb-ft)

• Install the oil filler cap @.

• Start up the engine and allow it to run for several minutes
at idling speed.
• Turn off the engine and wait about one minute, then check
the oil level through the inspection window ® · If the lev-
el is below mark "F", add oil to the level.

NECESSARY AMOUNT OF ENGINE OIL

Oil change : 2 300 ml (2.4/2.0 US/Imp qt)
Filter change : 2 400 ml (2.5/2.1 US/Imp qt)
Overhaul engine: 2 600 ml (2. 7 /2.3 US/Imp qt)
2-9 PERIODIC MAINTENANCE

DRIVE CHAIN
Inspect Initially at 1 000 km (600 miles, 2 months) and
Every 6 000 km (4 000 miles. 12 months) thereafter.
Clean and Lubricate Every 1 000 km (600 miles).

Visually check the drive chain for the possible defects list-
ed below. (Support the motorcycle by a jack and a wooden
block, turn the rear wheel slowly by hand with the trans-
mission shifted to Neutral.)
* Loose pins * Excessive wear
* Damaged rollers * Improper chain adjustment
* Dry or rusted links * Missing O-ring seals
* Kinked or binding links
If any defects are found, the drive chain must be replaced.

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

CHECKING
• Remove the axle cotter pin (Canada and U .S.A).
• Loosen the axle nut G) .
• Tense the drive chain fully by turning both chain adjusters
(;) .

• Count out 21 pins ( 20 pitches) on the chain and meas-

ure the distance b etween the two points. If the distance
exceeds the service limit, the chain must be replaced.

Service Limit
Drive chain 20-pitch length 319.4 mm
(12.6 in)

ADJUSTING
• Turn both chain adjusters 0 until the chain has 30-45
mm ( 1. 2 - 1 . 8 in) of slack in the middle between engine
and rear sprockets. The number on both chain adjusters
must be at the same number on th e scal e to ensure that
the front and rear wheels are correctly aligned.
• Place the motorcycle on its side-stand for accurate ad-
justment.
• After adjusting the drive chain, tighten the axle nut G) to
the specified torque.

r!J Rear axle nut: 100 N·m (10.0 kg-m, 72.5 lb-ft)
(with cotter pin)
Rear axle nut: 110 N·m (11.0 kg-m, 79.5 lb-ft)
(Self-locking)
 PERIODIC MAINTENANCE 2-10

CLEANING AND LUBRICATING

• Wash the chain with kerosene. If the chain tends to rust
quickly, the intervals must be shortened.
I A CAUTION I
Do not use trichlene, gasoline or any similar fluids:
These fluids have too great a dissolving power for this
chain and, what is more important, they can damage
the "O" -rings (or seals) confining the grease in the bush
to pin clearance. Remember, high durability comes from
the presence of grease in that clearance.
• After washing and drying the chain, oil it with a heavy-
weight motor oil.
I A CAUTION I
* Do not use any oil sold commercially as "drive chain
oil". Such oil can damage the "O" -rings (or seals).
* The standard drive chain is D.I.D. 525 V9, 110 links.
SUZUKI recommends that this standard drive chain
should be used for the replacement.

BRAKES
(BRAKE)
Inspect Initially at 1 000 km (600 miles, 2 months) and
Every 6 000 km (4 000 miles, 12 months) thereafter.

(BRAKE HOSE AND BRAKE FLUID)

Inspect Every 6 000 km (4 000 miles, 12 months). Replace
hoses Every 4 years. Replace fluid Every 2 years.

BRAKE FLUID LEVEL

• Keep the motorcycle upright and place the handlebars
straight.
• Check the brake fluid level by observing the lower limit
lines on the front and rear brake fluid reservoirs .
• When the level is below the lower limit line, replenish with
brake fluid that meets the following specification.
r!I Specification and Classification: DOT 4
A WARNING
The brake system of this motorcycle is filled with a
glycol-based brake fluid. Do not use or mix different
types of fluid such as silicone-based or petroleum-
based. Do not use any brake fluid taken from old, used
or unsealed containers. Never re-use brake fluid left over
from the last servicing or stored for a long period.
A WARNING
Brake fluid, if it leaks, will interfere with safe running
and immediately discolor painted surfaces. Check the
brake hoses and hose joints for cracks and oil leakage
before riding.
2-11 PERIODIC MAINTENANCE

BRAKE PADS
The extent of brake pad wear can be checked by observing
the grooved limit line G) on the pad. When the wear exceeds
the grooved limit line, replace the pads with new ones. (Refer
to pages 5-7 and 5-34.)

I A CAUTION I
Replace the brake pad as a set, otherwise braking per-
formance will be adversely affected.

BRAKE PEDAL HEIGHT

• Loosen the lock nut @ and rotate the push rod @ to lo-
cate brake pedal 5 mm below the top face of the footrest.
• Retighten the lock nut @ to secure the push rod @ in the
proper position.

Brake pedal height @: 5 mm (0.2 in)

AIR BLEEDING THE BRAKE FLUID CIRCUIT

Air trapped in the fluid circuit acts like a cushion to absorb
a large proportion of the pressure developed by the master
cylinder and thus interferes with the full braking performance
of the brake caliper. The presence of air is indicated by
"sponginess" of the brake lever and also by lack of brak-
ing force. Considering the danger to which such trapped air
exposes the machine and rider, it is essential that , after re-
mounting the brake and restoring the brake system to the
normal condition, the brake fluid circuit be purged of air in
the following manner:

• Fill up the master cylinder reservoir to the "UPPER" line.

Replace the reservoir cap to prevent entry of dirt.
• Attach a pipe to the caliper bleeder valve, and insert the
free end of the pipe into a receptacle .

~ Air bleeder valve: 8 N·m (0.8 kg-m, 6.0 lb-ft)

 PERIODIC MAINTENANCE 2-12

• Front brake: Bleed the air from the air bleeder valve.
• Squeeze and release the brake lever several times in rapid
succession and squeeze the lever fully without releasing
it. Loosen the bleeder valve by turning it a quarter of a
turn so that the brake fluid runs into the receptacle; this
will remove the tension of the brake lever causing it to
touch the handlebar grip. Then, close the valve, pump and
squeeze the lever, and open the valve. Repeat this process
until the fluid flowing into the receptacle no longer con-
tains air bubbles.

NOTE:
Replenish the brake fluid in the reservoir as necessary while
bleeding the brake system. Make sure that there is always
some fluid visible in the reservoir.

• Close the bleeder valve, and disconnect the pipe. Fill the
reservoir with brake fluid to the "UPPER" end of the in-
spection window.

IA CAUTION I
Handle brake fluid with care: the fluid reacts chemically
with paint, plastics, rubber materials etc.

• The only difference between bleeding the front and rear

brakes is that the rear master cylinder is actuated by a
pedal.

TIRES

Inspect Every 6 000 km (4 000 miles, 12 months).

TIRE TREAD CONDITION

Operating the motorcycle with excessively worn tires will
decrease riding stability and consequently invite a danger-
ous situation . It is highly recommended to replace a tire when
the remaining depth of tire tread reaches the following
specification .

Tire tread depth limit: FRONT & REAR 3.0 mm (0.12 in)
2-13 PERIODIC MAINTENANCE

TIRE PRESSURE
If the tire pressure is too high or too low, steering will be
adversely affected and tire wear increased . Therefore , main-
tain the correct tire pressure for good roadability or shorter
tire life will result. Cold inflation tire pressure is as follows.

COLD INFLATION SOLO RIDING DUAL RIDING

TIRE PRESSURE kPa kg/cm 2 psi kPa kg/cm 2 psi
FRONT 150 1 .50 22 175 1. 75 25
REAR 175 1. 75 25 200 2.00 29

I A CAUTION I

The standard tire fitted on this motorcycle is 90/90-21

54S for front and 120/90-17 64S for rear. The use of
tires other than those specified may cause instability.
It is highly recommended to use a SUZUKI Genuine Tire.

SPARK ARRESTER (For U.S.A. and CANADA)

I Clean Every 6 000 km (4 000 miles).

If the muffler is clogged with carbon particles, exhaust

resistance will be increased with a resultant decrease in pow-
er output.
• Remove the drain plugs.
• Start the engine and rev it to blow out the accumulated
carbon particles.
• Turn off the engine and wait until the muffler cools, then
replace the drain plugs and tighten them securely.

STEERING
Inspect Initially at 1 000 km (600 miles, 2 months) and
Every 12 000 km (7 500 miles, 24 months) thereafter.

Taper roll er type bearings are used on the steering system

for better handling. Steering should be adjusted properly for
smooth turning of handlebars and safe running. Overtight
•~w+ A ' ; : ~ ~~~•

steering prevents smooth turning of the handlebars and too

~---·
;'>_

loose steering will cause poor stability. Check that there is

no play in the front fork assembly by supporting the machine
so that the front wheel is off the ground, with the wheel
straight ahead, grasp the lower fork tubes near the axle and
pull forward. If play is found, perform steering bearing ad-
justment as described in page 5-20 of this manual.
 PERIODIC MAINTENANCE 2-14

FRONT FORKS

Inspect Every 12 000 km (7 500 miles. 24 months).

Inspect the front forks for oil leakage, scoring or scratches

on the outer surface of the inner tubes. Replace any defec-
tive parts, if necessary . (Refer to page 5-14.)

REAR SUSPENSION

Inspect Every 12 000 km (7 500 miles. 24 months).

Inspect the rear shock absorber for oil leakage and check
that there is no play in the swingarm assembly.

EXHAUST PIPE AND MUFFLER BOLTS

Tighten Initially at 1 000 km (600 miles, 2 months) and
Every 12 000 km (7 500 miles, 24 months) thereafter.

• Remove the right frame cover.

• Tighten the exhaust pipe bolts G), muffler connection bolt
@ and muffler bolts G) to the specified torque.
~ Exhaust pipe bolt/Muffler connection bolt/
Muffler bolt: 26 N·m (2.6 kg-m, 19.0 lb-ft)
2-15 PERIODIC MAINTENANCE

CHASSIS BOLTS AND NUTS

Tighten Initially at 1 000 km (600 miles, 2 months) and
Every 6 000 km (4 000 miles, 12 months) thereafter.

Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2- 16
for the locations of the following nuts and bolts on the motorcycle.)

Item N-m kg-m lb-ft

G) Steering stem head nut 90 9.0 65.0
@ Front fork upper clamp bolt 29 2.9 21.0
@ Front fork lower clamp bolt 26 2 .6 19.0
@ Front fork cap bolt 23 2 .3 16.5
® Front axle 65 6.5 47.0
® Front axle holder nut 10 1.0 7.0
(J) Handlebars clamp bolt 23 2.3 16.5
® Front brake master cylinder mounting bolt 10 1.0 7.0
® Front brake caliper mounting bolt 26 2.6 19.0
@ Front brake caliper pad mounting bolt 18 1.8 13.0
@ Brake hose union bolt (Front & Rear) 23 2.3 16.5
@ Air bleeder valve (Front & Rear) 8 0.8 6.0
@) Brake disc bolt (Front & Rear) 23 2.3 16.5
@ Rear brake caliper pad mounting bolt 18 1.8 13.0
@ Rear brake master cylind er mounting bolt 10 1.0 7.0
@ Rear brake master cylinder rod lock nut 18 1.8 13.0
@ Front footrest bracket mounting bolt 39 3 .9 28.0
@ Rear footrest bracket mounting bolt 23 2.3 16.5
@ Swingarm pivot nut 77 7.7 55.5
® Rear shock absorber mounting bolt
55 5.5 40.0
(Upper & Lower)
® Rear cushion lever/rod mounting nut 100 10.0 72.5
@ Rear cushion lever mounting bolt 80 8 .0 58.0
@ Rear axle nut (with cotter pin) 100 10.0 72.5
@ Rear axle nut (Self-locking) 110 11 .0 79.5
@ Rear sprocket nut/bolt 27 2.7 19.5
PERIODIC MAINTENANCE 2-16
2-17 PERIODIC MAINTENANCE

COMPRESSION PRESSURE CHECK

The compression of a cylinder is a good indicator of its internal condition.
The decision to overhaul the cylinder is often based on the results of a compression test. Periodic
maintenance records kept at your dealership should include compression readings for each main-
tenance service.

COMPRESSION PRESSURE SPECIFICATION

Standard
850 kPa
Approx. (8.5 kg/cm 2 )
120 psi

Low compression pressure can indicate any of the following conditions:

* Excessively worn cylinder wall
* Worn-down piston or piston rings
* Piston rings stuck in grooves
* Poor seating of valves
* Ruptured or otherwise defective cylinder head gasket

COMPRESSION TEST PROCEDURE

NOTE:
* Before testing the engine for compression pressure, make sure that the cylinder head bolts are
tightened to the specified torque values and valves are properly adjusted.
* Have the engine warmed up by idling before testing.
* Be sure that the battery used is in fully-charged condition.

Remove the parts concerned and test the compression pres-

sure in the following manner.
• Remove the spark plug.
• Fit the compression gauge in the plug hole, while taking
care that the connection tight.
• Keep the throttle grip in full-open position.
• While cranking the engine a few seconds with the start-
er, and record the maximum gauge reading as the com -
pression of that cylinder.

~ 09915-64510: Compression gauge

09915-63310: Adaptor
 PERIODIC MAINTENANCE 2-18

OIL PRESSURE CHECK

Check periodically the oil pressure in the engine to judge roughly the condition of the moving parts.

OIL PRESSURE SPECIFICATION

Above 30 kPa (0.3 kg/cm2 , 4.3 psi)

at 3 000 r/min., Oil temp. at 60°C (140°F)
Below 70 kPa (0.7 kg/cm2 , 10 psi)

If the oil pressure is lower or higher than the specification, the following causes may be considered.

LOW OIL PRESSURE

* Oil leakage from the oil passage way
* Damaged O-ring
* Defective oil pump
* Combination of above items

HIGH OIL PRESSURE

* Used a engine oil which is too high viscosity
* Clogged oil passage way
* Combination of above items

OIL PRESSURE TEST PROCEDURE

Check the oil pressure in the following manner.
• Remove the oil pressure inspection plug.
• Install the oil pressure gauge in the position shown in the
figure.
• Warm up the engine as follows:
Summer 10 min. at 2 000 r/mi n .
Winter 20 min. at 2 000 r/min.
• After warming up, increase the engine speed to 3 000
r/min. (with the engine tachometer), and read the oil pres-
sure gauge.

iitJ 09915-74510: Oil pressure gauge

09900-26006: Tachometer
 ENGINE

~ - - - -- -- -- CONTENTS- - - - - - -- ----.
ENGINE COMPONENTS REMOVABLE WITH THE ENGINE
IN PLACE ······ ···· ················--··· ·--· ···--········ ··· ····· ·········· ··················· 3- 1
ENGINE REMOVAL AND REINSTALLATION ............. ............ ........ 3- 2
ENGINE REMOVAL ··· ···· ····· · .. ······ ··· ··································· ··· ····· 3- 2
ENGINE REINSTALLA TION ........ ....... .... ... ....... · ····· · · ····· .. ····· ··· .. · 3- 6
ENGINE DISASSEMBLY ·· ·· · ·· ·· · · · ·· ·· · · · ·· ·· · · · · · ·· · · · · · ·· · · · · · · · · · · · · · · · · · · · · · ·· · · · 3- 9
ENGINE COMPONENTS INSPECTION AND SERVICE · · · · · · · · · · · · · · · ·· ·· · 3-17
CYLINDER HEAD COVER· ......... ··· .. ..... .. ·· ·· ·· .... .... ················ ·· ... . 3-17
ROCKER ARM ·· · · · · · · · · ·· · ·· ·· ·· · ·· · · · ·· ·· · · · ·· ·· · · · · · ·· · · · · · ·· ·· · · · · ·· · · · ·· · · · · · ·· · ·· · 3-18
CYLINDER HEAD·· ···· ·· ·····-- ·· ··· ·· ····· ····· ······· ····· ········ ······ ······ ··· ··· 3-19
VALVE ·· ····· ·········· ·····--·· ·--·· ·· ······· --·· · -- ···· ··--··· ......... .... ... .. ... .. ... . 3-20
CAMSHAFT/AUTOMATIC DE-COMP. ASSEMBLY ......... ···· .. ... .. 3-25
CYLINDER · · · · · · · · · · · · · · · ·· · ·· · · · ·· ·· · ·· ·· · ·· ·· ·· · ·· ·· · · · · · ··· · · · · · ·· · · · · · · · ·· · · · · · · · · · · ·· 3-27
PISTON · · · · · · · · · ·· · · · ·· · · · · · · · · ·· · ·· ·· · · · ·· · · · ·· ·· · · · ·· ·· · · · · ·· · ·· · · · · ·· · · · · · · · ·· · · · ·· · · · · · 3-27
PISTON RING·· ···· ···· ···· ·· ·········· ·· ············ ··· ······· ··· ·· ··· ········· ···· ·· ·· 3-28
CONROD · · · · · · · · · · · · · · · · · · · ·· · ·· · · · ·· ·· · · · ·· · · · ·· ·· · · · ·· · · · · ·· · ·· · · · · ·· ·· · · · · · ·· · · · ·· · · · · · 3-29
CRANKSHAFT · · · · · · ·· · · · · · · · · ·· · · · ·· ·· · ·· · · · ·· ·· ·· · ·· ·· · · · · · ·· ·· · · · · · ·· · · · · · · ·· · · · ·· · · · 3-30
BALANCERSHAFT AND GEAR .. .. .. .... ... ............ ......................... 3-31
CLUTCH · ·· · · ·· · · · · · · ·· · · · · · · · · · · ·· ·· · ·· ·· · · · ·· ·· · ·· ·· ·· · · · ·· · .. · · · · ·· · · · · ·· · · · · · ·· · · · ·· · · · 3-32
STARTER CLUTCH ··· ···· ·· ·· ······ ·· ··· ··· .. ··· ···· ····· ··-- ······· ················· 3-34
TRANSMISSION · · · · · · · · · · · · · · · ·· ·· · ·· ·· · · · ·· · · · ·· ·· ·· · ·· ·· ·· · · · · · · · · · · · · · · · · · · · · · · · · · · 3-36
OIL NOZZLE AND OIL JET .. ·· · .. ·· .. .. · ·· .. .. · ·· .. · ·· ·· .. .. · · · .. · · · ·· .. · · · ·· · · · · · 3-40
CRANKCASE BEARINGS · ·· · ·· · · · ·· ·· · ·· ·· · · · ·· ·· · ·· ·· ·· · · · · · · · ·· · · · ·· · · · · ·· · · · ·· · 3-40
OIL FILTER · · · · · · · · · · · · · · · · · · · · · · · · · ·· ·· · ·· ·· · ·· ·· · · · ·· ·· · · · ·· ·· · · · · · ·· ·· · · · · · · · · · · · · · · · · · 3-41
GENERA TOR · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · ·· · · · ·· ·· · ·· ·· · · · ·· ·· · · · · · · · ·· ·· · ·· · · · · · · · · · · · · 3-41
ENGINE REASSEMBLY · · · · · · · · · · · · · ·· ·· · ·· ·· · ·· ·· · ·· ·· ·· · ·· ·· ·· · · · · · · · ·· · · · · · · · · · · · · · · · 3-42
3-1 ENGINE

ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE

The parts listed below can be removed and reinstalled without removing the engine from the frame.
Refer to the page listed in each section for removal and reinstallation instructions.

ENGINE CENTER
Refet to page
Cam drive chain tensioner ................... 3- 9 and 57
Cylinder head cover ................. . .... ... .. 3-10 and 56
Camshaft/auto-decompression ........ . .... 3-10 and 55
Cylinder head .... .... ........... .... ... .. ........ 3-10 and 54
Cylinder ....................... ...... .... ... ........ 3-11 and 54
Piston . ...................................... ... ... .. 3-11 and 53
Starter motor ... . ............ ........ ............. 3-11 and 52
Cam drive chain ......................... . ....... 3-14 and 48

ENGINE LEFT SIDE ENGINE RIGHT SIDE

Refer to page Refer to page
Engine sprocket ..... . .............. .. 3- 5 and 7 Clutch cover ........ ......... ......... 3-13 and 50
Generator cover ..................... 3- 9 and 52 Clutch .. ........................... ...... 3-13 and 49
Starter torque limiter ... ............ 3-11 and 52 Primary driven gear ...... .......... . 3-14 and 49
Starter idle gear ................ . .... 3 - 11 and 52 Primary drive gear .................. 3-14 and 48
Generator rotor ..... . ..... ...... ... ..3-11 and 51 Oil pump driven gear ............... 3- 14 and 48
Starter clutch .......... . .............. 3-34 and 35 Oil pump assembly ................. 3- 14 and 48
Starter gear . .... .. ... ..... ..... .. .....
3-1 2 and 51 Neutral position indicator
Gearshift shaft ........ . .......... . ...3- 13 and 4 7 switch .. . ............. . ............. ..... 3-1 4 and 4 7
Gearshift cam pawl and cam Oil filter ....... ... .... . .. ................ 3-41
driven gear ..... ... .. ...... .. ...... .... 3- 13 and 46
 ENGINE 3-2

ENGINE REMOVAL AND

REIN ST ALLATl ON
ENGINE REMOVAL
Before taking the engine out of the frame, thoroughly clean
the engine with a suitable cleaner. The procedure of engine
removal is sequentially explained in the following steps:

• Remove the oil drain plug G) to drain out engine oil.

• Remove the frame covers. (Refer to page 5-1.)
• Remove the seat. (Refer to page 5- 1.)

• Remove the battery holder plate @ .

• Disconnect the battery 8 lead wire @ from the battery

terminal.
• Remove the fuel tank. (Refer to page 4-3.)

• Remove the oil cooler hose mounting bolts.

• Remove the oil cooler holder with cooler by removing the

mounting bolts.
3-3 ENGINE

• Remove the exhaust pipe bolts.

I
• Remove the exhaust pipe by loosening the connection
bolt.

• Disconnect the pick-up coil/power source coil lead wire

coupler G). G)

• Disconnect the generator coil and neutral position indi-

cator switch lead wires.

• Disconnect the spark plug caps.

 ENGINE 3-4

• Disconnect the throttle cables and starter (choke) cable.

• Disconnect the air vent hose.

• Remove the carburetor by loosening the mounting clamp

screws.

• Disconnect the clutch cable by removing the cable lever.

• Disconnect the starter motor lead wire CD and crankcase

breather hose @ .

• Remove the left front footrest @.

• Remove the engine sprocket cover @ and gearshift lever
®·
3-5 ENGINE

• Remove the engine sprocket bolts while depressing the

rear brake pedal.
• Remove the engine sprocket.

NOTE:
If it is difficult to remove the engine sprocket, loosen the
rear axle nut and then adjust the chain adjusters to provide
additional chain slack.

• Remove the engine ground wire and lead wire clamp.

• Remove the engine mounting nuts, bolts, spacers and

brackets.

• Remove the engine through the left side of the frame.

 ENGINE 3-6

ENGINE REINSTALLATION
Reinstall the engine in the reverse order of engine removal.
• Insert the two long bolts from left side. Install the brackets, spacers, bolts and nuts properly , as
shown in the following illustration.

NOTE:
The engine mounting nuts are self-locking. Once the nut has been removed, it is no longer of any use.
Be sure to use new nuts and tighten them to the specified torque.

~~ ~ . •"<'., .><'J .
e If r V I,, ,, ="" ,~™ ;

@
LENGTH
ITEM N·rn kg-rn lb-ft Bolt CD 53 mm (2. 1 in)
@ 40 4.0 29.0 Bolt @ 100 mm (3.9 in)
@©@® 65 6.5 47.0 Bolt @ 235 mm (9.3 in)
®® 40 4.0 29.0 Bolt @ 235 mm (9.3 in)
(8) 23 2.3 16.5 Bolt @ 130 mm (5.1 in)
Spacer ® 27 mm ( 1. 1 in)
Spacer (J) 65 mm (2.6 in)
3-7 ENGINE

• Apply THREAD LOCK SUPER " 1303" to the engine

sprocket mounting bolts and tighten them to the speci-
fied torque.

,tf1S 99000-32030: THREAD LOCK SUPER "1303"

~ Engine sprocket bolt: 6 N·m (0.6 kg-m, 4 .5 lb-ft)

• Install the oil cooler hoses to the clutch cover and cylinder
head correctly.

I A CAUTION I
Replace the 0 -rings G) with new one to prevent oil
leakage.

• Tighten the oil cooler hose securing bolts to the speci-

fied torque.

t!Jrn1 cooler hose bolt: 10 N·m (1.0 kg-m, 7.0 lb-ft)

• Tighten the front footrest bolts to the specified torque .

t!J Front footrest bolt: 39 N·m (3 .9 kg-m, 28.0 lb-ft)

• After remounting the engine, route the wiring harness-

es, cables and hoses properly by referring to the sections,
for wire routing, cable routing and hose routing . (Refer
to pages 7- 12 through 7- 18.)
 ENGINE 3-8

• Adjust the following items to the specification.

* Throttle cable play ................. (Refer to page 2-6.)
* Idling adjustment ................... (Refer to page 2-6.)
* Clutch cable play ................... (Refer to page 2- 7.)
* Drive chain slack .................... (Refer to page 2-9 .)

• Pour 2.6 L (2.7/2.3 US/Imp qt) of engine oil SAE 10W/40

graded SE, SF or SG into the engine after overhauling
engine.
* Start up the engine and allow it run for several minutes
at idle speed. About five minutes after stopping engine,
check oil level.
If the level is below the "F" mark, add oil until the level
reaches the "F" mark.

Change 2 300 ml (2.4/ 2 .0 US/Imp qt)

Filter change 2 400 ml (2.5/2 . 1 US/Imp qt)
Overhaul 2 600 ml (2.7/2 .3 US/Imp qt)
3-9 ENGINE

ENGINE DISASSEMBLY
• Remove the oil pipe by removing the mounting bolts.

• Remove the cam drive chain tensioner by removing the

bolts.

• Remove the two spark plugs.

• Remove the generator cover by removing the bolts.

NOTE:
When removing the cylinder head cover, the piston must
be at top dead center on the compression stroke.
Align "TOP" line G) on the generator rotor with index mark
@ on the crankcase.
 ENGINE 3-10

• Remove the valve inspection caps (Intake and Exhaust)

by removing the bolts.

• Loosen the cylinder head cover bolts in the ascending ord-

er numbers and remove the cylinder head cover.

• Flatten the lock washer and remove the camshaft sprocket

bolts.
• Remove the sprocket and camshaft/ auto-decompression
assembly.

NOTE:
The cam chain tensioner bolt (i) is to be removed only when
disassembling the engine.

I A CAUTION I
Do not drop camshaft drive chain. pin, C-ring or sprock-
et into the crankcase.

• Remove the cylinder head by removing the bolts and nuts

diagonally.

NOTE:
If it is
difficult to remove the cylinder head, gently pry it off
while tapping the finless portion of the cylinder head with
a plastic hammer. Be careful not to break the fins.
3-11 ENGINE

• Remove the cylinder by removing the nuts .

IA CAUTION I
If tapping with a plastic hammer is necessary , do not
break the fins.

• Place a clean rag over the cylinder base to prevent the

piston pin circlips from dropping into crankcase. Remove
the piston pin circlips with a long-nose pliers .
• Remove the piston by removing the piston pin.

• Remove the clutch cable holder and starter motor.

• Remove the starter torque limiter G) and starter idle gear

@ with shaft.

• Loosen the generator rotor bolt with the 36 mm offset

wrench.

NOTE:
Do not remove the generator rotor bolt after loosening the
bolt. The generator rotor bolt is used in conjunction with
the rotor remover, when removing the generator rotor.
 ENGINE 3-12

• Remove the generator rotor with the special tool.

S 09930-33720: Rotor remover

• Remove the key (D.

• Remove the starter gear 0 .
• Remove the thrust washer @.

• Remove the ring nut with the special tools, then remove
the spacer.

S 09917-23711: Ring nut socket wrench

09910-20116: Conrod holder

• Remove the crankcase oil separator@) by removing the

screws.
• Remove the spacer ®·

• Remove the gearshift cover by removing the bolts.

3-13 ENGINE

• Extract the gearshift shaft CD and remove th e cam driven

gear 0 by removing the screws @.

NOTE:
When removing the cam driven gear, do not lose gearshift
pawl @, pin ® and spring ®·

• Remove the clutch cover by removing the bolts.

• Remove the clutch pressure plate by removing the bolts

diagonally.

• Remove the clutch drive and driven plates.

• Flatten the lock washer and remove the clutch sleeve hub
nut with the special tool.

~ 09920-53740: Clutch sleeve hub holder

 ENGINE 3-14

• Remove the thrust washer CD and primary driven gear as-

sembly.
• Remove the thrust washer @.

• Remove the primary drive gear nut with the special tool.

~ 09910-20116: Conrod holder

I A CAUTION I
I This nut has left-hand thread nut.

• Remove the cam drive chain @ and key @.

• Remove the idle gear and oil pump driven gear by remov-
ing the circlips.

~ 09900-06107: Snap ring pliers

• Remove the oil pump by removing the mounting screws.

• Remove the breather cover.

• Remove the neutral position indicator switch.

NOTE:
Do not loose the switch contact® and spring®·
3-15 ENGINE

• Remove the crancase securing bolts.

• Separate the crankcase into 2 parts, right and left with
the crankcase separating tools.

~ 09920-13120: Crankcase separating tool

09910-33210: Crankshaft installer attachment

NOTE:
Fit the crankcase separating tool, so that the tool plate is
parallel with the end face of the crankcase.

I A CAUTION I
The crankshaft and transmission components must re-
main in the right crankcase half . This is necessary be-
cause the gearshift cam stopper is mounted on the right
crankcase half and will be damaged if the transmission
components remain in the left half.

• Remove the gearshift cam stopper.

• Remove the gearshift fork shafts and gearshift forks.

• Remove the gearshift cam.

• Remove the driveshaft assembly and countershaft as-

sembly.
 ENGINE 3-16

• Align the punched marks on the balancer drive gear and

driven gear.
• Remove the balancershaft assembly.

• Remove the crankshaft from the crankcase by using a

crankshaft remover.

~ 09920-13120: Crankshaft remover

(Crankcase separating tool)

• Remove the oil sump filter cover G) by removing the bolts.

• Remove the oil sump filter @.
3-17 ENGINE

ENGINE COMPONENTS INSPECTION AND SERVICE

CYLINDER HEAD COVER SERVICE

I.A CAUTION I
Be sure to identify each removed part as to its loca-
tion, and lay the parts out in groups designated as "Ex-
haust", "Inlet", so that each will be restored to the
original location during assembly.

• Remove the intake and exhaust rocker arm shaft set bolts.

• Remove the intake and exhaust rocker arm shafts with

a 6 mm bolt.
 ENGINE 3-18

CYLINDER HEAD COVER DISTORTION

After removing sealant from the fitting surface of the cylinder
head cover, place the cylinder head cover on a surface plate
and check for distortion with a thickness gauge.

Service Limit: 0.05 mm (0.002 in)

If the distortion exceeds the limit, replace the cylinder head

cover.

ROCKER ARM SHAFT O.D.

Measure the diameter of rocker arm shaft with a micrometer.

Standard: 11 .973-11.984 mm (0.4714-0.4718 in)

mm 09900-20205: Micrometer (0-25 mm)

ROCKER ARM I.D.

When checking the rocker arm , the inside diameter of the
rocker arm and wear of the camshaft contacting surface
should be checked .

Standard: 12.000 - 12.018 mm (0.4724-0.4731 in)

mm 09900-20605: Dial calipers

ROCKER ARM AND SHAFT REASSEMBLY

• Apply SUZUKI MOLY PASTE to the rocker arm shafts.

~99000-25140: SUZUKI MOLY PASTE

• Install the rocker arms and shafts as shown in the illus-

tration .

• Tighten the rocker arm shaft set bolts G) to the specified

torque.

~ Set bolt G) : 28 N·m (2.8 kg-m, 20.0 lb-ft)

NOTE:
Use new gasket on the set bolts G).

CD
3-19 ENGINE

CYLINDER HEAD SERVICE

• Remove the cam chain tensioner by removing the bolt.

• Compress the springs with the special tools.

• Remove the valve cotters from the valve stem .

lmiJ 09916-14510: Valve spring compressor

09916-14910: Valve spring compressor attachment
0991 6-84511 : Tweezers

• Remove the valve spring retainer, inner spring and outer

spring.
• Remove the vlave stem from the other side.

• Remove the oil seal with a long-nose pliers .

• Remove the spring seat.

NOTE:
Removal of the valves completes ordinary disassembling
work. If valve guides have to be removed for replacement
after inspecting related parts, carry out the steps shown in
valve guide servicing.

CYLINDER HEAD DISTORTION

Decarbonize the combustion chamber.
Check the gasketed surface of the cylinder head for distor-
tion with a straightedge and thickness gauge, taking a clear-
ance reading at several places as indicated. If the largest
reading at any position of the straightege exceeds the limit,
replace the cylinder head.

Service Limit: 0.05 mm (0.002 in)

 ENGINE 3-20

VALVE FACE WEAR

Measure the thickness d) and, if the thickness is found to
have been reduced to the limit, replace the valve.

NOTE:
Visually inspect each valve for wear of its seating face.
Replace any valve with an abnormally worn face.

Service Limit: 0.5 mm (0.02 in)

VALVE STEM RUNOUT

Support the valve with "V" blocks, as shown, and check
its runout with a dial gauge. The valve must be replaced if
the runout exceeds the limit.

Service Limit: 0.05 mm (0.002 in)

·mm 09900-20701: Megnetic stand

09900-20606: Dial gauge (1/100 mm)
09900-21304: V-block (100 mm)

VALVE HEAD RADIAL RUNOUT

Place the dial gauge at right angles to the valve head, and
measure the valve head radial runout.
If it measures more than limit, replace the valve.

Service Limit: 0.03 mm (0 .001 in)

VALVE STEM DEFLECTION

Lift the valve about 10 mm (0.39 in) from the valve seat.
Measure the deflection in two directions, "X" and "Y" per-
pendicular to each other, by positioning the dial gauge as
shown. If the deflection measured exceeds the limit speci-
fied below, then determine whether the valve or the guide
should be replaced with a new one.

Ei1 09900-20606: Dial gauge (1/100 mm)

09900-20701 : Magnetic stand
Service Limit
Intake and exhaust valves: 0.35 mm (0 .014 in)
3-21 ENGINE

VALVE STEM WEAR

If the valve stem is worn down to the limit, when measured
with a micrometer, where the clearance is found to be in
excess of the limit indicated, replace the valve; if the stem
is within the limit, then replace the guide. After replacing
valve or guide, be sure to recheck the clearance.
S 09900-20205: Micrometer (0-25 mm)
Standard
IN.: 5.475-5.490 mm (0.2156 - 0.2161 in)
EX.: 5.455-5.470 mm (0.2148-0.2154 in)

VALVE GUIDE SERVICING

• Remove the valve guide toward the camshaft side with
the valve guide remover.

S 09916-44910: Valve guide remover/installer

NOTE:
* Discard the removed valve guide subassemblies.
* Only oversized valve guides are available as replacement
part. (Part No. 11115-32£70.)

• Re-finish the valve guide holes in cylinder head with the

reamer G) and handle @ .

S 09916-34580: Valve guide reamer

09916-34541: Reamer handle

• Fit a ring to each vlave guide. Be sure to use new rings

and valve guides.
• Oil the stem hole, too, of each valve guide and drive the
guide into the guide hole with the valve guide installer.

~ 0991 6-44910: Valve guide remover /installer

I A CAUTION I
Failure to oil the valve guide hole before driving the new
guide into place may result in a damaged guide or head.

• After fitting the valve guides, re-finish their guiding bores

with the reamer @ and handle @ . Be sure to clean and
oil the guides after reaming.

lmtJ 09916-34550: Valve guide reamer

09916-34541: Reamer handle
 ENGINE 3-22

VALVE SEAT WIDTH

• Coat the valve seat uniformly with Prussian blue. Fit the
valve and tap the coated seat with the valve face in a
rotating manner, in order to obtain a clear impression of
the seating contact. In this operation, use the valve lap-
per to hold the valve head.
• The ring-like dye impression left on the valve face must
be continuous-without any break. In addition, the width
of the dye ring, which is the visualized seat "width", must
be within the specification.
Standard
Valve seat width@: 0.9-1.1 mm (0 .035-0.043 in)
If either requirement is not met, correct the seat by servic-
ing it as follows.

VALVE SEAT SERVICING

The valve seats for both intake and exhaust valves are
machined to two different angles. (The seat contact surface
is cut 45° .)
INTAKE EXHAUST
-----------
45° N-615 N-615
15° N-615 N-121

(For U.S.A.)
Valve seat cutter (N-615) Valve seat
Valve seat cutter (N-121)
Solid pilot (N-140- 7 .0)

(For the Others)

ltitJ 09916-24900: Valve seat cutter set
09916-20610: Valve seat cutter (N-121)
09916-24210: Valve seat cutter (N-615)
(N-140-7.0) : Solid pilot
NOTE:
The vlave seat contact area must be inspected after each
cut.
• Insert the solid pilot with a slight rotation, seat the pilot
snugly. Install the 45 ° cutter and T-handle.
• Using the 45° cutter, descale and clean up the seat with
one or two turns.
• Inspect the seat by the previously described seat width
measurement procedure. If the seat is pitted or burned ,
additional seat conditioning with the 45° cutter is re-
quired .
NOTE:
Cut the minimum amount necessary from the seat to pre-
vent the possibility of the valve stem becoming too close
to the rocker arm for correct valve contact angle.
3-23 ENGINE

If the contact area is too high on the valve, or if it is too Contact area too high and too
wide, use the 15° cutter to lower and narrow the contact wide on face of valve
area.

If the contact area is too low or too narrow, use the 45 ° Contact area too low and too
cutter to raise and widen the contact area. narrow on face of va lve

• After the desired seat position and width is achieved, use

the 45 ° cutter very lightly to clean up and burrs caused
by the previous cutting operations.

I A CAUTION I
DO NOT use lapping compound after the final cut is
made. The finished valve seat should have a velvety
smooth finish and not a highly polished or shiny finish.
This will provide a soft surface for the final seating of
the valve which will occur during the first few seconds
of engine operation.

• Clean and assemble the head and valve components. Fill

the intake and exhaust ports with gasoline to check for
leaks. If any leaks occur, inspect the valve seat and face
for burrs or other things that could prevent the valve from
sealing.

A WARNING
Always use extreme caution when handling gasoline.

NOTE:
After servicing the valve seats, be sure to check the valve
clearance after the cylinder head has been reinstalled. (Refer
to page 2-3.)
 ENGINE 3-24

VALVE STEM END CONDITION

Inspect the valve stem end face for pitting and wear. If pit- _l
ting or wear of the stem end face are present, the valve stem G)
end should be resurfaced, providing that the length G) will 7
not be reduced to less than 2. 7 mm (0. 11 in). If this length
becomes less than 2. 7 mm (0.11 in), the valve should be
replaced. After installing a valve whose stem end has been
ground off as above, check to ensure that the face 0 of
the valve stem end is above the cotters @ .

VALVE SPRING
The force of the coil spring keeps the valve seat tight.
Weakened spring result in reduced engine power output, and
often account for the chattering noise coming from the valve
mechanism.
Check the springs for proper strength by measuring their
free length and also by the force required to compress them.
If the spring length is less than the service limit, or if the
force required to compress the spring does not fall within
the range specified, replace both inner and outer springs as
a set.
S 09900-20102: Vernier calipers 5 .9-6.7 kg
,0,
Valve spring free length
Service Limit
INNER : 34.4 mm ( 1.35 in)
OUTER: 38.1 mm (1.50 in)
Valve spring tension
Standard
INNER : 5.9 - 6.7 kg/27.5 mm (13.0-14.8 lbs/1.1 in)
OUTER: 13.8-15.8 kg/31.0 mm (30 .4-34.8 lbs/1.2 in)

VALVE AND VALVE SPRING REASSEMBLY

• Install the valve spring seat G) . Be careful not to confuse
the lower seat with the spring retainer @.

• Lubricate each seal with oil, and fit the seals onto each
guide.

IA CAUTION I
I Do not reuse the oil seals.
3-25 ENGINE

• Insert the valves, with their stems coated with (SUZUKI

MOLY PASTE) all around and along the full stem length
without any break.
Similarly oil the lip of the stem seal.

~99000-25140: SUZUKI MOLY PASTE

IACAUTION I
When inserting each valve, take care not to damage
the lip of the stem seal.

• Install the valve springs, making sure that the close-pitch

end CD of each spring goes in first to rest on the head.
The coil pitch of both inner and outer springs vary: the
Towards
pitch decreases from top to bottom, as shown in the il-
lustration . 9
Head

• Put on the valve spring retainer, and using the valve lifter,
press down the springs, fit the cotter halves to the stem
end , and release the lifter to allow the cotter @ to wedge
in between retainer and stem . Be sure that the rounded
lip @ of the cotter fits snugly into the groove @ in the
stem end.

ditJ 09916-14510: Valve spring compressor

09916- 14910: Valve spring compressor attachment
09916-84511 : Tweezers

I A CAUTION I
Be sure to locate each spring and valve to their origi-
nal positions.

CAMSHAFT /AUTOMATIC DE-COMP.

ASSEMBLY

I A CAUTION I
Do not attempt to disassemble the camshaft/automatic
de-comp. assembly. It is not serviceable.
 ENGINE 3-26

AUTOMATIC DE-COMP.
Move the automatic de-comp. weight by hand to inspect
if operating smoothly.
If it does not smoothly must be replaced with a new cam-
shaft/automatic de-comp. assembly.

CAMSHAFT
The camshaft should be checked for runout and also for wear
of cams and journals if the engine has been noted to produce
abnormal noise or vibration or to lack output power. Any
of these malconditions could be caused by a worn camshaft.

CAMSHAFT CAM WEAR

Worn-down cams are often the cause of mistimed valve
operation resulting in reduced output power.
The limit of cam wear is specified for both intake and ex-
haust cams in terms of cam height (8), which is to be meas-
ured with micrometer.
Replace the camshaft if found it worn down to the limit.

S 09900-20202: Micrometer (25-50 mm)

Cam height (8)

Intake cam : 33.410 mm (1.3154 in)
Service Limit
Exhaust cam: 33.400 mm (1.3150 in)

CAMSHAFT JOURNAL WEAR

Determine whether each journal is worn down to the limit
or not by measuring camshaft journal oil clearance with the
camshaft installed. Use plastigauge to read the clearance,
which is specified as follows:

Camshaft journal oil clearance

Service Limit: 0.150 mm (0.0059 in)

• Tighten the cylinder head cover bolts evenly and diagonal-

ly to the specified torque.

r!J Cylinder head cover bolt: 10 N·m ( 1.0 kg-m, 7 .0 lb-ft)

Gm 09900-22301 : Plastigauge
NOTE:
To properly measure the oil clearance with plasti-gauge, all
gasket material must be removed from fitting surfaces of
cylinder head and cover. Do not apply SUZUKI BOND
No. 12078 until after the oil clearance has been determined.
3-27 ENGINE

If the camshaft journal oil clearance measured exceeds the

limit, measure the outside diameter of camshaft.
Replace either the cylinder head set or the camshaft if the
clearance is incorrect.

GEJ 09900-20205: Micrometer (0-25 mm)

Camshaft journal O.D .: 21 .959-21.980 mm
(Right & Center) (0.8645-0.8654 in)
Camshaft journal O.D. : 17.466-17.484 mm
(Left) (0.6877-0 .6883 in)
CAMSHAFT RUNOUT
Measure the runout with a dial gauge. Replace the camshaft
if the runout exceeds the limit.

Service Limit: 0.10 mm (0.004 in)

GEJ 09900-20701: Magnetic stand
09900-20606: Dial gauge (1/100 mm)
09900-21304: V -block

CYLINDER DISTORTION
Check the gasketed surface of the cylinder for distortion with
a straightedge and thickness gauge, taking a clearance read -
ing at several places as indicated. If the largest reading at
any position of the straightedge exceeds the limit, replace
the cylinder.

Service Limit: 0.05 mm (0 .002 in)

CYLINDER BORE
Inspect the cylinder wall for nicks, scratches or other
damage.

mil 09900-20508: Cylinder bore gauge set

09900-20513: Gauge rod
Standard : 100.000-100.015 mm (3.9370-3.9376 in)

PISTON DIAMETER
Using a micrometer, measure the piston outside diameter
at the place 21 mm (0.8 in) from the skirt end as shown
in Fig. If the measurement is less than the limit, replace the
piston.

mil 09900-20204: Micrometer (75-100 mm) 2 1 mm

__i
Service Limit: 99.880 mm (3.9323 in)
 ENGINE 3-28

PISTON-CYLINDER CLEARANCE
As a result of the previous measurement, if the piston to
cylinder clearance exceeds the limit, replace both cylinder
and piston.

Service Limit: 0.120 mm (0.0047 in)

PISTON RING-GROOVE CLEARANCE

Using a thickness gauge, measure the side clearance of the
1st and 2nd rings. If any of the clearances exceeds the limit,
replace both piston and piston rings.

~ 09900-20803 : Thickness gauge

09900-20205: Micrometer (0-25 mm)
Piston ring-groove clearance
Service Limit
1st : 0.180 mm (0.0071 in)
2nd: 0.150 mm (0.0059 in)
Piston ring groove width
Standard
1st : 1.23 - 1.25 mm (0.048-0.049 in)
2nd: 1.21-1.23 mm (0 .047-0.048 in)
Oil : 2.81-2.83 mm (0.110-0.111 in)
Piston ring thickness
Standard
1st : 1.170-1.190 mm (0.0461-0.469 in)
2nd: 1.150 - 1.170 mm (0.0453-0.0461 in)

NOTE:
Using a soft-metal scraper, decarbon the crown of the
piston. Clean the ring grooves similarly.

PISTON RING FREE END GAP AND

PISTON RING END GAP
Before installing piston rings, measure the free end gap of
each ring using vernier calipers.
Next, fit the ring in the cylinder, and measure each ring end
gap using a thickness gauge.
If any ring has an excess end gap, replace the ring.

~ 09900-20102: Vernier calipers

Piston ring free end gap
Service Limit
1st : 10.8 mm (0.43 in)
2nd: 9.1 mm (0.36 in)
~ 09900-20803: Thickness gauge
Piston ring end gap
Service Limit
1st: 0.50 mm (0.020 in)
2nd: 1.00 mm (0 .039 in)
3-29 ENGINE

PISTON PIN AND PIN BORE

Using a caliper gauge, measure the piston pin bore inside
diameter, and using a micrometer measure the piston pin
outside diameter. If the difference between these two meas-
urements is more than the limits, replace both piston and
piston pin.

am 09900-20605: Dial calipers

09900-20205: Micrometer (0-25 mm)
Piston pin bore
Service Limit: 23.030 mm (0.9067 in)

Piston pin O. D.
Service Limit: 22.980 mm (0.9047 in)

CONROD SMALL END I.D.

Using a caliper gauge, measure the conrod small end inside
diameter.

am 09900-20605: Dial calipers

Service Limit: 23.040 mm (0.9071 in)

If the conrod small end bore inside diameter exceeds the

limit, replace conrod.

CONROD DEFLECTION AND

CONROD BIG END SIDE CLEARANCE
Wear on the big end of the conrod can be estimated by
checking the movement of the small end of the rod. This
method can also check the extent of wear on the parts of
the conrod's big end.

am 09900-20701: Magnetic stand

09900-20606: Dial gauge (1/100 mm)
09900-21304: V-block

Service Limit: 3.0 mm (0.12 in)

 ENGINE 3-30

Push the big end of the conrod to one side and measure the
side clearance with a thickness gauge.

Imm 09900-20803: Thickness gauge

Service Limit: 1.00 mm (0.039 in)

Where the limit is exceeded, replace crankshaft assembly

or reduce the deflection and the side clearance to within the
limit by replacing the worn parts - conrod, big end bearing
and crank pin etc.

CRANKSHAFT RUNOUT
Support the crankshaft with "V" blocks as shown , with the
two end journals resting on the blocks.
Position the dial gauge, as shown, and rotate the crankshaft
slowly to read the runout .
Correct or replace the crankshaft if the run out is greater than
the limit.

Imm 09900-20606: Dial gauge (1/100 mm)

09900-20701: Magnetic stand
09900-21304: V-block (100 mm)

Service Limit: 0.05 mm (0.002 in)

3-31 ENGINE

BALANCERSHAFT AND GEAR

G) Balancershaft
@ Key
@ Inner race
@ Spring (6 pcs)
® Pin (3 pcs)
® Driven gear
0 Washer
® Washer
® Circ lip

DISASSEMBLY
• Remove the circlip G) and washers (@ , @ ). G)
• Remove the balancer driven gear.

®
®

• Remove the 6 springs and 3 pins.

Inspect the crank balancershaft wear or damage.

 ENGINE 3-32

REASSEMBLY
• When installing the inner race, align the pin with groove
of inner race.

• When installing the balancer driven gear, align the two

punched marks as shown in photo.

• When installing the 6 springs G) and 3 pins @ , set the

pins @ to the triangle position as shown in photo.

G)

CLUTCH DRIVE PLATE

Measure the thickness of each drive plate with vernier
calipers. Replace drive plates found to have worn down to
the limit.

em 09900-20102: Vernier calipers

Standard
Thickness No.1 & No.2: 2 .9 - 3.1 mm (0.11-0.12 in)
Measuring t hickness
Service Limit
Thickness No.1 & No.2: 2.6 mm (0.10 in)
3-33 ENGINE

CLUTCH DRIVEN PLATE

Measure each driven plate for distortion with a thickness
gauge. Replace driven plates which exceed the limit.

~ 09900-20803: Thickness gauge

Service Limit: 0.1 mm (0.004 in)

Measuring distortion

CLUTCH SPRING FREE LENGTH

Measure the free length of each coil spring with a vernier
calipers, and determine the elastic strength of each. Replace
any spring not within the limit.

~ 09900-20102: Vernier calipers

Service Limit: 33.0 mm (1.30 in)

Measuring clutch spring

CLUTCH RELEASE BEARING

Inspect the release bearing for any abnormality, particular-
ly cracks, to decide whether it can be reused or should be
replaced . Smooth engagement and disengagement of the
clutch depends much on the condition of this bearing .

CLUTCH RELEASE PINION AND RACK

Rotate the clutch release pinion by hand to inspect for a
smooth roration. If a large resistance is felt to rotation, in-
spect the pinion and rack for damage or wear. If the defect
is found, replace them as a set.
 ENGINE 3-34

ST ARTER CLUTCH

G) Starter clutch
0 Bearing
@ Starter idle gear
@ Idle gear shaft
@ Starter torque limiter

I @I ITEM I N·m
25
kg-m
2.5
lb-ft
18.0
CD

DISASSEMBLY
• Remove the starter clutch gear.

• Remove the 3 bolts with a 6 mm hexagon wrench and

36 mm offset wrench.
3-35 ENGINE

STARTER CLUTCH
lnspcet the stater clutch wear or damage.

REASSEMBLY
• Apply THREAD LOCK SUPER "1303" to the bolts and
tighten them to the specified torque.

~ 99000-32030: THREAD LOCK SUPER "1303"

~Bolt: 25 N·m (2.5 kg-m, 18.0 lb-ft)

Check that the rotor G) turns in the direction of the arrow

mark @ on the rotor while holding the starter gear, and that
the rotor never turns in the opposite direction of the arrow
mark.

STARTER TORQUE LIMITER

I A CAUTION I
Do not attempt to disassemble the starter toque limiter.
It is not serviceable.

Check the slip torque with the special tools .

Slip torque: 42 - 64 N·m (4.2-6.4 kg-m, 30.5-46.5 lb-ft)

S 09930-7311 0: Starter torque limiter holder

09930-73120: Starter torque limiter socket

Set the starter torque limiter to the special tools and vise
as shown in the photograph.
If the slip torque is not within the specification, replace the
starter torque limiter with a new one.
 ENGINE 3-36

TRANSMISSION
• Disassemble the transmission gears as shown in the illustration.

G) Low driven gear

@ Top driven gear
@ 3rd driven gear
@) 4th driven gear
® 2nd driven gear
® Driveshaft
CZ) Countershaft/Low drive gear
® Top drive gear
® 3rd drive gear ®
@ 4th drive gear
@ 2nd drive gear

2ND DRIVE GEAR DISASSEMBLY

• Remove the 2nd drive gear by using the gear puller and
appropriate attachment.

~ 09913-60910: Gear puller

3-37 ENGINE

SHIFT FORK-GROOVE CLEARANCE

Using a thickness gauge, check the shifting fork clearance
in the groove of its gear.
The clearance for each of the three shifting forks plays an
important role in th e smoothness and positiveness of shift-
ing action.

Shift fork-Groove clearance

Standard: 0 .10-0.30 mm (0.004-0 .012 in)
Service Limit: 0.50 mm (0.020 in)

If the clearance checked is noted to exceed the limit speci-

fied, replace the fork or its gear, or both .

dmJ 09900-20803: Thickness gauge

09900-20102: Vernier calipers

Checking clearance

Shift fork groove width

Standard: 5.0-5.1 mm (0.197-0.200 in)

Checking groove width

Shift fork thickness

Standard: 4.8-4.9 mm (0.189-0.193 in)

Checking t hickness
 ENGINE 3-38

REASSEMBLY
Assemble the countershaft and driveshaft, in the reverse
order of disassembly. Pay attention to following points:

NOTE:
Before installing the gears, lightly coat moly paste or engine
oil to the driveshaft and countershaft.

~ 99000-25140: SUZUKI MOLY PASTE

• When installing a new circlip, pay attention to the direc-

tion of the circlip. Fit it to the side where the thrust is as

r{""
shown in the illustration.

I A CAUTION[

* Never reuse a circlip. After a circlip has been removed

from a shaft, it should be discarded, and a new cir- Sharp edge
clip must be installed .
* When installing a new circlip, care must be taken not
to expand the end gap larger than required to slip the
circlip over the shaft.
* After installing a circlip, always insure that it is com-
pletely seated in its groove and securely fitted.

2ND DRIVE GEAR

• Press-fit 2nd drive gear G) onto the countershaft.

NOTE:
Before reassembling, coat the internal face of the 2nd drive
gear with THREAD LOCK SUPER "1303".

~ 99000-32030: THREAD LOCK SUPER "1303"

CD
NOTE:
Take care not to smear 4th drive gear with THREAD LOCK
SUPER "1303".

NOTE:
* After mounting the 2nd drive gear, check that 4th drive
gear spins smoothly by moving it with your fingers.
* This procedure may be performed only twice before shaft
replacement is required.

3RD DRIVEN GEAR BUSHING

• When installing the gear bushing onto the driveshaft, align
the oil hole 0 of the shaft with the bushing oil hole @.
3-39 ENGINE

NOTE:
In reassembling the transmission, attention must be given to the locations and positions of washers
and circlips. The cross sectional view given here will serve as a reference for correctly mounting
the gears, washers and circlips.
 ENGINE 3-40

OIL NOZZLE AND OIL JET

REMOVAL
• Remove the oil nozzle G) and oil jet @ of the right
crankcase.

I A CAUTION]
The removed oil jet @ should be replaced with a new
one.

INSPECTION
Check the oil nozzle for any damage or clogging.

REASSEMBLY
• Install the new oil jet @ as shown in the illustration.

• Install the oil nozzle G).

• Apply THREAD LOCK SUPER "1 303" to the bolt and
tighten to the specified torque .

. . 99000-32030: THREAD LOCK SUPER "1303"

~ Bolt: 10 N·m (1.0 kg-m, 7.0 lb-ft)

CRANKCASE BEARINGS Play Play

Inspect the play of the crankcase bearings by hand while
they are in the left and right crankcase. Rotate each crank-
case bearing inner race by hand to inspect for abnormal noise
and smooth rotation. Replace the bearing if there is anything
unusual.

NOTE:
When reassembling the bearing retainer @, apply a small
quantity of THREAD LOCK "1342 " to the bearing retainer
screws and bolts.
3-41 ENGINE

OIL FILTER
• Remove the oil filter cap.
• Remove the oil filter G).
• Install the new oil filter.

NOTE:
Before installing the oil filter and oil filter cap, check to be
sure that the spring @ and new 0 -rings (@ and @ ) are in-
stalled correctly.

GENERATOR
• Remove the generator coil.

• Remove the bearing by removing the circlip.

 ENGINE 3-42

ENGINE REASSEMBLY
The engine is reassembled by carrying out the steps of dis-
assembly in the reverse order, but there are a number of
steps that demand special descriptions or precautionary
measures.

NOTE:
Apply engine oil to each running and sliding part before reas-
sembling.

OIL SEALS
• Fit the respective oil seals to the crankcase, clutch cover
and gearshift cover.
• Apply SUZUKI SUPER GREASE" A" to the lip of oil seals.

~ 99000-32030: SUZUKI SUPER GREASE "A"

I A CAUTION I
Replace the oil seals with new ones every disassem-
bly to prevent oil leakage.
3-43 ENGINE

CRANKSHAFT

G) Crankshaft (R)
@ Conrod
@ Crank pin
@) Crankshaft (L)
® Crankshaft bea ring nut
® Balancer drive gear
0 Primary drive gear

CD

®
®

ITEM N·m kg-m lb-ft

® 80 8.0 58.0
® 100 10.0 72.5

• Decide the width between the webs referring to the figure

below when rebuilding the crankshaft. 'I

STD width between webs: 71 .0±0.1 mm

(2.795±0.004 in)

• When mounting the crankshaft in the crankcase, it is 71.0 ± 0.1 mm I

(2.795 ± 0.004 in)--l
necessa ry to pull its right end into the crankcase.

dm1 09910-32812: Crankshaft installer

09910-32830: Attachment
09910-32860: Attachment

I.A CAUTION I
Never fit the crankshaft into the crankcase by striking
it with a plastic hammer.
Always use the special tool, otherwise crankshaft align-
ment accuracy will be affected.
 ENGINE 3-44

BALANCERSHAFT
• When installing the balancershaft, align the punched
marks (G), 0 ) on the balancer drive gear and driven gear.

GEARSHIFT MECHANISM

CD Gearshift arm stopper

@ Gearshift shaft
@ Gearshift lever
@ Cam stopper plate
® Cam stopper
® Cam stopper bolt
(J) Gearshift cam
@ Gearshift fork No . 1
® Gearshift fork No. 2
@) Gearshift fork No.3
® Pawl lifter N·m kg-m lb-ft
@ Cam guide
19 1.9 13.5
@ Cam driven gear
3-45 ENGINE

• After installing the countershaft assembly and driveshaft

assembly into the right crankcase, fit the gearshift forks
(D, @ and @ into the gearshift fork grooves.

CD For Topdriven gear (No. 1)

@ For 4th driven gear (No.2)
@ For 3rd drive gear (No.3)
NOTE:
Three kinds of gearshift forks, (D, @ and @ are used. They
resemble each other very closely in external appearance and
configuration.
Carefully examine the illustration for correct installing posi-
tions and directions.

• Position the gearshift cam as shown in photo so that the

gearshift fork shafts can be installed easily.

NOTE:
When replacing the gearshift cam stopper bolt @, apply a
small quantity of THREAD LOCK "1342" to the threaded
part of the bolt.

~ 99000-32050: THREAD LOCK "1342"

• Hook the gearshift cam stopper spring .

 ENGINE 3-46

CRANKCASE
When reassembling the crankcase pay attention to the fol-
lowing points:
• Remove sealant material on the mating surfaces of right
and left halves of crankcase and thoroughly remove oil
stains.
• Apply SUZUKI BOND NO.12078 uniformly to the mating
surface of the left half of the crankcase, and assemble
the cases within few minutes.

~99104-31140: SUZUKI BOND NO.1207B

• Fit the dowel pins G) on the right half as shown in photo.

• Apply engine oil to conrod big end of the crankshaft and
all parts of the transmission gears. G)

• After the crankcase bolts have been tightened, check if

driveshaft and countershaft rotate smoothly.

t.!J Crankcase bolt: 11 N·m (1.1 kg-m, 8.0 lb-ft)

• If a large resistance is felt to rotation, try to free the shafts
by tapping the driveshaft or countershaft with a plastic
hammer.
;I

CAM DRIVEN GEAR

• Install the gearshift pawls into the cam driven gear. The
large shoulder @ must face to the outside as shown in
the illustration.
• When installing the cam guide @ and pawl lifter @, ap-
ply a small quantity of THREAD LOCK "1342" to the
securing screws @.

~ 99000-32050: THREAD LOCK "1342"

3-47 ENGINE

GEARSHIFT SHAFT
• Fit a spring to the gearshift shaft correctly.
• Install the gearshift shaft. Match the center teeth of the
gear on the gearshift shaft with the center teeth on the
cam driven gear as shown.

NOTE:
When replacing the gearshift arm stopper (D, apply a small
quantity of THREAD LOCK SUPER "1303 " to its threaded
part and tighten it to the specified torque. (See page 7-24.)

~ 99000-32030: THREAD LOCK SUPER "1303"

• Fit the dowel pins @ and new gasket.

• Fit the gearshift cover and tighten the bolts diagonally.

NOTE:
After the gearshift cover and g earshift lever have been fit-
ted, confirm that gear change is normal while turning the
countershaft and driveshaft. If gear change is not obtained,
it means that assembly of gears or installation of gearshift
fork is incorrect. If this is the case, disassemble and trace
the mistake.
.. -
NEUTRAL POSITION INDICATOR SWITCH
• Install the neutral position indicator switch spring @ and
switch contact @ .

• Install the neutral position indicator switch with two

screws .
• Install the breather cover.
 ENGINE 3-48

OIL PUMP
• Before mounting oil pump, apply engine oil to the sliding
surfaces of the case, outer rotor, inner rotor and shaft.
• Apply a small quantity of THREAD LOCK "1342" to the
oil pump mounting screws .

,tS 99000-32050: THREAD LOCK "1342"

• Tighten the oil pump mounting screws.

• Fix the oil pump driven gear with the circlip.

NOTE:
After installing the oil pump driven gear, rotate the pump
gear by hand to see if it turns smoothly.

• Fix the idle gear with the circlip.

CAM DRIVE CHAIN AND PRIMARY DRIVE

GEAR
• Engage the cam drive chain.
• Fit the key G) in the key slot on the crankshaft, then in-
stall the primary drive gear and nut.

• Tighten the primary drive gear nut to the specified tor-

que with the special tool.

~ 09910-20116: Conrod holder

t!J Primary drive gear nut: 100 N·m (10.0 kg-m, 72.5 lb-ft)
NOTE:
This nut has left-hand thread nut.
3-49 ENGINE

CLUTCH

lease arm
CD Clutchrel ase pinion
0 Clutch re ease rack
@ Clutch relessure plate
@ Clutch pre hub
® Clutch sleeve
® Washer seat
d washer
0 Concave ·ven plate
® Clutch dr_1 plate, 1 pc)
No. 2 (Thicker
® Stopper ring No.2 (1 pc)
@) Cluteh drive plate
late No. 1 (7 pcs)
~
"" Clutch driven P
drive plate
No.1 (7 pcs)
,
@ Clutch
@ Primary dn ·ven gear ass Y

NOTE: be sure that concaved washer (j)

Check toly installed.
is proper

•
Install the thrust washer
he spacer w
G). drive
ith primary . n g ear assembly.
• Install t . gear ap-

NOTE: . the . dnven '

When insert,~g b spacer mto
· and
th inside theou tside
pnmary of the spacer.
- e oil to 0
ply engm '2'.
• lnsta II the thrust washer ½J

I tch sleeve h u band I oc k washer @ .

• Install the c u f't © of lock
NOTE: . e lock washer @, align
hub.the s '
When installmg th .b of clutch sleeve
washer w,"th the rt
 ENGINE 3-50

• Tighten the clutch sleeve hub nut to the specified torque

with the special tool.

miJ 09920-53740: Clutch sleeve hub holder

t!J Clutch sleeve hub nut: 50 N·m (5.0 kg-m, 36.0 lb-ft)

• After tightening the clutch sleeve hub nut, be sure to lock

the nut by firmly bending the tongue of the lock washer.
• Install the clutch drive plates and driven plates one by one .
• Install the clutch pressure plate .

• Tighten the clutch spring mounting bolts diagonally to the

specified torque with the special tool.

BiJ 09910-20116: Conrod holder

t!J Clutch spring mounting bolt: 10 N·m (1.0 kg-m, 7.0 lb-ft)

• Fit the dowel pins.

I A CAUTION [
J Use a new gasket to prevent oil leakage.

• Engage the teeth of clutch release rack with those of pin-

ion gear at the clutch cover side, and replace clutch cover.
Make sure that the rack and pinion gear engage positive-
ly. To install the cover, tap lightly with plastic hammer,
and tighten the bolts.

G): Gasket
3-51 ENGINE

STARTER CLUTCH AND GENERATOR

• Install the crankcase oil separator and spacer (D.

• Tighten the ring nut to the specified torque with the spe-
cial tools.

1-&cih 09917-23711 : Ring nut socket wrench

09910-20116: Conrod holder

t!] Ring nut: 80 N·m (8.0 kg-m, 58.0 lb-ft)

• Install the starter gear and thrust washer.

• Degrease the tapered portion of the generator rotor and
also the crankshaft.

• Fil the key @ in the key slot on the crankshaft, then in- . -· /. ,
stall the generator rotor.
~ - ,,

• Apply a small quantity of THREAD LOCK SUPER "1303"

to the threaded part of rotor bolt .

,telJ 99000-32030: THEAD LOCK SUPER "1303"

 ENGINE 3-52

• Tighten the generator rotor bolt to the specified torque

with the 36 mm off-set wrench.

t!J Generator rotor bolt: 160 N·m (16.0 kg-m, 115.5 lb-ft)

• Install the starter torque limiter and idle gear.

• Install the starter motor.

• Fit the dowel pin and install the new gasket.

• Install the generator cover.

OIL RING
Install the spacer G) into the oil ring groove first. Then in-
stall both side rails @ , one on each side of the spacer. The
spacer and side rails do not have a specific top or bottom IF;,#c-®
=='"ii
when they are new. When reassembling used parts, install --+-4;;..;+-CD
them in their original place and direction.
~ ~ ~+--®

CORRECT
3-53 ENGINE

TOP RING AND 2ND RING

~
a:,, ,g
Top and 2nd rings differ in the shape of the ring face. Top

~
and 2nd rings have a letter "R" or "RN" marked on the side.
Be sure to bring the marked side to top when fitting them
to the piston.

~
I / /2nd ri ng

• Position the gaps of the three rings as shown. Before in-

EX.
serting piston into the cylinder, check that the gaps are
so located. • 2nd ring
• Lower side • Upper side
rail rail

• Top ring
IN . • Spacer

• Place a clean rag over the cylinder base to prevent the

piston pin circlips from dropping into the crankcase.
• Rub a small quantity of SUZUKI MOLY PASTE onto the
piston pin .

~99000-25140: SUZUKI MOLY PASTE

• When fitting the piston, turn arrow mark CD on the piston

head to exhaust side.
• Fit the piston pin circlips with long-nose pliers.

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

• Fit the dowel pins @ to the crankcase and attach a new

gasket.

I A CAUTION I
I Use a new gasket to prevent oil leakage.
 ENGINE 3-54

• Hold each piston ring with properly position, and insert

the piston into the cylinder.

NOTE:
When mounting the cylinder, keep the camshaft drive chain
CD taut. The camshaft drive chain must not be caught be-
tween cam drive chain sprocket and crankcase when crank-
shaft is rotated.

• Install the cam chain guide.

NOTE:
There is 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.

• Temporarily tighten the cylinder base nuts.

• Fit the dowel pins @ to the cylinder and attach a new

gasket.

I .A CAUTION I
Use a new cylinder head gasket to prevent oil leakage.
Do not use the old gasket.

• Place the cylinder head on the cylinder.

• Cylinder head bolts and new gaskets must be fitted in the
correct position, as shown in the photograph.

@ : 200 mm bolt
®: 190 mm bolt
©: 180 mm bolt

NOTE:
Apply engine oil to the new gaskets before installing.

• Fasten the cylinder head by tightening the bolts and nuts

diagonally. Tighten each bolt and nut to the specified
torque.

~ Cylinder head bolt: 38 N·m (3.8 kg-m, 27.5 lb-ft)

Cylinder head nut: 25 N·m (2.5 kg-m, 18.0 lb-ft)
3-55 ENGINE

• After tightening the cylinder head bolts and nuts, tight-

en the cylinder base nut to the specified torque.

~ Cylinder base nut: 10 N ·m ( 1 .0 kg-m, 7 .0 lb-ft)

CAMSHAFT
• Turn the crankshaft counterclockwise with the box
wrench and align "T" line CD on the generator rotor with
the center of hole on the generator cover keeping the cam-
shaft drive chain pulled upward .

I A CAUTION I

If crankshaft is turned without drawing the camshaft

drive chain upward, the chain will be caught between
crankcase and cam chain drive sprocket.

• Install the C-ring 0 into the ring groove of the cylinder

head.

NOTE:
Apply grease on the cam sprocke t locating pin and install
the pin into the camshaft.
• Engage the chain on the cam sprocket with the locating
pin hole @ at two o'clock position.

NOTE:
Do not rotate the generator rotor while doing this. When the
sprocket is not positioned correctly, turn the sprocket. When
installing the camshaft into the cam sprocket, pay attention
not to dislodge the locating pin or it may fall into the
crankcase.
• Align the engraved line mark @ on the camshaft so it is
parallel with the surface of the cylinder head.
 ENGINE 3-56

• Fit the lock washer so that it is covering the locating pin.

• Apply THREAD LOCK SUPER "1303" to the cam sprock-
et bolts and tighten them to the specified torque.

~ Cam sprocket bolt: 15 N·m (1.5 kg-m, 11.0 lb-ft)

,tf& 99000-32030: THREAD LOCK SUPER "1303"

• Bend up the washer tongue positively to lock the bolts.

• Apply SUZUKI MOLY PASTE to the camshaft journals and

cam faces .

.....@499000-25140: SUZUKI MOLY PASTE

• Thoroughly wipe off oil from the fitting surfaces of cylinder

head and cover.
• Fit the dowel pins CD and camshaft end cap @ to the
cylinder head side.

• Apply SUZUKI BOND NO.1207B uniformly to the mating

surface of the cylinder head cover, and install the cylinder
head cover within few minutes.

~ 99104-31140: SUZUKI BOND NO. 1207B

• Fit the two gaskets @ to the head cover bolts correctly

as shown in Fig.

IACAUTION I
I Use a new gasket to prevent oil leakage.

NOTE:
When tightening the cylinder head cover bolts, the piston
must be at top dead center on the compression stroke. l
3-57 ENGINE

• Lightly tighten the cylinder head cover bolts sequentially

in the ascending order of numbers, and then if everything
is satisfactory, tighten securely with a torque wrench to
the specified torque.

~ Cylinder head cover bolt: 10 N·m (1.0 kg-m, 7.0 lb-ft)

• Turn the slotted end of the chain tensioner adjuster to lock

it with a screwdriver in the clockwise direction.
• Install the chain tensioner adjuster on the cylinder.

~ Cam chain tensioner adjuster mounting bolt CD:

10 N ·m ( 1 .0 kg-m, 7 .0 lb-ft)

• Turn back and pull out the screwdriver from the chain ten-
sioner adjuster. As the cylinder turns, the tensioner rod
is advanced under spring force and pushes the tensioner
against the cam drive chain.

NOTE:
The cam drive chain tensioner adjuster is maintained at the
proper tension by an automatically adjusted tensioner. Be-
fore installing the cam drive chain tensioner adjuster, inspect
the smooth movement.
• Tighten the tensioner adjuster cap bolt @ .

~Bolt @ : 6 N·m (0.6 kg-m, 4.5 lb-ft)

• Install the oil pipe and tighten the union bolt to the speci -
fied torque.

~ Oil pipe union bolt @ : 23 N·m (2.3 kg-m, 16 .5 lb-ft)

@ : 20 N·m (2.0 kg-m, 14.5 lb-ft)
 FUEL AND LUBRICATION SYSTEM

~ - - - - - - -- - CONTENTS - - - - -- - -- ~
FUEL SYSTEM .. · ·· ·· · · · ·· ·· · ·· ·· · ·· .. · · .. · · · .. · · · .. · · · · · .. · · · · · · · · · · · · · · · ·· ·· · · · ·· .. · ·.... 4- 1
FUEL VALVE ............... ..................................... .... ....... ...... ....... .... 4- 2
FUEL TANK· ····· ·············· ·· ········ ········································ ······ ····· 4- 3
CARBURETOR · · · · · ·· · · · ·· ·· · ·· ·· · ·· ·· · · · ·· · · · · · ·· · · · ·· · · · · · · · · · · · · ·· · · · · · · · .. · · · ·· .. · · · .. · 4- 4
CONSTRUCTION · · · ·· ·· · · · ·· · ·· ·· · · · .. · · · .... · · ·· .. · · · ·· · · · ·· · · · · · · · · · · ·· ·· · ·· ·· ·· · ·· · 4- 4
SPECIF/CATIONS · · · ·· ·· · · · ·· · ·· ·· · · · ·· ·· · ·· ·· · · · · · · · · · · · · · · · · · ·· · · · · · ·· ·· ·· · ·· ·· ·· · ·· · 4- 5
I.D. NO. LOCATION ·· · · · ·· · · · ·· · · · ·· · · · · · ·· · · · ·· · · · · ·· · · · .. · · · · · · · · ·· ·· ·· · ·· ·· ·· · ·· · 4- 6
SLOW SYSTEM ·· ·· · ·· ·· · · · ·· · · · ·· · · · · · ·· · · · ·· · · ·· .. · · · ·· ·· · · · · · · · · · · ·· · ·· ·· · ·· ·· ·· · .. · 4- 7
MAIN SYSTEM · ·· ·· · ·· ·· · · · ·· · · · ·· · · · ·· · · .. · ·· · · · ·· · · · · ·· ·· · .. · · · · · · · ·· · ·· ·· · ·· ·· ·· · ·· · 4- 8
STARTER SYSTEM ................................................................. .. 4- 9
FLOAT SYSTEM ···· ·· ···· · .... · ···· · ·.. . · · .... · ···· · · · .... · ..... · · ····· ·· ···· · ·· ···· · · 4- 9
REMOVAL ······· ·--··········--················ ... · ........................... ........... 4-10
DISASSEMBLY · ·· ·· · · · ·· ·· · ·· · · · ·· ·· · · · ·· · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·· ·· · · · ·· ·· · · 4-10
CARBURETOR CLEANING · ·· ·· · · · ·· · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · ·· ·· · · 4-11
INSPECTION · · · · · ·· ·· · ·· ·· ·· · ·· · · · ·· ·· · · · ·· · · · ·· ·· · · · ·· · · · · · · · · · · · · · · · · · · · · · ·· ·· · · · ·· ·· · · 4-13
NEEDLE VAL VE INSPECTION .. · ·.. · · .. ·· · ·· · · · · · · · · · · · · · · · .. · · · · · .. · ·· · · .. · ·· · · 4-13
FLOAT HEIGHT ADJUSTMENT .... ... .... ..................... ..... ........ .... 4-13
THROTTLE POSITION SWITCH ············ ·················· ····· ·············· 4-13
REASSEMBLY AND REMOUNTING .. · · .. .......... · .... · · · · .. · · · · · ·· ·· .. · ·· ·· 4-14
LUBRICATION SYSTEM AND COOLING SYSTEM ......... ............... 4-14
ENGINE LUBRICATION/CYLINDER HEAD
COOLING SYSTEM CHART .. .................................... ...... ....... ... 4-15
OIL COOLER · · · · · ·· ·· · · · ·· ·· · · · ·· · · · ·· ·· · .. ·· · · · .. · · .... · · · .. · .. · · · · · · · · · .... · .... · ·· ·.. · 4-1 7
4-1 FUEL AND LUBRICATION SYSTEM

FUEL SYSTEM
When turning starter motor, negative pressure is generated in the combustion chamber. This nega-
tive pressure works on the diaphragm of fuel valve through passage way provided in the carburetor
main bore and vacuum hose, and diaphragm builds up a negative pressure which is higher than the
spring pressure. Valve in the fuel valve is forced to open due to diaphragm operation, and thus al-
lows fuel to flow into carburetor float chamber.

Fu el tank

Vacu u m ~

Fuel ...
 FUEL AND LUBRICATION 4-2

FUEL VALVE
FUEL VALVE MECHANISM
A valve is provided at the end of the fuel valve lever and can switch over to "ON", "PRI" and "RES".

"ON" position

"PAI" position "RES" position

FUEL VALVE/FUEL FILTER REMOVAL

• Remove the frame cover and seat. (Refer to pages 5-1
and 2.)
• Remove the fuel tank. (Refer to page 4-3.)
• Remove the fuel valve by removing the mounting bolts.
A WARNING
Gasoline is very explosive. Extreme care must be taken.
Gaskets and O-ring must be replaced with new ones
to prevent fuel leakage.
4-3 FUEL AND LUBRICATION SYSTEM

INSPECTION AND CLEANING

If the fuel filter is dirty with sediment or rust, fuel will not
flow smoothly and loss in engine power may result. Clean
the fuel filter with compressed air.

FUEL TANK
FUEL TANK REMOVAL
• Remove the frame cover and seat. (Refer to pages 5-1
and 2.)
• Turn the fuel valve to "ON" position.

• Remove the fuel tank mounting bolts G) .

• Slide the fuel tank backward and lift up it after discon-
necting the fuel hose @ and vacuum hose @ .
• Remove the fuel tank.

A WARNING
Gasoline is very explosive. Extreme care must be taken.
 FUEL AND LUBRICATION 4-4

CARBURETOR
CONSTRUCTION

CD

G) Top cap
@ Spring
@ Spring seat
@ E-ring
@,_ _../, ® Washer
® Jet needle
0 0 -ring
® Diaphragm
® Piston valve
@ Needle jet
® Main jet
@ Pilot jet
@ Main air jet
® Starter plunger
@ Pilot screw
@ 0-ring
® 0 -ring
@ Float
~ Thr.ottle stop screw
1€;1 0-nng
® Drain screw
4-5 FUEL AND LUBRICATION SYSTEM

SPECIFICATIONS
SPECIFICATION
ITEM
E-02,04,34 E-37 E-17, 22,24 U-type E-22
Carburetor type MIKUNI +- +- +-
BST40SS
Bore size 40 mm +- +- +-

I.D. No. 32E0 32E8 32E3 32E4

Idle r/min. 1 500± 100 +- +- +-
r/min
Float height 14.7± 1.0 mm +- +- +-
(0.58 ± 0.04 in)
Main jet (M.J .) # 140 +- +- +-

Jet needl e (J.N .) 6F19-3rd +- +- +-

Needle jet (N.J .) Y-5 +- +- +-

Throttle valve (Th.V.) #95 +- +- +-

Pilot jet (P.J .) # 42.5 +- +- +-

Starter j et (G .S.) #40 +- +- +-

Pilot screw (P.S.) PRE-SET +-

PRE-SET PRE-SET
( 1½ turns back) ( 1 .0 turn back) ( 11/a turns back)
Throttle cable play 0.5-1.0 mm +- +- +-
(pulling c able) (0.02-0.04 in)
Starter ca ble play 0 .5 - 1.0 mm +- +- +-
(0.02 - 0 .04 in)

COUNTRY OR AREA
E-02 : U.K. E-24 : Australia
E-03 : U.S.A. E-28 : Canad a
E-04 : France E-33 : California (U.S.A.)
E- 1 7 : Sweden E-34: Italy
E- 1 8 : Switzerland E-37 : Brazil
E-22 : Germany
 FUEL AND LUBRICATION 4-6

SPECIFICATION
ITEM
E-03 E-33 E-28 E- 18
Carburetor type MIKUNI +- +- +-
BST40SS
Bore size 40 mm f- +- +-
1.D. No. 32E1 32E6 32E5 32E2
Idle r/min. 1 500± 100 1 500± 50
+- +-
r/min r/min
Float height 14.7± 1.0 mm +- +- f-
(0.58 ±0.04 in)
Main jet (M.J.) # l'-10 +- # 140 # 137. 5
Jet needle (J.N.) 6F23 +- 6F19-3rd 6H21-4th
Needle jet (N.J.) Y-5M +- Y-5 +-
Throttle valve (Th.V.) #95 +- +- +-
Pilot jet (P.J.) #'-12.5 +- #42.5 +-
Starter jet (G.S.) #40 +- +- +-
Pilot screw (P.S.) PRE-SET PRE-SET
PRE-SET +-
( 1 ½ turns back) ( 1 .0 turn back)
Throttle cable play 0 .5 - 1.0 mm f- +- +-
(pulling cable) (0.02 - 0.04 in)
Starter cable play 0 .5- 1.0 mm +- +- f-
(0.02-0.04 in)

I.D. NO. LOCATION

Each carburetor has I.D. Number G) printed on the carbure-
tor body according to its specification.
4-7 FUEL AND LUBRICATION SYSTEM

SLOW SYSTEM
This system supplies fuel during engine operation with throttle valve G) closed or slight opened . The
fuel from float chamber @ is metered by pilot jet @ where it mixes with air coming in through pilot
air jet @ . This mixture, rich with fuel, then goes up through pilot passage to pilot screw ® . A part
of the mixture is discharged into the main bore out of bypass ports ® . The remainder of mixture
is metered by pilot screw ® and sprayed out into the main bore through pilot outlet (j) .

··-·--·-,\
'7
d.,
'--··,
r··_)
I '

I I
'

~Air

~ Fu el/A ir mixture
Fuel
 FUEL AND LUBRICATION 4-8

MAIN SYSTEM
As throttle valve CD is opened, engine speed rises, and this increases negative pressure in the ventu-
ri@. Consequently the piston valve @ moves upward.
Meanwhile, the fuel in float chamber @ is metered by main jet @ , and the metered fuel enters nee-
dle jet ® , in which it mixes with the air admitted through main air jet ® to form an emulsion.
The emulsified fuel then passes through the clearance between needle jet ® and jet needle (j) , and
is discharged into the venturi @, in which it meets main air stream being drawn by the engine.
Mixture proportioning is accomplished in needle jet ® ; the clearance through which the emulsified
fuel must flow in large or small, depending ultimately on throttle position.

¢:=JAir

~ Fuel/ Air mixture

Fuel

5 4
4-9 FUEL AND LUBRICATION SYSTEM

STARTER SYSTEM
Pulling the starter cable G) , fuel is drawn into the starter circuit from the float chamber @ .
Starter jets (@ , @) meters this fuel, which then flows into fuel pipe ® and mixes with the air com-
ing from the float chamber . The mixture, rich in fuel content, reaches starter plunger ® and mixes
again with the air coming through a passage extending from behind the diaphragm.
The two successive mixings of fuel with air are such that proper fuel/air mixture for starting is produced
when the mixture is sprayed out through starter outlet port (-f) into the main bore.

® CD

~Air

~ Fuel/Air mixture

Fuel

FLOAT SYSTEM
Floats G) and needle valve @ are associated with the same
mechanism, so that, as the floats G) move up and down,
the needle valve @ too moves likewise.
When fuel level is up in float chamber @ , floats G) are up
and needle valve @ remains pushed up against valve seat.
Under this condition, no fuel enters the float chamber @ .
As the fuel level falls, floats G) go down and needle valve
@ unseats itself to admit fuel into the chamber @ .
In this manner, needle valve @ admits and shuts off fuel
alternately to maintain a practically constant fuel level in-
side the float chamber @ .
 FUEL AND LUBRICATION 4-10

REMOVAL
Refer to page 3-4.

DISASSEMBLY
NOTE:
Before disassembly, prepare a clean and well lit work place
where carburetor components can be fayed out neatly and
won't get lost.

• Remove the carburetor top cap G).

IACAUTION[
Do not blow the carburetor body with compressed air,
before removing the diaphragm. It may cause a damage
to the diaphragm.

• Remove the piston valve return spring @ and piston valve

with diaphragm @ .

• Remove the jet needle @ out of the piston valve.

:. #r_..
©
~f::~

• Remove the float chamber body ®·

4-11 FUEL AND LUBRICATION SYSTEM

• Remove the float assembly G) and needle valve @ .

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

• Remove the main jet @, pilot jet @ and pilot screw ®

(Refer to PILOT SCREW REMOVAL of page 4 - 12 for E-03,
18 and 33 models).

I A. CAUTION I
Do not use a wire for cleaning of passage and jets.

NOTE:
Before removing the pilot screw ® , slowly turn the pilot
screw in clockwise and count the number of turns until the
screw is lightly seated. Make a note of how many turns were
made so the screw can be reset correctly after removing.

• Remove the main air jet ®·

I A. CAUTION I
I Do not use a wire for cleaning of jet.

CARBURETOR CLEANING
AWARNING
Some carburetor cleaning chemicals, especially dip-type
soaking solutions, are very corrosive and must be han-
dled carefully. Always follow the chemical manufac-
turer's instructions on proper use, handling and strage.

NOTE:
Remove the pilot screw as described next page before
cleaning.
 FUEL AND LUBRICATION 4-12

• Clean all jets with a spray-type carburetor cleaner and

blow dry with compressed air .
• Clean all circuits of the carburetor thoroughly - not just
the perceived problem area. Clean the circuits in the car-
buretor body with a spray-type cleaner and allow each
circuit to soak if necessary to loosen dirt and varnish. Blow
the body dry with compressed air.

IA CAUTION I
Do not use wire to clean jets or passageways. Wire can
damage jets and passageways . If the components can-
not be cleaned with a spray cleaner it may be neces-
sary to use a dip-type cleaning solution and allow them
to soak. Always follow the chemical manufacturer's in-
structions for proper use and cleaning of the carbure-
tor components.

• After cleaning, reassemble the carburetor with new seals

and gaskets. Reinstall the pilot screw to the original fac-
tory setting with a new 0-ring seal.
• Install a new cap over the pilot screw opening. (for
E-03, 18,33 models)

PILOT SCREW REMOVAL

(FOR E-03, 18 AND 33 MODELS)
Because harsh cleaning solvents can damage the 0 -ring seals
in the pilot system, the pilot system components should be
removed before cleaning.

• Use a 1 /8" size drill bit with a drill-stop to remove the

pilot screw plug. Set the drill-stop 6 mm from the end of
Carburetor
the bit to prevent drilling into the pilot screw. Carefully body
Pilot
drill through the plug. screw
• Thread a self-tapping sheet metal screw into the plug. Pull
on the screw head with pliers to remove the plug. Care-
fully clean any metal shavings from the area.
• Slowly turn the pilot screw in clockwise and count the
number of turns until the screw is lightly seated. Make
a note of how many turns were made so the screw can
be reset correctly after cleaning.
• Remove the pilot screw with the spring, washer, and
0 -ring.
• After cleaning reinstall the pilot screw to the original set-
ting by turning the screw in until it lightly seats, and then
backing it out the same number of turns counted during
disassembly .
• Install new plug by tapping it into place with a punch.
4-13 FUEL AND LUBRICATION SYSTEM

INSPECTION
Check the following items for any damage.
* Pilot jet * Needle valve
* Main jet * Starter jet
* Main air jet * Gasket and O-ring
* Pilot air jet * Throttle shaft oil seal
* Needle jet air bleeding hole * Diaphragm
* Float * Pilot outlet and by-pass holes

NEEDLE VALVE INSPECTION

If foreign matter is caught between the valve seat and the
needle, the gasoline will continue flowing and cause it to
overflow. If the seat and needle are worn beyond the per-
missible limits, similar trouble will occur. Conversely, if the
needle sticks, the gasoline will not flow into the float cham-
ber. Clean the float chamber and float parts with gasoline.
If the needle is worn as shown in the illustration, replace
it together with a valve seat. Clean the fuel passage of the CORRECT INCORRECT
mixing chamber with compressed air .

FLOAT HEIGHT ADJUSTMENT

To check the float height, invert the carburetor body, with
the float arm kept free, measure the height @while float
arm is just in contact with needle valve by using calipers.
Bend the tongue as necessary to bring the height @
to this value.

Float height @ : 14.7±1.0 mm (0.58±0.04 in)

1.f&b 09900-20102: Vernier calipers

THROTTLE POSITION SWITCH (Except for E-03, 18,24,28 and 33 models)

• Remove the fuel tank. (Refer to page 4-3.)

Inspect the throttle position switch for continuity with pock-

et tester. If any abnormality is found, replace the respec-
tive switch assemblies with new ones.

ditJ 09900-25002: Pocket tester

~Tester knob indication : X 10 range

~
n B B
ON (full-throttle) 0 -0
OFF
B: Black

NOTE:
When making above test, it is not necessary to start the
engine.
 FUEL AND LUBRICATION 4-14

REASSEMBLY AND REMOUNTING

Reassemble and remount the carburetor assembly in the
reverse order of removal and disassembly.

• When installing the carburetor top cap, align the vacuum

ports (G), @).

• After remounting the carburetor, the following adjust-

ments are necessary.
* Engine idle r/min ......... .. ..................... .. . Page 2-6
* Throttle cable play .. . .... ....... ..... ...... . . ... .. . Page 2-6

LUBRICATION SYSTEM AND COOLING SYSTEM

OIL PRESSURE
Refer to page 2-1 8.

OIL FILTER
Refer to page 2-8.

OIL SUMP FILTER

Refer to page 3- 16.

NOTE:
When separating the crankcase, wash the oil sump filter with
cleaning solvent, and then blow compressed air through it
to dry off solvent.
4-15 FUEL AND LUBRICATION SYSTEM

ENGINE LUBRICATION/CYLINDER HEAD COOLING SYSTEM CHART

CAMSHAFT
CAMSHAFT r--- - - -- - - - - - - - RIGHT-SIDE JOURNAL

INTAKE ROCKER CAM CHAIN

CYLINDER HEAD CYLINDER HEAD
ARM SHAFT OIL HOSE AND CAM
COVER LEFT-SIDE COVER RIGHT-SIDE
,-✓ AND ROCKER ARM SPROCKET
.,,,✓,✓

~1-NT-A-KE_ A
EXHAUST
,,-;-;',,J
,;,;,Ir
_N_D---=-, ;j-
1
l•,
HH
CAM FACE
CYLINDER
HEAD

"·
'6\
HH
COOLING

...
'l:•,
CYLINDER
WALL
-------< PISTON
CYLINDER HEAD
CONROD
SMALL STARTER
END CLUTCH
CYLINDER

OIL JET
CRANKSHAFT
RIGHT-SIDE
'
H\
...
JI

OIL HOSE

OIL PIPE

r -------
1

BY-PASS ~ OIL FILTER

COUNTERS HAFT
LEFT-SIDE L- ------
BEARING

DRIVESHAFT
LEFT-SIDE
BEARING OIL JET

DRIVESHAFT COUNTERSHAFT
AND GEARS AND GEARS

l:1,
HH PRIMARY DRIVEN
GEAR AND CLUTCH PLATES
JI
H\
HH

----- - - - - --OIL PAN=-- - - - - - -

FUEL AND LUBRICATION 4-16
4-17 FUEL AND LUBRICATION SYSTEM

OIL COOLER

CD Oil cooler
@ O-ring
@ Oil cooler hose
(To cylinder head)
@ Oil cooler hose
(From clutch cover)
® Oil cooler cover
@ Oil cooler guard

N-m
10

REMOVAL
• Drain engine oil. (Refer to page 3-1 . )
• Remove the oil cooler hose mounting bolts.

• Remove the oil cooler holder with cooler by removing its

mounting bolts.
 CHASSIS

.---- - - -- - -- - CONTENTS - - -- - - - - -~
FRAME COVER AND SEAT ·· ·· · ...... ·· .. · · ·· .. ·· · · · ·· · · · .... ·· · ·· ·· · · · ·· ... · · ·· · ·· · 5- 1
FRONT WHEEL · · · ·· ·· · ·· ·· ·· · ·· · · · ·· · · · ·· · · · · · · · · · · · · · · ·· · · · ·· · · · · · · · · · · ·· ·· · ·· ·· ·· · ·· · · · · 5- 2
REMOVAL ······ ········ ········· ···· ··········· · ......................................... 5- 2
INSPECTION AND DISASSEMBLY ...... · · · · · · · ...... · .... · · · · · · ·· · · · ·· ·· .. · ·· 5- 3
REASSEMBLY AND REMOUNTING · ·· ........ · · ·· · · · · · · · · · · · · · .... · · .. ·· · · · ·· 5- 4
FRONT BRAKE · · · · · · ·· .... · .... · .. ·· · ·· ·· · · .. · · · .. .. · .. · · · · · · · .. · .... · · · · · · · · ·· ·.. · · ·.. · .. · 5- 6
BRAKE PAD REPLACEMENT .. ......... ............ ... ........................... 5- 7
BRAKE FLUID REPLACEMENT .................................................. 5- 7
CALIPER REMOVAL AND DISASSEMBLY ................................. 5- 8
CALIPER INSPECTION ·· ·· · ·· ·· · ·· ·· · · · ·· · · · · · ·· · · · · · · · · · · · · · · · · · · · ·· · · · · · ·· ·· ·· · ·· · 5- 9
CALIPER REASSEMBLY AND REMOUNTING ...... · .... · ...... · ...... · .. 5- 9
BRAKE DISC INSPECTION .... · .......... ·.. · · · · · .... · .... .. · · .. · · · · ...... · .. ·.... 5-10
MASTER CYLINDER REMOVAL AND DISASSEMBLY ................ 5-11
MASTER CYLINDER INSPECTION .......... .. · .............. · .. .. · ...... · .... · 5-12
MASTER CYLINDER REASSEMBLY AND REMOUNTING .......... . 5-13
FRONT FORK · .... · .... · · ··· · ·... · ·..... · .... · ·.... · · .... · · ...... · .... · · · ...... · .... · · ..... · 5-14
REMOVAL AND DISASSEMBLY ................................................ 5-14
INSPECTION · · · · · · · · · · · · · · · · ·· ·· · · · ·· · · · ·· · · · ·· ·· · · · ·· ·· · · · ·· ·· · · · · · · · · · · · · · · · · · · · · · · · · · · 5 -16
REASSEMBLY AND REMOUNTING .......... · ........................ · · .... .. 5-17
STEERING · ·· · · · ·· · · · · · · · · · · · · · · · · · ·· · · · ·· ·· · · · ·· · · · ·· ·· · · · ·· ·· · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · 5-20
REMOVAL AND DISASSEMBLY ............ .. ................. ...... ........... 5-20
INSPECTION .. · · .... · .. · · · · .... · ·.. · · ·.... ·.... · · ·· .. ·· · ·.... · · · .... · · .... · · · · · · .. · .... · · 5-25
REASSEMBLY AND REMOUNTING .............. ·.............. · .......... · .. 5-25
REAR WHEEL · · · · · · · · ·· · · · · · · · · · · · · · ·· · · · ·· ·· · ·· ·· · · · ·· ·· ·· · ·· ·· · · · ·· ·· · · · · ·· · · · · · · · · · · · · · · 5-27
REMOVAL ......... ... .............. ............ ......... ... ......... .... ..... ..... ....... 5-27
INSPECTION AND DISASSEMBLY · · · ·· · · · ·· ·· · · · ·· ·· · · · · · ·· · · · · · · · · · · · · · · · · · · 5-29
REASSEMBLY AND REMOUNTING · .......... ·· .... · .... ........ .... .... · · .. · 5-31
REAR BRAKE · · ·· · · · · · · · · · · · · · · · · · · · · · · ·· ·· · · · ·· ·· · · · ·· ·· · · · ·· ·· · · · ·· ·· · · · · · ·· · · · · · · · · · · · · · · 5-33
BRAKE PAD REPLACEMENT ......................... .. ...... ....... ............. 5 -34
BRAKE FLUID REPLACEMENT ................. .. ............................... 5-34
CALIPER REMOVAL AND DISASSEMBLY ................................. 5-35
CALIPER AND DISC INSPECTION ........ · .... · ........ .. .. ·...... ·...... · .... 5-36
CALIPER REASSEMBLY AND REMOUNTING .... ·· ...... · ...... .... · .... 5-36
MASTER CYLINDER REMOVAL AND DISASSEMBLY ..... .... ....... 5-37
MASTER CYLINDER INSPECTION .. ·· ........ ................ .. ·· ............. 5-38
MASTER CYLINDER REASSEMBLY AND REMOUNTING · · · ·· ·· · · · · 5-38
REAR SWINGARM AND SUSPENSION ·· ...... · ........ · .... · .................. 5-39
REMO VAL · · · · ·· · · · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · ·· ·· · · · ·· · · · · · ·· · · · · · ·· ·· · · · ·· · · · · · · · ·· · · 5-40
INSPECTION AND DISASSEMBLY · · .. · ·.. · .... .. .. .......................... · 5-42
REASSEMBLY AND REMOUNTING · · ·· ·· ·· · ·· ·· ·· · ·· ·· ·· · ·· ·· ·· · · · ·· ·· · · · · ·· · 5-44
REASSEMBLING INFORMATION · · · · · · · · ·· ·· · · · ·· ·· · · · ·· ·· · · · ·· ·· ·· · · · ·· · · · · · ·· 5-45
FINAL INSPECTION AND ADJUSTMENT · ...... · .. ...... · ........ .. ·· ·.... 5-46
LOWERING THE SEAT HEIGHT .... · .......... .......... .......................... · 5-47
OPTIONAL PARTS SUPPLY ...... ...................... ...... .................... 5-47
SPECIAL TOOLS .. ....................................... ......... ............. ... ..... 5-47
FRONT FORK · · ·· ·· · ·· ·· · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · ·· ·· ·· · ·· ·· ·· · · · ·· ·· ·· · · · ·· · 5-48
REAR SHOCK ABSORBER · ·· · · · · · · · · · · ·· · · · ·· ·· · ·· · · · ·· ·· ·· ·· · ·· ·· ·· · · · ·· ·· ·· · ·· · 5-53
SIDE STAND .............. ..... .. ..... ........ .... .. ... ....... ............. .... ......... 5-56
WARNING LABEL ··· ···· ·············· ····· ······· ·· ··· ······ ························· 5-57
5-1 CHASSIS

FRAME COVER AND SEAT

REMOVAL AND REMOUNTING
• Remove the right and left frame covers by removing the
mounting screws.

• Remove the seat by removing the mounting bolts.

• Remount the seat and frame covers.

 CHASSIS 5-2

FRONT WHEEL
(D Axle holder
0 Speedometer gearbox
@ Bearing (R)
@ Spacer
® Bearing (L)
® Dust seal
(J) Spacer
@ Disc

ITEM N-m kg-m lb-ft

® 65 6.5 47.0
® 10 1.0 7.0
© 4.5 0.45 3.0 ®
© 23 2.3 16.5

REMOVAL
• Loosen the front axle holder nuts G) and axle shaft @.
• Carefully position a jack under the chassis tubes and raise
until the front wheel is slightly off the ground.
• Remove the front wheel by removing the front axle.

NOTE:
Do not operate the brake lever while dismounting the front
wheel.

• Remove the disc by removing the mounting bolts .

5-3 CHASSIS

INSPECTION AND DISASSEMBLY Play

WHEEL BEARING
Inspect the play of bearing inner ring by hand while mount-
ed in the wheel.
Rotate the inner ring by hand to inspect if any abnormal noise
occurs or rotating smoothly.
Replace the bearing if there is anything unusual.

• Remove the dust seal.

• Drive out the both bearing with the special tool in the fol-
lowing procedures.

~ 09941-50111 : Bearing remover

• Insert the adapter into the bearing.
• After inserting the wedge bar from the opposite side, lock
the w edge bar in the slit of the adapter.
• Drive out the bearing by knocking the wedge bar.

IA CAUTION I
The removed bearing should be replaced with new
ones.

FRONT AXLE
Check the front axle runout with a dial gauge and replace
it if the runout exceeds the limit.

miJ 09900-20606: Dial gauge (1/100 mm)

09900-20701 : Magnetic stand
09900-21304: "V" block set
Service Limit: 0.25 mm (0.010 in)

WHEEL RIM
Make sure that the wheel rim runout does not exceed the
service limit when checked as shown.
An excessive runout is usually due to worn or loose wheel
bearings and can be reduced by replacing the bearings . If
bearing replacement fails to reduce the runout, replace the
wheel.
Service Limit : 2.0 mm (0.08 in)
(Axial and Radial)
 CHASSIS 5-4

SPOKE NIPPLE
Check to be sure that all nipples are tight, and retighten them
as necessary.

~ Spoke nipple: 4.5 N ·m (0.45 kg-m. 3.0 lb-ft)

TIRE (Refer to page 2-12.)

REASSEMBLY AND REMOUNTING

Reassemble and remount the front wheel in the reverse order
of removal and disassembly, and also carry out the follow-
ing steps:

WHEEL BEARING
• Apply grease to the bearings.

~ 99000-25030: SUZUKI SUPER GREASE "A"

• Install the wheel bearings with the special tools.

miJ 09924-84510: Bearing installer

09924-84521: Bearing installer
NOTE:
First install the wheel bearing for left side.

Spacer

~
Bearing (L)
Bearing (R)

..
Cl earance
5-5 CHASSIS

BRAKE DISC
• Make sure that the brake disc is clean and free of any
greasy matter. Apply THREAD LOCK SUPER " 1360" to
the disc mounting bolts and tighten them to the speci-
fied torque.

-dEI 99000-32130: THREAD LOCK SUPER "1360"

~ Disc bolt: 23 N-m (2.3 kg-m, 16.5 lb-ft)

• Align the drive lugs CD to the recesses @ of the wheel hub.

• Before tightening the front axle , position the stopper @

of speedometer gearbox against stopper @.

• Tighten the front axle to the specified torque and then

move the front fork up and down.
• Tighten the axle holder nuts to the specified torque.
NOTE:
When tightening the axle holder nuts, first tighten the up-
per nuts.
~ Front axle: 65 N-m (6.5 kg-m, 47 .0 lb-ft)
Axle holder nut: 10 N•m (1.0 kg-m, 7.0 lb-ft)
 CHASSIS 5-6

FRONT BRAKE
G) Piston/cup set
@ Brake hose
@ Pad
© Piston set ITEM N-m kg-m lb-ft
@ 10 1.0 7.0
®
©
23
18
2.3
1.8
16.5
13.0
~
©~ ~
~~
i
© 2.5 0.25 1.8
© '.)\
® 8 0.8 6.0
® 23 2.3 16.5
@ 13 1.3 9.5 ~~
~ '
- I ~
~
(8) 26 2.6 19.0

A.WARNING
* This brake system is filled with a ethylene glycol-based DOT 4 brake fluid. Do not use or mix
different types of fluid such as silicone-based or petroleum-based.
* Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake
fluid left over from the last servicing or stored for long periods.
* When storing the brake fluid, seal the container completely and keep away from children.
* When replenishing brake fluid, take care not to get dust into fluid.
* When washing brake components, use fresh brake fluid. Never use cleaning solvent.
* A contaminated brake disc or brake pad reduces braking performance. Discard contaminated
pads and clean the disc with high quality brake cleaner or neutral detergent.

IA CAUTION I
Handle brake fluid with care: the fluid reacts chemically with paint, plastics rubber materials etc.
5-7 CHASSIS

BRAKE PAD REPLACEMENT

• Remove the plug G).
• Remove the brake pads by removing the mounting pin @ .

I A CAUTION I
* Do not operate the brake lever while dismounting the
pads.
* Replace the brake pad as a set, otherwise braking
performance will be adversely affected.

• Install the new pads .

A WARNING
Make sure that the pads are properly engaged with the
guide plates as shown in photo .

• Tighten the pad mounting pin @ and plug G) to the speci-

fied torque.

~ Pad mounting pin: 18 N-m (1.8 kg-m, 13.0 lb-ft)

Plug: 2.5 N-m (0.25 kg-m, 1.8 lb-ft)

NOTE.-
After replacing the brake pads, pump with the brake lever
few times to operate the brake correctly and then check the
brake fluid level.

BRAKE FLUID REPLACEMENT

• Place the motorcycle on a level surface and keep the han-
dlebars straight .
• Remove the master cylinder reservoir cap and diaphragm.
• Suck up the old brake fluid as much as possible.
• Fill the reservoir with fresh brake fluid.

Ill Specification and classification: DOT 4

• Connect a clear hose @ to the air bleeder valve @, and

insert the free end of hose into a receptacle.
• Loosen the bleeder valve and pump the brake lever until
no more old brake fluid flows out of the bleeder valve .
• Close the air bleeder valve, and disconnect a clear hose.
Fill the reservoir with fresh brake fluid to the upper end
of the inspection window.

I A CAUTION I
Bleed air in the brake fluid circuit. (Refer to page 2-11.)
 CHASSIS 5-8

CALIPER REMOVAL AND DISASSEMBLY

• Disconnect the brake hose by removing the union bolt and
catch the brake fluid in a suitable receptacle.
• Remove the caliper by removing the mounting bolts.

IA CAUTION I
Never reuse the brake fluid left over from previous ser-
vicing and stored for long periods.

A WARNING
Brake fluid, if it leaks, will interfere with safe running
and descolor painted surfaces.
Check the brake hose and hose joints for cracks and
oil leakage .

• Remove the brake pad. (Refer to page 5- 7.)

• Remove the caliper holder CD and spring (?).

CD

• Place a rag over the piston to prevent its popping out and
push out the pistons with an air gun.

IA CAUTION I
Do not use high pressure air to prevent piston damage.

• Remove the dust seals and piston seals.

IA CAUTION I
Do not reuse the remored seals to prevent fluid leakage.

00
00
5-9 CHASSIS

CALIPER INSPECTION
Inspect the caliper cylinder wall for nicks, scratches or other
damage.

Inspect the piston surface for any scratches or other

□
damage.

CALIPER REASSEMBLY AND REMOUNTING

□
Reassemble and remount the caliper in the reverse order of
removal and disassembly. Pay attention to the following
points:
• Wash the caliper bores and pistons with specified brake
fluid . Particularly wash the dust seal grooves and piston
seal grooves.

I Specification and classification: DOT 4

I A CAUTION I
* Wash the caliper components with fresh brake fluid
before reassembly.
* Do not wipe the brake fluid off after washing the
components.
* When washing the components, use the specified
brake fluid. Never use different types of fluid or clean-
ing solvent such as gasoline, kerosine or the others.
* Replace the piston seals and dust seals with new
ones when reassembly. Apply the brake fluid to both
seals when installing them.

• Apply SUZUKI SILICONE GREASE to the caliper axles.

~ 99000-25100: SUZUKI SILICONE GREASE

 CHASSIS 5-10

• Tighten each bolt to the specified torque .

~Caliper mounting bolt G): 26 N-m (2.6 kg-m, 19.0 lb-ft)

Pad mounting pin @: 18 N-m (1.8 kg-m, 13.0 lb-ft)
Plug @: 2.5 N-m (0.25 kg-m, 1.8 lb-ft)
Brake hose union bolt @ : 23 N-m (2.3 kg-m, 16.5 lb-ft)
Air bleeder valve @ : 8 N-m (0.8 kg-m, 6.0 lb-ft)
NOTE:
Before remounting the caliper, push the piston all the way
into the caliper.

IA CAUTION I
Bleed air from the system after reassembling the caliper.
(Refer to page 2-11.)

BRAKE DISC INSPECTION

• Remove the front and rear wheels . (Refer to pages 5-2
and 5-27.)

Visually check the brake disc for damage or cracks.

Measure the thickness with a micrometer.
Replace the disc if the thickness is less than the service limit
or if damage is found.

Bil 09900-20205: Micrometer (0-25 mm)

Service Limit
Front disc: 3.5 mm (0 .14 in)
Rear disc : 4.0 mm (0.16 in)

Measure the runout with a dial gauge.

Replace the disc if the runout exceeds the service limit.

Bil 09900-20606: Dial gauge (1/100 mm)

09900-20701: Magnetic stand
Service Limit
Front and Rear disc: 0.3 mm (0.012 in)
• Remove the disc. (Refer to pages 5-3 and 5-29.)
• Install the disc. (Refer to pages 5-5 and 5-32.)
5-11 CHASSIS

MASTER CYLINDER REMOVAL AND

DISASSEMBLY
• Remove the brake lever cover and rear view mirror.

• Remove the brake lever.

• Disconnect the front brake switch lead wires.

• Place a rag underneath the union bolt on the master

cylinder to catch any spilled drops of brake fluid. Remove
the union bolt and disconnect the brake hose/master
cylinder joint.

I .A CAUTION I

Immediately and completely wipe off any brake fluid

contacting any part of the motorcycle. The fluid reacts
chemically with paint, plastics and rubber materials, etc.
and will damage them severely.

• Remove the master cylinder assembly .

• Remove the front brake switch .

 CHASSIS 5-12

• Remove the reservoir cap and diaphragm .

• Drain brake fluid.

• Remove the dust boot.

• Remove the circlip with the special tool.

ell 09900-06108: Snap ring pliers

• Remove the piston/secondary cup, primary cup and
spring.

MASTER CYLINDER INSPECTION

Inspect the master cylinder bore for any scratches or other
damage.
Inspect the piston surface for any scratches or other
damage.
Inspect the primary cup, secondary cup and dust seal for
wear or damage.
5-13 CHASSIS

MASTER CYLINDER REASSEMBLY AND

REMOUNTING
Reassembl e the master cylinder in the reverse order of
removal and disassembly. Pay attention to the following
points:

IA CAUTION I
* Wash the master cylinder components with fresh
brake fluid before reassembly. Never use cleaning sol-
vent or gasoline to wash them .
* Do not wipe the components with a rag.
* Apply brake fluid to the cylinder bore and all the com-
ponent to be inserted into the bore.

11:1 Specification and classification : DOT 4

• When remounting the master cylinder on the handlebars,

align the master cylinder holder's lower mating surface
G) with punched mark @ on the handlebars and tighten
the upper clamp bolt first as shown.

~ Master cylinder mounting bolt:

10 N-m (1.0 kg-m, 7 .0 lb-ft)

I A CAUTION I
Bleed air from the system after reassembling master
cylinder. (Refer to page 2-11 . )
M aster cylinder

Upper
clamp
bolt

"UP" mark

Clearance
 CHASSIS 5-14

FRONT FORK

n,
' @_~
~ I.,!)

@
CD Spacer
0 Washer
@ Spring
© Damper rod
® Spring
i~---- ")/~
~
@ Inner tube
0 Inner tube metal
®
®
Boot
Stopper ring
1.· 1 r®
© rte\
@ Dust seal ®
@ Oil seal ITEM N-m kg-m lb-ft
@ Retainer
@
@ 23 2 .3 16.5
@ Outer tube met al
@ Oil loc k piece @ 30 3 .0 21.5
@) Outer tube
@ Front axle holder © 10 1.0 7 .0

REMOVAL AND DISASSEMBLY

• Remove the front wheel. (Refer to page 5-2.)
• Remove the front brake caliper. (Refer to page 5-8.)
• Remove the front brake hose clamp bolt G).
• Remove the speedometer cable guide bolt @ .
5-15 CHASSIS

• Slightly loosen the front fork cap bolt CD after loosening

the front fork upper clamp bolt@ to facilitate later disas-
sembly.
• Remove the front fork by loosening the lower clamp bolts
@.

• Remove the front fork cap bolt CD, spacer@, washer®

and spring ® ·

• Invert the fork and stroke it several times to drain fork oil.
• Hold the fork inverted for a few minutes to drain fork oil.

• Remove the damper rod bolt with a 8 mm hexagon wrench

and special tools.

ditJ 09940-34520: "T" handle

09940-34592: Attachment "G"

• Remove the damper rod with spring.

 CHASSIS 5-16

• Remove the boot by loosening the clamp screws.

• Remove the dust seal stopper ring.

• Separate the inner tube from the outer tube.

IA CAUTION I
* The removed dust seal and oil seal should be
replaced.
* When separating the inner tube from the outer tube,
both anti-friction metals may be damaged and must
be replaced with new ones.

INSPECTION
FORK SPRING
Measure the fork spring free length. If it is shorter than serv-
ice limit, replace it.
Service Limit: 548 mm (21.6 in)

INNER TUBE AND OUTER TUBE

Inspect the inner tube sliding surface for any scuffing and
check for bend. Inspect the outer tube sliding surface for
any scuffing.
5-17 CHASSIS

DAMPER ROD RING

Inspect the damper rod ring for wear or damage.

REASSEMBLY AND REMOUNTING

Reassemble and remount the front fork in the reverse order
of removal and disassembly, and also carry out the follow-
ing steps:

INNER TUBE METAL

• Install the metal by hand as shown in the illustration.

I A CAUTION I
Use special care to prevent damage to the "Teflon"
coated surface of the Anti-friction metal when mount-
ing it.

OUTER TUBE MET AL, OIL SEAL AND DUST SEAL

• Clean the metal groove of outer tube and metal outer
surface.
• Apply grease to the lip of new oil seal @.

~ 99000-25030: SUZUKI SUPER GREASE "A"

• Install the outer tube metal (D, oil seal retainer @ , oil seal
@ and dust seal @).
~ 09940-52860: Front fork oil seal installer

I A CAUTION I

Use special care to prevent damage to the "Teflon"

coated surface of the Anti-friction metal when mount-
ing it.

• Install the dust seal stopper ring ®·

IA CAUTION I ®
Make sure that the oil seal stopper ring fitted securely.
.,,.,,.,,_(D
®
~ -®
CD
 CHASSIS 5-18

DAMPER ROD BOLT

Apply THREAD LOCK "1342" to the damper rod bolt and
tighten it to the specified torque with the special tools and
8-mm hexagon wrench .

~ 99000-32050: THREAD LOCK "1342"

~
miJ 09940-34520: "T" handle ~
09940-34592: Attachment "G" !
THREAD LOCK "1342"

(.!J Damper rod bolt: 30 N-m (3.0 kg-m, 21.5 lb-ft)

FORK OIL
• For the fork oil, be sure to use a front fork oil whose vis-
cosity rating meets specifications below.

Fork oil type: Fork oil # 10

Fork oil capacity: 565 ml (19.1/19.9 US/Imp oz)

• Hold the front fork vertical and adjust the fork oil level
with the special tool.

NOTE:
When adjusting oil level, remove the fork spring and com-
press the inner tube fully.

diJ 09943-74111: Fork oil level gauge

Oil level: 164 mm (6.5 in)

FORK SPRING
• Install the fork spring close pitch side up.

Upper
= ~ 'o d❖
5-19 CHASSIS

FRONT FORK REMOUNTING

• Align the top surface G) of the inner tube to the top sur-
face @ of the steering stem upper bracket.

• Tighten each bolt to the specified torque .

t!] Front fork cap bolt @ : 23 N-m

(2.3 kg-m, 16.5 lb-ft)
Upper clamp bolt@: 29 N-m (2.9 kg-m, 21.0 lb-ft)
Lower clamp bolt @ : 26 N-m (2.6 kg-m, 19.0 lb-ft)
 CHASSIS 5-20

STEERING
G) Handlebar clamp
@ Handlebar holder
@Cap
© Damper (Upper)
® Steering stem upper bracket
@ Damper (Lower)
(J) Steering stem nut
@ Bearing (Upper)
® Bearing (Lower)
@ Steering stem lower bracket

>----- @)

ITEM N•m kg-m lb-ft

® 23 2.3 16.5
® 90 9.0 65.0
© 25 2.5 18.0
© 29 2.9 21.0
® 26 2.6 19.0

REMOVAL AND DISASSEMBLY

• Remove the front wheel. (Refer to page 5-2.)
• Remove the front fork. (Refer to page 5-14.)
• Remove the speedometer cable clamp and the front
fender.
5-21 CHASSIS

• Remove the headlight cover by removing the three

screws .

• Remove the lead wire cover (D.

• Disconnect each lead wire coupler.

• Remove the headlight bracket with headlight by remov-

ing the four bolts.

• Remove the front brake master cylinder with brake hose.

• Remove the left turn signal light.
 CHASSIS 5-22

• Unlock the clamps.

• Remove the right turn signal light.

.~

• Remove the headlight bracket holders.

• Remove the speedometer cable G).

• Remove the speedometer by removing the nuts.

• Remove the throttle grip case screws.

• Disconnect the throttle cables.

• Remove the left handlebar switch case screws .

• Disconnect the starter cable.
5-23 CHASSIS

• Remove the clutch lever cover.

• Remove the clutch cable (D.

• Remove the indicator light panel @.

• Remove the ignition switch mounting bolts with the spe-

cial tools .

'5tJ 09930-11920: Torx bit JT40H

09930-11940: Bit holder

• Remove the handlebars by removing the four mounting

bolts.

• Remove the handlebar holder by removing the mounting

nuts.
 CHASSIS 5-24

• Remove the steering stem upper bracket by removing the

stem head nut.

• Loosen the steering stem nut with the special tools.

l5iJ 09940-14911 : Steering stem nut socket wrench

09940-14960: Steering stem nut socket

• Remove the steering stem lower bracket.

NOTE:
Hold the steering stem lower bracket by hand to prevent
it from falling.

• Remove the upper bearing .

• Remove the steering stem lower bearing with a chisel.

IA CAUTION ! ,-~.
\ •;- ·
,

The removed bearing should be replaced with a new

one.

• Remove the steering stem bearing races, upper and low-

er with the special tools.

l5iJ 09941-54911: Steering race remover

09941-74910: Steering bearing remover and installer
5-25 CHASSIS

INSPECTION
Inspect the removed parts for the following abnormalities .
* Handlebars distortion
* Handlebar clamp wear
* Race wear and brinelling
* Abnormal noise of bearing
* Distortion of steering stem
Inspect the play of dampers by hands while f ixing it in the
steering stem upper bracket. If the play can be found, replace
the dampers.

REASSEMBLV AND REMOUNTING

Reassemble and remount the steering stem in the reverse
order of removal and disassembly. Pay attention to the fol-
lowing points:

BEARING RACES
• Press in the upper and lower bearing races with the spe-
cial tool.

di;I 09941-34513: Steering outer race installer

BEARING
• Press in the lower bearing with the special tool .

1-Woh 09925-18010: Steering bearing installer

• Apply grease to the upper and lower bearings.

~99000-25030: SUZUKI SUPER GREASE "A"

STEM NUT
• Tighten the steering stem nut to 45 N -m (4 . 5 kg-m , 32.5
lb-ft) with the special tools .

~ 09940-14911 : Steering stem nut wrench

09940-14960: Steering stem nut socket
 CHASSIS 5-26

• Turn the steering stem bracket about five or six times to

the left and right until it locks in position so that the taper
roller bearing will be seated properly.
• Turn back the stem nut by 1/4 - 1 / 2 turn .
... ' 1 /4 - 1/ 2 turn

NOTE:
This adjustment will vary from motorcycle to motorcycle.

• Tighten the steering stem nut to the specified torque .

t!J Steering stem head nut: 90 N-m (9.0 kg-m, 65.0 lb-ft)
NOTE:
Before tightening the steering stem nut, install the front fork
temporarily.

• Tighten the handlebar holder nuts to the specified torque.

t!J Handlebar holder nut: 25 N·m (2.5 kg-m, 18.0 lb-ft)

NOTE:
Before tighten the handlebar holder nuts, install the handle-
bars temporarily.

HANDLEBARS
• Set the handlebars to match its punched mark to the mat-
ing face of the holder.
• Secure the each handlebar clamp in such a way that the
clearances @ ahead and behind of the handlebars are
equalized.

t!J Handlebar clamp bolt: 23 N-m (2.3 kg-m, 16.5 lb-ft)

I A CAUTION I
After performing the adjustment and installing the steer-
ing stem upper bracket, "rock" the front wheel assem-
bly forward and back to ensure that there is no play
and that the procedure was accomplished correctly. Fi-
nally check to be sure that the steering stem moves
freely from left to right with own weight. If play or stiff-
ness is noticeable, re-adjust the steering stem nut.
5-27 CHASSIS

REAR WHEEL

G) Chain adjuster
@ Disc
@ Dust seal ITEM N-m kg-m lb-ft
@ Bearing *100 *10.0 * 72.5
® Spacer ®
® Damper 110 11.0 79.5
(J) Sprocket drum
® Rear sprocket ® 4.5 0.45 3.0
® Spacer © 23 2.3 16.5
@ Bearing
@ Dust seal © 27 2.7 19.5
@ Spacer
NOTE:
@ Rear axle
@ Cotter pin (For Canada and U.S.A.) Asterisk mark (* I indicates the
Canada and U.S.A. models.

REMOVAL
• Remove the cotter pin. (For Canada and U.S.A.)
• Loosen the axle nut.
• Support the motorcycle with a jack.
• Remove the axle nut and axle.
 CHASSIS 5-28

• Remove the rear wheel by disengaging the drive chain.

IA CAUTION I
Do not operate the brake pedal while dismounting the
rear wheel.

• Remove the rear sprocket mounting drum from the wheel.

• Remove the cushions.

• Remove the spacer G) .

• Remove the rear sprocket by removing the mounting nuts
and bolts.

• Remove the dust seal with the special tool.

EiJ 09913-501 21 : Dust seal remover

5-29 CHASSIS

• Remove the brake disc by removing the mounting bolts.

INSPECTION AND DISASSEMBLY

TIRE .... .... . ............. .......... ... . ..... .. Refer to page 2-12.
REAR WHEEL ....................... ..... .. Refer to page 5-10.

WHEEL BEARING AND SPROCKET DRUM BEARING Play

Inspect the play of bearing inner ring by hand while mount-
ed in the wheel or sprocket drum. Rotate the inner ring by
hand to inspect any abnormal noise occurs or rotating
smoothly. Replace the bearing if there is anything unusual.

Remove the both bearing with the special tool in the follow-
ing procedures.
• Insert the adapter into the bearing.

S 09941-50111: Bearing remover

• After inserting the wedge bar from the opposit side, lock
the wedge bar in the slit of the adapter.
• Drive out the bearing by hammering the wedge bar.

I A CAUTION I
The removed bearings should be replaced with new
ones.
 CHASSIS 5-30

• Remove the sprocket drum bearing with the special tool.

l!;tJ 09913-75830: Bearing remover

IA CAUTION I
The removed bearing should be replaced with a new
one.

REAR AXLE
Using a dial gauge, check the rear axle for runout.
If the runout exceeds the limit, replace the rear axle.

Gm 09900-20606: Dial gauge ( 1/100 mm)

09900-20701 : Magnetic stand
09900-21304: "V" block set
Service Limit: 0.25 mm (0.010 in)

REAR SPROCKET
Inspect the sprocket teeth for wear . If they are worn as il-
lustrated, replace the sprocket and drive chain.

Normal wear Excessive wear

REAR SPROCKET DAMPER

Inspect the dampers for wear and damage. If any defects
are found, replace the dampers as a set.
5-31 CHASSIS

REASSEMBLY AND REMOUNTING

Reassemble and remount the rear wheel in the reverse ord-
er of removal and disassembly. Pay attention to the follow-
ing points:

WHEEL BEARING
• Apply grease to the bearings.

~99000-25030: SUZUKI SUPER GREASE "A"

• Install the wheel bearings with the special tools.

em 09924-84510: Bearing installer

09924-84521: Bearing installer
NOTE:
First install the bearing for right side. Seal side of bearing
goes toward outside.

Spacer
Bearing (R) Bearing (L)

Clearan ce

• Install the rear sprocket drum bearing by using a bearing

installer.

em 09913-75810: Bearing installer

NOTE:
Seal side of bearing goes toward outside.
 CHASSIS 5-32

BRAKE DISC
• Apply THREAD LOCK SUPER "1360" to the disc bolts
and tighten them to the specified torque.
NOTE:
Make sure that the brake disc is clean and free of any greasy
matter.
~ 99000-32130: THREAD LOCK SUPER "1360"
~ Disc bolt: 23 N-m (2.3 kg-m, 16.5 lb-ft)

SPROCKET
• Tighten the sprocket nuts to the specified torque.

~Sprocket nut: 27 N-m (2.7 kg-m, 19.5 lb-ft)

NOTE:
Face the stamped mark on the sprocket to outside.

REAR AXLE NUT

• Adjust the chain slack after rear wheel installation. (Refer
to page 2-9.)
• Tighten the axle nut to the specified torque.

~Axle nut: 100 N-m (10.0 kg-m, 72.5 lb-ft)

... For Canada and U.S.A.
110 N-m (11.0 kg-m, 79.5 lb-ft)
... For the others
5-33 CHASSIS

REAR BRAKE

ITEM N-m kg-m lb-ft

® 18 1.8 13.0
® 8 0.8 6.0
© 23 2.3 16.5
© 13 1.3 9.5
G) Piston ® Reservoir t ank
® 10 1.0 7.0 @ Pad (J) Reservoir ta nk hose
® 23 2.3 16.5 @ Insulator @ Brake hose
@Shim ® Piston/cup set
@ 18 1.8 13.0 ® Caliper ho lder

A WARNING
* This brake system is filled with a ethylene glycol-based DOT 4 brake fluid. Do not use or mix
different types of fluid such as silicone-based or petroleum-based.
* Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake
fluid left over from the last servicing or stored for long periods.
* When storing the brake fluid, seal the container completely and keep away from children.
* When replenishing brake fluid, take care not to get dust into fluid.
* When washing brake components, use fresh brake fluid . Never use cleaning solvent .
* A contaminated brake disc or brake pad reduces braking performance. Discard contaminated
pads and clean the disc with high quality brake cleaner or neutral detergent.

IA CAUTION I
Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials etc.
 CHASSIS 5-34

BRAKE PAD REPLACEMENT

• Remove the brake pad mounting pins G).
• Remove the inside pad first.

• Slide the caliper housing to outside then remove the pad

@.

IA CAUTION I
* Do not operate the brake pedal while dismounting
the pads.
* Replace the brake pad as a set, otherwise braking
performance will be adversely affected .

• Install the new pads correclty.

• Tighten th e pad mounting pin G) to the specified torque.

t!JPad mounting pin: 18 N-m (1.8 kg-m, 13.0 lb-ft)

NOTE:
After replacing the brake pads, pump with brake pedal few
times to operate the brake correctly and then check the brake
fluid.level.

BRAKE FLUID REPLACEMENT

• Remove the reservoir tank mounting bolt.
• Replace brake fluid in the same mann er of the front brake.
(Refer to page 5-7.)

1:11 Specification and classification: DOT 4

IA CAUTION I
Bleed air in the brake fluid circuit. (Refer to page 2-11 .)
5-35 CHASSIS

CALIPER REMOVAL AND DISASSEMBLY

• Remove the rear w heel. (Refer to page 5-27 .)
• Place a rag underneath the union bolt on t he brake caliper
to catch any spilled drops of brake fluid.
• Remove the union bolt and cat c h brake fluid in a su itable
receptacle.

I A CAUTION I
Never reuse the brake fluid left over from previous ser-
vicing and stored for long periods.

A WARNING
Brake fluid, if it leaks, will interfere with safe running
and discolor painted surfaces . Check the brake hose
and hose joints for cracks and fluid leakage.

• Remove the caliper with ca liper holder.

• Remove the caliper holder (D.
• Remove the pads. (Refer t o page 5-34.)

• Place a rag over the piston to prevent popping up. Force

out the p iston w ith an air gun.

IACAUTION !
Do not use high pressure air to prevent piston damage.

• Remove the dust seal and piston sea l.

IA CAUTION I
Do not reuse the removed seals to prevent fluid leakage.
 CHASSIS 5-36

CALIPER AND DISC INSPECTION

Inspect the caliper cylinder bore wall for nicks, scratches
or other damage.

Inspect the pistons for damage and wear.

DISC .. ............... ... ................... .... Refer to page 5-10.

0
CALIPER REASSEMBLY AND REMOUNTING
Reassemble and remount the caliper in the reverse order of
removal and disassembly. Pay attention to the following
points :

I A. CAUTION I
* Wash the caliper components with fresh brake fluid
before reassembly. Never use cleaning solvent or
gasoline to wash them.
* Apply brake fluid to the caliper bore and piston to
be inserted into the bore.

I Specification and classification: DOT 4

• Tighten the brake hose union bolt to the specified torque.

~ Brake hose union bolt: 23 N-m (2.3 kg-m, 16.5 lb-ft)

I A. CAUTION I
Bleed air from the system after reassembling the caliper.
(Refer to page 2-11.)
5-37 CHASSIS

MASTER CYLINDER REMOVAL AND

DISASSEMBLY
• Place a cloth underneath the union bolt on the master
cylinder to catch spilled drops of brake fluid.

• Loosen the rear brake rod lock nut G).

• Remove the master cylinder mounting bolts @ .
• Disconnect the brake rod by rotating brake rod G) .

• Disconnect the brake hose @ .

• Remove the reservoir tank by removing the mounting bolt
®·

• Remove the connector by removing the circlip ®·

em 09900-06108: Snap ring pliers
• Remove the 0 -ring (j) .

I A. CAUTION I
The removed O-ring should be replaced with a new one.

• Remove the dust boot.

• Remove the circlip with the special tool.

em 09900-06108: Snap ring pliers

• Remove the rod, piston, primary cup and spring.

 CHASSIS 5-38

MASTER CYLINDER INSPECTION

Inspect the cylinder bore wall for any scratches or other
damage .

Inspect the piston surface for scratches or other damage.

Inspect the primary cup for damage.

MASTER CYLINDER REASSEMBL V AND

REMOUNTING
Reassemble and remount the master cylinder in the reverse
order of removal and disassembly. Pay attention to the fol-
lowing points:

IA CAUTION I
* Wash the master cylinder components with fresh
brake fluid before reassembly. Never use cleaning sol-
vent or gasoline to wash them.
* Apply brake fluid to the cylinder bore and all the in-
ternals to be inserted into the bore.

I Specification and classification: DOT 4

MASTER CYLINDER
• Tighten the bolts and nut to the specified torque.

C!J Master cylinder

mounting bolt CD : 10 N-m (1.0 kg-m, 7 .0 lb-ft)
Master cylinder
rod lock nut @: 18 N-m (1.8 kg-m, 13.0 lb-ft)
Brake hose
Union bolt @ : 23 N -m (2.3 kg-m, 16.5 lb-ft)

IA CAUTION I
* Bleed air from the system after reassembling master
cylinder. (Refer to page 2-11 .)
* Adjust the brake pedal height. (Refer to page 2-11 .)
5-39 CHASSIS USPENSION
MAND
REAR SWINGA=R=- -S
--

G) Shock absorber
0 Cushion rod
@ Cushion lever
@ Swingarm
® Chain guide
® Chain buffer
CZ) Rear axle
® Chain cover
 CHASSIS 5-40

REMOVAL
• Remove the frame covers and seat. (Refer to page 5- 1.)
• Remove the rear wheel. (Refer to page 5-27.)
• Loosen the carburetor clamp screw G).
• Disconnect the crankcase breather hose @ .

• Remove the air cleaner by removing the mounting bolts @ .

• Disconnect the brake hose from the hose guides.

• Remove the drive chain cover and guide.

• Remove the rear shock absorber lower mounting bolt @ .

• Remove the cushion lever mounting nut ® and bolt.
5-41 CHASSIS

• Remove the rear swingarm pivot nut after removing the

caps.
• Remove the rear swingarm by removing the pivot shaft.

• Remove the rear shock absorber.

• Remove the cushion rods with cushion lever.

;:p

• Remove the drive chain buffer.

• Remove the brake hose guides and mud guard.

 CHASSIS 5-42

• Remove the cushion rods.

• Remove the swingarm dust seals and spacers.

• Remove the cushion lever dust seals and spacers.

INSPECTION AND DISASSEMBLY

SWINGARM
Inspect the swingarm for wear or damage.
Inspect the spacer for any flaws or other damage.
Insert the spacer into the bearing and check the play to move
the spacer up and down.
If an excessive play is noted, replace the bearing with a new
one.

• Draw out the swingarm bearings and spacer with the spe-
cial tools.

lmil 09923-74510: Bearing remover

09930-30102: Sliding shaft

IA CAUTION I
The romoved bearings should be replaced with new
ones.
5-43 CHASSIS

CUSHION LEVER
Inspect the spacer for any flaws or other damage.
Insert the spacer into the bearing and check the play to move
the spacer up and down. If an excessive play is noted,
replace the bearing with new ones.

• Draw out the bearing with the special tools and appropri-
ate tool.

S 09923-73210: Bearing remover

09930-30102: Sliding shaft

I A CAUTION I

The removed bearing should be replaced with new

ones.

SHOCK ABSORBER
Inspect the shock absorber for oil leakage or other damage.
If any defects are found, replace the shock absorber with
new a one.

SWINGARM PIVOT SHAFT

Using a dial gauge, check the pivot shaft runout and replace
it if the runout exceeds the limit.

mil 09900-20606: Dial gauge

09900-20701: Magnetic stand
09900-21304: V-block
Service Limit: 0.3 mm (0.01 in)
 CHASSIS 5-44

REASSEMBLY AND REMOUNTING

Reassemble and remount the rear swingarm and suspension
in the reverse order of removal and disassembly. Pay atten-
tion to the following points:

SWINGARM BEARING
• Install the new bearing with the special tool.

mm 09941-34513: Bearing installer

NOTE:
When installing the bearing, punch-marked side of bearing
faces outside.

CUSHION LEVER BEARING

• Install the new bearing with the special tool.

mm 09924-84521: Bearing installer

NOTE:
When installing the bearing, punch-mark side of bearing
faces outside.

• Remount the rear suspension. (Refer to page 5-45.)

5-45 CHASSIS

REASSEMBLING INFORMATION

Left+- . . Right

ITEM N -m kg-m lb-ft

® 55 5.5 40.0
® 55 5.5 40.0
© 100 10.0 72.5
© 80 8.0 58.0
® 100 10.0 72.5
CE) 77 7.7 55.5
 CHASSIS 5-46

FINAL INSPECTION AND ADJUSTMENT

After installing the rear suspension and wheel, the follow-
ing adjustments are required before driving.
* Drive chain ............................. . ............. Page 2- 9.
* Rear brake pedal height .... .. .... . ............... Page 2- 11 .
* Tire pressure .. ..................... ... ...... ........ . Page 2- 13.

SHOCK ABSORBER SPRING PRE-LOAD

ADJUSTMENT
Spring pre-load is adjustable by changing the spring adjuster
ring position after removing the shock absorber. Turning the
spring adjuster ring counterclockwise or clockwise as viewed
from for increase or decrease the spring pre-load after
loosening the adjuster lock ring. The standard set length is
247.5 mm.
After adjusting the pre-load, tighten the spring adjuster lock
ring securely.

~ 09910-60611: Universal clamp wrench

IACAUTION I
Do not set the spring to the length less than 238.5 mm
(9 .4 in).

--------
SPRING SETTING TABLE

Spring pre-set length

Softest 253. 5 mm ( 10.0 in)

Standard 247.5 mm (9.7 in)

Stiffest 238.5 mm (9.4 in)

SHOCK ABSORBER DAMPING FORCE ADJUSTMENT

Fully turn the damping force adjuster clockwise. It is at
stiffest position and turn it out to the standard setting po-
sition.

STD position: 8 clicks turns out

5-47 CHASSIS

LOWERING THE SEAT HEIGHT

The seat height can be lowered 40 mm by changing the lo-
cation of the inner parts of the front fork and rear shock ab-
sorber and replace the optional side stand.

OPTIONAL PARTS SUPPLY

Part No. Part Name PCS Note
Non Side stand @ (Silver painting) 1
For E-03
09248- 10006 Plug 1 E-24
42300-32820 E-28
62184-32E00 Plate 1
E-33
68380-32E 1 0 Label set 1
Non Side stand @ (Silver painting) 1
09248-10006 Plug 1
42300-32810 For the others
62184-32E00 Plate 1
68380-32E00 Label set 1

NOTE:
Side stand length @is defferent from @in the above chart.

SPECIAL TOOLS

This special tool is used with tool

This special tool is used for loosening and tight- (09940-34520) for loosening and tightening the
ening the front fork damper rod bolt. front fork damper rod bolt.
09940-34520: "T" handle 09940-34592: Attachment "G"

This special tool is used for adjusting the front This special tool is used for loosening and tight-
fork oil level. ening the rear shock absorber ring .
09943-7 4111 : Front fork oil level gauge 09910-60611: Universal clamp wrench
FRONT FORK

~ tt:::l,
r ------
71
//
©
~1
I
©-----0 I
®U
G) Spacer
@ Wa~her
@ Spring
@ Da~per
@ Spring

®
0 Gasket
Speedom eter gearbox
@ Front wheel
® Fron
@ Spacte~rake caliper

Standard Spacer CD Changed sp acer CD

position position
5-49 CHASSIS

REMOVAL AND DISASSEMBLY

• Loosen the front axle holder nuts G) and axle @.
• Carefully position a jack under the chassis tubes and raise
until the front wheel is slightly off the ground.
• Remove the front wheel by removing the axle.

• Remove the front brake caliper mounting bolts @.

• Remove the front brake hose clamp bolt @) and speedom-
eter cable guide bolt ® ·

• Slightly loosen the front fork cap bolt ® after loosening

the front fork upper clamp bolt (J) to facilitate later disas-
sembly .
• Remove the front fork by loosening the lower clamp bolts
®·
• Remove the other side front fork the same way.

• Remove the front fork cap bolt @ , spacer®, washer @)

and spring @.

.,
ii
- ~ - - - -- ,., . ~1.

• Invert the front fork and stroke it several times to drain

fork oil.
 CHASSIS 5-50

• Remove the damper rod bolt with a 8 mm hexagon wrenc h

and special tools.

Em 09940-34520: "T" handle

09940-34592: Attachment "G"

• Remove the damper rod G) with spring @ .

REASSEMBLY AND REMOUNTING

Reassemble and remount th e front fork and front wheel in
the reverse order of removal and disassembly. Pay atten-
tion to the following points:
• Install the removed spacer @ and spring @ to the damp-
er rod as shown in the photo.

• Insert the damper rod assembly to the inner tube with the
special tool.

Em 09940-34520: "T" handle

09940-34592: Attachment "G"

• Apply THREAD LOCK "1342" to the damper rod bolt.

. . 99000-32050: THREAD LOCK "1342" ©

IA CAUTION I
Use a new gasket @ to prevent oil leakage.
~

I
THREAD LOCK " 1342"
5-51 CHASSIS

• Tighten the damper rod bolt to the specified torque with

a 8 mm hexagon wrench and special tools .

~ Damper rod bolt: 30 N·m (3.0 kg-m, 21.5 lb-ft)

~ 09940-34520: "T" handle
09940-34592: Attachment "G"

• Pour specified fork oil into the inner tube.

G Fork oil type: Fork oil # 10

99000-99044-10G: SUZUKI FORK OIL #10
Capacity (each leg): 563 ml (19.0/19.8 US/Imp oz)

• Hold the front fork vertical and adjust the fork oil level
with the special tool.

1Mih 09943-74111: Fork oil level gauge

Oil level: 150 mm (5.9 in)
NOTE:
When adjusting the oil level, remove the fork spring and com-
press the inner tube fully.

• Install the fork spring close pitch side up.

• Install the washer and fork cap bolt, and tighten the cap
bolt your hand.

• When remounting the front fork, align the upper surface

G) of the inner tube with the upper surface 0 of the steer-
ing stem upper bracket.
 CHASSIS 5-52

• Tighten the front fork lower clamp bolts and fork c ap bolt
to the specified torque .
• Tighten the front fork upper clamp bolt to the specified
torque.

t!J Front fork cap bolt: 23 N-m (2 .3 kg-m, 16.5 lb-ft)

Upper clamp bolt : 29 N·m (2.9 kg-m, 21.0 lb-ft)
Lower clamp bolt : 26 N·m (2.6 kg-m, 19.0 lb-ft)

• Install the brake hose clamp and speedometer cable guide

correctly.
• Tighten the front brake caliper mounting bolts to the speci-
fied torque.

t!J Brake caliper mounting bolt: 26 N ·m

(2.6 kg-m, 19 .0 lb-ft)

• Align the drive lugs G) with the recesses 0 of the wheel

hub.

• Before tightening the front axle, position the stopper @

of the speedometer gearbox against stopper @.

• Tighten the front axle to the specified torque and then

move the front fork up and down .
• Tighten the upper axle holder nuts first and then lower
nuts to the specified torque.

t!J Front axle: 65 N ·m (6.5 kg-m, 4 7 .0 lb-ft)

Axle holder nut: 10 N·m (1.0 kg-m, 7 .0 lb-ft)
5-53 CHASSIS

REAR SHOCK ABSORBER

G) Rear shock absorber

@ Plate (Optional part)
@ Plug (Optional part)
@ Spring seat

©
U....---Eh---1@

@@-➔11 ®
Standard spring seat @ and mounting Changed spring seat @ and mounting
position position.

ITEM N•m kg-m lb-ft

® 55 5.5 40.0
@ 30 3.0 21.5
 CHASSIS 5-54

REMOVAL AND DISASSEMBLY

• Remove the right and left frame covers.

• Remove the seat by removing mounting bolts.

• Loosen the carburetor clamp screw G).

• Disconnect the crankcase breather hose @ .
• Remove the air cleaner by removing mounting bolts ®·

• Remove the rear shock absorber by removing mounting

bolts (@ , @ ).
5-55 CHASSIS

• Loosen the spring pre-load adjuster lock ring and adjuster

ring fully with the special tool.

lmi1 09910-60611 : Universal clamp wrench

• Remove the spring seat G) and plate @ by moving the

cushion @ to the shock absorber cylinder side.

NOTE:
The removed plate @ will not be used when reassembling
the shock absorber.

REASSEMBLY AND REMOUNTING

Reassemble and remount the rear shock absorber and air
cleaner in the reverse order of removal and disassembly. Pay
attention to the following points:
• When installing the spring seat G) to the shock absorber,
invert it from standard position.

• Position the cushion @ against washer @ .

• Tighten the spring adjuster ring and adjust the spring pre-
load with the special tool. The standard set length is 24 7. 5
mm.
• After adjusting the pre-load, tighten the adjuster lock ring
securely.

lmi109910-60611: Universal clamp wrench

SPRING SETTING TABLE

-------
Softest
Standard
Spring pre-set length
253.5 mm (10.0 in)
247.5 mm (9.7 in)
Stiffest 238.5 mm (9.4 in)
 CHASSIS 5-56

• Tighten the plug G) (optional part) to the lower mounting

part of shock absorber@ to the specified torque. LH- -RH

~ Plug: 30 N·m (3.0 kg-m, 21.5 lb-ft) ®

• Install the shock absorber lower plate @ (optional part)
as shown in the illustration .
• Install the rear shock absorber and tighten it to the speci-
fied torque.

~ Mounting bolt : 55 N·m (5.5 kg-m, 40.0 lb-ft)

1 (j)

(Upper and lower)

SIDE STAND

G) Side stand
@ Inner spring
® Outer spring

ITEM N-m kg-m lb-ft

® 50 5.0 36.0
® 55 5.5 40.0
5-57 CHASSIS

SIDE STAND REMOVAL AND INSTALLATION

• Support the motorcycle with jack or wooden block.
• Remove the original side stand by removing mounting nut
and bolt.

• Apply SUZUKI SUPER GREASE "A" to the side stand

pivot portion and spring hooks .

~99000-25030: SUZUKI SUPER GREASE " A"

Side stand
• Install the optional shorter side stand (silver-colored) and
springs correctly as shown in the illustration.

• Tighten the side stand mounting bolt and nut to the speci-
fied torque.

~ Bolt: 50 N·m (5.0 kg-m, 36.0 lb-ft)

Nut: 55 N·m (5.5 kg-m, 40.0 lb-ft)

A WARNING
A new, shorter, silver-colored optional side stand must
be installed for safe parking.

NOTE:
Make sure that the side stand switch operation after in-
stalling the side stand.

WARNING LABEL Warning label

• Attach the warning label (optional part) to the swingarm
Tire pressure label
as shown in the illustration.
NOTE:
Select the appropriate language label for your country.

Swingarm left side

 ELECTRICAL SYSTEM

- - - -- - - - - - CONTENTS--- -- - - - -~
CA UT/ONS IN SERVICING · ·· ·· · · · ·· · · · ·· ·· · ·· · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · 6- 1
LOCATION OF ELECTRICAL COMPONENTS ............ · .... · ...... · .... · .. 6- 3
CHARGING SYSTEM .......... .......... ... .... .... ............... ............. ..... ... 6- 4
DESCRIPTION · .. · .... · .... · ·.. · .. · .... · .. · · · ·· .. · .. .. · · · .... · · .. .. · · · .... · .... · · · .. · ·.. · 6- 4
TROUBLESHOOTING · · · · · ·· · · · ·· ·· · · · ·· · ·· ·· · · · ·· · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · ·· 6- 5
INSPECTION .. · .. .. · .... · .... · .... · ·· .... · .... · ·.. · · .. .. · · .... · · .. · .. · ...... · .... · · · .... · 6 - 6
STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK
SYSTEM ........ .............. ............. ............. .................... ..... ............. 6- 9
STARTER SYSTEM DESCRIPTION ......... ............ ........... ............ 6- 9
SIDE-STAND/IGNITION INTERLOCK SYSTEM DESCRIPTION .... 6- 9
TROUBLESHOOT/NG · .. · .... · ·.. · · ·· .. · ·.... · · .... · ·.... · · .... · · .... · · · .... · .... · · · · 6-11
STARTER MOTOR REMOVAL AND DISASSEMBLY .................. 6-12
STARTER MOTOR INSPECTION ............................................... 6-12
STARTER MOTOR REASSEMBLY ............................................. 6-13
STARTER RELA Y INSPECTION ...... · .... · ...... · .............. · ·.. · .......... · 6-14
SIDE-STAND/IGNITION INTERLOCK SYSTEM INSPECTION ..... . 6-15
IGNITION SYSTEM .. · · .. .. · .... · · · .... · .. · ·· .... · .... · · · .... · · .... · · · .... · .. .... · · ..... · 6-17
DESCRIPTION · · · · · · · · · · · · · · · · · · · · · · · · · · ·· ·· · ·· ·· · · · ·· · · · ·· ·· ·· · ·· ·· · · · ·· ·· · · · ·· ·· · · · · · · · 6-17
TROUBLESHOOTING · · · · · · · · · · · · · · · · · ·· · ·· ·· ·· · ·· ·· · · · ·· ·· · · · ·· · · · · · · · ·· · · · · · · · · · · · · 6-18
INSPECTION · · ·.... · .... · .... · .... · · · .... · .... · ·· .. · ·· .... · ·· .. · · .... · · · · ·.... · ...... · .. · 6-19
SPEEDOMETER AND PILOT IND/CA TOR ...... · ...... · ................ .. · .... · 6-22
REMOVAL AND DISASSEMBLY ..... .. .. ..... ............ ...................... 6-22
INSPECTION · ·· · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · ·· ·· · ·· ·· ·· · ·· · · · · · ·· ·· · · · ·· ·· · ·· ·· ·· · · · · · ·· · 6-22
LAMPS ........................................................................................ 6-24
HEADLIGHT·················· ······ ················ ······ ····· ·· ···· ·········· ····· ·· ···· 6-24
TAIL/BRAKE LIGHT, TURN SIGNAL LIGHT AND
LICENSE PLATE LIGHT · · · · · · · · · · · · · · · · · · · · ·· · · · ·· ·· · · · ·· ·· · ·· ·· ·· · ·· ·· · · · · · ·· · · · · · · 6-25
TURN SIGNAL RELAY · · · · · · · · · · · · · · · · · · · · · ·· · · · · · ·· · · · ·· ·· · ·· ·· ·· · ·· ·· · · · · · · · · · · · · · 6 -26
SWITCHES · · · ·· ·· · · · ·· · · · ·· · · · · · ·· · · · · · · · · · · · · · · · · · · · ·· · · · ·· ·· · · · ·· · · · ·· ·· · · · ·· ·· · · · · · ·· · · · · 6-26
BATTERY ....................... .. ... ..... .... ............ .. ... .. ..... ......... .............. 6-27
SPECIFICATIONS .............. ........... ............ ..... ............................ 6-27
INITIAL CHARGING ············ ·· ········ ··· ···· ··········· ····· ·· ·· ····· ··· ········ · 6-27
SERVICING .. · · ·.. · · · .. · · · .... · .... · · · .. .. · .. · · · · · .. · ·· .. · ·· .......... · · ·· .... · · · ·.... · · · · 6-28
RECHARGING OPERATION · · · · · · · · · · · · · · · · · · ·· ·· · · · ·· ·· · · · ·· ·· · ·· ·· ·· ·· · · · ·· ·· · · · 6-29
6-1 ELECTRICAL SYSTEM

CAUTIONS IN SERVICING
CONNECTOR
• When connecting a connector, be sure to push it in untill
a click is felt.
• Inspect the connector for corrosion, contamination and
breakage in its cover .

COUPLER
• With a lock type coupler, be sure to release the lock be-
fore disconnecting it and push it in fully till the lock works
when connecting it.
• When disconnecting the coupler, be sure to hold the cou-
pler itself and do not pull the lead wires.
• Inspect each terminal on the coupler for being loose or
bent.
• Inspect each terminal for corrosion and contamination.

CLAMP
• Clamp the wire harness at such positions as indicated in
CORRECT INCORRECT
" WIRE HARNESS ROUTING" (Refer to pages 7-12 and
13.).
• Bend the clamp properly so that the wire harness is
clamped securely.
• In clamping the wire harness, use care not to allow it to
hang down.
• Do not use wire or any other substitute for the band type
clamp.

FUSE
• When a fuse blows, always investigate the cause , cor-
rect it and then replace the fu se.
• Do not use a fuse of a different capacity.
• Do not use wire or any oth er substitute for the fus e.

SEMI-CONDUCTOR EQUIPPED PART

• Be careful not to drop the part with a semi-conductor built INCORRECT

in such as a COi unit and regulator/ rectifier .

• When inspecting these parts, follow inspection instruc-
tion strictly. Neglecting proper procedure may cause
damage to these parts.
 ELECTRICAL SYSTEM 6-2

BATTERY
• The MF battery used in this vehicle does not require main-
tenance as inspection of electrolyte level and replenish -
ment of water.
• No hydrogen gas is produced during normal charging of
the battery, but such gas may be produced when it is over-
charged . Therefore, do not bring fire near the battery while
it is being charged.
• Note that the charging system for the MF battery is differ-
ent from that of an ordinary battery . Do not replace with
an ordinary battery.

CONNECTING BATTERY
• When disconnecting terminals from the battery for dis-
assembly or servicing, be sure to disconnect the nega-
tive ( 8 ) terminal first.
• When connecting terminals to the battery, be sure to con-
nect the positive ( (±) ) terminal first.
• If the terminal is found corroded, remove the battery, pour
warm water over it and clean with a wire brush.
• Upon completion of connection, apply grease lightly.
• Put a cover over the positive ( (±) ) terminal .

WIRING PROCEDURE
• Route the wire harness properly according to "WIRE HAR-
NESS ROUTING" (Refer to pages 7- 12 and 13.).

USING POCKET TESTER

• Be sure to use positive ( (±) ) and negative { 8 ) probes
of the tester properly. Their false use may cause damag e
in the tester.
• If the voltage and current values are not known, start
measuring in the higher range.
• Before measuring the resistance and after changing the
resistance range, always perform O n adjustment.
• Taking a measurement where voltage is applied in the
resistance range may cause damage in the tester. When
measuring resistance, check to make sure that no voltage
is applied there.
• After using the tester, turn the switch to the OFF position .
6-3 ELECTRICAL SYSTEM

LOCATION OF ELECTRICAL COMPONENTS

CD Battery
@ Fuse
G) Starter relay
© Generator
® Ignition coil
® Starter motor
(j) Horn
@ CDI unit
® Diode
@ Turn signal relay
@ Regulator/rectifier
@ Side-stand/ignition interlock relay
@ Side-stand switch
 ELECTRICAL SYSTEM 6-4

CHARGING SYSTEM
DESCRIPTION
The circuit of the charging system is indicated in the figure, which is composed of an AC generator,
regulator/rectifier unit and battery.
The AC current generated from AC generator is converted by rectifier and is turned into DC current,
then it charges the battery.

,----------- ------------, Ignition switch

-:-
1
0
SCR SCR SCR : Ba t tery <{
I
I 0
...J

AC generator

L - - - - - - - _______________ J
Regulator /rectifier

/ /
6-5 ELECTRICAL SYSTEM

TROUBLESHOOTING

Battery runs down quickly.

Check accessories which excessively

Installed - - ---• Remove accessories.
waste electric power.

Not installed
t
Inspect battery leak current. f - -- - - Leak ----J► • Short circuit of wire harness.
(Refer to page 6-6.) • Loose or disconnected wires.
I • Faulty battery.
No leak
t
Inspect charging voltage
between battery terminals. f----- Correct-- -....- • Faulty battery.
(Refer to page 6-6.) • Abnormal driving condition.
I
Incorrect
t
Inspect continuity generator >---- No continuity----,►~ • Faulty generator coils or discon-
coils. (Refer to page 6-7 .) nected lead wires.
I
Correct
f
Inspect generator no-load f---- Incorrect-----• Faulty generator rotor.
voltage. (Refer to page 6- 7.)
I
Correct
t
Inspect regulator /rectifier.
>---- Incorrect- - -....-• Faulty regulator/rectifier.
(Refer to page 6-8.)
I
Correct

Inspect wiri~gs. 1---- lncorrect------1~ • Short circuit of wire harness.

• Poor contact of couplers.
Correct

[__ _ _ _ _ _ _ _ _ _ __ __ _ • Faulty battery .

( Others )

Battery overcharge • Faulty regulator/rectifier

• Faulty battery
• Poor contact of generator lead wire coupler
 ELECTRICAL SYSTEM 6-6

INSPECTION
BATTERY LEAK CURRENT INSPECTION
• Remove the frame covers and seat.
• Remove the battery holder plate CD .
• Turn the ignition switch to the OFF position.
• Disconnect the battery 8 lead wire.
Note that leakage is indicated if the needle swings even a
little when the milliampare meter of the pocket tester is con-
nected between a 8 terminal and the lead wire of the bat-
tery as shown.

1-Moh 09900-25002: Pocket tester

IA CAUTION I
• Because the 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 measuring current.

When leakage is found , look for the part where the needle
does not swing through the couplers and connectors are re-
moved one by one.

CHARGING OUTPUT INSPECTION

• Remove the frame covers and seat.
• Remove the battery holder plate.
• Start the engine and keep it running at 5 000 r/min. with
lighting switch turned ON and dimmer switch turned HI
position.
Measure the DC voltage between the battery terminals (±)
and 8 with a pocket tester. If the tester reads under the
specified value, inspect the generator coil and regula-
tor/rectifier.

IA CAUTION I
If the pocket tester is set to read current or resistance
and a voltage is applied across the test probes, damage
will result . Therefore, it is important that the tester knob
on the pocket tester be set the proper position before
making any measurements. (D C V )
Tester

NOTE:
When making this test, be sure that the battery is fully-
charge d condition.
miJ 09900-25002: Pocket tester
~Tester knob indication : DC 25V

Charging output
Standard: 13.0-16.0 at 5 000 r/min.
6-7 ELECTRICAL SYSTEM

GENERATOR COIL CONTINUITY INSPECTION

• Remove the frame covers and seat.
• Disconnect the generator lead wire coupler (D.

Using a pocket tester, inspect the continuity between the

three lead wires.
If there is no continuity, replace the generator coil with a
new one.

ail 09900-25002: Pocket tester

~Tester knob indication: X 10 range

GENERATOR NO-LOAD PERFORMANCE INSPECTION

• Remove the frame covers and seat.
• Disconnect the generator lead wire coupler CD .
• Start the engine and keep it running at 5 000 r/min.

Using a pocket tester, measure the voltage between the

three lead wires.
If the tester reads under the specified value, replace the
generator coil with a new one.

miJ 09900-25002: Pocket tester

~Tester knob indication: AC250V

Generator no-load performance:

More than 75V/5 000 r/min
(When engine is cold)
 ELECTRICAL SYSTEM 6-8

REGULATOR/RECTIFIER INSPECTION
• Remove the right frame cover.
• Disconnect the regulator/rectifier coupler G).
Using a pocket tester ( x 1 kQ range), measure the resistance
between the terminals in the following table.
If resistance is incorrect, replace the regulator/rectifier.

Imm 09900-25002: Pocket tester

~Tester knob indication: X 1 kQ range
Unit: kO
~ ® Probe of tester to:
....,
0

cii
....,
® e Y1 Y2 Y3
Cf) ------------
® 00 00 00 00

-
....,
e
Q)

0 ----------
1 -20 1 - 10
........._____
1 - 10 1 - 10
Q)
..Cl
Y1 1-10 --------------
00 00 00
0
ct Y2 1 - 10 00 00 00

CD Y3 1-10 00 00
------------
00

oo: Infinity ----------

NOTE:
As diodes, thyristors are used inside this regulator/rectifi-
er, the resistance values will differ when an ohmmeter other
than the SUZUKI pocket tester is used.
6-9 ELECTRICAL SYSTEM

STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK

SYSTEM
STARTER SYSTEM DESCRIPTION
The starter system is shown in the diagram below: namely, the starter motor, starter relay, side-stand
relay, side-stand switch, neutral switch, clutch lever position switch, starter switch, engine stop
switch, IG switch and battery.
Depressing the starter switch (on the right handlebars switch box) energizes the relay , causing the
contact points to close which connects the starter motor to the battery. The motor draws about
70 amperes to start the engine.

Starter
relay

Side-stand Clutch lever Starter Engine stop

position switch switch switch
;,ci:

Diode Ignition
switch

■ switch Neutral -' >

......ai
l~
switch

SIDE-STAND/IGNITION INTERLOCK SYSTEM DESCRIPTION

This side-stand/ignition interlock system is to prevent starting the motorcycle with the side-stand
left down. The system is operated by an electric circuit provided between the battery and ignition coil.
To CDI and ignition coil
Engine &tarter Clutch lever
stop witch position switch
switch ~
Ignition Side-stand relay
Fuse switch

Starter relay Starter motor

Neutral
indicato r
R light
J_
TBattery
'
~i
Bl
I
--i Side-stand
YB

\ Neutral ? switch
switch B/W

l/ i
WIRE COLOR
R : Red B/W : Black with White tracer O : Orange
G : Green BI/B : Blue with Black tracer Y/B : Yellow with Black tracer
Bl : Blue
 ELECTRICAL SYSTEM 6-10

The circuit consists of relay, lamp, diode and switches and decides to live the ignition coil depending
on the position of the TRANSMISSION and SIDE-STAND with the neutral and side-stand switches
working mutually.
The ignition coil lives only in two situations as follows.
1. Transmission: "NEUTRAL (ON)" Side-stand: " DOWN (OFF)"
The current flow @turns "ON" the relay and the ignition coil lives even the side-stand is kept
down. This is or warming up the engine.

To CDI and ignition coil

Engine Starter Clutch lever
stop switch position switch
,.........sw.,.i tc h - - u ~ Side-stand relay
0 7 0
Ignition
switch

Side-stand

r switch
Side-stand
" DOWN POSITION"

2. Side-stand: "UP-RIGHT (ON)"

The current flow @turns "ON" the relay and the ignition coil lives. The engine can be easily
started at any transmission position.

Side-stand
relay

Ignition
switch

Neutral
indicator
light

Neutral Side-stand
switch switch
"OFF" Side-stand
"UP-RIGHT POSITION"
6-11 ELECTRICAL SYSTEM

TROUBLESHOOTING

( Starter motor will not run. )

The transmission is in neutral . Check whether to run the

Turn on the ignition switch with starter motor when connect the
the engine stop switch in "RUN" starter motor terminal to the
position. t---- Clicks--- --1-~ battery (±) terminal directly.
Check whether to hear the click (Do not use thin wire, because
noise from the starter relay when a large amount of current
the starter button is pushed. flows .)
I I
Run Not run

No click i
l
• Faulty starter motor

• Faulty starter relay

• Loosen or disconnected starter
motor lead wire
Measure the starter relay voltage
at the starter relay connectors
voltage---;•
►•
(between Y /G (±) and B/W Gl - Not Faulty ignition switch
when the starter button is pushed . • Faulty engine stop switch
• Faulty neutral switch
• Faulty diode
I
Voltage measured
•
•
Faulty side-stand relay
Faulty starter button
• Faulty clutch lever position switch
• Poor contact of connector

l
Check the starter relay.
• Open circuit in wiring harness

(Refer to page 6-1 4.) Incorrect·- -- -• Faulty starter relay

Correct
' - - - - - -- -- -- -- - - - - - - • Poor contact of the starter relay

Starter motor runs when the transmission is in neutral, but does not run with the transmission in
any position except neutral, with the side-stand up position.

Check the side-stand switch .

(Refer to page 6-1 6.) - Incorrect- --~• Faulty side-stand switch

I
Correct
' - - - - - -- - -- - - - - - -- - - • Open circuit in wiring harness
• Poor contact of connector

( Others )

Engine does not turn • Faulty starter clutch

though starter motor runs .
 ELECTRICAL SYSTEM 6-12

STARTER MOTOR REMOVAL AND

DISASSEMBLY
• Remove the exhaust pipe.
• Remove the cam drive chain tensioner.
• Disconnect the starter motor lead wire and remove the
starter motor by removing the mounting bolts.
(Refer to page 3-11.)

• Disassemble the starter motor as shown in the illustration.

CD 0-ring
@ Housing end (inside )
@ Washer set
© 0-ring (2 pcs)
® Starter motor case
® Armature
(j) Washer set
@ Brush holder
® Brush spring
@ Housing end (outside)

STARTER MOTOR INSPECTION

CARBON BRUSH
Inspect the brushed for abnormal wear, crack or smooth-
ness in the brush holder.
If the brush has failed, replace the brush sub assy.
6-13 ELECTRICAL SYSTEM

COMMUTATOR
Inspect the commutator for discoloration, abnormal wear
Segment
or undercut @ .
If the commutator is abnormally worn, replace the armature.
When surface is descolored, polish it with # 400 sand paper ~
and clean it with dry cloth . ~ © r
If there is no undercut, scrape out the insulator G) with saw
blade.

ARMATURE COIL INSPECTION

Check for continuity between each segment.
Check for continuity between each segment and the arma-
ture shaft.
If there is no continuity between the segments or there is
continuity between the segments and shaft, replace the ar- -:~.
mature with a new one. ·<:~_
.____=' ,:.·.·--.·-~--' ''"":

OIL SEAL INSPECTION

Check the seal lip for damage or leakage.
If any damage is found, replace the bracket.

STARTER MOTOR REASSEMBLY

Reassemble the starter motor in the revers e order of disas-
sembly. Pay attention to the following points:

IACAUTION I
Replace the O-rings with new ones to prevent oil leak-
age and moisture.

• Apply SUZUKI SUPER GREASE "A" to the lip of the oil

seal.

~99000-25030 : SUZUKI SUPER GREASE "A"

 ELECTRICAL SYSTEM 6-14

• Apply a small quantity of MOLY PASTE to the armature

shaft .

~ 99000-25140: SUZUKI MOLY PASTE

• Apply a small quantity of THREAD LOCK" 1342" to the

starter motor housing bolts .

. . 99000-32050: THREAD LOCK "1342"

STARTER RELAY INSPECTION

• Remove the right frame cover .
• Remove the starter relay cover.
• Disconnect the starter motor lead wire and battery lead
wire at the starter relay.
• Disconnect the lead wire coupler from the starter relay .

Apply 1 2 volts to G) and 0 terminals, inspect the continui-

ty between the terminals, positive and negative.
If the starter relay is in sound condition, continuity is found.

E 09900-25002: Pocket tester

~Tester knob indication: X 10 range

IA CAUTION I
Do not apply a battery voltage more than 5 seconds
to the starter relay as it may overheat and cause
damage to the relay coil.

Check the coil for "open", "ground" and ohmic resistance .

The coil is in good condition if the resistance is as follows.

E 09900-25002: Pocket tester

~Tester knob indication : X 10 range
Starter relay resistance
Standard : 3- 50
6-15 ELECTRICAL SYSTEM

STARTER RELAY CIRCUIT

DIAGRAM
To starter motor 8 (±) To battery

I
I

L ._
SIDE-STAND/IGNITION INTERLOCK SYSTEM
INSPECTION
If the interlock system does not operate properly, check each
component. If any abnormality is found, replace the com-
ponent with a new one.

lmiJ 09900-25002: Pocket tester

DIODE
The diode is located under the seat.
The diode can pass current only in one direction.
Check the continuity between CD and @ . If one way con-
tinuity the diode is in good condition .
Also check the continuity between @ and @ as required.

~ f ~,~ I
-rIT CD ® ®
 ELECTRICAL SYSTEM 6-16

NEUTRAL SWITCH
The neutral lead wire coupler is located behind the left frame
cover.
• Remove the frame covers and seat.
• Disconnect the neutral switch lead and check the con-
tinuity between Blue and Ground with the transmission
in "NEUTRAL".

SIDE-STAND SWITCH

~
Green Black/White
(8 Proboe) ((±) Proboe)
ON
(UP-right position)
OFF
(Down position)

SIDE-STAND/IGNITION INTERLOCK RELAY

The side-stand/ignition interlock relay is located under the
seat.
• Remove the frame covers and seat.

First, check the insulation between G) and @ terminals with

pocket tester. Then apply 12 volts to @ and @ terminals, G) @
(±) to @ and 8 to @ , and check the continuity between
G) and @ .
If there is no continuity, replace it with a new one.

1ii1o9900-25002: Pocket tester

~ Tester knob indication: X 10 range
2 ©

CLUTCH LEVER POSITION SWITCH

~ Yellow /Green Yellow /Green

ON
(Squeeze)

OFF
6-17 ELECTRICAL SYSTEM

IGNITION SYSTEM
DESCRIPTION
In the capacitor discharged ignition system, the electrical energy generated by the magneto charges
the capacitor. This energy is released in a single surge at the specified ignition timing point, and
current flows through the primary side of the ignition coil. A high voltage current is induced in the
secondary windings of the ignition coil resulting in strong spark between the spark plug gap.

Neutral indicator
light
w
,I I Ignition
Engine stop

w(D switch
switch
0--0-e------<T o---+--0/W

Lg

R . - - - - - - - - - - - - + - - W/BI
~ - - - - - - - - - 1 - - B/W CDI
unit

-I Side-stand

-·-
: Battery

l
switch

G) : Pick-up coil Spark

l plug1
I
@ : Power source coil
@ : Neutral switch

WIRE COLOR
B Black 0 Orange
W White R Red
G Green Lg Light green
Bl Blu e 0 /W: Orange with White tracer
B/W: Black with White tracer
W /BI: White with Blue tracer
 ELECTRICAL SYSTEM 6-18

TROUBLESHOOTING

No spark at plugs * Check that the transmission is in neutral position and

the engine stop switch is in the RUN position. Inspect
that the fuse is not blown before the diagnosis.

Check the CDI couplers for poor

contact.
Looseness----l►► • Poor contact of coupler

Correct

Inspect the battery voltage between

input lead wires (0/W and B/ W) at the
Incorrect - -.....,• -• Faulty ignition switch
CDI unit with the ignition switch "ON"
• Faulty side-stand relay
position.
• Faulty engine stop switch
• Broken wire harness or poor
Correct contact of related circuit
connecters

Inspect the resistance of pick-up coil (Bl

and G) and power source coil (B and lncorrect ---1►►• Faulty pick-up coil
W). (Refer to page 6-20.) • Faulty power source coil

Correct
~ - - - -- - - - - - - - - - - - - • Faulty CDI
• Faulty ignition coil

* If only one spark plug does not spark, it is defective

or high-tension cord is disconnected because one ig-
nition coil furnishes two spark plugs.
6-19 ELECTRICAL SYSTEM

INSPECTION
IGNITION COIL (Checking with Electro Tester)
• Remove the fuel tank.
• Remove the ignition coil .

NOTE:
Make sure that the three-needle sparking distance of elec-
tro tester is set at 8 mm (0. 3 in).

With the tester and jumper wire, test the ignition coil for
sparking performance in accordance with the following two
steps.
STEP G) : Connect the jumper wire to the spark plug cap
and ignition coil ground.
STEP @ : Switch over the jumper wire to the other plug cap
and ground.
If no sparking or orange color sparking occures in the above
conditions, it may be caused by defective coil.

~ 09900-28107: Electro tester

Spark performance: Over 8 mm (0.3 in)

AWARNING
Do not touch the wire clips to prevent an electric shock 8 mm
when testing.

IGNITION COIL (Checking with Pocket Tester)

A SUZUKI pocket tester or an ohm meter may be used, in-
stead of the electro tester. In either case, the ignition coil
is to be checked for continuity in both primary and secon-
dary windings. Exact ohmic readings are not necessary, but,
if the windings are in sound condition, their continuity will
be noted with these approximate ohmic values.

~ 09900-25002: Pocket tester

Ignition coil resistance

Primary: 0.07-0.12 Q ((±) Black lead - 8 Black/white lead)
~Tester knob indication: X 1n range
Secondary: 23-25 kQ (Plug cap-Plug cap)
.11
~ Tester knob indication: X 1 kQ range
 ELECTRICAL SYSTEM 6-20

POWER SOURCE COIL AND PICK-UP COIL

• Remove the frame covers and seat.
• Disconnect the lead wire coupler CD from the CDI unit.
Measure each coil resistance between lead wires. If the
resistance is infinity or less than the specifications, the
power source coil and pick-up coil must be replaced.

S 09900-25002: Pocket tester

Power source coil resistance: 0.1-0 .2!2
(Black-White)
~ Tester knob indication: X 1n range
Pick-up coil resistance: 170-256!2
(Blue-Green)
~Tester knob indication: X 100!2 range

CDI UNIT
• Remove the frame covers and seat.
• Disconnect the lead wire couplers @ from the CDI unit.
Measure the CDI unit resistance between the terminals. If
the resistance is incorrect, the CDI unit must be replaced.

NOTE:
As capacitor, thyristors, diodes, etc. are used inside this CD/
unit, the resistance values will differ when an ohmmeter
other than SUZUKI pocket tester is used.

1.fcffih 09900-25002: Pocket tester

~Tester knob indication: X 1 kD range

Unit: kQ
(±) Probe of tester

"" ------- 1
1 2
0
3 4
6 - 26 12-50 2.4- 10 2.6-12
5 6 7
0
8
0 50-400
9 10 11
200 - co 35-400 1.2-5
12

2 -------
0 5.5 - 24 12 - 50 2.4-10 2.6 -12 0 0 50- 400 200 - co 35- 500 1.2-5

...
3
4 15 - 70
-------
5.5 - 24 5.5-24
15 - 70 26-150
20- 90 8- 35
16 - 70
8 - 35 5.5 - 24 5.5- 24 50- 400
17- 80 5.5- 70 5.5- 70 80- 500
200 - co 45- 500 7-28
Q)
+-'
(/)
---------- ...____________
200 - co 80- co 14- 60
Q) 5 2.2-9.5 2.2 -9.5 8-35 11 - 70
-------------- 3- 13 2.2 - 9.5 2.2-9.5 50- 400 200- co 40- 500 1.4- 6
+-'

0 6 2.8 - 12 2.8- 12 8- 35 17 - 70 3 - 13 ...____________ 2.8- 12 2.8 - 12 50- 400 200- co 40- 500 1.8- 8
Q)
..0 7 0 0 6- 26 12- 50 2.2 - 9.5 2.6- 11 0 50- 400 200- co 35 - 500 1.2 - 4 .8
0
ct
CD
8
9
0 0
1.8-7.5 1.8 - 7.5
6- 26 12 -50 2.2 - 9.5 2.6- 11
10- 45 24-200 5- 22
-------
0
6 - 24 1.8-7.5 1.8 - 7.5
50-400
...____________
200- co 70- 500 3.6 -4.8
200- co 70- co 3.6- 11
----------
10 11-50 11-50 22 - 100 35 - 400 17- 70 17- 70 11 - 50 12 - 50 80-1 000 200- co 14 - 60
11 co co co co co co co co co co co
--------------
12 1.2-5 1.2-5 7- 28 14-60 1.4-6 1.8 - 8 1.2-5 1.2 - 5 50-400 200 - co 35- 500

NOTE: When the capacitor is discharged state, the needle of tester swings first then return to
-------
a certain value.
oo : Infinity
6-21 ELECTRICAL SYSTEM

SPARK PLUG
• Remove the spark plugs.
citJ 09930-101 21 : Spark plug socket wrench set
Carbon Deposit
Check to see the carbon deposit on the plug.
If the carbon is deposited, remove it with a spark plug cleaner
machine or carefully using a tool with a pointed end .

Spark Plug Gap

Measure the plug gap with a thickness gauge if it is correct.
If not, adjust it to the following gap. 0

1-Mol. 09900-20803: Thickness gauge

Standard: 0.7-0.8 mm (0.028 - 0.031 in)

Electrode's Condition
Check to see a worn or burnt condition of the electrode . If
it is extremely worn or burnt, replace the plug . Also replace
the plug if it has a broken insulator, damaged thread, etc.

Heat Range
NGK CR10E or NIPPONDENSO U31 ESR-N should be used
as the standard. However, the heat range of the spark plug
should be selected to meet the requirements of speed , ac-
tual load, fuel and etc. Proper heat range would be indicat-
ed if all insulators were LIGHT BROWN in color. If they are 7
~ 0 . 7 - 0. Bmm
(0.028 - 0.03 1 in)
blackened by carbon, they should be replaced with a hot
type plug NGK CR9E or NIPPONDENSO U27ESR-N.

---------
NGK
NIPPON DENSO
Standard
CR10E
U31 ESR-N
Hot type
CR9E
U27ESR-N

I A.CAUTION I
Confirm the thread size and reach when replacing the
plug. If the reach is too short, carbon will be deposited
on the screw portion of the plug hole and engine
damage may result.
 ELECTRICAL SYSTEM 6-22

SPEEDOMETER AND PILOT INDICATOR

REMOVAL AND DISASSEMBLY
• Remove the speedometer and pilot indicator. (Refer to page 5-4 .)
• Disassemble the speedometer and pilot indicator as follows .

INSPECTION
Using the pocket tester, check the continuity between lead
wires in the diagram on next page.
If the continuity measured is incorrect, replace the respec-
tive parts.

mil 09900-25002: Pocket tester

~Tester knob indication: X 10 range

NOTE:
When making this tes t, it is not necessary to remove the
speedometer and pilot indicator.
6-23 ELECTRICAL SYSTEM

B/W : HIGH BEAM 8 B/R : HIGH BEAM (£)

Gr: ILLUMINATION (£)

B/O : NEUTRAL (£)

BIBI : NEUTRAL 8
B/Lg : TURN (R) (£)

B : Black
ITEM
(±) Probe of 8 Probe of
Gr : Gray
tester to: tester to:
BI BI : Black with Blue tracer
ILLUMI Gr B/W B/O : Black with Orange tracer
B/R : Black with Red tracer
HIGH BEAM B/R B/W
B/Lg: Black with Light green tracer
NEUTRAL B/O BIBI B/W : Black with White tracer
TURN (L) B B/Lg
TURN (R) B/Lg B
 ELECTRICAL SYSTEM 6-24

LAMPS
HEADLIGHT

Headlight bulb: 12V 60/55W

Position light bulb: 12V 4W (Except E-03.24.28.33I
NOTE:
Adjust the headlight, both vertical and horizontal, after reassembling.

BULB REPLACEMENT
• Remove the headlight. (Refer to page 5-21 .)
• Disconnect the socket G) and remove the rubber cap @ .
• Remove the bulb @ by unlocking the bulb holder spring @ .
• Reassemble the bulb in the reverse order of removal.

I A CAUTION I
When replacing the headlight bulb, do not touch the
glass. Grasp the new bulb with a clean cloth. If you
touch the bulb with your bare hands. clean it with a
cloth moistened with alcohol or soapy water to prevent
early failure.
6-25 ELECTRICAL SYSTEM

TAIL/BRAKE LIGHT, TURN SIGNAL LIGHT AND LICENSE PLATE LIGHT

Tail/Brake light bulb : 12V 5/21W

Turn signal light bulb: 12V 21W
License plate light bulb: 12V 5W

BULB REPLACEMENT
• Remove each light lens.
• Push in on the bulb, turn it to the left, and pull it out.

I A CAUTION I

Do not overtighten the lens fitting screws.

 ELECTRICAL SYSTEM 6-26

TURN SIGNAL RELAY

The turn signal relay G) is located under the seat.
If the turn signal light does not light. Inspect the bulb or repair
the circuit connection .
If the bulb and circuit connection checked are correct, the
turn signal relay may be faulty, replace it with a new one.

NOTE:
Be sure that the battery used is in full-charged condition.

SWITCHES
Inspect each switch for continuity with the pocket tester . If any abnormality is found, replace the
respective switch assemblies with new ones.
8 09900-25002: Pocket tester
~Tester knob indication: X 1n range

IGNITION SWITCH
STARTER BUTTON
R 0 0/Y 8/W Gr Br
~
p 0 /W Y/G
•
LOCK PUSH n
p HORN BUTTON
LIGHTING SWITCH ~n r 8/ 81 8 /W
~r
Pos1t1on 0 Gr Y /W •
OFF PUSH C -0
• FRONT BRAKE SWITCH
ON 0
p> ~ r 0 B
DIMMER SWITCH
OFF
~ r Y/W w y ON 0 -0
p 0
HI 0 REAR BRAKE SWITCH
LO 0 0 ~r
Past on 0 W /8
TURN SIGNAL SWITCH
OFF
~r Lg Lbl B ON
P S 0
L C 0
WIRE COLOR
PUSH
B : Black Lbl : Light blue R : Red
R 0 0 Br: Brown Lg : Light green Y : Yellow
PASSING LIGHT SWITCH Gr : Gray O : Orange W: White
BIBI : Black with Blue tracer
~r 0 /R y B/W: Black with White tracer
Pos1t1on
O/BI: Orange with Blue tracer
• O/R : Orange with Red tracer
PUSH C O/W: Orange with White tracer
ENGINE STOP SWITCH O/Y : Orange with Yellow tracer
W /B: White with Black tracer
~r 0 0 /W Y/G : Yellow with Green tracer
Pos1t1on
OFF Y/W: Yellow with White tracer

RUN
6-27 ELECTRICAL SYSTEM

BATTERY
Filter
SPECIFICATIONS Upper cover
breather
Type designation YTX9-BS
Cathode---tti=-s...~~1~ 1
Capacity 12V, 28.8 kC (8 Ah) / 1OHR plates
Separator
Standard electrolyte (fiberglass
1.320 at 20°C (68°F) plate)
S .G .
Anode plates

INITIAL CHARGING
Filling electrolyte
• Remove the aluminum tape G) sealing the battery elec-
trolyte filler holes.

• Remove the caps @ .

NOTE:
* After filling the electrolyte completely, use the removed
cap @ as the sealed caps of battery-filler holes.
* Do not remove or pierce the sealed areas @ of the elec-
trolyte container.

• Insert the nozzles of the electrolyte container into the bat-

tery's electrolyte filler holes, holding the container firmly
so that it does not fall. Take precaution not to allow any Electroyte
of the fluid to spill. containers

Insert in
filler holes

• Make sure air bubbles are coming up each electrolyte con-

tainer, and leave in this position for about more than 20
minutes.
Air
bubbles
 ELECTRICAL SYSTEM 6-28

NOTE:
If no air bubbles are coming up from a filler port, tap the
bottom of the two or three times.
Never remove the container from the battery.

• After confirming that the electrolyte has entered the bat-

tery completely, remove the electrolyte containers from
the battery. Wait for around 20 minutes.
• Insert the caps into the filler holes, pressing in firmly so
that the top of the caps do not protrude above the upper
surface of the battery's top cover.

I A CAUTION I
* Never use anything except the specified battery.
* Once install the caps to the battery; do not remove
the caps. (V)

• Using SUZUKI pocket tester, measure the battery voltage.

-13

12
..- 30 seconds
(at 25°C)

The tester should indicate more than 12.5 - 12.6V (DC)

as shown in the Fig. If the battery voltage is lower than 11

the specification, charge the battery with a battery charg- 10

er. (Refer to the recharging operation.)
0 2 4 6 8 10 (Minutest
NOTE:
Time
Initial charging for a new battery is recommended if two
years have elapsed since the date of manufacture.

SERVICING
Visually inspect the surface of the battery container. If any
signs of cracking or electrolyte leakage from the sides of
the battery have occurred, replace the battery with a new
one. If the battery terminals are found to be coated with rust
or an acidic white powdery substance, then this can be
cleaned away with sandpaper.
6-29 ELECTRICAL SYSTEM

RECHARGING OPERATION Charging period

• Using the pocket tester, check the battery voltage. If the (V)
-1.. ---- Stop charging
18
voltage reading is less than the 12.0V (DC), recharge the
battery with a battery charger.
17
16 -
15
14 \
I A CAUTION I .......
13
12
When recharging the battery, remove the battery from
the motorcycle. 0 10 20 30 40 50 60
Time (Minutes)
NOTE:
Do not remove the caps on the battery top while recharging. (V)
14+--,---.--~~-~
Recharging time: 4A for one hour or 0.9A for 5 hours

I A CAUTION I
Be careful not to permit the charging current to exceed
4A at any time. 10-t---t----t----lt----+--l

100 75 50 25 0(%)
• After recharging, wait for more than 30 minutes and check
Battery charged condition
the battery voltage with a pocket tester.
• If the battery voltage is less than the 1 2. 5V, recharge the
battery again.
• If battery voltage is still less than 12.5V, after recharg-
ing, replace the battery with a new one.
• When the motorcycle is not used for a long period, check
the battery every 1 month to prevent the battery dis-
charge.
 SERVICING INFORMATION

. - - - - - -- - - -- - CONTENTS - -- - - - - -- ~
TROUBLESHOOT/NG ············································ ·· ······ ··· ··· ···· ····· 7- 1
WIRING DIAGRAM ······ ·· ··············································· ····· ········ ·· 7- 8
WIRE, CABLE AND HOSE ROUTING · · · · · · · · · · · · · · · · · ·· ·· · · · ·· ·· ·· ·· · ·· ·· · · · ·· ·· 7-11
WIRE ROUTING ·· · · · ·· · ·· ·· · · · · · · · · · · · · ·· · · · · · · · · · · · · · · · · · · · · · ·· ·· ·· · · · ·· ·· ·· · ·· ·· · ·· ·· 7-12
CABLE ROUTING ·············· ············· ······· ····················· ···· ··········· 7-15
CARBURETOR AND AIR CLEANER HOSE ROUTING ·· ·· · ·· ·· · · · ·· ·· · 7-17
PAIR (AIR SUPPL YJ SYSTEM HOSE ROUTING · · · · · · · · · ·· ·· ·· · ·· ·· · · · ·· · 7-18
FRONT BRAKE HOSE ROUTING ············ ··· ··· ·· ··· ···· ·· ·· ·· ······ ··· ····· 7-19
REAR BRAKE HOSE ROUTING · · · · · ·· · · ·· · · · · · · · ·· ·· · ·· ·· · · · · · ·· ·· · ·· ·· · · · ·· ·· · · 7-20
HEAT SHIELD ADHERING · ·· ·· · ·· ·· ·· · · · ·· ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·· ·· · ·· ·· ·· 7-21
SIDE STAND SPRING SET-UP········· ··············· ······························ 7-21
SPECIAL TOOLS· ··· ·············· ·········· ·················· ············· ······· ········ 7-22
TIGHTENING TORQUE ·· ·· · ·· · · · · · ·· ·· · ·· ·· · · · · · · · ·· · · · ·· ·· · · · · · · · · · · · · · · · · · · · · · · · ·· ·· · 7 -25
SERVICE DA TA · · ···· · ··· ·· ··· · · ···· · ·· ··· · · ····· · · · · ····· · ···· ·· · · · ····· · · ···· · · · ···· · ··· 7-28
7-1 SERVICING INFORMATION

TROUBLESHOOTING
ENGINE
Complaint Symptom and possible causes Remedy

Engine will not start, Compression too low

or is hard to start . 1. Out of adjustment valve clearance. Adjust.
2. Worn valve guides or poor seating of valves. Repair or replace.
3 . Mistiming valves . Adjust.
4 . Excessively worn piston rings. Replace.
5. Worn-down cylinder bores. Replace or rebore.
6 . Too slowly starter motor cranks. See electrical section.
7. Poor seating of spark plugs. Retighten.

Plugs not sparking

1. Fouled spark plugs. Clean.
2. Wet spark plugs. Clean and dry.
3. Defective ignition coil. Replace .
4. Open or short in high-tension cords. Replace.
5. Defective generator or CDI unit . Replace.
6 . Defective side stand switch or side stand relay. Replace.
No fuel reaching the carburetor
1. Clogged fuel tank cap . Clean or replace.
2. Clogged or defective fuel valve. Clean or replace.
3. Defective carburetor needle valve. Replace.
4. Clogged fuel hose or vacuum hose. Clean or replace.
5. Clogged fuel filter. Clean or repl ace.

Engine stalls easily. 1. Fouled spark plugs. Clean.

2. Defective signal generator or COi unit. Replace.
3. Clogged fuel hose. Clean.
4. Clogged jets in carburetor. Clean .
5. Out of adjustment valve cl earance. Adjust .

Noisy engine. Excessive valve chatter

1. Too large valve clearan ce. Adjust.
2. W eakened or broken valve springs. Replace.
3. Worn down rocker arm or rocker arm shaft. Replace.
4. Worn and burnt camshaft journal. Replace.
Noise seems to come from piston
1. Worn down piston or cylinder . Replace.
2. Fouled with carbon combustion chamber. 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. Stretched chain. Replace.
2 . Worn sprocket. Replace.
3. Not working tension adjuster. Repair or replac e.
Noise seems to come from clutch
1. Worn splines of countershaft or hub. Replace .
2. Worn· teeth of clutch plates. Replace .
3. Distorted clutch plates , driven and drive. Replace .
4 . Worn clutch release bearing. Replace.
5. Weakened clutch dampers. Replace the primary
driven gear.
 SERVICING INFORMATION 7-2

Complaint Symptom and possible causes Remedy

Noisy engine. Noise seems to come from crankshaft

1. Due to wear rattling bearings. Replace.
2. Worn and burnt big-end bearings. Replace.
3. Too large thrust clearance. Replace con rod.
Noise seems to come from transmission
1. Worn or rubbing gears. Replace.
2. Badly worn splines. Replace.
3. Worn or rubbing primary gears. Replace .
4. Badly worn bearings. Replace.

Slipping clutch. 1. Out of adjustment or loss of play clutch control. Adjust.

2. Weakened clutch springs. Replace.
3. Worn or distorted pressure plate. Replace.
4. Distorted clutch plates, driven and drive. Replace.

Dragging clutch. 1. Clutch control out of adjustment or loss of play. Adjust

2. Some clutch springs weakened while others are not. Replace.
3. Distorted pressure plate or clutch plates. Replace.

Transmission will 1. Broken gearshift cam. Replace.

not shift. 2. Distorted gearshift forks. Replace.
3. Worn gearshift pawl. Replace .

Transmission will 1. Broken return spring on shift shaft. Replace.

not shift back. 2. Rubbing or stickly shift shaft. Repair or replace.
3. Distorted or worn gearshift forks. Replace.

Transmission jumps 1. Worn shifting gears on driveshaft or countershaft. Replace.

out of gear. 2. Distorted or worn gearshift forks. Replace.
3. Weakened stopper spring on gearshift cam. Replace.
4. Worn gearshift pawl. Replace.

Engine idles poorly. 1. Out of adjustment valve clearance. Adjust.

2. Poor seating of valves. Replace or repair.
3. Defective valve guides. Replace .
4. Worn rocker arms or arm shafts . Replace.
5. Too wide spark plug gaps. Adjust or replace.
6. Defective ignition coil. Replace .
7. Defective generator or CDI unit. Replace.
8. Out of adjustment in carburetor float-chamber Adjust .
fuel level.
9. Clogged jets. Clean.
7-3 SERVICING INFORMATION

Complaint Symptom and possible causes Remedy

Engine runs poorly 1. Weakened valve 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. Ignition not advanced sufficiently due to poorly Replace COi unit.
working timing advance circuit.
6. Defective ignition coil. Replace .
7. Defective generator or COi unit. Replace.
8. Too low float-chamber fuel level . Adjust.
9. Clogged air cleaner element. Clean.
10. Clogged fuel hose , resulting in inadequate fuel Clean and prime.
supply to carburetor.

Dirty or heavy 1. Too much engine oil in the engine. Check with inspection
exhaust smoke. window drain out
excess oil.
2. Worn piston rings or cylinder. Replace.
3. Worn valve guides. Replace.
4. Scuffed cylinder wall. Replace .
5. Worn valves stems. Replace.
6. Defective stem seal. Replace.
7. Worn oil ring side rails. Replace.

Engine lacks power. 1. Loss of valve clearance. Adjust.

2. Weakened valve springs. Replace.
3. Out of adjustment valve timing. Adjust.
4. Worn piston rings or cylinder. Replace.
5. Poor seating of valves. Repair.
6. Fouled spark plug. Clean or replace.
7. Incorrect spark plug. Adjust or replace.
8. Clogged jets in carburetor . Clean.
9. Out of adjustment float-chamber fuel level. Adjust.
10. Clogged air cleaner element. Clean.
11. Sucking air from intake pipe . Ret ighten or replace .
12. Too much engine oil. Drain out excess oil.
13. Diffective generator, COi unit or ignition coil. Replace.

Engine overheats . 1. Heavy carbon deposit on piston crown. Clean.

2. Not enough oil in the engine. Add oil.
3. Defective oil pump or clogged oil circuit. Replace or clean.
4. Too low in float chamber fuel level. Adjust.
5. Sucking air from intake pipes. Retighten or replace.
6. Use incorrect engine oil. Change.
7. Oil cooler. Clean.
 SERVICING INFORMATION 7-4

CARBURETOR
Complaint Symptom and possible causes Remedy

Trouble with starting. 1. Clogged starter jet. Clean.

2. Clogged starter pipe. Clean.
3. Air leaking from a joint between starter body and Check starter body and
carburetor. carburetor for tightness,
adjust and replace
gasket.
4. Air leaking from carburetor's joint or vacuum Check and adjust.
gauge joint .
5. Not operation properly starter plunger. Check and adjust.

Idling or low-speed 1. Clogged or loose pilot jet, pilot air jet. Check and clean.
trouble. 2. Air leaking from carburetor's joint, vacuum hose Check and adjust.
joint, or starter.
3. Clogged pilot outlet or bypass. Check and clean.
4. Not fully closed starter plunger. Check and adjust.

Medium-or high 1. Clogged main jet or main air jet. Check and clean.
speed trouble . 2. Clogged needle jet. Check and clean.
3. Not operating properly throttle valve. Check throttle valve
for operation.
4. Clogged fuel filter . Check and clean.

Overflow and fuel 1. Worn or damaged needle valve. Replace.

level fluctuations. 2. Broken spring in needle valve . Replace.
3. Not working properly float. Check and adjust.
4. Foreign matter has adhered to needle valve. Clean.
5. Too high or low fuel level. Adjust float height.

CHASSIS
Complaint Symptom and possible causes Remedy

Heavy steering . 1. Overtightened steering stem nut. Adjust.

2. Broken bearing in steering stem . Replace.
3. Distorted steering stem. Replace.
4. Not enough pressure in tires. Adjust.

Wobbly handlebars. 1. Loss of balance between right and left front forks. Replace.
2. Distorted front fork. Repair or replace .
3. Distorted front axle or crooked tire. Replace.

Wobby front wheel. 1. Distorted wheel rim. Replace.

2. Worn front wheel bearings. Replace.
3. Defective or incorrect tire. Replace.
4. Loose axle or axle holder nuts . Retighten.
5. Incorrect front fork oil level. Adjust.

Front suspension 1. Weakened springs. Replace.

too soft. 2. Not enough fork oil. Replenish.

Front suspension 1. Too viscous fork oil. Replace.

too stiff. 2. Too much fork oil. Drain excess oil.

Noisy front 1. Not enough fork oil. Replenish.

suspension. 2. Loose bolts and nuts on suspension. Retighten.
7-5 SERVICING INFORMATION

Complaint Symptom and possible causes Remedy

Wobbly rear wheel. 1. Distorted wheel rim . Replace.

2. Worn rear wheel bearings or swingarm bearings. Replace.
3. Defective or incorrect tire. Replace.
4. Worn swingarm and rear suspension related bearings. Replace.
5. Loose nuts or bolts on rear suspensions. Retighten.

Rear suspension 1. Weakened shock absorber spring. Replace.

too soft. 2. Improperly set rear suspension adjuster. Adjust.
3. Leakage oil of shock absorber. Replace.

Rear suspension 1. Improperly set rear suspension adjuster. Adjust.

too stiff . 2. Bent shock absorber shaft. Replace.
3. Bent swingarm. Replace.
4. Worn swingarm and rear suspension related bearings. Replace.

Noisy rear 1. Loose nuts or bolts on rear suspension. Retighten.

suspension. 2. Worn swingarm and rear suspension related bearings. Replace.

BRAKES
Complaint Symptom and possible causes Remedy

Insufficient brake 1. Leakage of brake fluid from hydraulic system. Repair or replace.
power. 2. Worn pads . Replace.
3. Oil adhesion of engaging surface of pads. Clean disc and pads.
4. Worn disc. Replace.
5. Air in hydraulic system. Bleed air.

Brake squeaking. 1. Carbon adhesion on pad surface . Repair surface with

sandpaper.
2. Tilted pad. Modify pad fitting or
replace.
3. Damaged wheel bearing. Replace.
4. 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. Disassemble and clean
master cylinder.

Excessive brake 1. Air in hydraulic system. Bleed air.

lever or pedal stroke. 2. Insufficient brake fluid. Replenish fluid to spe-
citied level; bleed air.
3. Improper quality of brake fluid. Replace with correct
fluid.

Leakage of brake 1. Insufficient tightening of connection joints. Tighten to specified

fluid. torque.
2. Cracked hose. Replace.
3. Worn piston and /or cup. Replace piston and /or
cup.
 SERVICING INFORMATION 7-6

ELECTRICAL
Complaint Symptom and possible causes Remedy
No sparking or poor 1. Defective ignition coil. Replace.
sparking. 2. Defective spark plugs. Replace.
3. Defe ctive generator or CDI unit. Replace.
Spark plug soon 1. Mixture too rich. Adjust carburetor.
become fouled with 2. Idling speed set too high. Adjust carburetor.
carbon. 3. Incorrect gasoline. Change.
4. Dirty element in air cleaner. Clean.
5. Too cold spark plugs. Replace with hot type
plugs.

Spark plugs become 1. Worn piston rings. Replace.

fouled too soon. 2. Worn piston or cylinder. Replace.
3. Excessive clearance of valve stems in valve Replace.
guides.
4. Worn stem oil seal. Replace.

Spark plug electrod- 1. Too hot spark plugs. Replace with cold type
es overheat or burn. plugs.
2. Overheated the engine. Tune up.
3. Loose spark plugs. Retighten.
4. Too lean mixture. Adjust carburetor.
Generator does not 1. Open or short lead wires, or loose lead Repair or replace or
charge. connections. retighten.
2. Shorted, grounded or open generator coils. Replace.
3. Shorted or panctured regulator/rectifier. Replace.

Generator does 1. Lead wires tend to get shorted or open-circuited Repair or retighten.
charge, but charging or loosely connected at terminals.
rate is below the 2. Grounded or open-circuited stator coils or Replace.
specification. generator.
3. Defective regulator/ rectifier. Replace.
4 . Defective cell plates in the battery. Replace the battery.
Generator 1. Internal short-circuit in the battery. Replace the battery.
overcharges. 2. Damaged or defective regulator/rectifier. Replace .
3. Poorly grounded regulator/rectifier. Clean and tighten
ground connection.
Unstable charging. 1. Lead wire insulation frayed due to vibration, Repair or replace.
resulting in intermittent shorting.
2. Internally shorted generator. Replace.
3. Defective reg u Iator/rectifier. Replace.

Starter button is not 1. Run down battery. Repair or replace.

effective. 2. Defective switch contacts. Replace.
3. Not seating properly brushes on commutator in Repair or replace.
starter motor.
4. Defective starter relay/starter interlock switch. Replace.
7-7 SERVICING INFORMATION

BATTERY
Complaint Symptom and possible causes Remedy

"Sulfation", acidic 1. Cracked battery case. Replace the battery.

white powdery sub- 2. Battery has been left in a run -down condition for Replace the battery.
stance or spots on a long time.
surfaces of cell
plates.

Battery runs down 1. Not correct the charging system. Check the generator,
quickly. regulator / rectifier
and circuit connections
and make necessary
adjustments to obtain
specified charging
operation.
2. Cell plates have lost much of their active Replace the battery,
material as a result of overcharging. and correct the charg-
ing system.
3. A short-circuit condition exists within the battery. Replace the battery.
4. Too low battery voltage. Recharge the battery
fully.
5. Too old battery. Replace the battery.

Battery "sulfation" . 1. Too low or too high charging rate. Replace the bat tery.
(When not in use batteries should be checked at
least once a month to avoid sulfation .)
2. Left unused the battery for too long in cold Replace the battery, if
climate. badly sulfated .

Battery discharges Dirty container top and sides. Clean.

too rapidly.
 ENGINE FRONT
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G/ 8 I Green with Blue tracer C
M: STARTER MOTOR
0/W Orange with White tracer :a
0/Y Orange w ith Yellow tracer 3:
R/ 8
W/8
Red with Black tracer
White with Black tracer
>
-I
W /81 : White with Blue tracer 0
Y/ 8 Yellow with Black tracer z
Y/G Yellow with Green tracer
--..I
Y/W Yellow with White tracer
=
 "Tl """'
0 ca
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en
ENGINE FRONT m
KILL
SWITCH
BRAKE
SWITCH
~
STARTER
BUTTON
REAR BRAKE
)>
C: =
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H : HIGH BEAM INDICATOR LIGHT
N : NEUTRAL INDICATOR LIGHT
I ,,,,, , =
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r;;::n..s-fli... Lo Lo-l'h--a--{'1;'\
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II I 11111 II 1 11111 ' 11.1 I Ill 1L~o:Jw® 1
LICENSE LIGHT

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FRONT TURN SIGNAL LIGHT i l l I I I III II I REAR TURN SIGNAL LIGHT Ill

WIRE COLOR
B Black

jj Bl Blue

gL., m1gill i
>- ~ .:. iii Br Brown
";;: >I >I >I >I I 5'I. ~I I !;

£
iiici> I
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f11iJ I
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G Green

., ~ 1,
Gr
Lbl
Lg
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Light blue

I
Light green
! .. 11• ~
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-w
R Red

~~
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~
w White
y Yellow
FUSEBOX
7 1 : HEADLIGHT IHI!

~
BIBI Black with Blue tracer
L Lbi s ~Rv v r,,:~::~101nt~~~ 1svm1
I
35: HEADLIGHT (LO: . • ro F B/Lg Black with light green tracer
L • HI ON BIO Black with Orange tracer
PUSH PUSH PUSH LO Im: ~
M
BATTERY BIR Black with Red tracer
HORN BUTTON R PASSING DIMMER CLUTCH NEUTRAL REGULATOR/ GENERATOR STARTER B/W Black with White tracer
TURN SIGNAL LIGHT SWITCH LEVER SWITCH RECTIFIER RELAY B1/B Blue with Blac k t racer
LIGHT SWITCH BUTTON POSITION ~ B1/W : Blue w ith Whit e t racer
SWITCH F: MAIN FUSE
GIBI Green with Blue t racer
M : STARTER MOTOR
0/W Orange with White tracer
0/Y Orange with Yellow tracer
RIB Red w ith Black tracer
W/B White with Black tracer
W /81 : White w ith Blue tracer
YIB Ye llo w with Black t racer
YIG Yellow with Green tracer
Y/W Yellow with W hite tracer
 "T1
LIGHTING 0
SIDE STAND ""I
SWITCH
SWITCH
SPEEDOMETER )>
TURN C
• ~•
9v rrl
II
I fl !~ I ~ SIGNAL
RELAY

IDE\
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--
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11
in # i
H: HIGH BEAM IN Q)

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HEA TAIL/BRAKE LIGHT

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N
G
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FRONT TURN !GHT Ill :EAR TURN SIGNAL LIGHT Ill

WIRE COLOR

™lg
B Black

£
Bl Blue
e, Brown

llf
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m_
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Lbl light blue
Lg Light green

y
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> ► ►

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w
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White m
r =
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y Yellow
<
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n
I• I
I PUSHI -
I

H JRN BUTTON I R " - "

II L I
I I PUSHI
I
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I IPUS HI -
•

PASSING
I
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DIMMER
>+CI I I
P
LOCK
OFF I
ON
OFF
CLUTCH
IOFF I
I ON -.
NEUTRAL! REGULATOR/ GENERATOR
M
WYI
STARTER
BATTERY
EDI 8 /Lg
8/0
8 /R
8 /W
Black with Ligh t green trac er
Black with Orange tracer
Black with Red tracer
Black with White trac er
z
C,

TURN SIGNAL LIG_H_T_ SWITCH ON LEVER SWITCH RECTIFIER ., ,•• --~ RELAY
'-
81/ 8 Blue w ith Black trace r 2
"Tl
81/W : Blue w ith White tracer
SWITCH G): HEADLIGHT (HII F: MAIN FUSE Cl
@ : HEADLIGHT (LOI M: STARTER MOTOR
G /BI
0 /W
OtY
Green w ith Blue tracer
Orange with White tracer
Orange with Yellow tracer
=
31:
>
R/B Red with Black tracer -I
W /8 White with Black tracer
W / BI : White with Blu e tracer
5
Y/ 8 Yellow with Black tracer
z
Y/G
Y/W
Yellow with Green tracer
Yellow w ith White tracer ...=
';-I
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LIGHTING
... ...
....:J'" Cl)
SWITCH SIDE STAND m
SWITCH :i:,
SPEEDOMETER REAR BRA KE CD
RUN
0 ..L[I~~~~ ~~]Ilt;i~r: [[I~~~a~~
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WIRE COLOR
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Bl Blue

!liJ I\! 'l

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c.:,

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mm

#} »" g 3

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G
Gr
Lbl
Brown
Green
Gray
Light blue

I HORN
0
IT, > > > © ()) '--~a: ,:
Lg
0
R
w
Light green
Orange
Red

~ ~ Ll ~ ,~
Whit e

I -
•.
IPUSHI -
B}-BII-L;::::·:::
11 L
IIPUSH I I IIPUSII -
ir -,~·
- :::_,[IL~I B ;--::-:;RIV I

' ILO ,_..

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LOCK
R O BIWG, B,

I
I ONI'~
IOFFI
Y/GIY/GI
IOFFI
■ N
B B 1i1 I1o1lJ 1
'l ~
IF) e
BATTERY
©I
I
y
B/81
B/Lg
B/0
Yellow
Black w it h Blue t racer
Black w ith light green tracer
Black w it h Orange tracer
B/R Black w ith Red tracer
HORN BUTTON 1 R - >I I PASSING DIMMER OFF I CLUTCH REGULATOR/ GENERATOR THROTTLE SWITCH M STARTER B/W Black with White t racer
TURN SIGNAL LIGHT SWITCH ON >I LEVER

SWITCH NEUTRAL
RECTIFIER

G): HEADLIGHT IHI)

RELAY
,~, 81/8 Blue with Black tracer
81/W : Blue with Wh ite tracer
F: MAIN FUSE
SWITCH G): HEADLIGHT I LO J G/BI : Green w ith Blue tracer
M: STARTER M OTO R
0/W Orange wit h White tracer
0/Y Orange wit h Yellow tracer
R/8 Red with Black tracer
W/B White w ith Black tracer
W/81 : White with Blue tracer
Y/8 Yellow with Black tracer
Y/G Yellow with Green t racer
Y/W Yellow with White tracer
 SERVICING INFORMATION 7-12

WIRE, CABLE AND HOSE ROUTING

WIRE ROUTING
Clamp
Clamp Handlebar switch (L)

Handlebar switch (R) Clutch lever position switch

Speedometer

Lead w ire cover

Handlebar
switch (L)
Clutch lever
-+-- - Front brake position switch
hose
Clamp
Clamp
Wiring harness
Blue tape
Clutch lever position switch
Throttle cable
Starter cable
Blue tape

Clamp
Wiring harness
Ignition
Throttle position switch switch
(Except for E-03, 18,28 and 33)
Wiring
harness
Clamp

Wiring harness Wiring harness

Ignition switch
Clamp
Clamp
Battery 8
Clamp

Wiring harness
Rear turn signal
light (R)
Li cense light

Wiring harness
Starter motor

Clamp

Starter
motor
Clamp
7-13 SERVICING INFORMATION

Clamp
Wiring harness
Clutch lever Clamp
position switch
Wiring harness
Throttle cable Clamp
Generator
Starter cable Wiring harness
Neutral switch
Throttle position switch
(Except for E-03, 18, 28 and 33) Rear brake
switch

White tape

Rear brake
switch

Clamp

Clamp Clamp
Wiring harness
Tail/Brake light
Rear brake switch
Rear turn signal light
Side stand switch Grenerator Wiring harness
Generator lead wire
Generator
Clamp
License light

Rear brake----
switch coupler

Side stand switch

Rear turn Rear turn
Clamp
signal light (R) signal light (L)
License light Tail/ Brake light
Side stand switch
Clamp Clamp
Clamp (Right side) (Left side)
 SERVICING INFORMATION 7-14

Starter motor Starter moto r Iead wire

Forward
◄
vr-- Ground
wire

Pick-up
coil
Crankcase (R)
Breather
cover

Ignition coil

High-tension cord
(short cord)

0
~igh-tension cord
( ong cord)
7-15 SERVICING INFORMATION

CABLE ROUTING

Clutch cable

Clutch cable
Throttle cables
Starter cable

Clutch cable holder

Throttle cable

Fix the clutch cable

with a clamp. Brake hose

Clutch cable

Clutch cable

( Starter cable Clamp

Starter cable
Clutch cable Throttle cable
(pull}
 SERVICING INFORMATION 7-16

Ignition switch
lead wire

Cable guide

Speedometer---~l\\
cable
 (")
)>
........
';'.I

Carburetor clamp position :::0 en

cc m
:::r:,
Upper C <
:::0 n
z
LH -(t)-RH m
-I
0
C,

z
"Tl

VIEWA :::0 C,
:::r:,
)> 3:
Upper • Pass through t he air vent hose outside :i::,,
2 -t

LHWRH
of the clutch cable. C C,
@ • Pass t hrough t he breather hose inside of z
the clutch cable. )>
• Pass through the crankcase breather :::0
hose inside of the carburetor air hose.
VIEW B (")
r-
m
Carburetor air hose )>
"'-·."'.V acuum hose
2
/ Fuel hose m
, Carburetor air hose Air vent hose :::0
:::c
-·- 0
(/)
m
Crankcase
.breather hose :::0
0
C
-I
2
C)

Neutral switch
Rear brake switch

Carburetor overflow hose

Pass t hrough t he carburetor
overflow hose between t he
engine and frame.
 SERVICING INFORMATION 7-18

PAIR (AIR SUPPLY} SYSTEM HOSE ROUTING

(For Austria and Switzerland}

Pass through the PAIR control valve vacuum

hose and air supply hose between the engine
mounting plates.
Air supply hose

PA IR control valve - - -+-- - - - - - t - ---lfh

vacuum hose

PAIR air pipe-----,

 ,, ... ~
lJ t0
When installing the brake hose, 0 Cl.I
face the mark on the brake hose 2 m
::lCI
union to the master cylinder . --t ::5
c:, ~
z
. lJ C')
)>
2

~
"
"Tl

® Clutch cable
m Cl
::lCI
' .
J: s::
~

Brake hose :'°'/ 0 -I

c
Washer Cl)
m z
~ "' Hose guide Clamp lJ
Brake hose 0
C
Throttle cable

Starter cable
---t2
C)

rA Brake hose

After touch ing the

brake hose union
Master cylinder /---v=-r:;:;\'l' Hose guide ~ t o the stopper,
tighten the union
bolt to the
specified torque.

r Brake hose union bolt

Washer

WL±:::r'-Clamp
 SERVICING INFORMATION 7-20

REAR BRAKE HOSE ROUTING

Master cylinder

Brake hose guide

Reservoir tank

VIEWA

After touching the brake hose

union to the stopper, tighten the Set the brake hose to
union bolt to the specified torque. the hose guide.

Pass through the reservoir

tank hose between the frame
and brake hose un ion .

Brake hose guide

Brnke hose--i
VIEW B
7-21 SERVICING INFORMATION

HEAT SHIELD ADHERING

Right frame cover

SIDE ST AND SPRING SET-UP

Side stand

Inner spring
Outer spring
 SERVICING INFORMATION 7-22

SPECIAL TOOLS

09900-00401 09900-00410
"L" type hexagon Hexagon bit wrench 09900-06107 09900-06108 09900-09003
wrench set set Snap ring pliers Snap ring pliers Impact driver set

09900-20508
Cylinder bore gauge
09900-20202 09900-20204 09900-20205 set
09900-20102 Micrometer Micrometer Micrometer 09900-20513
Vernier calipers (25 - 50 mm) (75-100 mm) (0 - 25 mm) Gauge rod 94 mm

09900-20605 09900-20606 09900-20701 09900-20803 09900-21304

Dial calipers Dial gauge ( 1/100) Magnetic stand Thickness gauge V-block (100 mm)

09900-22301 09900-25002 09900-28106 09910-20116 09910-32812

Plastigauge Pocket tester Electro tester Conrod holder Crankshaft installer

09910-32830
Crankshaft installer
09910-32860
Crankshaft installer
~
09910-33210
0991 0-60611
Universal clamp
09913-10720
Compression gauge
attachment attachment Attachment wrench attachment

09913-50121 09913-60910 09913-75810 09913-75830 0991 5-6451 0

Oil seal remover Bearing/gear puller Bearing installer Bearing installer Compression gauge
7-23 SERVICING INFORMATION

09916-14510 09916-14910 09916-20610 09916-24210

09915-74510 Valve spring Valve spring com- Valve seat cutter Valve seat cutter
Oil pressure gauge compressor pressor attachment head 15° (N-121) head 45° (N-6151

09916-24900 09916-34550 09916-34580 09916-44910 09916-84511

5 .5 mm reamer 10.8 mm reamer Valve guide remover Tweezers

09917-23711 09920-13120 09920-53740

Ring nut socket Crankcase separator/ Clutch sleeve hub 09923-73210 09923-74510
wrench crankshaft remover holder Bearing remover Bearing remover

09925-18010
09924-84510 09924-84521 Steering bearing 09930-11920 09930-11940
Bearing installer set Bearing installer set installer Torx bit JT40H Torx bit holder

09930-33720 09930 -73110 09930-73120 09940- 14911

09930-30102 Generator rotor Starter torque Starter torque Steering nut
Sliding shaft remover limiter holder limiter socket socket wrench

09941-34513
09940-14960 09940-52860 Steering race and
Steering nut 09940-34520 09940-34592 Front fork oil swingarm bearing
wrench socket " T" handle Attachment G seal installer installer
 SERVICING INFORMATION 7-24

09941 -50111 09941 -54911 09941-74910 09943-74111

Wheel bearing Bearing outer race Steering bearing Front fork oil
remover remover remover level gauge
7-25 SERVICING INFORMATION

TIGHTENING TORQUE
ENGINE
ITEM N•m kg-m lb-ft
Cylinder head cover bolt 10 1.0 7 .0
Camshaft sprocket bolt 15 1.5 11.0
Cylinder head bolt 38 3.8 27. 5
Cylinder head nut 25 2.5 18.0
Cylinder base nut 10 1.0 7.0
Cam drive chain tensioner fitting bolt 13 1.3 9.5
Generator rotor bolt 160 16.0 115.5
Can drive chain adjuster mounting bolt 10 1.0 7.0
Spark plug 11 1. 1 8.0
Crankcase bolt 11 1. 1 8.0
T.D.C. plug 23 2.3 16.5
Oil gallery 23 2 .3 16.5
Oil nozzle bolt 10 1.0 7.0
Generator cover plug 15 1.5 11.0
Starter clutch bolt 25 2.5 18.0
Primary drive gear nut 100 10.0 72 . 5
Clutch spring mounting bolt 10 1.0 7.0
Clutch sleeve hub nut 50 5.0 36.0
Gearshift arm stopper 19 1.9 13. 5
Engine oil drain plug 23 2.3 16.5
Engine sprocket bolt 6 0.6 4.5
Engine mounting bolt 8 mm Diam. 40 4 .0 29.0
Engine mounting bolt 10 mm Diam. 65 6.5 47.0
Engine mounting bracket bolt (Upper and
Front) 40 4.0 29.0
(Rear) 23 2.3 16.5
Exhaust pipe bolt 26 2.6 19.0
Muffler mounting bolt 26 2.6 19.0
Crankshaft bearing ring nut 80 8.0 58.0
Engine oil pipe union bolt (Cylinder head) 23 2.3 16.5
(Crankcase) 20 2.0 14.5
Engine oil cooler hose bolt 10 1.0 7.0
Cam drive chain adjuster cap bolt 6 0 .6 4 .5
 SERVICING INFORMATION 7-26

CHASSIS
ITEM N -m kg-m lb-ft
Front axle 65 6.5 47.0
Front axle holder nut 10 1.0 7.0
Front fork damper rod bolt 30 3.0 21.5
Front fork lower clamp bolt 26 2.6 19.0
Front fork upper clamp bolt 29 2.9 21 .0
Front fork cap bolt 23 2 .3 16.5
Steering stem head nut 90 9.0 65.0
Handlebar clamp bolt 23 2 .3 16.5
Handlebar holder nut 25 2.5 18.0
Front brake master cylinder mounting bolt 10 1.0 7.0
Front brake caliper mounting bolt 26 2.6 19 .0
Brake caliper axle bolt (Front & Rear) 23 2 .3 16. 5
13 1.3 9.5
Brake hose union bolt (Front & Rear) 23 2.3 16. 5
Brake pad mounting pin (Front & Rear) 18 1.8 13.0
Front brake pad mounting pin plug 2.5 0.25 1.8
Brake air bleeder valve (Front & Rear) 8 0.8 6 .0
Brake disc mounting bolt (Front & Rear) 23 2.3 16.5
Swingarm pivot nut 77 7 .7 55.5
Front footrest bolt 39 3.9 28 .0
Chain roller mounting bolt (Upper & Lower) 40 4.0 29 .0
Rear brake master cylinder mounting bolt 10 1.0 7.0
Rear brake rod lock nut 18 1 .8 13.0
Rear shock absorber bolt (Upper & Lower) 55 5.5 40.0
Rear c ushion lever nut (Front) 80 8.0 58.0
Rear cushion lever nut (Center) 100 10 .0 72.5
Rear cushion rod nut 100 10.0 72.5
Rear axle nut For Canada and U.S .A. 100 10.0 72. 5
For the others 110 11 .0 79.5
Rear sprocket mounting nut 27 2.7 19.5
Spoke nipple (Front & Rear) 4.5 0.45 3.0
7-27 SERVICING INFORMATION

TIGHTENING TORQUE CHART

For other bolts and nuts listed previously, refer to this chart:

Bolt Diameter Conventional or "4" marked bolt "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 0.23 1.5
5 3 0.3 2.0 4 .5 0.45 3.0
6 5.5 0.55 4 .0 10 1.0 7.0
8 13 1.3 9.5 23 2.3 16.5
10 29 2.9 21.0 50 5.0 36.0
12 45 4.5 32.5 85 8.5 61.5
14 65 6.5 47.0 135 13.5 97.5
16 105 10.5 76.0 210 21.0 152.0
18 160 16.0 115. 5 240 24.0 173.5

®~
-·- ~
Conventional bolt " 4" marked bolt "7" marked bolt
 SERVICING INFORMATION 7-28

SERVICE DATA
VALVE+GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diam. 33
IN. (1.3) - -
28
EX. (1 . 1)
- -

Valve clearance 0.08 - 0.13

(when engine is cold) IN. (0.003-0.005)
- -
0 . 17-0.22
EX.
(0.0067 - 0.0087)
--
Valve guide to valve stem 0.010-0.037 - -
clearance IN. (0.0004 - 0.0015)
0 .030 - 0.057
EX. (0 .0012-0.0022)
--
Valve stem deflection 0.35
IN. & EX. --
(0.014)
Valve guide I.D. 5.500 - 5 .512
IN. & EX. - -
(0. 2165 - 0.2170)
Valve stem O.D. 5.475 - 5.490
IN. (0.2156 - 0.2161)
--

5.455-5.470
EX. --
(0.2148-0.2154)
Valve stem runout - - 0.05
IN. & EX.
(0.002)
Valve head thickness - - 0.5
IN . & EX.
(0.02)
Valve stem end length 2.7
IN . & EX . --
(0. 11)
Valve seat width 0 .9-1.1
IN. & EX.
(0.035 - 0.043)
- -
Valve head radial runout 0 .03
IN. & EX. --
(0 .001)
Valve spring free length -- 34.4
(IN. & EX.) INNER
(1.35)
OUTER - - 38.1
(1.50)
Valve spring tension 5.9-6.7 kg
(IN. & EX.) INNER (13.0-14.8 lbs) - -

at length 27.5 mm (1.1 in)

13.8 - 15.8 kg
OUTER (30.4-34.8 lbs) - -
at length 31.0 mm (1.2 in)
7-29 SERVICING INFORMATION

CAMSHAFT+ CYLINDER HEAD Unit: mm (in)

ITEM STANDARD LIMIT
Cam height 33. 710 -33. 750 33.410
IN. (1.3272-1.3287) (1.3154)
33 . 700 - 33. 740 33.400
EX. (1.3268-1.3283) ( 1.3150)
Camshaft journal oil clearance Right & 0.032 - 0.066 0.150
Center (0.0013-0.0026) (0.0059)
0.028 - 0.059 0.150
Left (0.0011 -0.0023) (0.0059)
Camshaft journal holder 1.0. Right & 22.012 - 22.025 --
Center (0.8666 - 0.8671)
17.512 - 17.525 --
Left (0.6894-0.6900)
Camshaft journal 0.0. Right & 21.959 - 21.980 --
Center (0.8645 - 0.8654)
17.466 - 17.484 --
Left (0.6877-0.6883)
Camshaft runout --
0.10
(0.004)
Rocker arm 1.0. 12.000 - 12.018 --
IN. & EX. (0.4 724 - 0.4 731)
Ro cker arm shaft 0.0. 11.973 - 11.984 --
IN. & EX. (0.47 14- 0.4718)
Cylinder head distortion --
0.05
(0.002 )
Cylinder head cover distortion --
0.05
(0.002 )

CYLINDER+ PISTON+ PISTON RING Unit: mm (in )

ITEM STANDARD LIMIT
Piston to cylinder clearance 0.020 - 0.030 0.120
(0.0008-0.0012) (0.0047)
Cylinder bore 100.000-100.015 Nicks or
(3.937 -3 .9376) Scratches
Piston diam. 99.975 - 99.990 99.880
(3.9360-3.9366) (3.9323)
M easure at 21 mm (0.8 in) from the skirt end.
Cylinder distortion -- 0.05
(0.002 )
Pisto n ring free end gap 13.5 10.8
1st R Approx. (0 .53) (0.43)
11.4 9.1
2nd R Approx. (0.45) (0.36)
Pisto n ring end gap 0.30 - 0.45 0.50
1st (0. 012 - 0.018) (0 .0 20)
0.45-0.60 1.00
2nd (0.018 - 0.024) (0.039 )
Compression pressure 850 kPa
(Automatic decamp. actuated) Approx. (8 .5 kg /cm 2 ) - -

120 psi
 SERVICING INFORMATION 7-30

ITEM STANDARD LIMIT

Piston ring to groove clearance 0 . 180
1st --
(0.0071)
0.150
2nd --
(0.0059)
Piston ring groove width 1.230-1.250
1st (0.048 - 0.049)
--

1 . 21 0- 1 . 2 30 - -
2nd (0.047-0.048)
2.810-2.830
Oil (0.110- 0.111)
--

Piston ring thickness 1 . 170- 1. 190

1st (0.0461 - 0.0469)
--

1.150-1.170
2nd (0.0453 - 0.0461)
--

Piston pin bore 23.002-23.008 23.030

(0.9056 - 0.9058) (0.9067)
Piston pin O.D. 22.996-23.000 22.980
(0.9054 - 0.9055) (0.9047)

CONROD+ CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 23.006-23.014 23.040
(0.9057 - 0.9061) (0.9071)
Conrod deflection -- 3.0
(0.12)
Conrod big end side clearance 0.10-0.65 1.00
(0.004 - 0.026) (0.039)
Conrod big end width 24.95 - 25.00 --
(0.982-0.984)
Crankshaft runout -- 0.05
(0.002)
Crank web to web width 71 .0 ± 0.1 - -
(2. 795 ± 0.004)

OIL PUMP
ITEM STANDARD LIMIT
Oil pump reduction ratio 1.633 (61 / 28 X 30/ 20 X 15/30) --

Oil pressure (at 60°C, 140°F) Above 30 kPa (0.3 kg /cm 2 , 4.3 psi)
Below 70 kPa (0. 7 kg/cm 2 , 10.0 psi) - -
at 3 000 r/min.
7-31 SERVICING INFORMATION

CLUTCH Unit: mm (in)

ITEM STANDARD LIMIT
Clutch lever play 10- 15
(0.4-0.6) --
Drive plate thickness No.1 & 2.9-3.1 2 .6
No.2 I (0.11 -0.12) (0 . 10)
Driven plate distortion 0.10
--
(0.004)
Clutch spring free length 33.0
--
( 1.30)

TRANSMISSION+ DRIVE CHAIN Unit: mm (in) Except ratio

ITEM STANDARD LIMIT
Primary reduction ratio 2. 1 78 (61 / 28) - -
Final reduction E-03,28,33 2.800 (42/ 15) - -
ratio The others 2.733 (41 / 15) - -
Gear ratios Low 2.416 (29/ 12) --
2nd 1.625 (26/ 16) - -
3rd 1.238 (26/ 21) - -
4th 1.000 (21 / 21) - -
Top 0. 826 ( 19/ 23) - -
Shift fork to groove clearance 0 . 10 - 0 .30 0.50
(0.004 - 0 .012) (0 .020)
Shift fork groove width 5.0 - 5.1
- -
(0.197 - 0.200)
Shift fork thickness 4 .8-4.9
(0.189 - 0.193) - -
Drive chain Type I DAIDO:DID525V9 - -
Links I 110 - -

20-pitch length - - 319.4

j ( 12.57)
Drive chain slack 30 - 45
(1.2 - 1.8) --
 SERVICING INFORMATION 7-32

CARBURETOR
SPECIFICATION
ITEM
E-03 E-33 E-28 E-18
-
Carburetor type MIKUNI f- f- f-
BST40SS
Bore size 40 mm f- f- f-

I.D. No. 32E1 32E6 32E5 32E2

Idle r/min. 1 500± 100 f- f-
1 500± 50
r/min. r/min.
Float height 14.7± 1.0 mm f- f- f-
(0.58±0.04 in)
Main jet (M.J.) # 11..fO f- # 140 # 137.5
Jet needle (J.N .) 6F23 f- 6F19-3rd 6H21-4th
Needle jet (N.J .) Y-5M f- Y-5 f-

Throttle valve (Th.V.) #95 f- f- f-

Pilot jet (P.J.) #'-12.5 f- #42.5 f-

Starter jet (G.S.) #40 f- f- f-

Pilot screw (P.S .) PRE-SET PRE-SET

PRE-SET f- (1 ½ turns (1.0 turn
back) back)
Throttle cable play 0.5 - 1.0 mm f- f- f-
(pulling cable) (0.02-0.04 in)
Starter cable play 0.5 - 1.0 mm f- f- f-
(0.02-0.04 in)

CARBURETOR
SPECIFICATION
ITEM
E-02,04,34 E-37 E-17,22,24 U-type E-22
Carburetor type MIKUNI f- f- f-
BST40SS
Bore size 40 mm f- f- f-

I.D. No. 32E0 32E8 32E3 32E4

Idle r/min. 1 500± f- f- f-
100 r/min.
Float height 14. 7± 1.0 mm f- f- f-
(0.58±0.04 in)
Main jet (M.J.) # 140 f- f- f-

Jet needle (J.N.) 6F19-3rd f- f- f-

Needle jet (N.J.) Y-5 f- f- f-

Throttle valve (Th.V.) #95 f- f- f-

Pilot jet (P.J.) #42.5 f- f- f-

Starter jet (G.S.l #40 f- f- f-

Pilot screw (P .S.) PRE-SET f-

PRE-SET PRE-SET
( 1 ½ turns back) ( 1.0 turn back) ( 1 1/a turns back)
Throttle cable play 0.5-1.0 mm f- f- f-
(pulling cable) (0.02-0.04 in)
Starter cable play 0.5 - 1.0 mm f- f- f-
(0.02-0.04 in)
7-33 SERVICING INFORMATION

ELECTRICAL Unit: mm (in)

ITEM SPECIFICATION NOTE
Ignition timing 10° B.T.D.C. at 1 500 r/min.
Spark plug ND.: U31 ESR-N
Type N.G.K.: CR 1 OE
0.7 - 0.8
Gap (0.028 - 0.031)
Spark performance Over 8 (0.3) at 1 atm .
Ignition coil resistance Primary 0.07 - 0.12 n B- B/W
Plug cap -
Secondary 23 - 25 kn Plug cap
Generator coil resistance Charging o.5-0.9 n Y-Y
Power source 0.1-0.2 n B-W
Pick-up 170 - 256 n BI-G
Generator no-load voltage More than 75 V(AC) at 5 000 r/min.
Generator Max. output Approx. 200W at 5 000 r/min.
Regulated voltage 13.0-16.0 V at 5 000 r/min.
Starter relay resistance 3 - 5n
Battery Type designation YTX9-BS
Capacity 12V 28 .8 kC (8Ah) / 10 HR
Standard
electrolyte S.G. 1.320 at 20°C (68°F)
Fuse size Main 30 A
Headlight (H) 10 A
Headlight (L) 10 A

WATTAGE Unit:W
SPECIFICATION
ITEM
E-03, 24,28,33 Th e others
Headlight I HI 60 +-

I LO 55 +-
Parking or position light 4
Tail/ Brake light 5/21 +-

Turn signal light 21 +-

Speedometer light 3 +-
Turn signal indicator light 2 +-

High beam indicator light 2 +-

Neutral indicator light 2 +-

License light 5 +-

BRAKE+ WHEEL Unit: mm (in)

ITEM STANDARD LIMIT
Rear brake peda l height 5 --
(0.2)
Brake disc thickness 4.0 ± 0.2 3.5
Front (0.157 ± 0.008) (0.14)
4.5 ± 0.2 4 .0
Rear (0.177 ± 0 .008) (0.16)
Brake disc runout --
0.30
( 0.012 )
 SERVICING INFORMATION 7-34

ITEM STANDARD LIMIT

Master cylinder bore 12. 700-12. 743
Front
(0.5000-0.5017) --
12. 700-12. 743
Rear --
(0.5000 - 0.5017)
Master cylinder piston diam. 12.657- 12.684
Front
(0.4983-0.4994) - -
12.657 - 12.684
Rear - -
(0.4983-0.4994)
Brake caliper cylinder bore 27.000-27.050
Front
(1.0630 - 1.0650)
- -
30.23-30.28
Rear
( 1. 1902 - 1.1 921) - -
Brake caliper piston diam. 26.90-26.95
Front - -
(1.0591 - 1.0610)
30.16-30.18
Rear - -
(1.1874 - 1.1882)
Wheel rim runout 2.0
Axial - -
(0.08)
Radial - - 2.0
(0.08)
Wheel axle runout 0.25
Front - -
(0.010)
Rear - - 0.25
(0.010)
Tire rim size Front 21 X 1.85 - -
Rear 17 x MT2. 50 - -
Tire size Front 90/90-21 54S - -
Rear 1 20/90- 1 7 64S - -

Tire tread depth 3.0

Front --
(0.12)
Rear - - 3.0
(0.12)

SUSPENSION Unit: mm (in)

ITEM STANDARD LIMIT NOTE
Front fork stroke 260 - -
(10.2)
220 - -
(8.7) Low seat
Front fork spring free length - - 548
(21.6)
Front fork oil level 164 - -
(6.5)
150 --
(5.9) Low seat
7-35 SERVICING INFORMATION

ITEM STANDARD LIMIT NOTE

Rear shock absorber spring 247.5 - -
pre-set length (9.74)
Rear wheel travel 260 --
(10.2)
220 - -
(8.7) Low seat
Swingarm pivot shaft runout - - 0.3
(0.01)

TIRE PRESSURE
COLD INFLATION SOLO RIDING DUAL RIDING
TIRE PRESSURE kPa kg/cm 2 psi kPa kg / cm 2 psi
FRONT 150 1.50 22 175 1. 75 25
REAR 175 1.75 25 200 2 .00 29

FUEL+ OIL
ITEM SPECIFICATION NOTE
Fuel type Use only unleaded gasoline of at least 87
pump octane ( R ~ M) or 91 octane or higher
rated by the research method.
Gasoline containing MTBE (Methyl Tertiary
Butyl Ether), less than 10% ethanol, or E-03,33
less than 5% methanol with appropriate
cosolvents and corrosion inhibitor is
permissible.
Use only unleaded gasoline of at least 87
pump octane ( R ~ M method) or 91 octane E-28
or higher rated by the Research Method.
Gasoline used should be graded 85-95
octane or higher. An unleaded gasoline is The others
recommended.
Fuel tank including reserve 12 L
(3.2/ 2.6 US /Imp gal) E- 33
13 L
(3.4/2.9 US/ Imp gal) The others
reserve 3.0 L
(0.8/0. 7 US/ Imp gal)
Engine oil type SAE 1OW/40, API SE, SF or SG
Engine oil capacity 2 300 ml
Change
(2.4/ 2.0 US/Imp qt)
2 400 ml
Filter change
(2.5 / 2.1 US/Imp qt)
2 600 ml
Overhaul
(2.7/ 2.3 US/Imp qt)
Front fork oil type Fork oil # 10
Front fork oil capacity (each leg) 565 ml
(19.1 / 19.9 US/Imp oz)
563 ml
Low seat
( 19.0/ 19.8 US/Imp oz)
Brake fluid type DOT 4
 EMISSION CONTROL INFORMATION

- - - - - - -- - CONTENTS - - - - -- - -~
EMISSION CONTROL CARBURETOR COMPONENTS · ·· · · · ·· · · · · · ·· · · · · 8- 1
EVAPORATIVE EMISSION CONTROL SYSTEM ·· ·· ·········· ............ .. 8- 2
CANISTER HOSE ROUTING · · · · · · · · · · · · · · · · · · ·· ·· · ·· ·· ·· · ·· ·· ·· · ·· ·· ·· · ·· ·· · · · · · ·· ·· 8- 3
8-1 EMISSION CONTROL INFORMATION

EMISSION CONTROL CARBURETOR COMPONENTS

DR650SE motorcycles are equipped with precision, manufactured carburetors for emission level con-
trol. These carburetors require special mixture control components and other precision adjustments
to function properly.

There are several carburetor mixture control components in each carburetor assembly. Three (3) of
these components are machined to much closer tolerances than standard machined carburetor jets.
These three (3) particular jets-MAIN JET, NEEDLE JET, PILOT JET -must not be replaced by stan-
dard jets. To aid in identifying these three (3) jets a different design of letter and number are used.
If replacement of these close tolerance jets becomes necessary, be sure to replace them with the
same type c lose tolerance jets marked as in the examples shown below.

The jet needle is also of special manufacture. Only one clip position is provided on the jet needle.
If replacement becomes necessary the jet needle may only be replaced with an equivalent perform-
ing replacement component. Suzuki recommends that Genuine Suzuki Parts be utilized whenever
possible for the best possible performance and durability.

Conventional Figures Used

on Standard Tolerance Jet
Components
1 2 3 4 5 6 7 8 9 0
Emission Type Figures
Used on Close Tolerance
Jet Components
I 2 3 L/- 5 5 1 B g 0
The carburetor specifications for the emission-controlled DR650SE are as follows.

Carburetor Main Needle J et Pilot Pilot

I.D. No. Jet Jet Needle Jet Screw

32E6
(California model only)
#l'-10 Y-5M 6F23 #'-/2.5 PRE-SET
32E1

Adjusting, interferring with, improper replacement, or resetting of any of the carburetor components
may adversely affect carburetor performance and cause the motorcycle to exceed the exhaust emission
level limits. If unable to effect repairs, contact the distributors representative for further technical
information and assistance.
 EMISSION CONTROL INFORMATION 8-2

EVAPORATIVE EMISSION CONTROL SYSTEM

(California model only)

Fuel tank
Fuel f iller pipe

Fuel valve

Vacuum hose

~ ~ _______; f---.-___,,,

Fuel hose

Carburetor

Purge port

E: HC VAPOR

• FUEL
◄:---- FRESH AIR
 -n
("'):t>
c;o
~

Q) l'TI
::2
-h-
3:
Cl)
o (J) Cl)

""'II -I C
0 2,m 2
n
Q) lJ C
2
Clamp
3 :::c -I
:,:,
Purge air hose
oo
C. (J)
....
C

2
~m "Tl
C
:,:,
0 lJ 3:
:r:,,
2-o ::::!
<c C
2
- -I
Fuel tank Surge hose
Purge hose
-
2
G')

Cushion~\
Spacer

Purge ai r hose
-----:-t7
....... _ , /,

Surge hose
(Red stripe)

Canister

Purge hose
I
Surge hose
(Red stripe)

Surge hose
Purge hose

Clamp
DR650SEV/WIXIY ('97/'98/'99/'00-MODEL)

~ - - - - - - - CONTENTS - - - - ---___,
SPECIF/CATIONS · · ·· · · · · · ·· · · · · · ·· · · .... · · · ·· · · · ·· ·· · · · ·· ·· .. · ·· ·· ·· ·· ·· ·· · ·· ·· · · · ·· ·· .. · 9- 1
SERVICE DA TA · ····· · ······ · ······ · · ········· .. · ·..... ......... · ·················· · · ··· · · 9- 3
WIRING DIA GRAM ·· · · · · · · · · · · · ·· · · · · · · · · · ·· ·· · ·· ·· ·· · ·· ·· ·· · · · ·· ·· ·· ·· ·· · · · ·· ·· · · · ·· ·· · 9-11
 9-1

SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 345 mm (92.3 in) ..... E- 17, 18, 22
2 325 mm (91.5 in) ..... E- 17, 18, 22 (Low seat)
2 255 mm (88.8 in) ..... Others
2 235 mm (88.0 in) ..... Others (Low seat)
Overall width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 865 mm (34. 1 in)
Overall height ...... . ...... ... . ....... . . .. . 1 205 mm (47.4 in)
1 165 mm (45.9 in) ..... (Low seat)
Wheelbase........................... . ..... 1 490 mm (58.7 in)
1 475 mm (58.1 in) ..... (Low seat)
Ground clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 265 mm (10.4 in)
225 mm ( 8.9 in) ..... (Low seat)
Seat height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 885 mm (34.8 in)
845 mm (33 in) ..... (Low seat)
Dry mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 kg (324 lbs)

ENGINE
Type....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four-stroke, air-cooled, with SACS, OHC
Valve clearance (IN) . . . . . . . . . . . . . . . . . . . . . . . . 0.08- 0.13 mm (0.003 - 0.005 in)
(EX) .................. . .. .. 0. 17-0.22 mm (0.007-0.009 in)
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . 1
Bore. .. .......... ....... . .... ............ . . 100 mm (3.937 in)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 mm (3.228 in)
Piston displacement . . . . . . . . . . . . . . . . . . . . . . . . 644 cm 3 (39.3 cu. in)
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 : 1
Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BST40, single
Air cleaner........................ .... ..... Polyurethane foam element
Starter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric
Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . Wet sump

TRANSMISSION
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wet multi-plate type
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-speed constant mesh
Gearshift pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-down, 4-up
Primary reduction ratio . . . . . . . . . . . . . . . . . . . . . 2.178 (61/28)
Gear ratios, Low . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.416 (29/ 12)
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.625 (26/16)
3rd ................... . ........ 1.238(26/21)
4th ... ... . ........... . . . .. . .... 1.000 (21/21)
Top . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.826 (19/23)
Final reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . 2.800 (42/15) ..... E-03, 28, 33
2.733 (41/15) ..... Others
Drive chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DID525 V9, 110 links
 9-2

CHASSIS
Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . Telescopic, coil spring, oil damped
Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . Link type, coil spring, gas/ oil damped,
spring pre-load fully adjustable, compression
damping force adjustable
Front fork stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 mm (10.2 in)
220 mm ( 8.7 in) ..... (Low seat)
Rear wheel travel . . . . . . . . . . . . . . . . . . . . . . . . . . 260 mm (10.2 in)
220 mm ( 8.7 in) ..... (Low seat)
Steering angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43°
Caster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28° 30'
Trail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 mm (4.37 in)
Turning radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 m (8.2 ft)
Front brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disc brake
Rear brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disc brake
Front tire size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90/90-21 54S, tube type
Rear tire size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120/90-17 64S, tube type

ELECTRICAL
Ignition type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic ignition (CDI)
Ignition timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10° B.T.D.C. at 1 500 rpm
Spark plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK CR10E or DENSO U31 ESR-N
Battery .. . .. .. . .. . . .. . . .. .. .. .. .. .. .. . .. . .. 12V 28.8 kC (8 Ah)/ 10 HR
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three-phase AC. generator
Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30/ 10/10A
Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 60/ 55W
Parking or city light . . . . . . . . . . . . . . . . . . . . . . . . 12V 4W ..... except E-03, 24, 28, 33
Turn signal light . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 21W
Brake light/Taillight . ......... .. ........ . .... 12V 21/5W
License plate light . . . . . . . . . . . . . . . . . . . . . . . . . 12V 5W
Speedometer light . . . . . . . . . . . . . . . . . . . . . . . . . 12V 3W
Neutral indicator light . . . . . . . . . . . . . . . . . . . . . . 12V 2W
High beam indicator light . . . . . . . . . . . . . . . . . . 12V 2W
Turn signal indicator light 12V 2W

CAPACITIES
Fuel tank, including reserve 12.0 L (3.2/2.6 US/Imp gal) ..... E-33
13.0 L (3.4/2.9 US/Imp gal) ..... Others
reserve ......................... . 3.0 L (0.8/ 0.7 US/Imp gal)
Engine oil, oil change .... ..... . ..... .. .... . 2 300 ml (2.4/2.0 US/Imp qt)
with filter change .............. . 2 400 ml (2.5/ 2. 1 US/ Imp qt)
overhaul ...................... . 2 600 ml (2.7/2.3 US/Imp qt)
Front fork oil (each leg) ................... . 565 ml (19.1/19.9.US/lmp oz)
563 ml (19.0/ 19.8 US/Imp oz) ..... (Low seat)
9-3

SERVICE DATA
VALVE+ GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diam. 33 - -
IN. (1.3)
28 - -
EX. ( 1. 1)
Valve clearance 0.08-0.13 --
(when engine is cold) IN. (0.003 - 0.005)
0.17-0.22 --
EX. (0.0067 - 0.0087)
Valve guide to valve stem 0 .010-0.037 --
clearance IN. (0 .0004- 0.0015)
0 .030-0.057 - -
EX. (0 .0012 - 0 .0022)
Valve stem deflection 0.35
IN. & EX. - -
(0.014)
Valve guide 1.0. 5.500-.5.512 --
IN. & EX. (0.2165 - 0.2170)
Valve stem 0 .0 . 5.4 75 - 5.490 - -
IN. (0 .2156-0.2161)
5.455-5.470
EX. (0.2148-0.2154)
--

Valve stem runout -- 0 .05

IN . & EX. (0.002)
Valve head thickness 0.5
IN. & EX. --
(0.02)
Valve stem end length -- 2.7
IN. & EX . (0. 1 1)
Valve seat width 0.9-1.1
IN. & EX. (0.035 - 0.043)
--

Valve head radial runout -- 0.03

IN. & EX . (0.001)
Valve spring free length -- 34.4
(IN. & EX.) INNER (1.35)
-- 38.1
OUTER (1.50)
Valve spring tension (IN. & EX.) 5.9-6. 7 kg
INNER (13.0-14.8 lbs) --
at length 27. 5 mm (1.1 in)
13.8-15.8 kg
OUTER (30.4-34.8 lbs) --
at length 31.0 mm (1.2 in)
 9-4

CAMSHAFT+ CYLINDER HEAD Unit: mm (in)

ITEM STANDARD LIMIT
Cam height 33.710- 33.750 33.410
IN.
(1.3272-1.3287) (1.3154)
33. 700-33. 740 33.400
EX.
(1.3268-1.3283) (1.3150)
Camshaft journal oil clearance Right & 0.032 - 0 .066 0.150
Center (0.0013-0.0026) (0.0059)
Left 0.028 - 0.059 0.150
(0.0011 - 0.0023) (0.0059)
Camshaft journal holder I. D. Right & 22.012-22.025 - -
Center (0.8666-0.8671)
17.512-17.525
Left --
(0.6894-0.6900)
Camshaft journal O.D. Right & 21.959 - 21.980 - -
Center (0.8645-0.8654)
17.466-17.484
Left - -
(0.6877 - 0.6883)
Camshaft runout 0.10
- -
(0.004)
Rocker arm I.D. 12.000-12.018
IN. & EX. - -
(0.4724 - 0.4731)
Rocker arm shaft O.D. 11.973-11.984
IN . & EX. - -
(0.4714 - 0.4718)
Cylinder head distortion - - 0.05
(0.002)
Cylinder head cover distortion 0 .05
- -
(0.002)

CYLINDER+ PISTON + PISTON RING Unit: mm (in )

ITEM STANDARD LIMIT
Piston to cylinder clearance 0.020 - 0.030 0 . 120
(0.0008-0.0012) (0 .0047)
Cylinder bore 100.000 - 100.015 Nicks or
(3 .937 - 3.9376) Scratches
Piston diam. 99.975 - 99 .990
(3 .9360 - 3.9366) 99.880
Measure at 21 mm (0.8 in) from the skirt end. (3.9323)
Cylinder distortion 0.05
- -
(0.002)
Piston ring free end gap 13. 5 10.8
1st R Approx. (0.53) (0.43)
2nd 11.4 9.1
R Approx. (0.45)
(0.36)
Piston ring end gap 0.30-0.45 0.50
1st
(0.012 - 0.018) (0.020)
0 .45 - 0 .60 1.00
2nd
(0.018 - 0.024) (0 .039)
Compression pressure Approx. 850 kPa
(Automatic decamp. actuated) ( 8.5 kg /cm 2 ) --
120 psi
9-5

ITEM STANDARD LIMIT

Piston ring to groove clearance - - 0 . 180
1st (0.0071)
- - 0.150
2nd (0.0059)
Piston ring groove width 1.230- 1.250 - -
1st (0.048 - 0.049)
1.210- 1.230
2nd (0.04 7 -0.048)
--

2.810- 2.830
Oil (0.110 - 0.111)
--

Piston ring thickness 1.170-1.190 --

1st (0.0461 - 0 .0469)
1.150 - 1.170 --
2nd (0.0453-0.0461)
Piston pin bore 23.002-23.008 23.030
(0.9056-0.9058) (0.9067)
Piston pin O.D. 22.996 - 23.000 22.980
(0.9054 - 0.9055) (0.9047)

CONROD+CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 23.006-23.014 23.040
(0.9057-0.9061) (0.9071 )
Conrod deflection - - 3.0
(0.12)
Conrod big end side clearance 0.10-0.65 1.00
(0 .004 - 0 .026) (0.039)
Conrod big end width 24.95 - 25.00 --
(0.982 - 0.984)
~

Crankshaft runout -- 0.05

(0 .002)
Crank web to web width 71.0 ± 0 . 1 --
(2 . 795 ± 0.004)

OIL PUMP
ITEM STANDARD LIMIT
Oil pump reduction ratio 1 .633 (61 /28 X 30/ 20 X 15/30) --
Oil pressure (at 60 ° C, 140°F) Above 30 kPa (0.3 kg /cm 2 , 4.3 psi)
Below 70 kPa (0. 7 kg/cm 2 , 10.0 psi) - -
at 3 000 r/min.
 9-6

CLUTCH Unit: mm (in)

ITEM STANDARD LIMIT
Clutch lever play 10-15 - -
(0.4 - 0.6)
Drive plate thickness No.1 & 2.9 - 3.1 2.6
No.2 I (0. 11 -0. 12) (0.10)
Driven plate distortion - - 0.10
(0.004)
Clutch spring free length -- 33.0
(1.30)

TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio

ITEM STANDARD LIMIT
Primary reduction ratio 2 . 178 (61 / 28) --
Final reduction E-03,28,33 2.800 (42/ 15) --

ratio The others 2.733 (41 / 15) - -

Gear ratios Low 2.416 (29/ 12) --
2nd 1.625 (26/ 16) --

3rd 1.238 (26/ 21) --

4th 1.000 (21 / 21) --
Top 0. 826 ( 19/ 23) --
Shift fork to groove clearance 0.10-0.30 0.50
(0.004-0.012) (0.020)
Shift fork groove width 5.0 - 5. 1 --
(0.197-0.200)
Shift fork thickn ess 4.8 - 4.9 --
(0.189 - 0.193)
Drive chain Type DAIDO :DID525V9 - -
Links 110 --

-- 319.4
20-pitch length
I (12.57)
Drive chain slack 30 - 45 --
(1.2 - 1.8)
9-7

CARBURETOR
SPECIFICATION
ITEM
E-03 E-33 E-28 E-18
Carburetor type MIKUNI +- +- +-
BST40SS
Bore size 40 mm +- +- +-

I.D. No. 32E1 32E6 32E1 32E2

Idle r/min. 1 500± 100 +- +-
1 500± 50
r/min. r/min.
Float height 14.7± 1.0 mm +- +- +-
(0. 58 ± 0.04 in)
Main jet (M.J.) #/1-IO +- +- # 137.5
Jet needle (J .N.) 6F23 +- +- 6H21 -4th
Needle jet (N.J .) Y-5M +- +- +-

Throttle valve (Th.V.) #95 +- +- +-

Pilot jet (P.J.) #'--12.5 +- +- +-

Starter jet (G.S.) #40 +- +- +-

Pilot screw (P.S.) PRE-SET

PRE-SET +- +- (1.0 turn
back)
Throttle cable play 0.5-1.0 mm +- +- +-
(pulling cable) (0.02 - 0.04 in)
Starter cable play 0.5 - 1.0 mm +- +- +-
(0.02-0.04 in)

CARBURETOR
SPECIFICATION
ITEM
E-02,04,34 P-37 E-17,22,24 U-type E-22
Carburetor type MIKUNI +- +- +-
BST40SS
Bore size 40 mm +- +- +-

I.D. No. 32E0 32E8 32E3 32E4

Idle r/min. 1 500± +- +- +-
100 r/min.
Float height 14.7± 1.0 mm +- +- +-
(0. 58 ± 0.04 in)
Main jet (M.J.) # 140 +- +- +-

Jet needle (J.N.) 6F1 9-3rd +- +- +-

Needle jet (N.J.) Y-5 +- +- +-

Throttle valve (Th.V.) #95 +- +- +-

Pilot jet (P .J.) #42.5 +- +- +-

Starter jet (G.S.) #40 +- +- +-

Pilot screw (P.S.) PRE-SET +-

PRE-SET PRE-SET
( 1½ turns back) ( 1.0 turn back) ( 11/s turns back)
Throttle cable play 0.5 - 1.0 mm +- +- +-
(pulling cable) (0.02 - 0.04 in)
Starter cable play 0.5-1.0 mm +- +- +-
(0.02-0.04 in)
 9-8

ELECTRICAL Unit: mm (in)

ITEM SPECIFICATION NOTE
Ignition timing 10° B.T.D.C. at 1 500 r/min.
Spark plug ND.: U31ESR-N
Type
N.G.K. : CR10E
0.7 - 0.8
Gap
(0.028 - 0.031)
Spark performance Over 8 (0.3) at 1 atm.
Ignition coil resistance Primary 0.07-0.12 n B- B/W
Plug cap-
Secondary 23 - 25 kQ
Plug cap
Generator coil resistance Charging o . 5 - 0.9 n Y- Y
Power source 0.1 - 0.2 n B- W
Pick-up 170 - 256 n BI - G
Generator no-load voltage More than 75 V(AC) at 5 000 r/min.
Generator Max. output Approx. 200W at 5 000 r/min.
Regulated voltage 13.0 - 16.0 V at 5 000 r/min.
Starter relay resistance 3-5!2
Battery Type designation YTX9-BS
Capacity 12V 28.8 kC (8Ah) / 10 HR
Standard
electrolyte S.G . 1.320 at 20°C (68°F)
Fuse size Main 30 A
Headlight (H) 10 A
Headlight (L) 10 A

WATTAGE Unit:W
SPECIFICATION
ITEM
E-03 ,24,28 ,33 Other markets
Headlight I HI 60 +-

I LO 55 +-
Parking or position light 4
Tail/Brake light 5/ 21 +-
Turn signal light 21 +-
Speedometer light 3 +-
Turn signal indicator light 2 +-
High beam indicator light 2 +-
Neutral indicator light 2 +-
License light 5 +-

BRAKE+ WHEEL Unit: mm (in)

ITEM STANDARD LIMIT
Rear brake pedal height 5 --
(0.2)
Brake disc thickness 4 .0 ± 0.2 3.5
Front
(0.157 ± 0.008) (0. 14)
Rear
4.5 ± 0.2 4 .0
(0.177 ± 0.008) (0.16)
Brake disc runout 0.30
--
( 0.012)
9.9

ITEM STANDARD LIMIT

Master cylinder bore 12. 700 - 12. 743 --
Front (0.5000 - 0.5017)
12. 700-12 . 743 - -
Rear (0.5000-0.5017)
Master cylinder piston diam. 12.657 - 12.684 - -
Front
(0.4983-0.4994)
12.657-12.684 --
Rear (0.4983-0.4994)
Brake caliper cylinder bore 27.000 - 27.050 - -
Front (1.0630 - 1.0650)
30.23 - 30.28 --
Rear
(1.1902-1.1921)
Brake caliper piston diam. 26.90-26.95 - -
Front (1.0591-1.0610)
30.16-30.18 - -
Rea r
(1.1874 - 1. 1882)
Wheel rim runout - - 2.0
Axial (0.08)
-- 2.0
Radial (0.08)
Wheel axle runout -- 0.25
Front
(0.010)
-- 0 .25
Rear (0.010)
Tire rim size Front J21 X 1.85 --
Rear J17xMT2.50 --
Tire size Front 90/90-21 54S - -
Rear 1 20/90-1 7 64S --

Tire tread depth - - 3.0

Front (0.12)
3.0
Rear --
(0.12)

SUSPENSION Unit: mm (in)

ITEM STANDARD LIMIT NOTE
Front fork stroke 260
(10.2)
--
220
(8.7)
-- Low seat
Front fork spring free length -- 548
(21 .6)
Front fork oil level 164 --
(6.5)
150 --
(5.9) Low seat
 9-10

ITEM STANDARD LIMIT NOTE

Rear shock absorber spring 247.5 --
pre-set length (9.74)
Rear wheel travel 260 --
(10.2)
220 --
(8.7) Low seat
Swingarm pivot shaft runout - - 0.3
(0.01)

TIRE PRESSURE
COLD INFLATION SOLO RIDING DUAL RIDING
TIRE PRESSURE kPa kg/cm2 psi kPa kg/cm 2 psi
FRONT 150 1.50 22 175 1. 75 25
REAR 175 1. 75 25 200 2.00 29

FUEL+OIL
ITEM SPECIFICATION NOTE
Fuel type Use only unleaded gasoline of at least 87
pump octane ( R; M) or 91 octane or higher
rated by the research m ethod .
Gasoline containing MTBE (Methyl Tertiary
Butyl Ether), less than 10% ethanol, or E-03,33
less than 5% methanol with appropriate
cosolvents and corrosion inhibitor is
permissible.
Use only unleaded gasoline of at least 87
pump octane ( R; M method) or 91 octane or E-28
higher rated by the Research Method .
Gasoline used should be graded 85-95
octane or higher. An unleaded gasoline is Other markets
recommended .
Fuel tank capacity 12 L
(3.2/ 2 .6 US/Imp gal) E-33
Including
reserve 13 L
(3.4/ 2 .9 US/Imp gal) Other markets
Only 3.0 L
reserve (0 .8 /0. 7 US/Imp gal)
Engine oil type SAE 10W/40, API SF or SG
Engine oil capacity Oil 2 300 ml
change (2.4/ 2.0 US/Imp qt)
Oil and 2 400 ml
filter change (2.5/ 2.1 US/Imp qt)
Engine 2 600 ml
overhaul (2 .7/ 2.3 US/Imp qt)
Front fork oil type Fork oil # 10
Front fork oil capacity (each leg) 565 ml
(19.1 / 19.9 US/Imp oz)
563 ml Low seat
( 19.0/ 19.8 US/ Imp oz)
Brake fluid type DOT 4
 -
Iffi' --:E I~
0
ENGINE FRONT 2
KILL BRAKE STARTER SIDE STAND
::r,
~ 2►
SWITCH BUTTON SWITCH
SPEEDOMETER =-r- REAR BRAKE

""',Y~-!P_u.s_H:.Ii. ;,.::~r9t!
SWITCH TURI\,
C 2
U i
SIGNAL
C)
►
RELAY
"T1

-l>
SIDE
STAND -I C
CDI UNIT
m

Irr #,'! it~

H: HIGH BEAM INDICATOR LIGHT IGNITION COIL
N: NEUTRAL INDICATOR LIGHT :II

If ~.l Wffll
T : TURN SIGN A L INDICATOR LIGHT
r (D C)
~ ::r,
l I lH !
# ### s: l>

ft llll l~, .. ,,.,

cain 0
!,, :: 0
s:
-m

C
-;: m
".; >! 9! cc3' 5~?~9> ► ;: ~ "o:i r-
-1
:II
FRONT TURN SIGNAL LIGHT (RI
,m,....,.",, 0
/;h..s---ffi..Lg-
C
-Lg--<h--s---n=:;\ C
\.:;j.JB tw V,B1W Blw-lJJ"BIW~ (")
H EADLIGHT TAIL/BRAKE LIGHT
::::!
~~
G,--Cll-G•jfi'\ 0
111 1 , 1J II , I1 11
11 I I , 11
II 1
I1
I I111111
I 1111 I II II , I I ' 1111 1 JI l~~~~U;:.J 2

~~~~1.111 IIIII I I, I II II I II III II IIIIII I II I't;l:::,•:"""''

1 1

rno,rn"' 1 I ! j I
WIRE COLOR

~lg
B Black

m
Bl Blue

! a ci5
a: o ~ ~
B, Brown

M irl
G Green
III I II l,
Gr
Lbl
Gray
111111 111 Lg
Light blue
Light green
0 Orang e
~
I HORN A Red

a~
w White

Ir FUSEBOX y

ii
Yellow
fr 1 : HEADLIGHT (HII

~ 0 ~
BI BI Black with Blue tracer

=~~
2: HEA DLIGHT IL1 8/Lg Black with Light green tracer
BIO Black w ith Orange tracer
BATTERY BI R Black w it h Red tracer
t':'."R,t_+.if,/f.,;_-+•--1..1
HORN BUTTON DIMMER REGULATOR/ GENERATOR --
STARTER B/W Blac k with White tracer
TURN SIGNAL SWITCH ON RECTIFIER RELAY 8118 Blue with Black tracer
LIGHT SWIT CH IGNITION SWITCH ~
81/ W : Blue with Whit e tracer
F: MAIN FUSE
GISI Green with Blue tracer
M : STARTER MOTOR
0 /W Orange with White tracer
0 /Y Orange with Yellow t racer
RIB Red with Black tracer
WIB White with Black t racer
W/BI : W hite w ith Blue tracer
Y/8 Yellow with Black tracer
VIG Yellow with Green tracer
YIW Yellow w ith White tracer
 DR650SEK1 ('01-MODEL)

~ - - - - - - --CONTENTS--- - - - -- ~
SPECIFICATIONS ............................................................................... 10- 1
SERVICE DATA .................................................................................... 10- 2
LIQUID GASKET ................................................................................. 10- 10
10-1 DR650SEK1 ('01-MODEL)

SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length .................. ......................... .............................. . 2 345 mm (92.3 in) ..... E-17, 28, 22
2 325 mm (91.5 in) ..... E-17, 28, 22 (Low seat)
2 255 mm (88.8 in) ..... Others
2 235 mm (88.0 in) ..... Others (Low seat)
Overall width ................................ .. 865 mm (34.1 in)
Overall height .................................................................. .. 1 205 mm (47.4 in)
1 165 mm (45.9 in) ..... (Low seat)
Wheelbase .................................. . 1 490 mm (58.7 in)
1 475 mm (58.1 in) ..... (Low seat)
Ground clearance ........... .. 265 mm (10.4 in)
225 mm ( 8.9 in) ..... (Low seat)
Seat height ... 885 mm (34.8 in)
845 mm (33 in) ..... (Low seat)
Dry mass. 147 kg (324 lbs)
ENGINE
Type .............................................................. .................... . Four-stroke, air-cooled, OHC
Valve clearance (IN) .............................................................. 0.08 - 0.13 mm (0.003 - 0.005 in)
(EX) ............................................................ .. 0. 17 - 0.22 mm (0.007 - 0.009 in)
Number of cylinders .................... ........................................... .. 1
Bore.... ............................................................. .. 100 mm (3.937 in)
Stroke ................................................................................. . 82 mm (3.228 in)
Displacement ............................................................................ 644 cm' (39.3 cu. in)
Compression ratio .............................................................. .. .. .. 9.5: 1
Carburetor .............................................................................. . MIKUNI BST40SS, single
Air cleaner .... ...... .. ..... .......... .. Polyurethane foam element
Starter system .. .... .. .. .. ... .. .. .... ..... .. ...... .... ....... .. ............. . Electric
Lubrication system ...................................... .. Wet sump
Idle speed .............................................. . 1 500 ± 100 r/min
TRANSMISSION
Clutch ....................... Wet multi-plate type
Transmission ........ .. 5-speed constant mesh
Gearshift pattern ........... .. 1-down, 4-up
Primary reduction ratio ........................................... . 2.178 (61/28)
Gear ratios, Low ..................... ............... ................................. . 2.416 (29/12)
2nd ................. . 1.625 (26/16)
3rd .......................................................... .............. . 1.238 (26/21)
4th............ .................................. .............. . 1.000 (21/21)
Top.... .............................................. .. 0.826 (19/23)
Final reduction ratio ................................................. .. 2.800 {42/15) ..... E-03, 28, 33
2.733 (41/15) ..... Others
Drive chain .. ................................................................... .. DID 525 V8, 110 links
CHASSIS
Front suspension .... .. Telescopic, coil spring, oil damped
Rear suspension ....... . Link type, coil spring, oil damped, spring preload fully adjustable,
compression damping force adjustable
Front fork stroke ................................. .. 260 mm (10.2 in)
220 mm ( 8.7 in) .. ... (Low seat)
Rear wheel travel .... ....................... .. . 260 mm (10.2 in)
220 mm ( 8.7 in) ..... (Low seat)
Steering angle ................................ 43°
Caster ............................................. ............... .. 28° 30'
Trail ................................................ ..................................... .. 111 mm (4.37 in)
Turning radius .................................. .. 2.5 m (8.2 ft)
Front brake ......................................................... ................... .. Disc brake
Rear brake .............................................................................. .. Disc brake
Front tire size ........................... .. 90/90-21 54S, tube type
Rear tire size ......... ................................................................ .. 120/90-17 64S, tube type
ELECTRICAL
Ignition type .... .. ............................................................... . Electronic ignition (CDI)
Ignition timing . .. ............................................................... . 10° B.TD.C. at 1 500 rpm
Spark plug ...... .. ............................................................... . NGK CR1 OE or DENSO U31ESR-N
Battery .................................................................................... . 12V 28.8 kC (8 Ah)/10HR
Generator ............................................................................... .. Three-phase A.C. generator
Main fuse ................................................................................. . 30A
Fuse ........................................................................................ .. 10/10A
Headlight .................................................................................. 12V 60/55W
Parking or city light ................................................................. .. 12V 4W ..... Except E-03, 24, 28, 33
Turn signal light ....................................................................... . 12V 21W
Brake light/Taillight ...................................................... .. 12V 21/5W
License plate light ................................................................... . 12V 5W
Speedometer light ................................................................... . 12V 1.7W
Neutral indicator light ............................................................ .. 12V 2W
High beam indicator light ....................................................... . 12V 2W
Turn signal indicator light ........................................................ . 12V 2W
CAPACITIES
Fuel tank, including reserve .................................................... . 12.0 L (3.2/2.6 US/Imp gal) ..... E-33
13.0 L (3.4/2.9 US/Imp gal) ..... Others
reserve ................................................................... . 3.0 L (0.8/0 .7 US/Imp gal)
Engine oil, oil change .............................................................. . 2 300 ml (2.4/2.0 US/Imp qt)
with filter change ........................,............... ,.......... . 2 400 ml (2.5/2.1 US/Imp qt)
overhaul..... .. ............................... .. 2 600 ml (2.7/2.3 US/Imp qt)
Front fork oil (each leg) ................................................... .. 565 ml (19.1/19.9 US/Imp oz)
563 ml (19.0/19.8 US/Imp oz) ..... (Low seat)
 DR650SEK1 ('01-MODEL) 10-2

SERVICE DATA
VALV E + GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diam. 33
IN. (1.3)
28
EX. (1 .1)
Valve clearance 0.08 0.13
IN. (0.003 - 0.005)
(when engine is cold)
0.17- 0.22
EX. (0.0067 - 0.0087)
Valve guide to valve stem 0.010 0.037
IN. (0.0004 0.0015)
clearance
0.030 - 0.057
EX. (0.0012 - 0.0022)
Valve stem deflection 0.35
IN. & EX. (0.014)
Valve guide I.D. 5.500 5.512
IN. & EX. (0.2165 - 0.2170)
Valve stem O.D. 5.475 5.490
IN. (0.2156 - 0.2161)
5.455 - 5.470
EX. (0.2148 - 0.2154)
Valve stem runout 0.05
IN. & EX. (0.002)
Valve head thickness 0.5
IN. & EX. (0.02)
Valve stem end length 2.7
IN.& EX. (0.1 1)
Valve seat width 0.9 1.1
IN. &EX. (0.035 - 0.043)
Valve head radial runout 0.03
IN. & EX. (0.001)
Valve spring free length 34.4
INNER ( 1.35)
(IN. & EX.)
38.1
OUTER (1 .50)
Valve spring tension (IN. & EX.) 5.9 6.7 kg
INNER (13.0 - 14.8 lbs)
at length 27.5 mm (1.1 in)
13.8 - 15.8 kg
OUTER (30.4 - 34.8 lbs)
at length 31.0 mm (1.2 in)
10-3 DR650SEK1 ('01-MODEL)

CAMSHAFT + CYLINDER HEAD Unit: mm (in)

ITEM STANDARD LIMIT
Cam height 33.710 - 33.750 33.410
IN. (1 .3272 - 1.3287) (1.3154)
33.700 - 33.740 33.400
EX. (1 .3268 - 1.3283) (1.3150)
Camshaft journal oil clearance Right & 0.032 - 0.066 0.150
Center (0.0013 - 0.0026) (0.0059)
0.028 - 0.059 0.150
Left
(0.0011 - 0.0023) (0.0059)
Camshaft journal holder I.D. Right & 22.012 - 22.025
Center (0.8666 - 0.8671)
17.512 - 17.525
Left (0.6894 - 0.6900)
Camshaft journal O.D. Right & 21 .959 - 21 .980
Center (0.8645 - 0.8654)
17.466 - 17.484
Left (0.6877 - 0.6883)
Camshaft runout 0.10
(0.004)
Rocker arm I.D. 12.000 - 12.018
IN. & EX. (0.4724 - 0.4731)
Rocker arm shaft O.D. 11 .973 - 11.984
IN. & EX.
(0.4714 - 0.4718)
Cylinder head distortion 0.05
(0.002)
Cylinder head cover distortion 0.05
(0.002)

CYLINDER + PISTON + PISTON RING Unit: mm (in)

ITEM STANDARD LIMIT
Piston to cylinder clearance 0.020 - 0.030 0.120
(0.0008 - 0.0012) (0.0047)
Cylinder bore 100.000 - 100.015 Nicks or
(3.9371 - 3.9376) Scratches
Piston diam. 99.975 - 99.990
(3.9360 - 3.9366) 99.880
Measure at 21 mm (0.8 in) from the skirt end. (3.9323)

Cylinder distortion 0.05

(0.002)
Piston ring free end gap 13.5 10.8
1st R Approx.
(0.53) (0.43)
11.4 9.1
2nd R Approx. (0.45)
(0.36)
Piston ring end gap 0.30- 0.45 0.50
1st
(0.012 - 0.018) (0.020)
0.45 - 0.60 1.00
2nd (0.018 - 0.024) (0.039)
Compression pressure 850 kPa
(Automatic decomp. actuated) Approx. (8.5 kg/cm2 )
120 psi
 DR650SEK1 ('01-MODEL) 10-4

ITEM STANDARD LIMIT

Piston ring to groove clearance 0.180
1st
(0.0071)
0.150
2nd
(0.0059)
Piston ring groove width 1.230 - 1.250
1st
(0.048 - 0.049)
1 .210 - 1.230
2nd
(0.047 - 0.048)
2.810 - 2.830
Oil
(0.110 - 0.111)
Piston ring thickness 1 . 170 - 1 .1 90
1st
(0.0461 - 0.0469)
1 .150 - 1. 170
2nd
(0.0453 - 0.0461)
Piston pin bore 23.002 - 23.008 23.030
(0.9056 - 0.9058) (0.9067)
Piston pin O.D. 22.996 - 23.000 22.980
(0.9054 - 0.9055) (0.9047)

CONROD + CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 23.006 - 23.014 23.040
(0.9057 - 0.9061) (0.9071)
Conrod deflection 3.0
(0.12)
Conrod big end side clearance 0.10 - 0.65 1.00
(0.004 - 0.026) (0.039)
Conrod big end width 24.95 - 25.00
(0.982 - 0.984)
Crankshaft runout 0.05
(0.002)
Crank web to web width 71.0 ± 0.1
(2.795 ± 0.004)

OIL PUMP
ITEM STANDARD LIMIT
Oil pump reduction ratio 1.633 (61 /28 X 30/20 X 15/30)
Oil pressure (at 60°C, 140°F) Above 30 kPa (0.3 kg/cm 2 , 4.3 psi)
Below 70 kPa (0.7 kg/cm2 , 10.0 psi)
at 3 000 r/min.
10-5 DR650SEK1 ('01-MODEL)

CLUTCH Unit: mm (in)

ITEM STANDARD LIMIT
Clutch lever play 10 - 15
(0.4 - 0.6)
Drive plate thickness No.1 & 2.9 - 3.1 2.6
No.2 I (0.11-0.12) (0.10)
Driven plate distortion 0.10
(0.004)
Clutch spring free length 33.0
(1.30)

TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio

ITEM STANDARD LIMIT
Primary reduction ratio 2.178 (61/28)
Final reduction E-03,28,33 2.800 (42/15)
ratio The others 2.733 (41/15)
Gear ratios Low 2.416 (29/12)
2nd 1.625 (26/16)
3rd 1.238 (26/21)
4th 1.000 (21 /21)
Top 0.826 (19/23)
Shift fork to groove clearance 0.10 - 0.30 0.50
(0.004 - 0.012) (0.020)
Shift fork groove width 5.0 - 5.1
(0.197 - 0.200)
Shift fork thickness 4.8 - 4.9
(0.189 - 0.193)
Drive chain Type I DAIDO:DID525V9
Links I 110
3 19.4
20-pitch length
I (12 .57)
Drive chain slack 30-45
(1.2- 1.8)
 DR650SEK1 ('01-MODEL) 10-6

CARBURETOR
ITEM SPECIFICATION
E-03, 28 E-33 E-18
Carburetor type MIKUNI
BST40SS f- f-

Bore size 40 mm f- f-
I.D.No. 32E1 32E6 32E2
Idler/min. 1 500 ± 100 r/min. 1 500 ± 50 r/min.
Float height 14.7±1 .0mm
(0.58 ± 0.04in) f- f-

Main iet (M.J.) #14D f- # 137.5

Jet needle (J.N.) 6F23 f- 6H21-4th
Needle jet (N.J.) Y-5M f- Y-5
Throttle valve (Th.V.) #95 f- f-
Pilot jet (P.J.) #42.5 f- f-
Starter jet (G.S.) #40 f- f-
Pilot screw (P.S.) PRE-SET
PRE-SET f-
(1.0 turn back)
Throttle cable play 0.5-1.0 mm
(pulling cable) (0.02 - 0.04 in) f- f-

Starter cable play 0.5 - 1.0 mm

(0.02 - 0.04 in) f- f-

CARBURETOR
ITEM SPECIFICATION
E-04, 34, 54 E-17, 22, 24 U-type E-22
Carburetor type MIKUNI BST40SS f- f-
Bore size 40 mm f- f-
1.0. No. 32E0 32E3 32E4
Idler/min. 1 500 ± 100 r/min. f- f-
Float height 14.7 ± 1.0 mm
(0.58 ± 0.04 in) f- f-

Main iet (M.J.) #140 f- f-

Jet needle (J.N.) 6F19-3rd f- f-
Needle jet (N.J.) Y-5 f- f-
Throttle valve (Th.V.) #95 f- f-
Pilot jet (P.J.) #42.5 f- f-
Starter jet (G.S.) #40 f- f-
Pilot screw (P.S.) PRE-SET PRE-SET PRE-SET
(1 ½ turns back) (1.0 turn back) (1 1/s turns back)
Throttle cable play 0.5-1.0 mm
(pulling cable) (0.02 - 0.04 in) f- f-

Starter cable play 0.5 -1.0 mm

(0.02 - 0.04 in) f- f-
10-7 DR650SEK1 ('01-MODEL)

ELECTRICAL Unit: mm (in)

ITEM SPECIFICATION NOTE
Ignition timing 10° B.T.D.C. at 1 500 r/min.
Spark plug ND.: U31ESR-N
Type
N.G.K.: CR1 OE
0.7 - 0.8
Gap (0.028 - 0.031)
Spark performance Over 8 (0.3) at 1 atm.
Ignition coil resistance Primary 0.07 - 0.12 Q B-B/W
Secondary 23-25 kQ Plug cap -
Plug cap
Generator coil resistance Charging 0.5 - 0.9 Q Y-Y
Power source 0.1 - 0.2 Q B-W
Pick-up 170 - 256 Q BI-G
Generator no-load voltage More than 75 V (AC) at 5 000 r/min.
Generator Max. output Approx. 200 Wat 5 000 r/min.
Requlated voltaqe 13.0 - 16.0 V at 5 000 r/min.
Starter relay resistance 3-5Q
Battery Type designation YTX9-BS
Capacity 12V 28.8 kC (8Ah)/10 HR
Standard
electrolyte S.G. 1.320 at 20°c (68°F)
Fuse size Main 30 A
Headlight (H) 10 A
Headlight (L) 10 A

WATTAGE Unit: W
SPECIFICATION
ITEM
E-03, 24, 28, 33 Other markets
Headlight I HI 60 f--
I LO 55 f--
Parking or position light 4
Brake liqht/Tailliqht 5/21 f--
Turn siqnal liqht 21 f--
Speedometer light 3 f--
Turn signal indicator light 2 f--
High beam indicator light 2 f--
Neutral indicator light 2 f--
License light 5 f--

BRAKE + WHEEL Unit: mm (in)

ITEM STANDARD LIMIT
Rear brake pedal height 5
(0.2)
Brake disc thickness 4.0 ± 0.2 3.5
Front
(0.157 ± 0.008) (0.14)
4.5 ± 0.2 4.0
Rear (0.177 ± 0.008) (0.16)
Brake disc runout 0.30
(0.012)
 DR650SEK1 ('01-MODEL} 10-8

ITEM STANDARD LIMIT

Master cylinder bore 12.700 - 12.743
Front (0.5000 - 0.5017)
12.700 - 12.743
Rear (0.5000 - 0.5017)
Master cylinder piston diam. 12.657 - 12.684
Front (0.4983 - 0.4994)
12.657 - 12.684
Rear (0.4983 - 0.4994)
Brake caliper cylinder bore 27.000 - 27.050
Front (1.0630 - 1.0650)
30.23 - 30.28
Rear (1.1902 - 1.1921)
Brake caliper piston diam. 26.90 - 26.95
Front (1.0591 - 1.0610)
30.16 - 30.18
Rear (1.1874 -1.1882)
Wheel rim runout 2.0
Axial (0.08)
2.0
Radial (0.08)
Wheel axle runout 0.25
Front (0 .010)
0.25
Rear (0.010)
Tire rim size Front J21 X 1.85
Rear J17 x MT2.50
Tire size Front 90/90-21 54S
Rear 120/90-17 64S
Tire tread depth 3.0
Front (0.12)
3.0
Rear (0.12)

SUSPENSION Unit: mm (in)

ITEM STANDARD LIMIT NOTE
Front fork stroke 260
(10.2)
220
(8.7) Low seat
Front fork spring free length 548
(21.6)
Front fork oil level 164
(6.5)
150
(5.9) Low seat
10-9 DR650SEK1 ('01-MODEL)

ITEM STANDARD LIMIT NOTE

Rear shock absorber spring 247.5
pre-set length (9 .74)
Rear wheel travel 260
(10.2)
220
(8.7) Low seat
Swingarm pivot shaft runout 0.3
(0.01)

TIRE PRESSURE
COLD INFLATION SOLO RIDING DUAL RIDING
TIRE PRESSURE kPa kq/cm 2 psi kPa kq/cm2 psi
FRONT 150 1.50 22 175 1.75 25
REAR 175 1.75 25 200 2.00 29

FUEL+ OIL
ITEM SPECIFICATION NOTE
Fuel type Use only unleaded gasoline of at least 87 pump
octane ( R; M) or 91 octane or higher rated by the
research method.
Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33
Ether), less than 10% ethanol , or less than 5%
methanol with appropriate cosolvents and co rro-
sion inhibitor is permissible.
Gasoline used should be graded 85-95 octane or
higher. An unleaded gasoline is recommended. Other markets

Fuel tank capacity 12 L

(3.2/2.6 US/Imp gal) E-33
Including
reserve 13 L
(3.4/2.9 US/Imp gal) Other markets
Only 3.0 L
reserve (0.8/0.7 US/Imp gal)
Engine oil type SAE 10W/40, API SF or SG
Engine oil capacity Oil 2 300 ml
change (2.4/2.0 US/Imp qt)
Oil and 2 400 ml
filter change (2.5/2.1 US/Imp qt)
Engine 2 600 ml
overhaul (2.7/2.3 US/Imp qt)
Front fork oil type Fork oil #10
Front fork oil capacity (each leg) 565 ml
(19.1 /19.9 US/Imp oz)
563 ml
(19.0/19.8 US/Imp oz) Low seat
Brake fluid type DOT4
 DR650SEK1 ('01-MODEL) 10-10

LIQUID GASKET

CYLINDER HEAD COVER

NOTE:
SUZUKI BONO N0.1215
or NO. 12078 has to be
applied to the cylinder head
cover and cylinder head.

CYLINDER HEAD