OWNER'S SERVICE MANUAL

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Part No. 99011-36F56-01A
April, 2006 ENTK
RM125
OWNER’S SERVICE MANUAL
This manual should be considered a permanent part of
the motorcycle and should remain with the motorcycle
when resold or otherwise transferred to a new owner or
operator.
The manual contains important safety information and
instructions which should be read carefully before
operating the motorcycle.
FOREWORD
This manual is presented as a means whereby you
can maintain your RM125 in top working condition
at all times. Your riding skill and the maintenance
steps outlined in this manual will assure you of top
performance from your machine under any type of
competition.
We sincerely wish you and your Suzuki motorcycle
a successful partnership for many years of happy
riding.
All information, illustrations, photographs and specifications contained in the manual are based on the
latest product information available at the time of
publication. Due to improvements or other changes,
there may be some discrepancies in this manual.
Suzuki reserves the right to make production
changes at any time, without notice and without
incurring any obligation to make the same or similar
changes to vehicles previous built or sold.
Suzuki Motor Corporation believes in conservation
and protection of Earth’s natural resources. To that
end, we encourage every vehicle owner to recycle,
trade in, or properly dispose of, as appropriate,
used motor oil, engine coolant, and other fluid, and
tires.
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
attention to the messages highlighted by these signal words:
NOTE:
Indicates special information to make maintenance
easier or instructions clearer.
c COPYRIGHT SUZUKI MOTOR CORPORATION 2006
 WARNING
Indicates a potential hazard that could
result in death or injury.
CAUTION
Indicates a potential hazard that could
result in motorcycle damage.
GENERAL CONSIDERATIONS
• Wear a helmet and goggles
A helmet is the most important piece of gear to
wear. Helmets do not reduce essential vision or
hearing. Generally, helmets do not cause or
intensify injury if you crash. Helmets simply help
your skull protect your intelligence, your memory,
your personality, and your life.
Your eyesight is equally valuable. Wearing suitable eye protection can help keep your vision
unblurred by the wind and help shield your eyes
from branches and airborne matter like bugs, dirt,
or pebbles kicked up by tires. Wear a helmet and
eye protection every time you ride.
• Wear protective gear
Wear proper clothing when you ride. Avoid loose
clothes or scarves, which could get caught in
moving parts. Abrasion injuries can be minimized
by wearing protective clothing including gloves,
strong boots that fit over the ankle, long pants,
and a long sleeve shirt or jackets. Experienced
riders often wear a kidney belt and chest or back
protector for additional comfort and protection.
• Inspect your machine before riding
Before each use, perform an inspection per “Periodic Inspection” section starting on page 2-3.
• No Passengers
Suzuki RMs are designed for the rider only.
• Practice on level ground
Before you begin riding, you should find a good
place to practice the skills you need to ride
safely. Find a flat, open area with enough space
to maneuver. Check with your Suzuki dealer or
call police department if you do not know where
you can ride.
Review the controls on your motorcycle before
riding.
• Know your limits
Always ride within the boundaries of your own
skills. Knowing these limits and staying within
them will help you avoid accidents. Ride only in
events appropriate for your experience.
Safely competing on a motorcycle requires that
your mental and physical skills are fully part of
the experience. You should not attempt to operate a motor vehicle, especially one with two
wheels, if you are tired or under the influence of
alcohol or other drugs. Alcohol, illegal drugs, and
even some prescription and over-the-counter
drugs and cause drowsiness, loss of coordination, loss of balance, and loss of good judgement. If you are tired or under the influence of
alcohol or other drugs, PLEASE DO NOT RIDE
your motorcycle.
• Conclusion
The actions of other riders are unpredictable.
Your motorcyclee’s condition can change. These
factors can best be dealt with by giving every ride
your full attention.
Circumstances beyond your control could lead to
an accident. You need to prepare for the unexpected by wearing a helmet and other protective
gear, and practicing safe riding techniques to
minimize the damage to you and your machine.
May all of your rides on your new Suzuki be winning
rides!
SERIAL NUMBER LOCATION
The frame number 1 is stamped on the steering head as shown in the photograph. The engine serial number 2 is stamped on the right side of the crankcase assembly.
Write down the serial numbers here for your future reference.
Frame No.
Engine No.
WARNINGS FOR SERVICING
 WARNING
Never run the engine indoors or in a
garage. Exhaust gas contains carbon monoxide, a gas that is colorless and odorless
and can cause death or severe injury.
Only run the engine outdoors where there
is fresh air.
 WARNING
Hot engine and muffler can burn you.
Wait until the engine and muffler cools
before servicing.
 WARNING
Fuel can catch on fire if you do not handle
it properly. Gasoline vapors can catch fire
easily.
Do not smoke when servicing the machine.
Do not service the machine in an area
where there are open flames or sparks.
 WARNING
Brake fluids and engine coolant can be
hazardous to humans and pets. Brake fluid
and engine coolant are harmful or fatal if
swallowed, and harmful if it comes in contact with your skin or eyes.
Keep brake fluid and engine coolant away
from children. Call your doctor immediately if swallowed, and induce vomiting.
Flush eyes or skin with water if either
brake fluid or engine coolant gets in eyes
or comes in contact with skin.
PRECAUTIONS FOR SERVIC-
ING
• Replace gaskets, snap rings, circlips, O-rings
and cotter pins with new ones.
• Take care not to expand the end gap larger than
required to slip the circlip over the shaft when
installing a circlip.
• Use special tools where specified.
• Use genuine SUZUKI parts and recommended
oil.
• When two or more persons work together, pay
attention to the safety of each other.
• After reassembly, inspect parts for tightness and
operation.
REPLACEMENT PARTS
Use only genuine SUZUKI replacement parts or
their equivalent. Genuine SUZUKI parts are high
quality parts which are designed and built specially
for SUZUKI vehicles.
NOTE:
Use of replacement parts which are not equivalent
in quality to genuine SUZUKI parts can lead to performance problems and damage.
 WARNING
Servicing the machine with engine running
can be hazardous. You can be caught in
the moving parts such as the drive chain,
sprockets etc.
Be sure to stop the engine when servicing
the machine.
 WARNING
Servicing the machine without proper
clothes and protective gear can be hazardous. You can be injured if you do not wear
proper clothes and protective gear.
Be sure to wear proper clothes and shoes
for servicing and wear protective glasses,
mask or gloves as necessary.
SYMBOL MARKS AND MATERIALS
Listed in the table below are the symbols indicating instructions and other information. The meaning of each
symbol is also included in the table.
SYMBOL DEFINITION SYMBOL DEFINITION
Torque control required.
Data beside it indicates specified
torque.
Use SUZUKI FORK OIL SS-05 or
equivalent fork oil.
99000-99001-SS5
Apply oil. Use engine oil or transmission
oil unless otherwise specified.
Use SUZUKI REAR SUSPENSION OIL
SS-25 or equivalent rear suspension oil.
99000-99001-S25
Apply SUZUKI SUPER GREASE “A”
or equivalent grease.
99000-25010
Use engine coolant.
Apply SUZUKI SILICONE GREASE.
99000-25100
Apply or use brake fluid. (DOT 4)
Apply SUZUKI BOND “1207B”.
99000-31140
Measure in voltage range.
Apply SUZUKI BOND “1216B”.
99000-31230
Measure in resistance range.
Apply THREAD LOCK SUPER “1303”.
99000-32030
Use special tool.
Apply THREAD LOCK SUPER “1322”
or equivalent thread lock.
99000-32110
Indication of service data.
Apply THREAD LOCK “1342”.
99000-32050
Replace a part with a new one when
reassembling.
Apply THREAD LOCK SUPER “1360”.
99000-32130
1216
GROUP INDEX
GENERAL INFORMATION 1
PERIODIC MAINTENANCE 2
TROUBLESHOOTING 3
MACHINE TUNING 4
ENGINE REMOVAL AND INSTALLATION 5
CYLINDER, PISTON AND EXHAUST VALVE 6
CLUTCH 7
KICK STARTER 8
GEARSHIFTING 9
TRANSMISSION AND CRANKSHAFT 10
FUEL SYSTEM 11
COOLING SYSTEM 12
ELECTRICAL SYSTEM 13
FRONT AND REAR WHEELS 14
FRONT AND REAR BRAKES 15
FRONT FORK AND STEERING 16
REAR SUSPENSION 17
SERVICING INFORMATION 18
1
GENERAL INFORMATION 1-1
CONTENTS
GENERAL INFORMATION
COUNTRY AND AREA CODES
The following codes stand for the applicable country(-ies) and area(-s).
CODE COUNTRY or AREA EFFECTIVE FRAME NO.
000
E-03
E-19
E-28
Japan
U. S. A.
E. U.
Canada
JS1RF16A000 500001 –
JS1RF16C 72 100001 –
JS1RF16A000 500001 –
JS1RF16C 72 100001 –
LOCATION OF PARTS ............................................................................... 1- 2
FUEL AND OIL RECOMMENDATION ........................................................ 1- 3
OPERATING INSTRUCTIONS .................................................................... 1- 4
STARTING THE ENGINE ...................................................................... 1- 4
STOPPING THE ENGINE ..................................................................... 1- 4
TRANSMISSION .......................................................................................... 1- 5
BREAK-IN (RUNNING-IN) ........................................................................... 1- 5
WHEN THE MOTORCYCLE IS NEW ................................................... 1- 5
WHEN ENGINE PARTS ARE REPLACED ........................................... 1- 5
1-2 GENERAL INFORMATION
LOCATION OF PARTS
1 Clutch lever
2 Engine stop switch
3 Front brake fluid reservoir
4 Throttle grip
5 Front brake lever
6 Fuel tank cap
7 Fuel valve
8 Carburetor starter knob
9 Gearshift lever
0 Rear brake fluid reservoir
A Rear brake pedal
B Kick starter lever
C Front suspension compression damping adjuster
D Front suspension rebound damping
adjuster
E Rear suspension compression damping adjuster
F Rear suspension rebound damping
adjuster
GENERAL INFORMATION 1-3
FUEL AND OIL RECOMMENDATION
This motorcycle is of the two-stroke design, which requires a
premixture of gasoline and oil.
Gasoline: Use only unleaded gasoline of at least 90 pump
octane (R/2 + M/2 method). .....For USA and Canada
Use only unleaded gasoline of at least 95 octane
(Research method). .................For other countries.
Engine oil: SUZUKI CCI SUPER 2-CYCLE MOTOR LUBRICANT or equivalent Two Cycle Racing Lubricant
.................................................For USA
MOTUL 800 2T FACTORY LINE OFF ROAD
or equivalent Two Cycle Racing Lubricant
.................................................For other countries
Mixing ratio: 30 : 1
Fuel tank capacity: 8.0 L (2.1/1.8 US/lmp gal)
NOTE:
* Mix gasoline and the engine oil thoroughly when the temperature is below 0 °C (32 °F). Vegetable-based oils can separate
easier than mineral oils.
* Use premixture oil as soon as possible after mixing, or lubrication performance of the engine oil can decrease.
* Do not mix vegetable-based oil and mineral oil.
* Insert the end of the breather hose into the steering stem head
after refueling.
CAUTION
A mixture containing too little oil will cause piston seizure. Too much oil will cause excessive carbon formation resulting in preignition, fouled spark plug and
loss of engine power.
Mix fuel and the engine oil at the ratio of 30:1.
Gasoline
(L)
Oil
(ml)
Gasoline
(US gal.)
Oil
(US oz)
Gasoline
(Imp gal.)
Oil
(Imp oz)
5.0 167 1 4.3 1 5.4
10.0 333 2 8.6 2 10.7
15.0 500 3 12.8 3 16.0
20.0 667 4 17.1 4 21.4
1-4 GENERAL INFORMATION
OPERATING INSTRUCTIONS
STARTING THE ENGINE
Inspect the transmission oil level, coolant level and air cleaner
condition before starting the engine.
When the engine is cold:
1) Turn the fuel valve lever to the “ON” position.
2) Shift the transmission into neutral.
3) Pull the starter knob 1.
4) Close the throttle grip completely and depress the kick
starter lever forcefully.
5) Return the starter knob when the engine revs at steady
speed.
When the engine is warm:
1) Turn the fuel valve lever to the “ON” position.
2) Shift the transmission into neutral.
3) Open the throttle 1/8 – 1/4 turn and depress the kick starter
lever forcefully.
To restart after the motorcycle has fallen:
1) Shift the transmission into neutral.
2) Open the throttle completely and depress the kick starter
lever forcefully.
3) Close the throttle gradually as engine speed increases.
4) Wait until engine revs smoothly.
STOPPING THE ENGINE
1) Shift the transmission into neutral.
2) Turn the fuel valve lever to the “OFF” position.
3) Push the engine stop switch 1 to stop the engine.
CAUTION
Racing the engine in neutral will exceed the engine
speed limit. Exceeding the engine speed limit can
damage the engine moving parts.
Do not race the engine at high speed to avoid the
engine damage.
 WARNING
Leaving the fuel valve in the “ON” position may cause
carburetor overflow. This can cause a fire or severe
engine damage when you start the engine.
Always leave the fuel valve in the “OFF” position
when the engine is not running.
ON OFF
Full open
Closed
GENERAL INFORMATION 1-5
TRANSMISSION
This motorcycle has a 6-speed transmission. Neutral is located
between low and 2nd. Engage first gear by pressing the lever
down from the neutral position. You can shift into higher gears
by lifting on the shift lever once for each gear. When neutral is
desired, press or lift the lever to a position halfway between low
and 2nd gear.
BREAK-IN (RUNNING-IN)
WHEN THE MOTORCYCLE IS NEW
1) Warm up the engine before starting off.
2) Ride for 60 minutes using less than 1/2 throttle opening.
3) Ride for 60 minutes using less than 3/4 throttle opening.
NOTE:
* The break-in (running-in) period is the period of greatest wear.
* The bolts and nuts of the new machine can loosen quickly. Be
sure to retighten the bolts and nuts during the break-in (running-in) period.
WHEN ENGINE PARTS ARE REPLACED
Follow the same procedure when any of the following parts are
replaced:
Piston
Piston ring
Cylinder
Crankshaft
Crankshaft bearing
N
1/2
FULL
OPEN
CLOSED
– MEMO –
2
PERIODIC MAINTENANCE 2-1
CONTENTS
PERIODIC MAINTENANCEPERIODIC MAINTENANCE ........................................................................ 2- 3
INSPECTION BEFORE PRACTICE ...................................................... 2- 3
INSPECTION BEFORE RACE
(All items of inspection before practice above plus) ........................ 2- 3
PERIODIC MAINTENANCE CHART .................................................... 2- 4
SPARK PLUG .............................................................................................. 2- 6
AIR CLEANER ............................................................................................. 2- 7
AIR CLEANER ELEMENT REMOVAL ................................................. 2- 7
WASHING .............................................................................................. 2- 7
INSTALLATION ..................................................................................... 2- 7
TRANSMISSION OIL ................................................................................... 2- 8
TRANSMISSION OIL LEVEL INSPECTION
AND REPLENISHMENT ....................................................................... 2- 9
TRANSMISSION OIL CHANGE ............................................................ 2- 9
ENGINE COOLANT ..................................................................................... 2-10
ENGINE COOLANT LEVEL CHECK .................................................... 2-10
ENGINE COOLANT REPLENISHMENT ............................................... 2-11
COOLING SYSTEM INSPECTION ....................................................... 2-11
CLUTCH CABLE ......................................................................................... 2-12
MAJOR ADJUSTMENT ........................................................................ 2-12
MINOR ADJUSTMENT ......................................................................... 2-12
THROTTLE CABLE ..................................................................................... 2-12
FUEL HOSE ................................................................................................. 2-13
FUEL VALVE ............................................................................................... 2-13
CYLINDER HEAD, CYLINDER AND PISTON ............................................ 2-14
CYLINDER HEAD ................................................................................. 2-14
CYLINDER ............................................................................................. 2-14
PISTON .................................................................................................. 2-14
EXHAUST VALVE ....................................................................................... 2-15
EXHAUST SILENCER ................................................................................. 2-15
SILENCER INSPECTION AND REPLACEMENT ................................. 2-15
SILENCER REASSEMBLY ................................................................... 2-15
DRIVE CHAIN AND SPROCKETS .............................................................. 2-16
DRIVE CHAIN SLACK .......................................................................... 2-16
DRIVE CHAIN ADJUSTMENT .............................................................. 2-16
20TH PITCH LENGTH ........................................................................... 2-16
DRIVE CHAIN LUBRICATION .............................................................. 2-16
2-2 PERIODIC MAINTENANCE
CONTENTS
PERIODIC MAINTENANCESPROCKET INSPECTION ................................................................... 2-17
DRIVE CHAIN GUIDE, BUFFER, TENSIONER ROLLER .......................... 2-17
DRIVE CHAIN GUIDE ........................................................................... 2-17
DRIVE CHAIN GUIDE BUFFER ........................................................... 2-18
DRIVE CHAIN TENSIONER ROLLER ................................................. 2-18
BRAKES ...................................................................................................... 2-18
BRAKE FLUID LEVEL ......................................................................... 2-18
BRAKE PAD ......................................................................................... 2-19
FRONT BRAKE LEVER ADJUSTMENT .............................................. 2-19
BRAKE PEDAL HEIGHT ADJUSTMENT ............................................ 2-19
FRONT FORK ............................................................................................. 2-20
REAR SUSPENSION .................................................................................. 2-20
WHEELS AND TIRES ................................................................................. 2-20
WHEEL RIM .......................................................................................... 2-20
SPOKE NIPPLE AND RIM LOCK ........................................................ 2-21
TIRE PRESSURE ................................................................................. 2-21
STEERING .................................................................................................. 2-22
LUBRICATION ............................................................................................ 2-23
PERIODIC MAINTENANCE 2-3
PERIODIC MAINTENANCE
INSPECTION BEFORE PRACTICE
INSPECTION BEFORE RACE
(All items of inspection before practice above plus)
WHAT TO CHECK CHECK FOR
Spark plug • Heat range, fouled electrode, tightness
• Loose high-tension cord
Air cleaner element Lubrication
Transmission oil Oil level
Coolant Coolant level
Cooling system • Radiator hose damage
• Engine coolant leak
Clutch • Play
• Smooth operation
Throttle • Play
• Smooth operation
Brake fluid Fluid level
Brakes • Brake lever position
• Brake pedal height
• Operation
Drive chain Slack, lubrication, chain joint clip condition
Drive chain guide/buffer Wear, damage
Suspension • Smooth operation
• Front fork air pressure
Wheels • Spoke tension
• Rim lock tightness or damage
Tires Tire pressure
Steering Smoothness, play
Exhaust pipe Firm fixation
Bolts and nuts Tightening torque
WHAT TO CHECK CHECK FOR
Air cleaner Cleanliness
Clutch Clutch disc plates wear and distortion
Brake pads Wear
Sprockets Wear
Fuel tank • Leakage
• Fuel filter clogging
Fuel hose Damage
Exhaust pipe Damage
Piston and Cylinder • Combustion chamber carbon deposit
• Piston head carbon deposit
• Piston and cylinder wear
Suspension • Smooth operation
• Front fork air pressure
2-4 PERIODIC MAINTENANCE
PERIODIC MAINTENANCE CHART
It is very important to inspect and maintain the machine regularly. Follow the guideline in the chart. The life
of parts varies depending on the riding conditions. Perform more often than shown in the chart if you use the
motorcycle under severe conditions.
Interval
races
Every
race
Every
3 races
Every
5 races
Remarks
Service
Item
hours
Every
2 hours
Every
6 hours
Every
10 hours
Spark plug I R —
Air cleaner C — — Replace air cleaner element as necessary.
Transmission oil — R — Change after 1st initial break-in.
Cooling-system I — —
Replace radiator hose and engine coolant
every year.
Flushing for overhaul or storage.
Clutch I — — Replace clutch plates as necessary.
Throttle cable and clutch
cable
I & L — —
Carburetor I — —
Fuel hose I — — Replace every 4 years.
Piston — — R
Piston ring — R —
Cylinder head, cylinder — C —
Exhaust valve — C —
Crankshaft and
transmission bearing
Inspect as required
Muffler I — —
Drive chain I & L R — Adjust slack every 30 minutes.
Engine sprocket I — —
Rear sprocket I — —
Check and retighten sprocket bolts at initial
and subsequent 10 minutes of riding and
each race thereafter.
Drive chain buffer — R —
Drive chain guide — R —
Kick starter lever I & L — —
Brake I — — Replace brake hose and fluid every year.
Front fork oil — R — Change after 1st initial break-in.
Front fork I — —
Check front fork inner tube frequently for
abnormality. Check the air pressure.
Rear suspension
system pivoting portion
I — —
Check rear suspension system frequently
and apply the grease to the pivoting portion
as necessary.
PERIODIC MAINTENANCE 2-5
.
NOTE: R = Replace, C = Clean, T = Tighten, I = Inspect and clean, adjust lubricate or replace if necessary,
L = Lubricate
Interval
races
Every
race
Every
3 races
Every
5 races
Remarks
Service
Item
hours
Every
2 hours
Every
6 hours
Every
10 hours
Tire I — —
Spoke nipple I — —
Inspect every 20 min. up to initial 2 hours
then check before each ride.
Steering I — —
Bolts and nuts T — — Retighten every 1 hour.
2-6 PERIODIC MAINTENANCE
SPARK PLUG
• Inspect the spark plug condition, electrode color, carbon
deposits, spark plug gap, and washer damage, after removing
the spark plug.
NOTE:
Remove the dirt around the spark plug before removing the
spark plug to prevent dirt from entering the combustion chamber.
• Inspect the porcelain tip color.
• Clean the spark plug and check the spark plug gap with a
thickness gauge.
 09900-20803: Thickness gauge
 Spark plug gap: 0.55 – 0.65 mm (0.022 – 0.026 in)
 Standard Spark plug
• Tighten the spark plug with specified tightening torque after
tightening the spark plug temporarily with fingers.
 Spark plug: 17.5 N·m (1.75 kgf-m, 12.5 lb-ft)
Porcelain tip color Cause
White (overheated)
• Hot type spark plug
• Advanced ignition timing
• Lean air/fuel mixture
• Deteriorated fuel
Black (fouled)
• Cold type spark plug
• Retarded ignition timing
• Rich air/fuel mixture
• Rich oil/gasoline mixture
NGK R6918B-8
CAUTION
Changing the spark plug heat range improperly can
damage the engine.
Select the spark plug heat range only after adjusting
the ignition timing, carburetor setting and oil/gasoline
mixture.
0.55 – 0.65 mm
(0.022 – 0.026 in)
PERIODIC MAINTENANCE 2-7
AIR CLEANER
AIR CLEANER ELEMENT REMOVAL
• Remove the seat. (5-3)
• Remove the air cleaner box lid. (2-8)
• Remove the wing nut 1.
• Remove the element 2 from the element holder.
WASHING
• Fill a washing pan large enough to hold the element with a
non-flammable cleaning solvent A. Immerse the element in
the solvent and wash it.
A: MOTUL AIR FILTER CLEAN or equivalent cleaning solvent
• Squeeze the element by grasping it to remove excess solvent. Do not twist or wring the element or it will develop
cracks.
• Dry the element in a plastic bag, pour in some foam filter oil B
and work the oil into the element.
B: MOTUL AIR FILTER OIL or equivalent filter oil
• Squeeze the element to remove excess oil.
INSTALLATION
• Apply grease to the element base where it contacts the air
cleaner box.
• Fit the element onto the element holder.
NOTE:
Fit the projection 1 of the element holder in the hole of the element base 2.
• Install them in the air cleaner box by engaging the projection
A of the element holder with the hole B of the cleaner body.
CAUTION
Improper element installation allows dust and dirt to
enter the combustion chamber. It can result in piston
and cylinder wear.
Be sure to check the element seals properly after
installing the elements.
2-8 PERIODIC MAINTENANCE
• Install the air cleaner box lid properly as shown.
NOTE:
Running the engine without the air cleaner box lid can vary the
carburetion. Do not run the engine without the air cleaner box
lid.
NOTE:
Follow the instructions below to keep the air cleaner element dry
when cleaning the motorcycle.
• Cover the element with plastic bag.
• Install the seat.
• Cover the inlet hole on the frame cover in order to prevent
water from coming into the air cleaner box.
• Do not spray high pressure water to the air cleaner box.
TRANSMISSION OIL
Cap to the front.
Air cleaner
box front wall
Lid
WARNING
Transmission oil and exhaust pipes can be hot
enough to burn you.
Wait until the oil drain plug and exhaust pipes are cool
enough to touch with bare hands before draining oil.
PERIODIC MAINTENANCE 2-9
NOTE:
Recycle or properly dispose of used oil and solvent.
TRANSMISSION OIL LEVEL INSPECTION
AND REPLENISHMENT
• Place the motorcycle on level ground and hold the motorcycle
vertically.
• Run the engine for a few minutes and stop it. Wait 3 minutes.
• Remove the oil level bolt 1. Check that oil comes out of the
hole.
• If oil does not come out of the hole, open oil filler cap 2 and
add the specified oil. Tighten the filler cap and oil level bolt
firmly and inspect again as above procedure.
• Tighten the filler cap and oil level bolt firmly.
 Oil level bolt: 5.5 N·m (0.55 kgf-m, 4.0 lb-ft)
TRANSMISSION OIL CHANGE
• Warm up the engine.
• Place the motorcycle on the level ground and hold the motorcycle vertically.
• Remove filler cap and drain plug 1. Drain oil thoroughly.
• Tighten the drain plug firmly.
 Oil drain plug: 21 N·m (2.1 kgf-m, 14.5 lb-ft)
• Pour specified amount of motor oil.
 Oil change .....750 ml (0.8/0.7 US/Imp qt)
Overhaul ........800 ml (0.8/0.7 US/Imp qt)
Transmission oil type: SAE 10W-40, API SF/SG or
SH/SJ with JASO MA
• Tighten the filler cap.
• Run the engine for a few minutes and stop it. Wait a few minutes.
• Inspect the oil level.
WARNING
New and used oil and solvent can be hazardous. Children and pets may be harmed by swallowing new or
used oil or solvent. Repeated, prolonged contact with
used engine oil may cause skin cancer. Brief contact
with used oil or solvent may irritate skin.
* Keep new and used oil and solvent away from children and pets.
* Wear a long-sleeve shirt and waterproof gloves.
* Wash with soap if oil or solvent contacts your skin.
2-10 PERIODIC MAINTENANCE
ENGINE COOLANT
ENGINE COOLANT LEVEL CHECK
• Remove the radiator cap 1.
• Check that the engine coolant level is at the bottom of the inlet
hole. If not, replenish the radiator with specified engine coolant.
• Tighten the radiator cap securely.
NOTE:
* This motorcycle does not have an overflow tank at the end of
breather hose. Therefore, engine coolant level may decrease
while riding. Check the engine coolant level every time before
riding.
* When replenishing engine coolant, be sure to use engine coolant mixed with distilled water at the ratio of 50:50. Adding only
water will dilute engine coolant and it may decrease cooling
performance.
* If the motorcycle is to be exposed to temperatures below –31
°C (–24 °F), the percentage of antifreeze should be increased
to 55 % or 60 %, according to figure 1.
WARNING
You can be injured by scalding fluid or steam if you
open the radiator cap when the engine is hot.
Do not open the radiator cap when the engine is hot.
Wait until engine cools.
CAUTION
Improperly tightening the radiator cap will prevent the
cooling system from reaching the specified operating
pressure and will cause coolant overflow.
Tighten the radiator cap until it locks firmly.
Antifreeze density Freezing point
50 % –31 °C (–24 °F)
55 % –40 °C (–40 °F)
60 % –55 °C (–67 °F)
Fig. 1 Engine coolant density-freezing
point curve
Fr ee zi ng p oi nt Density (%)
PERIODIC MAINTENANCE 2-11
ENGINE COOLANT REPLENISHMENT
• Use an anti-freeze and Summer engine coolant which is compatible with aluminum radiator, mixed with distilled water at
the ratio of 50:50.
NOTE:
The radiator, cylinder and cylinder head are made of aluminum
alloy. Using non-recommended engine coolant may corrode aluminum alloy and may clog the coolant passageways.
COOLING SYSTEM INSPECTION
Inspect the following items before practice and races.
• Engine coolant leakage
• Radiator hose cracks and deterioration
• Radiator mounting condition
• Radiator breather hose condition
• Radiator fin condition
WARNING
Engine coolant is harmful if swallowed or if it comes in
contact with your skin or eyes.
Keep engine coolant away from children and pets. Call
your doctor immediately if engine coolant is swallowed and induce vomiting. Flush eyes or skin with
water if engine coolant gets in eyes or comes in contact with skin.
2-12 PERIODIC MAINTENANCE
CLUTCH CABLE
Adjust the clutch cable play as follows:
MAJOR ADJUSTMENT
• Loosen lock-nut 1.
• Turn adjuster 2 so the clutch lever has 10 – 15 mm (0.4 – 0.6
in) play at the clutch lever end before pressure is felt.
• Tighten lock-nut 1.
 Clutch lever play: 10 – 15 mm (0.4 – 0.6 in)
MINOR ADJUSTMENT
• Turn adjuster 3 so the clutch lever has 10 – 15 mm (0.4 – 0.6
in) play at the clutch lever end before pressure is felt.
 Clutch lever play: 10 – 15 mm (0.4 – 0.6 in)
THROTTLE CABLE
Adjust the throttle cable play as follows:
• Loosen lock-nut 1.
• Turn adjuster 2 so the throttle grip has 2.0 – 4.0 mm (0.08 –
0.16 in) play in circumference.
• Tighten lock-nut 1.
 Throttle cable play A: 2.0 – 4.0 mm (0.08 – 0.16 in)
• Remove the throttle housing cover.
10 – 15 mm
(0.4 – 0.6 in)
WARNING
Inadequate throttle cable play can cause engine speed
to rise suddenly when you turn the handlebars. This
can lead to loss of rider control.
Adjust the throttle cable play so that engine speed
does not rise due to handlebar movement.
PERIODIC MAINTENANCE 2-13
• Apply oil to the throttle cable.
• Apply grease to the throttle cable spool.
 99000-25010: SUZUKI SUPER GREASE “A”
(or equivalent grease)
FUEL HOSE
• Inspect the fuel hose for damage and fuel leakage. If any
defects are found, the fuel hose must be replaced.
• Replace the fuel hose every four years.
FUEL VALVE
• Drain the fuel.
• Disconnect the fuel hose 1 and remove the fuel valve 2.
• If the fuel filter is dirty with sediment, fuel will not flow
smoothly.
• Clean the fuel filter with compressed air.
WARNING
Gasoline is highly flammable and explosive.
Keep heat, sparks and flames away from gasoline.
CAUTION
The O-ring 3 must be replaced with a new one to prevent fuel leakage.
2-14 PERIODIC MAINTENANCE
CYLINDER HEAD, CYLINDER AND
PISTON
CYLINDER HEAD
• Remove the cylinder head. (6-3)
• Remove carbon deposits from the combustion chamber surface.
• Inspect for pinholes, cracks and other damage.
CYLINDER
• Remove the cylinder. (6-4)
• Remove carbon deposits from the exhaust port.
• Check for scratches and wear on the cylinder sleeve.
PISTON
• Remove the piston. (6-4)
• Remove carbon deposits from the top surface of the piston.
• Check for scratches, cracks, and wear around the piston
bosses.
• Remove minor scuffs with #1 000 – #1 200 sand paper.
• Check piston ring wear. Remove carbon deposits from the
piston ring groove.
PERIODIC MAINTENANCE 2-15
EXHAUST VALVE
• Remove the exhaust valve assembly. (6-5)
• Remove carbon deposits from the main exhaust valve, side
valve, spacer and exhaust valve guide.
• Check for wear and damage.
NOTE:
If tar drops from the exhaust valve breather hose when the
motorcycle is parked, change engine oil brand because some
engine oil can accumulate tar in the exhause valve chamber.
EXHAUST SILENCER
SILENCER INSPECTION AND REPLACE-
MENT
• Remove the seat and the right frame cover.
• Loosen the silencer mounting bolt and remove the silencer.
• Remove three bolts and extract the black frontal pipe from the
aluminum case.
• Inspect the glass wool 1 for clogging with carbon deposit or
tar.
• Replace the glass wool 1 with a new one if necessary.
SILENCER REASSEMBLY
• Fit the glass wool 1 and the black frontal pipe to the aluminum case.
• Tighten three bolts.
NOTE:
To seal between the black frontal pipe flange and the aluminum
case, apply SUZUKI BOND to the contact area of the flange.
 99000-31140: SUZUKI BOND “1207B”
2-16 PERIODIC MAINTENANCE
DRIVE CHAIN AND SPROCKETS
DRIVE CHAIN SLACK
• Place the motorcycle on the side stand.
• Inspect the drive chain slack at the middle point between the
drive chain buffer and rear sprocket.
 Drive chain slack: 40 – 50 mm (1.6 – 2.0 in)
DRIVE CHAIN ADJUSTMENT
• Loosen the axle nut 1.
• Loosen the lock-nuts 2 and adjust the drive chain slack to the
specification by turning the adjusters 3. Make sure that the
right and left adjuster plates 4 are at the same position on
scales 5.
• With the adjusters 3 held in position, tighten the lock-nuts 2.
• Push the adjuster plates 4 to the adjusters 3 and tighten the
axle nut 1.
 Axle nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft)
• Tighten the lock-nuts 2.
NOTE:
Pull the upper drive chain tight and lock it by placing a bar
between the drive chain and rear sprocket while tightening the
axle nut. This will help prevent the chain adjusters from loosening.
20TH PITCH LENGTH
• Pull the drive chain tight and measure the 20th pitch length.
 Service Limit: 323.8 mm (12.7 in)
DRIVE CHAIN LUBRICATION
• Remove the chain clip and master link from the drive chain
and remove the drive chain.
NOTE:
Be careful not to bend the chain clip.
• Inspect for wear and damage of the drive chain and replace it
if necessary.
0 – 50 mm
PERIODIC MAINTENANCE 2-17
• Clean the drive chain with non-flammable cleaning solvent.
• Do not use gasoline to clean the drive chain.
• Dry the drive chain.
• Apply Suzuki Chain Lube or equivalent to the link plates and
rollers.
• Reassemble the drive chain.
NOTE:
Reassemble the drive chain clip so the slit end faces opposite
the direction of rotation.
• Adjust the drive chain slack.
SPROCKET INSPECTION
• Inspect the engine sprocket and rear sprocket for wear and
cracks. Replace the sprockets as necessary.
NOTE:
When replacing a worn sprocket, it is likely that the drive chain
will need to be replaced as well.
DRIVE CHAIN GUIDE, BUFFER,
TENSIONER ROLLER
DRIVE CHAIN GUIDE
• Inspect the drive chain guide 1 for bends and damage.
NOTE:
The drive chain can hit a bent guide causing noise and drive
chain wear.
• Inspect the chain guide defense 2 for wear.
Direction of travel
2-18 PERIODIC MAINTENANCE
DRIVE CHAIN GUIDE BUFFER
• Inspect the drive chain guide buffer 1 for wear and cracks.
NOTE:
The drive chain can touch the swingarm directly if the chain
guide buffer is worn out. This will cause drive chain and swingarm damage.
DRIVE CHAIN TENSIONER ROLLER
• Inspect the drive chain tensioner rollers 2 for wear.
• Inspect the tensioner roller bolts for tightness.
 Drive chain tensioner roller bolt:
31 N·m (3.1 kgf-m, 22.5 lb-ft)
BRAKES
BRAKE FLUID LEVEL
• Inspect the brake fluid level in both front and rear reservoirs. If
the brake fluid level is lower than LOWER mark A, replenish
the reservoir with the specified brake fluid to the UPPER level.
Inspect brake pad wear and brake fluid leakage if the brake
fluid level decreases.
 Brake fluid: DOT 4
WARNING
Brake fluid can be hazardous to humans and pets.
Brake fluid is harmful or fatal if swallowed, and harmful if it comes in contact with your skin or eyes.
Keep brake fluid away from children. Call your doctor
immediately if brake fluid is swallowed, and induce
vomiting. Flush eyes or skin with water if brake fluid
gets in eyes or comes in contact with skin.
WARNING
The use of any fluid except DOT 4 brake fluid from a
sealed container can damage the brake system and
lead to an accident.
Use only DOT 4 brake fluid from a sealed container.
Never use or mix different types of brake fluid.
CAUTION
Spilled brake fluid can damage painted surfaces and
plastic parts.
Be careful not to spill any fluid when filling the brake
fluid reservoir. Wipe spilled fluid up immediately.
PERIODIC MAINTENANCE 2-19
BRAKE PAD
• Inspect the brake pads for wear. If the brake pads are worn,
replace them with new ones. (15-5)
NOTE:
* Pump the brake lever/pedal several times to restore the brake
pads after replacing the brake pads.
* Replace both right and left pads together when replacing the
brake pads.
FRONT BRAKE LEVER ADJUSTMENT
Adjust the brake lever position as follows:
• Loosen lock-nut 1.
• Turn in or out adjuster 2 to obtain the proper brake lever
position.
• The standard adjuster length A is from 11 mm to 15 mm.
• Tighten the lock-nut 1.
 Adjuster length A: 11 – 15 mm (0.4 – 0.6 in)
BRAKE PEDAL HEIGHT ADJUSTMENT
Adjust the rear brake pedal height as follows:
• Loosen lock-nut 1.
• Adjust the brake pedal height A by turning the adjuster 2 to
locate the pedal 0 – 10 mm (0 – 0.3 in) below the top face of
the footrest.
• Tighten lock-nut 1.
 Brake pedal height A: 0 – 10 mm (0 – 0.3 in)
Wear limit
Wear limit
2-20 PERIODIC MAINTENANCE
FRONT FORK
• Move the front fork up and down several times and inspect for
smooth movement.
• Inspect for damage and oil leaks.
• Inspect the bolts and nuts for tightness.
• Place a stand under the chassis tube to lift the front wheel off
the ground.
• Remove the air bleed screw and equalize the air pressure in
the front forks to atmospheric pressure.
• Refit the air bleed screw.
REAR SUSPENSION
• Move the rear suspension up and down several times and
inspect for smooth movement.
• Inspect for damage and oil leaks.
• Inspect the bolts and nuts for tightness.
WHEELS AND TIRES
WHEEL RIM
• Inspect the wheel bearing for rattles. Replace the bearings if
necessary. (14-4, -7)
• Inspect the wheel rim runout. (14-4)
PERIODIC MAINTENANCE 2-21
SPOKE NIPPLE AND RIM LOCK
• Inspect the spokes for tension by squeezing the spoke nipples.
• Retighten the spoke nipples with a spoke nipple wrench so as
all spokes have same tension.
 Spoke nipple: 4 N·m (0.4 kgf-m, 3.0 lb-ft)
• Inspect the rim lock 1 for tightness, damage and bend.
TIRE PRESSURE
• Inspect front and rear tire pressure.
 Tire pressure (cold): 70 – 110 kPa
(0.7 – 1.1 kgf/cm2, 10 – 16 psi)
CAUTION
Improperly tightening of the spoke nipples can damage the wheel.
Tighten the spoke nipples less than 1/2 turn at a time.
Inspect the spoke tension and then retighten the
spoke nipple.
Tighten additionally the nipples after breaking-in
runnning, until when initial looseness will eliminated.
For additional tightening, take care so that all nipples
are tightened uniformly without concentrating force
on one point.
2-22 PERIODIC MAINTENANCE
STEERING
• Inspect the steering by moving the front fork up and down,
and right and left. If the steering has play or binds, inspect
steering stem head nut tightness and steering bearings.
(16-20)
PERIODIC MAINTENANCE 2-23
LUBRICATION
Apply grease or oil to the moving parts to increase durability and prevent wear.
The following materials are necessary:
A. Lightweight oil such as WD-40 or penetrating oil.
B. Aerosol type Chain Lube.
C. SUZUKI SUPER GREASE “A” or Water-proof wheel bearing grease.
Follow the schedule closely. The disassembly necessary to lubricate many components is in itself valuable
preventative maintenance. It allows you to inspect for wear, fatigue, adjustment and fastener tightness and it
allows you to clean out the grit which otherwise cannot be gotten out.
No. ITEM LUBRICANT FREQUENCY COMMENTS
1
Inner cable
ends, lever A
Pre-race and between
every race
Run oil through cables until it exits the
lower end. Lube the cable ends where
they pivot.
2
Throttle grip,
throttle housing,
cable
A
Pre-race Lightly grease the inside of throttle
spool. Keep free from dirt.
3
Rear brake
pedal
C
Pre-race Grease the brake pedal pivot.
4
Swingarm
C
Every 3 races/More often
according to conditions
Clean and pack the bearings.
Keep seals fresh.
Grease the seals.
5
Rear suspension
linkage pivot
points
C
Every 1 race/More often
according to conditions
Clean and pack the bearings.
Keep seals fresh.
Grease the seals.
6
Steering stem
bearings
C
Every 5 races/More often
according to conditions
Clean and pack the bearings.
Keep seals fresh.
7 Starter shaft A Pre-race Lightly oil the plunger shaft.
8
Drive chain
B
Pre-race and between
every race
Keep chain thoroughly lubed at all
times. Always check wear and alignment.
– MEMO –
3
TROUBLESHOOTING 3-1
CONTENTS
TROUBLESHOOTING
TROUBLESHOOTING ................................................................................. 3- 2
ENGINE ................................................................................................. 3- 2
CHASSIS ............................................................................................... 3- 5
3-2 TROUBLESHOOTING
TROUBLESHOOTING
ENGINE
Complaint Possible Cause Remedy
Engine does not start
or hard to start
Fuel deterioration
No fuel flow to the carburetor
• Fuel valve clogged
• Fuel hose clogged
• Fuel tank cap breather hose clogged
• Carburetor float valve malfunction
Too rich air/fuel mixture in combustion chamber
Incorrect ignition timing
No spark at spark plug
Low compression
• Piston ring worn or stuck
• Cylinder worn
• Air leak from cylinder gasket
• Air leak from crankshaft oil seal
Replace
Clean
Clean or replace
Clean
Replace
Scavange
Adjust
13-6
Replace
Replace
Replace
Replace
Engine stalls Fuel deterioration
Fouled spark plug
Fuel hose clogged
Air cleaner clogged
Carburetor jets clogged
Low compression
• Piston ring worn or stuck
• Cylinder worn
• Air leak from cylinder gasket
• Air leak from crankshaft oil seal
Incorrect ignition timing
Replace
Clean or replace
Clean or replace
Clean or replace
Clean
Replace
Replace
Replace
Replace
Adjust
Insufficient power Fuel deterioration
Brake dragging
Exhaust pipe cracked or clogged with carbon
Exhaust valve maladjustment
Exhaust valve carbon deposits
Air cleaner element clogged
Carburetor jets clogged
Incorrect fuel level in carburetor
Incorrect spark plug gap
Cylinder or piston ring worn
Reed valve malfunction
Incorrect ignition timing
Replace
Adjust
Replace or clean
Adjust
Clean
Clean or replace
Clean or replace
Adjust
Adjust or replace
Replace
Replace
Adjust
TROUBLESHOOTING 3-3
Complaint Possible Cause Remedy
Engine runs poorly in
low speed range
Exhaust valve maladjustment
Wide spark plug gap
Carburetor air screw maladjustment
Incorrect carburetor fuel level
Improper jet needle size
Incorrect ignition timing
CDI unit malfunction
Ignition coil damage
Magneto malfunction
Magneto short circuit
Adjust
Adjust or replace
Adjust
Adjust
Replace
Adjust
Replace
Replace
Replace
Replace
Engine runs poorly in
high speed range
Narrow spark plug gap
Incorrect carburetor fuel level
Retarded ignition timing
CDI unit malfunction
Ignition coil damage
Air cleaner element clogged
Magneto short circuit
Exhaust pipe cracked
Exhaust valve malfunction
Piston ring stuck
Adjust or replace
Adjust
Adjust
Replace
Replace
Clean or replace
Replace
Replace
Clean, adjust or
replace
Replace
Exhaust valve does
not work
Carbon deposits on exhaust valve
Exhaust valve damage
Governer damage
Exhaust valve shaft damage
Valve spring damage
Exhaust valve breather hose clogged
Clean
Replace
Replace
Replace
Replace
Clean
Spark plug does not
ignite
Ignition coil malfunction
Spark plug malfunction
Magneto malfunction
CDI unit malfunction
Wide spark plug gap
Engine stop switch malfunction
Replace
Replace
Replace
Replace
Adjust
Repair or replace
Carbon deposits on
spark plug porcelain
Too rich air/fuel mixture
Too rich oil/gasoline mixture
Improper spark plug heat range
Adjust
Adjust
Replace
Spark plug electrode
damage
Improper spark plug heat range
Overheating
Incorrect ignition timing
Loose spark plug
Too lean air/fuel mixture
Replace
3-4
Adjust
Tighten
Adjust
3-4 TROUBLESHOOTING
Complaint Possible Cause Remedy
Overheating Low engine coolant level
Engine coolant leak
Too lean air/fuel mixture
Incorrect ignition timing
Water pump malfunction
Cylinder head carbon deposits
Exhaust pipe carbon deposits
Improper spark plug heat range
Fuel deterioration
Clutch slipping
Radiator cap loose
Radiator fins damaged
Replenish
Repair
Adjust
Adjust
Adjust or replace
Clean
Clean or replace
Replace
Replace
Adjust or replace
Tighten
Repair or replace
Excessive coolant
level decrease
Radiator hose cracked or damaged
Loose radiator hose connection
Radiator cracked or damaged
Water pump cover mating surface damage
Water pump cover crack
Water pump cover gasket damage
Water seal wear or damage
Radiator cap seal damage
Incorrect radiator cap valve pressure
Cylinder or cylinder head cracked
Cylinder or cylinder head O-rings damage
Replace
Repair
Repair or replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clutch does not
disengage
Clutch lever play maladjustment
Clutch spring damage
Clutch plates distortion
Tip of clutch release camshaft worn
Adjust
Replace
Replace
Replace
Clutch slipping Clutch cable play maladjustment
Weakened clutch spring
Clutch pressure plate wear
Clutch plates distortion
Clutch plates worn
Tip of clutch release camshaft worn
Adjust
Replace
Replace
Replace
Replace
Replace
Transmission does not
shift
Gearshift cam damage
Gearshift fork distortion
Gearshift pawl wear
Replace
Replace
Replace
Transmission gears
jump out
Gearshift fork groove wear or damage
Gearshift fork distortion or wear
Gearshift cam stopper damage
Transmission gear claw damage
Replace
Replace
Replace
Replace
Gearshift lever does
not return
Weakened gearshift return spring
Gearshift lever sticking
Replace
Repair or replace
TROUBLESHOOTING 3-5
CHASSIS
* Optional stiffer and softer springs are available.
Complaint Possible Cause Remedy
Heavy handling Steering stem nut overtightened
Steering head bearings damaged or rusted
Steering stem distortion
Adjust
Replace
Replace
Front wheel wobbling Loose spoke nipples
Wheel distortion
Front wheel bearing damage
Incorrect axle tightening torque
Adjust
Replace
Replace
Retighten
Rear wheel wobbling Loose spoke nipples
Wheel distortion
Rear wheel bearing damage
Swingarm pivot bearing damage
Incorrect axle tightening torque
Incorrect swingarm tightening torque
Adjust
Replace
Replace
Replace
Retighten
Retighten
Soft front suspension Weakened spring
Low oil level
Low fork oil viscosity
Damping force maladjustment
Damping valve malfunction
Stardard spring too soft
Replace
Replenish
Replace
Adjust
Replace
* Use optional spring
Hard front suspension High fork oil level
High fork oil viscosity
Damping force maladjustment
Inner tube distortion
Standard spring too hard
Adjust
Replace
Adjust
Replace
* Use optional spring
Soft rear suspension Weakened spring
Damping force maladjustment
Low gas pressure
Standard spring too soft
Replace
Adjust
Adjust
* Use optional spring
Hard rear suspension Damping force maladjustment
Damper rod distortion
Rear suspension pivoting portion out of grease
Standard spring too hard
Adjust
Replace
Lubricate
* Use optional spring
Poor braking Brake pads worn
Improper air bleeding
Dirty pads and disc
Brake fluid leak
Replace
Bleed air
Clean
Repair
Brake noise Brake pads worn
Brake disc worn
Dirty brake pads and disc
Replace
Replace
Clean
– MEMO –
4
MACHINE TUNING 4-1
CONTENTS
MACHINE TUNING
CARBURETOR TUNING ............................................................................. 4- 2
PRINCIPLES OF CARBURETOR TUNING .......................................... 4- 2
CARBURETOR TUNING IN PRACTICE ............................................... 4- 6
FRONT FORK TUNING ............................................................................... 4- 9
COMPRESSION DAMPING FORCE ADJUSTMENT ........................... 4- 9
REBOUND DAMPING FORCE ADJUSTMENT .................................... 4- 9
OIL QUANTITY MINOR ADJUSTMENT ............................................... 4-10
OIL CHANGE (Only for outer tube oil chamber) ............................... 4-11
SPRING CHANGE ................................................................................. 4-13
FRONT FORK TUNING PROCEDURE ................................................. 4-15
REAR SUSPENSION TUNING .................................................................... 4-16
COMPRESSION DAMPING FORCE ADJUSTMENT ........................... 4-16
REBOUND DAMPING FORCE ADJUSTMENT .................................... 4-16
SPRING PRE-LOAD ADJUSTMENT .................................................... 4-17
REAR SUSPENSION TUNING PROCEDURE ..................................... 4-18
SUSPENSION BALANCE ........................................................................... 4-20
BALANCE TEST ................................................................................... 4-20
BALANCING TIPS ................................................................................ 4-20
4-2 MACHINE TUNING
CARBURETOR TUNING
The carburetion of your motorcycle was carefully
selected after extensive testing. You will find that
the carburetion will function smoothly under many
varied operating conditions. For best results we recommend that the adjustments and carburetion jetting be left “as is” from the factory.
Some riders may operate their motorcycle under
extreme operating conditions such as; very high
altitudes or extreme cold and hot temperatures. In
these circumstances the jetting of the carburetor or
other adjustments may need to be altered slightly.
Riders who are not familiar with the operation and
jetting procedures of the MIKUNI carburetor should
have their local authorized Suzuki dealer perform
these alterations. Mechanically experienced riders
can alter the carburetor settings based on the following information and specifications.
Carburetor Specifications
PRINCIPLES OF CARBURETOR
TUNING
CARBURETOR COMPONENTS AND FUNC-
TIONS
The carburetor consists of a number of parts as
shown below. The asterisk (*) marked parts are precisely machined, which meter the intake air (oxygen) and fuel so that the air/fuel mixture ratio is
controlled accurately. They can be divided by three
operation-related groups; pilot (slow) system, intermediate system and main system, and they achieve
their functions in each corresponding throttle opening range. It is necessary to have a full understanding of them for proper carburetor tuning.
Bore 38 mm (1.5 in)
Main jet #370
Jet needle 6CHY17-65-3rd
Pilot jet #42.5
Air screw 2 turns out
Float height 8.7 ± 1.0 mm
(0.34 ± 0.04 in)
Setting parts Parts No.
Main jet #360 09491-72011
Main jet #380 09491-76003
Main jet #390 09491-78005
1. Top cap
2. Spring
3. Cable holder
4. * Clip
5. * Jet needle
6. Throttle valve
7. Starter knob
8. Throttle stop screw
9. * Air screw
10. * Main jet
11. * Pilot jet
12. Needle valve ass’y
13. Float
14. Float chamber
15. Holder
16. Power jet
17. Solenoid
18. Throttle position sensor
1
2
3
4
5
6
7
8
9
12
13
15
10
11
14
18
16
17
MACHINE TUNING 4-3
As shown below, each tuning part is located between the air/fuel passage and has its own air/fuel mixture
adjustable range in terms of the throttle valve opening. The chart indicates that the carburetor can supply
correct air/fuel mixture to the engine in any range because of the overlapping adjustable range of the each
part.
1 MAIN SYSTEM 2 INTERMEDIATE SYSTEM 3 PILOT SYSTEM
When performing carburetor tuning, first find out in
what throttle opening range an improper air/fuel
mixture is supplied, by checking the color of
exhaust smoke, spark plug, throttle response,
power, etc. Second, replace or adjust the part(s)
related to the throttle opening range by referring to
the following instructions. The sizes referred to in
the illustrations are those of standard setting.
PILOT JET
The pilot jet meters the fuel supplied to the pilot system. Each jet size is indicated by a number. Larger
number means a larger bore diameter and fitting a
larger numbered pilot jet enriches the air/fuel mixture.
AIR SCREW
The air screw is located in the inlet air passage and
meters the air for the slow system. As it has a
right-hand thread, tightening it makes the passage
narrower, allowing less amount of intake air to flow
and resulting in richer air/fuel mixture. Air flow
adjustment is effective within a range of 1/2 – 2
turns out.
POWER JET
The power jet supplies the necessary amount of
fuel to the carburetor bore for correcting fuel/air
mixture ratio. When engine speed is 9 000 to
11 000 r/min, the passage is opened by solenoid
valve. The solenoid valve opens the passage when
the current not flows from CDI unit.
TUNING PARTS THROTTLE VALVE OPENING
MAIN JET
JET NEEDLE CLIP POSITION
JET NEEDLE O.D.
PILOT JET AND AIR SCREW
POWER JET
THROTTLE OPENING 1/4 1/2 3/4
Rich
Lean
4-4 MACHINE TUNING
NEEDLE CLIP POSITION
The jet needle is linked to the throttle valve by
means of the needle clip. Its lower part is tapered
and it has five grooves cut in the upper part where
the needle clip fits.
To adjust the air/fuel mixture with the jet needle,
change position of the needle clip which is set in the
4th groove. The lower groove the clip is moved to,
the higher the jet needle rises and the larger the
clearance with the needle jet becomes, resulting in
a richer air/fuel mixture ratio.
The needle clip position can be changed by half to
fine-tune the setting as following manner.
• Replace the cable holder with the included holder
and included red washer.
The two holders are different in color. The standard holder is gray. The included holder is yellow. The included holder and red washer must be
installed as a set.
• Change the red washer location from over the
needle clip to under the needle clip. This change
will move the needle position by half to the richer
side. The original position of red washer is over
the needle clip.
By replacing the jet needle with the optional one, it
is possible to perform the same setting as describing above. Change the jet needle from 6CHY17
type to 6CHY16 type. This change will move the
needle position by half to the richer side. 6CHY16
type jet needles are available as optional parts.
For example, “6CHY17-65-3rd” with the red washer
installed under the needle clip is the same setting
as “6CHY16-65-3rd”.
JET NEEDLE
NEEDLE NUMBER
Changing the needle itself controls air/fuel mixture
ratio particulary on lower mid-throttle opening. (Size
65 indicates that O.D. is 2.65 mm) The smaller the
O.D., the richer the air/fuel mixture becomes.
EX.
MAIN JET
The main jet, like the pilot jet, meters fuel flow. Each
jet size is indicated by a number. Larger number
means a larger bore diameter and fitting a larger
number main jet enriches the air/fuel mixture.
Needle type and clip position
6CHY17-65-2nd
6CHY16-65-2nd
6CHY17-65-3rd
6CHY16-65-3rd
6CHY17-65-4th
6CHY16-65-4th
Lean
Rich
Needle
clip
Lean
Rich
Needle Number O.D.
6CHY17-66
2.66 mm
6CHY16-66
6CHY17-65
2.65 mm
6CHY16-65
6CHY17-64
2.64 mm
6CHY16-64
6CHY17-63
2.63 mm
6CHY16-63
6CHY17-62
2.62 mm
6CHY16-62
6CHY17-61
2.61 mm
6CHY16-61
6CHY17-60
2.60 mm
6CHY16-60
O.D. of needle
Taper portion
Clip
6CHY17-65-3rd
O.D. 2.65 mm
MACHINE TUNING 4-5
THROTTLE STOP SCREW
The throttle stop screw determines the full close position of the
throttle valve and should be adjusted in the following procedures.
• Loosen the throttle stop screw lock-nut.
• Adjust the throttle stop screw as follows:
* Turn in (to raise the throttle valve).
* Turn out (to lower the throttle valve).
• With the throttle stop screw held immovable, tighten the
lock-nut to lock the screw.
1 Throttle stop screw
2 Lock-nut
NOTE:
Opening the throttle valve slightly by adjusting the throttle stop
screw may often improve hesitation problem due to lack of mixture on returning the throttle.
If engine idling is desired, turn in the throttle stop screw to raise
the throttle valve in the above procedures.
 Throttle valve opening position
Standard
After touching the throttle stop screw to the
throttle valve, turn in the stop screw 1/4 –
3/4 turn to raise the throttle valve.
CAUTION
Too high an engine idle may cause driveability failure
such as lack of engine braking and poor deceleration
during brake application.
4-6 MACHINE TUNING
CARBURETOR TUNING IN PRACTICE
In the previous section, basic principles of carburetor tuning have been discussed. Described in this section
are the bases for carburetor tuning required when coping with variations in air (oxygen) concentration.
VARIATION IN AIR (OXYGEN) CONCENTRATION AND CARBURETOR CONDITIONS
As the air, affected by the temperature, altitude and humidity, gets expanded or compressed, air (oxygen)
concentration varies accordingly. Each of these three factors affects the air in different ways, and the following graphs show their effects respectively in terms of the oxygen concentration.
In the above graphs, oxygen concentration is graduated on the vertical axis while the temperature, altitude
and humidity are on the horizontal axis respectively. Oxygen concentration is set 100 % under the conditions of 20 °C (68 °F), 0 m (0 ft) and 50 % humidity. The standard carburetor setting is chosen to obtain the
best engine performance under these conditions.
The graph at the left shows that the oxygen concentration changes about 10 % in the 0 °C (32 °F) to 40 °C
(104 °F) temperature difference, the one in the center shows about 20 % change in the 0 to 2 000 m (6 562
ft) altitude difference and the one at the right shows about 5 % change in the 0 to 100 % humidity difference.
As for humidity, its normal range is from 20 to 95 %. Therefore the possible effect of humidity on the oxygen
concentration is so little that it can be disregarded. Consequently, we can say that the oxygen concentration
varies by as much as 20 % depending on the temperature and altitude under normal riding conditions. On
the other hand, different from the air, the fuel (gasoline) hardly changes in volume even when such environmental conditions change. Therefore, increase in oxygen concentration will make the air/fuel mixture richer
and decrease will make it lean.
As the carburetor mixes gasoline and air, which are metered by each jet in varying proportions to suit throttle
opening, the air/fuel mixture is affected if the air concentration itself varies as described above. Then proper
engine power output can not be attained and, should the mixture become too lean, a piston seizure may
result. To compensate for such change in the air concentration, it is required to carry out carburetor tuning
beforehand. This requirement applies to all models of motorcycles and ATVs if they are used in areas where
temperature and altitude range widely. The next section describes the procedure of the above tuning in
detail.
O
X
Y
G
E
N
C
O
N
C
E
N
T
R
AT
IO
N
[%
]
-10 0 10 20 30 40 [˚C]
10 30 50 70 90 110 [˚F]
ATOMOSPHERIC TEMPERATURE
500 1000 1500 2000 2500[m] 20 40 60 80 100 [%]
1600 3200 5000 6500 8200 [ft]
ALTITUDE HUMIDITY
100
90
80
[%]
100
90
80
MACHINE TUNING 4-7
JUDGING AIR/FUEL MIXTURE
For proper carburetor tuning, it is necessary to
know how to judge the air/fuel mixture made in the
carburetor; whether too rich, too lean or properly
mixed. Given below are the symptoms observed
when the engine is not supplied with the proper
air/fuel mixture ratio from the carburetor. Check
each item as reference for judging the air/fuel mixture condition.
When air/fuel mixture is too rich
1) The engine noise is dull and intermittent.
2) The engine condition becomes worse when the
bypass is applied.
3) The engine condition becomes worse as it is
warmed up.
4) The engine condition improves when the air
cleaner is removed.
5) The spark plug is fouled with carbon (wet and
oily).
6) The exhaust gas produces heavy smoke.
When air/fuel mixture is too lean
1) The engine overheats.
2) The engine condition improves when the
bypass is applied.
3) Acceleration is poor.
4) The spark plug is burned white.
5) The speed of the engine fluctuates and lack of
power is noticed.
6) Detonation and pinging are experienced.
TUNING PROCEDURE
The following indicates the correct tuning procedure
for this motorcycle. Understand the procedure by
first riding the motorcycle where it will be used and
adjust the engine to the best condition after judging
the air/fuel mixture.
Carburetor standard setting
Main jet: #370
Jet needle: 6CHY17-65-3rd
Pilot jet: #42.5
Air screw: 2 turns out
INCLUDED PARTS AND OPTIONAL PARTS
Main jet
Pilot jet
Air/fuel
mixture
SIZE P/NO
Lean #300 09491-60007
#310 09491-62005
#320 09491-64002
#330 09491-66002
#340 09491-68002
#350 09491-70011
* #360 09491-72011
#370 09491-74003
* #380 09491-76003
* #390 09491-78005
#400 09491-80010
#410 09491-82007
#420 09491-84008
#430 09491-86002
#440 09491-88001
#450 09491-90005
#460 09491-92002
#470 09491-94004
#480 09491-96001
#490 09491-98001
Rich #500 09491-10001
Air/fuel
mixture
SIZE P/NO
Lean #25 09492-25011
#27.5 09492-27011
#30 09492-30014
#32.5 09492-32010
#35 09492-35021
#37.5 09492-37003
#40 09492-40028
#42.5 09492-42023
#45 09492-45034
#47.5 09492-47022
Rich #50 09492-50024
4-8 MACHINE TUNING
Cable holder and washer
The cable holder and washer must be used as a
set.
Jet needle
NOTE:
SHADED: STANDARD
*: INCLUDED ALTERNATE PARTS
NONE: OPTIONAL PARTS
1 Adjustment of pilot system
1) Set the air screw as specified.
2) See if the selected pilot jet is correct or not by
judging the air/fuel mixture. If air/fuel mixture is
rich, replace it with smaller one. If air/fuel mixture is lean, replace it with larger one.
2 Adjustment of main system
With the throttle opened 3/4 to full, make main system adjustment monitoring the air/fuel mixture condition after completion of pilot system settings.
* Make sure to adjust the main system before
adjusting the intermediate system.
3 Adjustment of intermediate system
Monitor the air/fuel mixture condition and adjust the
intermediate system by changing the needle clip
position or cable holder. (4-4)
4 Fine adjustment of slow system
After a proper setting has been obtained by the procedure 1 through 3, fine tune the carburetor
according to the actual race conditions.
1) Adjust the air/fuel mixture by turning the air
screw within 1/2 – 2 turns out.
2) If the mixture can not be adjusted by the air
screw within 1/2 – 2 turns out range, readjust
the pilot system 1.
5 Fine adjustment of intermediate system
Fine tune the intermediate system by changing the
needle type and clip position.
ITEM P/NO Color
Cable holder * 13518-36F20 Yellow
Washer * 13394-36F20 Red
Air/fuel
mixture
SIZE P/NO
Lean 6CHY17-66 13381-36F60
6CHY16-66 13381-36F50
6CHY17-65 13381-36F40
6CHY16-65 13381-36F30
6CHY17-64 13383-36FM0
6CHY16-64 13383-36FL0
6CHY17-63 13383-36FP0
6CHY16-63 13383-36FN0
6CHY17-62 13383-36FR0
6CHY16-62 13383-36FQ0
6CHY17-61 13381-36F00
6CHY16-61 13383-36FS0
6CHY17-60 13381-36F20
Rich 6CHY16-60 13381-36F10
Ex. Pilot jet #42.5
If air/fuel mixture is rich, replace it with #40
pilot jet. If air/fuel mixture is lean, replace it
with #45 slow jet.
Ex. Main jet #370
If air/fuel mixture is rich, replace it with
#360 main jet. If air/fuel mixture is lean,
replace it with #380 main jet.
1/2 turn out
3/4 turn out
1 turn out
1-1/4 turns out
1-1/2 turns out
1-3/4 turns out
2 turns out................ STD
STD
Lean
Rich
MACHINE TUNING 4-9
FRONT FORK TUNING
The front fork compression and rebound damping force, and oil
level are adjustable for rider’s preference, rider’s weight and
course condition.
NOTE:
* Break-in new front forks before attempting adjustment.
* Be sure to adjust both right and left front forks equally.
* Inspect the following items before attempting adjustment.
* Front fork air pressure adjustment. (2-20)
* Front fork damage and oil leakage. (2-20)
* Tire pressure. (2-21)
* Tire and wheel damage. (2-20)
* Spoke nipple tension and rim lock tightness. (2-21)
* Steering movement. (2-22)
COMPRESSION DAMPING FORCE
ADJUSTMENT
• Turn the adjuster screw clockwise until it stops (full hard position).
NOTE:
To set the adjuster, you must gently turn the adjuster screw
clockwise until it stops, then back it out the recommended number of turns. Do not force the adjuster screw past the stopped
position or you may damage the adjuster.
• Turn the adjuster screw 1 counterclockwise and the 11th
clicks is the standard position.
 Compression damping force adjuster
Standard setting: 11 clicks turn back
REBOUND DAMPING FORCE ADJUSTMENT
• Turn the adjuster screw clockwise until it stops (full hard position).
NOTE:
To set the adjuster, you must gently turn the adjuster screw
clockwise until it stops, then back it out the recommended number of turns. Do not force the adjuster screw past the stopped
position or you may damage the adjuster.
• Turn the adjuster screw 1 counterclockwise and the 10th
clicks is the standard position.
 Rebound damping force adjuster
Standard setting: 10 clicks turn back
Soft
Hard
Soft
Hard
4-10 MACHINE TUNING
OIL QUANTITY MINOR ADJUSTMENT
ADDING THE FORK OIL
• Remove the air bleed screw 1.
• Add the fork oil with a injector from the air bleed hole.
REDUCING THE FORK OIL
• Remove the front forks. (16-4)
• Remove the air bleed screw.
• Leaning the front fork, reduce the fork oil from the air bleed
hole.
NOTE:
If 1 ml (0.34/0.35 US/Imp oz) of fork oil is added/reduced, the oil
level raises/falls approx. 1.8 mm (0.07 in). Measure the fork oil
quantity added/reduced and record it to know the oil quantity
after adjustment.
 Front fork oil quantity (With standard fork spring
used)
Standard: 357 ml (12.07 / 12.57 US/lmp oz)
Oil quantity adjustable range:
314 – 408 ml (10.61/11.06 – 13.79/14.37 US/lmp oz)
 99000-99001-SS5: SUZUKI FORK OIL SS-05
(or equivalent fork oil)
CAUTION
The fork oil quantity must be adjusted equally on both
fork legs to provide equal performance.
Operating the motorcycle with the fork oil quantity
unevenly adjusted can cause handling instability.
Never mix different types of fork oil. Different oils may
cause chemical reaction and deteriorate.
MACHINE TUNING 4-11
OIL CHANGE
(Only for outer tube oil chamber)
• Remove the front forks. (16-4)
• Thoroughly clean the fork before disassembly.
• Clamp the outer tube with a vise. Protect the outer tube with a
rag when using a vise. (16-5)
• Loosen and remove the fork cap bolt (sub-tank) from the outer
tube and slowly slide down the outer tube. (16-5)
 09941-53630: Front fork top cap wrench
• Hold the front fork inverted position for move than 20 minutes
to allow the fork oil to fully drain.
• Force out the remaining oil using compressed air completely.
CAUTION
The fork oil quantity must be adjusted equally on both
fork legs to provide equal performance.
Scratches or other damage on the inner tube or on the
oil seal lip will cause oil leak.
Avoid scratching or damaging the inner tube or the oil
seal. Use a mild detergent or car wash soap and
sponge out dirt with plenty of water.
4-12 MACHINE TUNING
• Slide down the outer tube.
• Pour the specified amount of fork oil into the outer tube.
 99000-99001-SS5: SUZUKI FORK OIL SS-05
(or equivalent fork oil)
NOTE:
Be sure to adjust the fork oil quantity within the above-mentioned range.
• Raise the outer tube and temporarily tighten the fork cap bolt
(sub-tank). (16-16)
 09941-53630: Front fork top cap wrench
• Install the front forks. (16-17)
• Install the handlebars. (16-22)
Parts No. Spring rate
Identification
(Slit mark
on the spring end)
STD
Oil quantity
Oil quantity
adjustable range
Soft 51171-36F60 4.0 N/mm (0.40 kgf/mm) None
354 ml
(11.97/12.46
US/Imp oz)
311 – 405 ml
(10.51/10.95 –
13.69/14.26
US/Imp oz)
STD 51171-37FD0 4.2 N/mm (0.42 kgf/mm) I
357 ml
(12.07/12.57
US/Imp oz)
314 – 408 ml
(10.61/11.06 –
13.79/14.37
US/Imp oz)
Hard 51171-37FC0 4.4 N/mm (0.44 kgf/mm) III
352 ml
(11.90/12.39
US/Imp oz)
309 – 403 ml
(10.44/10.88 –
13.62/14.19
US/Imp oz)
MACHINE TUNING 4-13
SPRING CHANGE
• Remove the front forks. (16-4)
• Thoroughly clean the fork before disassembly.
• Remove the fork cap bolt and drain fork oil. (16-5)
• Loosen the center bolt completely. (16-6)
• Compress the outer tube by hands and install the conrod
holder (special tool) between the axle holder bottom 1 and
lock-nut 2. (16-6)
 09910-20115: Conrod holder
• Hold the lock-nut with a wrench and remove the center bolt.
(16-6)
• Remove the push rod. (16-6)
• Remove the damper rod assembly and fork spring. (16-7)
• Hold the front fork inverted position for more than 20 minutes
the allow the fork oil to fully drain. (4-11)
• Force out the remaining oil using compressed air completely.
(4-11)
• Replace the spring.
CAUTION
The fork oil quantity must be adjusted equally on both
fork legs to provide equal performance.
Scratches or other damage the on inner tube or on the
oil seal lip will cause oil leak.
Avoid scratching or damaging the inner tube or the oil
seal. Use a mild detergent or car wash soap and
sponge out dirt with plenty of water.
SPRING/No. SPRING RATE
Identification
(Slit mark on
the spring end)
Soft 51171-36F60
4.0 N/mm
(0.40 kgf/mm)
None
STD 51171-37FD0
4.2 N/mm
(0.42 kgf/mm)
I
Hard 51171-37FC0
4.4 N/mm
(0.44 kgf/mm)
III
4-14 MACHINE TUNING
• Make sure approx. 10 mm (0.39 in) of inner rod thread is
exposed on the end. (16-14)
• Install the damper rod assembly. (16-14)
• Insert the push rod into the inner rod.
• Insert the shaped projection of center bolt into the push
rod. (16-15)
• Check or adjust the clearance between the lock-nut and center bolt to provide 1 mm (0.04 in) and more. (16-15)
• Tighten the lock-nut/center bolt to the specified torque.
 Lock-nut/center bolt: 22 N·m (2.2 kgf-m, 16.0 lb-ft)
• Tighten the center bolt to the specified torque.
 Center bolt: 70 N·m (7.0 kgf-m, 50.5 lb-ft)
• Pour the specified amount fork oil into the outer tube in accordance with the following table.
 99000-99001-SS5: SUZUKI FORK OIL SS-05
(or equivalent fork oil)
Approx.10 mm
(0.39 in)
Lock-nut
1 mm and more
(0.04 in)
SPRING
STD OIL
QUANTITY
OIL QUANTITY
ADJ. RANGE
Soft 51171-36F60
354 ml
(11.97/12.46
US/Imp oz)
311 – 405 ml
(10.51/10.95 –
13.69/14.26
US/Imp oz)
STD 51171-37FD0
357 ml
(12.07/12.57
US/Imp oz)
314 – 408 ml
(10.61/11.06 –
13.79/14.37
US/Imp oz)
Hard 51171-37FC0
352 ml
(11.90/12.39
US/Imp oz)
309 – 403 ml
(10.44/10.88 –
13.62/14.19
US/Imp oz)
MACHINE TUNING 4-15
FRONT FORK TUNING PROCEDURE
Test ride the motorcycle and find out how the front suspension reacts on various types of surface. According
to the symptom noticed, adjust the front fork to the best setting for rider and race track conditions. To adjust,
attempt changing fork oil capacity and compression/rebound damping following the instructions below.
NOTE:
When adjusting the front fork oil capacity, make sure that the oil level is within the specified range. Also, the
capacity should be increased or decreased by 1 ml (0.034/0.035 US/Imp oz) [Approx. 1.8 mm (0.07 in)] at a
time.
When adjusting the damping setting, attempt turning the adjuster 1 to 2 click stops at a time for each adjustment.
SYMPTOM SECTION ADJUSTMENT PROCEDURE
Feels too hard overall • Jump
• Large bumps
• Series of medium
bumps
1. Adjust both the compression and rebound
damping to a softer setting.
2. Decrease fork oil capacity.
3. Replace the spring with an optional softer one.
Feels too soft overall and
bottoms
• Jump
• Large bump
• When braking
1. Adjust the compression damping to a stiffer setting.
2. Increase fork oil capacity.
3. Replace the spring with an optional stiffer one.
Feels too hard near end of
travel
• Jump 1. Decrease fork oil capacity.
Feels too soft near end of
travel and bottoms
harshly
• Jump
• Large bump
1. Adjust the compression damping to a stiffer
settting.
2. Increase fork oil capacity.
Feels too hard in the
beginning of stroke
• Jump
• Large bump
• Series of medium
bumps
• Series of small bumps
1. Adjust the compression damping to a softer setting.
Feels too soft and unstable
• Series of medium
bumps
• Series of small bumps
1. Adjust the rebound damping to a stiffer setting.
Bounces • Jump
• Large bump
1. Adjust the rebound damping to a stiffer setting.
Bounces • Series of small bumps 1. Adjust the rebound damping to a softer setting.
4-16 MACHINE TUNING
REAR SUSPENSION TUNING
The rear suspension compression and rebound damping force,
and spring pre-load are adjustable for rider’s preference, rider’s
weight and course condition.
NOTE:
* Break-in the rear suspension when riding with a new rear
cushion unit. (1-5)
* Inspect the following items before attempting adjustment.
* Rear shock absorber damage and oil leakage. (2-20)
* Swingarm and links tighteness. (2-20)
* Tire pressure. (2-21)
* Tire and wheel damage. (2-20)
* Spoke nipple tension and rim lock tightness. (2-21)
COMPRESSION DAMPING FORCE ADJUST-
MENT
NOTE:
To set the adjuster, you must gently turn the adjuster screw or
bolt clockwise until it stops, then back it out the recommended
number of turns. Do not force the adjuster screw or bolt past the
stopped position, or you may damage the adjuster.
Low-side
• Turn the adjuster screw 1 clockwise until it stops (full hard
position).
• Turn the adjuster screw 1 counterclockwise about 10th clicks
where the punch mark A aligns with C.
 Standard setting: (Lo-side) 10 clicks turn back
High-side
• Turn the adjuster bolt 2 clockwise until it stops (full hard position).
• Turn the adjuster bolt 2 counterclockwise about 2 turns
where the punch mark B aligns with C.
 Standard setting: (Hi-side) 2 turns out
REBOUND DAMPING FORCE ADJUSTMENT
NOTE:
To set the adjuster, you must gently turn the adjuster screw
clockwise until it stops, then back it out the recommended number of turns. Do not force the adjuster screw past the stopped
position, or you may damage the adjuster.
• Turn the adjuster screw 1 clockwise until it stops (full hard
position).
• Turn the adjuster screw 1 counterclockwise about 12th clicks
where the punch mark A aligns with B.
 Standard setting: 12 clicks turn back
Soft Hard
Soft
Hard
MACHINE TUNING 4-17
SPRING PRE-LOAD ADJUSTMENT
• Place a block under the chassis tube.
• Remove the silencer and rear frame assembly. (17-3)
• Loosen the lock-nut 1 with the special tool.
 09910-60611: Universal clamp wrench
• Turn the adjuster 2 clockwise or counterclockwise to change
the spring pre-load.
• Tighten the lock-nut 1.
 Standard spring set length: 3.7 mm (0.146 in)
(Standard spring set length: 3.7 mm compressed from
spring free length)
Spring set length adjustable range:
245 – 263 mm (9.646 – 10.354 in)
[at spring free length 265 mm (10.433 in)]
NOTE:
Turning the adjuster 2 without loosening the lock-nut 1 can
damage the rear cushion unit.
(For E-19, 000)
4-18 MACHINE TUNING
REAR SUSPENSION TUNING PROCEDURE
• Adjust the rear suspension according to the rider’s weight and preference by referring to the table below.
• Measure the distance L1 from the seat bolt to the chain
adjuster lock-nut with the motorcycle on the stand and the
rear wheel lifted off the ground.
• Measure the distance L2 from the seat bolt to the chain
adjuster lock-nut with the motorcycle off the stand and riding
the motorcycle normally in full riding gear.
• Find the sag by subtracting L2 from L1. Standard sag range is
100 mm (3.937 in).
Spring Part No. Spring rate Marking paint Set-length adjustable range
Soft
62211-36F60
46 N/mm
(4.6 kgf/mm)
Green
245 – 263 mm
(9.646 – 10.354 in)
[at spring free length 265 mm
(10.433 in)]
62211-37FH0
48 N/mm
(4.8 kgf/mm)
Black
Standard 62211-37FJ0
51 N/mm
(5.1 kgf/mm)
Silver
Hard
62211-37FK0
53 N/mm
(5.3 kgf/mm)
Orange
62211-37FL0
55 N/mm
(5.5 kgf/mm)
Red
L1
When the sag measured is:
Adjustment procedure
Less than 100 mm
(3.937 in)
Reduce spring pre-set length by turning
the spring adjuster nut.
More than 100 mm
(3.937 in)
Increase spring pre-set length by turning
the spring adjuster nut.
L2
MACHINE TUNING 4-19
After the sag measurement has been set between 95 mm (3.74 in) to 105 mm (4.13 in), test ride the motorcycle and adjust the suspension for the rider and track conditions referring to the guide below.
NOTE:
When adjusting the damping setting, attempt turning the
adjuster 1 to 2 click stops at a time for each adjustment.
SYMPTOM SECTION ADJUSTMENT PROCEDURE
Feels too hard overall • Jump
• Series of bumps
1. Adjust the low speed compression damping to
a softer setting. (See note below.)
2. Adjust the rebound damping to a softer setting.
(See note below.)
3. Replace the spring with an optional softer one.
(4-18)
4. Adjust the high speed compression damping to
a softer setting. (See note below.)
Kicks up • Medium to large bumps 1. Adjust the low speed compression damping
and rebound damping to a harder setting.
(See note below.)
2. Adjust the high speed compression damping to
a harder setting. (See note below.)
Bottom feeling or feels too
soft and unstable
• Jump
• Large bump
• Series of bumps
1. Adjust the low speed compression damping to
a harder setting. (See note below.)
2. Adjust the rebound damping to a harder setting.
(See note below.)
3. Replace the spring with an optional stiffer one.
(4-18)
Feels harsh and hits
bumps too harshly
• Jump
• Large bump
• Series of bumps
1. Adjust the low speed compression damping to
a harder setting. (See note below.)
2. Adjust the rebound damping to a harder setting.
(See note below.)
3. If bottom feeling become after adjusting above
mentions, adjust the high speed compression
damping to a harder setting. (See note below.)
Provides poor traction • Accelerating
• Series of small bumps
1. Adjust the rebound damping to a harder setting.
(See note below.)
2. If traction feeling does not improve after adjusting above mention, adjust the low speed compression damping to a softer setting. (See note
below.)
3. If bottom feeling become after adjusting above
mentions, adjust the high speed compression
damping to a harder setting. (See note below.)
Tends to sink front than
rear
• Decelerating or braking 1. Adjust the high speed compression damping to
a softer setting. (See note below.)
2. Adjust the rebound damping to a harder setting.
(See note below.)
4-20 MACHINE TUNING
SUSPENSION BALANCE
Balancing the front to rear suspension properly is the most critical adjustment for suspension performance. If
the front forks are adjusted harder than the rear suspension, such as changing to heavier front fork oil, stiffer
compression and rebound setting, air pressure build up in the forks and so on, the front forks will collapse
less on bumps. This transfers more of the motorcycle and rider weight rearward, possibly causing the rear
suspension to bottom, where as it felt fine before the front fork adjustment was made.
BALANCE TEST
Stand next to the motorcycle on level ground. Place one foot on the footrest closest to you. Sharply push
down. The front and rear suspensions should both collapse equally.
BALANCING TIPS
• Check for air pressure build-up in front forks. Heat and altitude will increase air pressure in the front forks.
• Always stay within sag measurement limits, 95 – 105 mm (3.74 – 4.13 in), when using spring pre-set to
stiffen or soften rear suspension. If this is not possible, the next stiffer or softer accessory spring is
needed.
• The rear shock compression damping can be used to fine tune suspension balance and is easy to
access.
5
ENGINE REMOVAL AND INSTALLATION 5-1
CONTENTS
ENGINE REMOVAL AND INSTALLATION
EXTERIOR PARTS ...................................................................................... 5- 2
ENGINE REMOVAL AND INSTALLATION ................................................. 5- 3
REMOVAL ............................................................................................. 5- 3
INSTALLATION ..................................................................................... 5- 7
5-2 ENGINE REMOVAL AND INSTALLATION
EXTERIOR PARTS
5 N·m
(0.5 kgf-m, 3.5 lb-ft)
10 N.m
1.0 kgf-m
7.0 lb-ft
10 N.m
1.0 kgf-m
7.0 lb-ft
10 N.m
1.0 kgf-m
7.0 lb-ft
10 N.m
1.0 kgf-m
7.0 lb-ft
10 N·m
(1.0 kgf-m, 7.0 lb-ft)
10 N·m
(1.0 kgf-m, 7.0 lb-ft)
10 N·m
(1.0 kgf-m, 7.0 lb-ft)
10 N.m
1.0 kgf-m
7.0 lb-ft
FW
D
Seat
Bolt
Washer
Frame
Frame cover
Seat rail
For E-03, 28
For E-19, 000
10 N·m
(1.0 kgf-m, 7.0 lb-ft)
ENGINE REMOVAL AND INSTALLATION 5-3
ENGINE REMOVAL AND INSTALLATION
REMOVAL
• Drain transmission oil. (2-9)
• Drain engine coolant. (12-3)
• Remove the seat.
• Turn the fuel valve lever to the “OFF” position.
• Disconnect the fuel hose 1.
• Remove the fuel tank mounting bolts (LH and RH).
• Remove the fuel tank by unhooking the band 2.
• Remove the exhaust pipe fitting springs using the special tool.
 09920-20310: Spring hook
5-4 ENGINE REMOVAL AND INSTALLATION
• Remove the exhaust pipe.
• Remove the exhaust pipe gasket 3.
• Remove the radiator covers 4 and mounting bolts (LH and
RH).
• Disconnect the radiator hoses 5 6 7.
• Disconnect the spark plug cap 8.
• Loosen the carburetor clamp screws and remove the carburetor.
ENGINE REMOVAL AND INSTALLATION 5-5
• Disconnect the magneto lead wire coupler 9 and clamp.
• Unclamp the magneto lead wire and breathers hoses from the
frame.
• Remove the drive chain by removing the clip 0.
• Remove the cotter pins A.
• Remove the brake pedal.
• Remove the sprocket cover B.
• Remove the magneto cover C.
5-6 ENGINE REMOVAL AND INSTALLATION
• Unhook and extract the clutch cable D.
NOTE:
Loosen the clutch cable adjuster when disconnecting.
(2-12)
• Remove the engine mounting bolts and plates.
• Remove the swingarm pivot nut E and washer.
• Extract three quarters of the swingarm pivot shaft so as to
keep the swingarm in position.
NOTE:
The swingarm will come off when the swingarm pivot shaft is
completely removed.
• Dismount the engine from the frame.
ENGINE REMOVAL AND INSTALLATION 5-7
INSTALLATION
Reassemble the removed parts in the reverse order of removal.
• Fit the swingarm in its position and hold it with the swingarm
pivot shaft.
• Mount the engine on the frame.
• Tighten the engine mounting nuts.
 Tightening torque
NOTE:
* Replace the self-locking nuts with new ones.
* Apply THREAD LOCK SUPER to the engine mounting bolt 3.
99000-32110: THREAD LOCK SUPER “1322”
(or equivalent thread lock)
• Apply grease to the brake pedal pivot bolt.
 99000-25010: SUZUKI SUPER GREASE “A”
(or equivalent grease)
• Install the spring. (18-15)
• Install the brake pedal.
 Brake pedal pivot bolt: 29 N·m (2.9 kgf-m, 21.0 lb-ft)
• Replace the cotter pins with new ones.
Bolt Length Bolt Length
1 45 mm (1.8 in) 3 90 mm (3.5 in)
2 47.5 mm (1.9 in) 4 130 mm (5.1 in)
N·m kgf-m lb-ft
1 (Bolt,
Washer, Nut)
43 4.3 31.0
2, 3, 4
(Bolt, Nut)
45 4.5 32.5
5 (Shaft,
Washer, Nut)
70 7.0 50.5
5-8 ENGINE REMOVAL AND INSTALLATION
• Reassemble the drive chain clip so the slit end faces opposit
the direction of rotation.
• Fit the projection of carburetor to the depression of intake
pipe.
• Install a new O-ring 6 and connector rubber 7 to the exhaust
pipe.
• Apply a small quantity of transmission oil to the O-ring before
install the exhaust pipe.
• Replace the exhaust pipe gasket 8 with a new one.
INSPECTION AFTER INSTALLATION
After mounting the engine, inspect the following items.
• Transmission oil level (2-9)
• Engine coolant level (2-10)
• Throttle cable play (2-12)
• Clutch lever play (2-12)
• Drive chain slack (2-16)
• Brake pedal height (2-19)
• Wire, cable and hose routing (18-12 to -14)
Direction of travel
6
CYLINDER, PISTON AND EXHAUST VALVE 6-1
CONTENTS
CYLINDER, PISTON AND EXHAUST VALVE
CONSTRUCTION ........................................................................................ 6- 2
ENGINE TOP END ....................................................................................... 6- 3
CYLINDER HEAD REMOVAL .............................................................. 6- 3
CYLINDER REMOVAL .......................................................................... 6- 3
PISTON REMOVAL ............................................................................... 6- 4
EXHAUST VALVE REMOVAL .............................................................. 6- 5
CYLINDER HEAD INSPECTION .......................................................... 6- 6
CYLINDER INSPECTION ...................................................................... 6- 6
PISTON AND PISTON RING INSPECTION ......................................... 6- 7
EXHAUST VALVE INSPECTION .......................................................... 6- 8
CONROD INSPECTION ........................................................................ 6- 8
PISTON RING AND PISTON REASSEMBLY ...................................... 6- 9
EXHAUST VALVE REASSEMBLY ....................................................... 6- 9
CYLINDER REASSEMBLY ................................................................... 6-10
EXHAUST VALVE GOVERNOR REMOVAL
AND DISASSEMBLY ............................................................................ 6-12
EXHAUST VALVE GOVERNOR INSPECTION .................................... 6-13
EXHAUST VALVE GOVERNOR REASSEMBLY
AND INSTALLATION ............................................................................ 6-13
6-2 CYLINDER, PISTON AND EXHAUST VALVE
CONSTRUCTION
25 N.m
(2.5 kgf-m, 18.0 lb-ft)
17.5 N.m
(1.75 kgf-m, 12.5 lb-ft)
45 N.m
(4.5 kgf-m, 32.5 lb-ft)
4.5 N.m
(0.45 kgf-m, 3.0 lb-ft)
25 N.m
(2.5 kgf-m,
18.0 lb-ft)
1216
1216
CYLINDER, PISTON AND EXHAUST VALVE 6-3
ENGINE TOP END
CYLINDER HEAD REMOVAL
• Remove the seat. (5-3)
• Remove the fuel tank. (5-3)
• Drain engine coolant. (12-3)
• Disconnect the radiator hose 1.
• Disconnect the spark plug cap 2 and remove the spark plug
3.
 09930-10121: Spark plug wrench set
• Remove the engine mounting plates 4.
• Remove the cylinder head 5.
NOTE:
Loosen the cylinder head nuts diagonally to prevent cylinder
head distortion.
CYLINDER REMOVAL
• Remove the cylinder head. (above)
• Remove the exhaust pipe. (5-3, -4)
• Remove the radiator covers 1 and mounting bolts (LH and
RH).
• Remove the radiator hoses 2 and 3.
• Remove the cylinder head O-rings 4 and 5.
• Remove the exhaust valve rod cover 6 and gasket.
6-4 CYLINDER, PISTON AND EXHAUST VALVE
• Remove the exhaust valve rod bolt 7 using the pin A as a
stopper.
NOTE:
The pin A is one of the included parts.
• Remove the cylinder nuts diagonally.
• Remove the cylinder 8.
• Remove the gasket 9 and dowel pins.
PISTON REMOVAL
• Remove the cylinder head and cylinder. (6-3, above)
• Remove the piston pin circlip 1.
NOTE:
Place cloth under the piston to prevent the piston pin circlip from
dropping into the crankcase.
• Remove the piston pin 2.
• Remove the piston 3.
• Use the special tool if necessary.
 09910-34510: Piston pin puller
CYLINDER, PISTON AND EXHAUST VALVE 6-5
• Remove the conrod small end bearing 4.
EXHAUST VALVE REMOVAL
• Remove the cylinder head and cylinder. (6-3, -4)
• Remove the exhaust valve shaft stop retainer 1.
• Remove the breather hoses 2.
• Remove the exhaust valve cover 3.
• Remove the exhaust valve shaft 4, springs 5 and valve
shaft arm 6.
• Remove the exhaust valve assembly 7.
6-6 CYLINDER, PISTON AND EXHAUST VALVE
• Remove the side valves and spacers.
CYLINDER HEAD INSPECTION
• Remove carbon deposits from the cylinder head.
• Inspect the cylinder head for cracks around the spark plug
hole.
• Inspect for cylinder head distortion.
 Cylinder head distortion
Service Limit: 0.05 mm (0.002 in)
 09900-20803: Thickness gauge
CYLINDER INSPECTION
• Remove carbon deposits from the exhaust port.
• Inspect the cylinder for cracks and replace the cylinder if necessary.
• Inspect the cylinder bore for wear and scratches.
NOTE:
Chrome-plated cylinder bore can not be modified such as boring
and honing.
• Inspect for cylinder distortion.
 Cylinder distortion
Service Limit: 0.05 mm (0.002 in)
 09900-20803: Thickness gauge
CYLINDER, PISTON AND EXHAUST VALVE 6-7
• Measure the cylinder bore for wear with a cylinder gauge 20
mm (0.8 in) from the top surface.
NOTE:
The cylinder bore must be measured perpendicular to the crankshaft axis direction.
 Cylinder bore
Standard: 54.000 – 54.015 mm (2.1260 – 2.1266 in)
 09900-20508: Cylinder gauge set
PISTON AND PISTON RING INSPECTION
• Remove the piston ring from the piston ring groove.
• Remove carbon deposits from the piston.
• Inspect the piston for wear, scratches and damage.
• Measure the piston outer diameter 19 mm (0.75 in) from the
skirt end.
 Piston outer diameter
Service Limit: 53.880 mm (2.1213 in)
 09900-20203: Micrometer (50 – 75 mm)
• Measure the piston pin bore and piston pin diameter.
 09900-20205: Micrometer (0 – 25 mm)
09900-20605: Dial gauge
• Remove carbon deposits from piston ring and piston ring
groove.
• Fit the piston ring into the ring groove and measure the clearance with a thickness gauge.
 Piston ring to groove clearance
Standard: 0.020 – 0.060 mm (0.0008 – 0.0024 in)
 09900-20803: Thickness gauge
• Fit the piston ring into the cylinder and measure the piston
ring end gap with a thickness gauge.
 Piston ring end gap
Service Limit: 0.80 mm (0.031 in)
 09900-20803: Thickness gauge
Service Limit
Piston pin bore 15.030 mm (0.5917 in)
Piston pin O.D. 14.980 mm (0.5898 in)
20 mm
(0.8 in)
19 mm
(0.75 in)
6-8 CYLINDER, PISTON AND EXHAUST VALVE
• Measure the piston ring free end gap.
 Piston ring free end gap
Service Limit: 3.4 mm (0.13 in)
 09900-20101: Vernier calipers
PISTON-TO-CYLINDER CLEARANCE
As a result of the previous measurement, if the piston to cylinder
clearance exceeds the following limit, replace both cylinder and
piston.
 Piston to cylinder clearance
Service Limit: 0.120 mm (0.0047 in)
EXHAUST VALVE INSPECTION
• Remove carbon deposits from the exhaust main valve 1,
side valves 2 and spacers 3.
• Inspect the exhaust main valve, side valve and spacer for
wear and scratches.
• Inspect the cam groove of the side valve for wear.
• Inspect the return spring 4 for spring tension.
CONROD INSPECTION
• Measure the conrod small end bore.
 Conrod small end bore
Service Limit: 19.040 mm (0.750 in)
 09900-20605: Dial gauge
CYLINDER, PISTON AND EXHAUST VALVE 6-9
• Fit the piston pin and bearing into the conrod small end and
inspect the play.
• Inspect the bearing for smooth movement.
PISTON RING AND PISTON REASSEMBLY
• Apply engine oil to the piston ring and piston ring groove.
• Fit the piston ring into the piston ring groove so the ring end
comes to the piston ring locating pin. (6-10)
• Apply engine oil to the piston pin and bearing.
• Fit the bearing to the conrod small end.
• Face the “O” mark A on the piston top to the exhaust port.
• Insert the piston pin 1 and install the piston pin circlip 2. Piston pin circlip end should face upside.
NOTE:
* Replace the piston pin circlip with a new one.
* Place cloth on the crankcase to prevent piston pin circlip from
dropping into the crankcase.
EXHAUST VALVE REASSEMBLY
• Apply engine oil to the exhaust valves (main and side) and
spacers.
• The taper side of main valve should face downward and the
stamped marks “L”, “R” on the side valves should match with
the stamped marks “L”, “R” on the cylinder.
“L”
“R”
(White)
(Yellow)
(White)
“L”“R”
6-10 CYLINDER, PISTON AND EXHAUST VALVE
• Install the exhaust valve assembly to the cylinder.
• Inspect the main and side valves for smooth movement.
• Inspect if the side valves are closed when the main valve is
lowered and, at the same time, see if the side valvs are open
when the main valve is lifted.
• Install the exhaust valve shaft 1, springs 2 and valve shaft
arm 3.
• Tighten the exhaust valve shaft bolt.
• Install the exhaust valve shaft stop retainer 4.
• Install a new gasket and the exhaust valve cover 5 with hose
clamp 6.
• Install the breather hoses.
CYLINDER REASSEMBLY
• Install the dowel pins and new gasket 1.
• Apply engine oil to the cylinder bore.
• With Holding the piston and piston ring, insert the piston into
the cylinder.
CAUTION
If the piston ring end is not at the proper position, you
can not insert the piston into the cylinder properly and
the piston ring will be damaged.
Locate the piston ring end to the locating pin and
insert the piston into the cylinder.
CYLINDER, PISTON AND EXHAUST VALVE 6-11
• Tighten the cylinder nuts to the specified torque according to
the specified tightening order as shown.
 Cylinder nut: 25 N·m (2.5 kgf-m, 18.0 lb-ft)
• Install the exhaust valve rod 2 to the exhaust valve shaft.
• Tighten the exhaust valve rod bolt using the pin A as a stopper.
 Exhaust valve rod bolt: 4.5 N·m (0.45 kgf-m, 3.0 lb-ft)
NOTE:
The pin A is one of the included parts.
• Install a new gasket and tighten the exhaust valve rod cover
bolts.
• Apply grease to new O-rings and install them to the cylinder.
 99000-25010: SUZUKI SUPER GREASE “A”
(or equivalent grease)
• Install the cylinder head.
NOTE:
Apply Bond to the stud bolt threads when assembling the
removed stud bolts into the cylinder.
 99000-31140: SUZUKI BOND “1207B”
• Tighten the cylinder head nuts to the specified torque in two
steps according to the specified tightening order as shown.
 Cylinder head nut
Initial: 15 N·m (1.5 kgf-m, 11.0 lb-ft)
Final: 25 N·m (2.5 kgf-m, 18.0 lb-ft)
• Reassemble the engine mounting brackets.
 Engine mounting nut 3: 45 N·m (4.5 kgf-m, 32.5 lb-ft)
Engine plate nut 4: 43 N·m (4.3 kgf-m, 31.0 lb-ft)
• Reassemble the exhaust pipe. (5-8)
• Engine coolant level (2-10)
31
24
Forward
1
2
3
4
5
6-12 CYLINDER, PISTON AND EXHAUST VALVE
EXHAUST VALVE GOVERNOR REMOVAL
AND DISASSEMBLY
• Drain transmission oil. (2-9)
• Drain engine coolant. (12-3)
• Remove the exhaust pipe. (5-3, -4)
• Remove the exhaust valve rod bolt. (6-4)
• Remove the right crankcase cover. (8-3)
• Remove the exhaust valve governor 1.
• Remove the exhaust valve rod assembly 2.
• Remove the pin 3 by pushing down the retainer 4.
• Disassemble the following parts from governer.
1 Governer 8 Washer
3 Pin 9 Spacer
4 Retainer 0 Washer
5 Spring A Bearing
6 Retainer B Stater
7 Bearing C Balls
CYLINDER, PISTON AND EXHAUST VALVE 6-13
EXHAUST VALVE GOVERNOR INSPECTION
• Inspect hte bearings for abnormal noise, wear and damage.
• Replace the bearing if there is anything unusual.
• Inspect the governer for wear and damage.
• Replace the governer if there is anything unusual.
• Inspect the exhaust valve rod for abnormal bend and damage.
• Replace the exhaust valve rod if there is anything unusual.
EXHAUST VALVE GOVERNOR
REASSEMBLY AND INSTALLATION
Installation is in the reverse order of removal and disassembly.
Pay attention to the following points:
• Install the exhaust valve rod 1.
• Apply THREAD LOCK to the screws.
99000-32110: THREAD LOCK SUPER “1322”
(or equivalent thread lock)
• Apply transmission oil to the exhaust valve gevernor.
• Install the exhaust valve governor with the groove A engaged
with the actuator arm B.
6-14 CYLINDER, PISTON AND EXHAUST VALVE
• Tighten the exhaust valve rod bolt. (6-11)
 Exhaust valve rod bolt: 4.5 N·m (0.45 kgf-m, 3.0 lb-ft)
• Reassemble the exhaust pipe. (5-8)
• Transmission oil level (2-9)
• Engine coolant level (2-10)
• Brake pedal heignt. (2-19)
7
CLUTCH 7-1
CONTENTS
CLUTCH
CONSTRUCTION ........................................................................................ 7- 2
CLUTCH PLATE .......................................................................................... 7- 3
REMOVAL ............................................................................................. 7- 3
INSPECTION ......................................................................................... 7- 4
REASSEMBLY ...................................................................................... 7- 5
PRIMARY DRIVEN GEAR AND CLUTCH SLEEVE HUB .......................... 7- 6
REMOVAL ............................................................................................. 7- 6
INSPECTION ......................................................................................... 7- 7
REASSEMBLY ...................................................................................... 7- 7
CLUTCH RELEASE CAMSHAFT ............................................................... 7- 9
REMOVAL ............................................................................................. 7- 9
INSPECTION ......................................................................................... 7- 9
INSTALLATION ..................................................................................... 7- 9
7-2 CLUTCH
CONSTRUCTION
70 N.m
(7.0 kgf-m,
50.5 lb-ft)
4.5 N.m
(0.45 kgf-m, 3.0 lb-ft)
FW
D
No. 1 drive plate (Black paint)
No. 2 drive plate (Purple paint)
CLUTCH 7-3
CLUTCH PLATE
REMOVAL
• Drain transmission oil. (2-9)
• Remove the rear brake pedal. (5-5)
• Remove the clutch cover 1.
• Loosen the bolts diagonally and remove them.
• Remove the clutch springs.
• Remove the pressure plate 2.
• Remove the bearing 3, push piece 4 and push rod 5.
• Remove the drive plates and driven plates.
7-4 CLUTCH
INSPECTION
DRIVE PLATE
• Measure the drive plate thickness.
 Drive plate thickness
Service Limit: 2.42 mm (0.095 in)
 09900-20101: Vernier calipers
• Inspect the drive plates for wear, distortion and discoloration.
• Measure the drive plate claw width.
 Driven plate claw width
Service Limit: 13.35 mm (0.526 in)
 09900-20101: Vernier calipers
DRIVEN PLATE
• Measure the driven plate distortion.
 Driven plate distortion
Service Limit: 0.10 mm (0.004 in)
 09900-20803: Thickness gauge
• Inspect the driven plates for wear and discoloration.
CLUTCH SPRING
• Measure the clutch spring free length.
 Clutch spring free length
Service Limit: 37.8 mm (1.50 in)
 09900-20101: Vernier calipers
NOTE:
Replace five clutch springs together even if only one spring is
beyond the service limit.
PUSH ROD
• Inspect the clutch push piece, bearing and push rod for wear
and damage.
• Inspect the bearing for smooth movement.
CLUTCH 7-5
REASSEMBLY
• Apply transmission oil to each plates.
• Install the clutch drive plates and driven plates one by one
into the clutch sleeve hub in the prescribed order as show in
illustration.
• Apply transmission oil to the bearing.
• Insert the clutch push rod.
• Install the clutch push piece and bearing. The covered side A
of the bearing should face outside.
• Install the pressure plate 1.
• Insert the springs and tighten the bolts diagonally to the specified torque.
 Clutch spring bolt: 4.5 N·m (0.45 kgf-m, 3.0 lb-ft)
• Replace the O-ring with a new one.
• Apply grease to the O-ring.
 99000-25010: SUZUKI SUPER GREASE “A”
(or equivalent grease)
• Fit the clutch outer cover 2 and tighten the bolts diagonally.
 Clutch outer cover bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft)
• Pour transmission oil. (2-9)
• Adjust the clutch cable play. (2-12)
• Adjust the brake pedal height. (2-19)
Paint
Direction of outside
Outside
7-6 CLUTCH
PRIMARY DRIVEN GEAR AND
CLUTCH SLEEVE HUB
REMOVAL
• Remove the clutch outer cover.
• Remove the pressure plate and clutch plates. (7-3)
• Flatten the lock washer 1.
• Hold the clutch sleeve hub with the special tool and loosen
the nut 2.
 09920-53740: Clutch sleeve hub holder
• Remove the clutch sleeve hub 3.
• Remove the washer 4 and primary driven gear assembly 5.
• Remove the snap ring 6, washer and kick starter idle gear
7.
 09900-06107: Snap ring pliers
• Remove the needle bearing 8.
• Remove the spacer 9.
CLUTCH 7-7
INSPECTION
• Inspect the clutch sleeve hub and primary driven gear assembly for wear and cracks.
• Inspect the kick starer idle gear, needle bearing and spacer
for damage and wear.
REASSEMBLY
• Apply transmission oil to the spacer 1 and needle bearing 2.
• Install the kick starter idle gear 3, washer 4 and snap ring
5.
 09900-06107: Snap ring pliers
• Install the primary driven gear assembly 6.
• Install the washer.
• Fit the clutch sleeve hub 7, new lock washer 8 and clutch
sleeve hub nut 9.
NOTE:
The flat side of the nut 9 must face inside.
7-8 CLUTCH
• Tighten the clutch sleeve hub nut with the special tool to the
specified torque.
 09920-53740: Clutch sleeve hub holder
 Clutch sleeve hub nut: 70 N·m (7.0 kgf-m, 50.5 lb-ft)
• Bend the lock washer to secure the nut 0.
• Reassemble the clutch plates and pressure plate. (7-5)
• Replace the O-ring with a new one.
• Apply grease to the O-ring.
 99000-25010: SUZUKI SUPER GREASE “A”
(or equivalent grease)
• Fit the clutch outer cover and tighten the bolts diagonally.
 Clutch outer cover bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft)
• Pour transmission oil. (2-9)
• Adjust the clutch cable play. (2-12)
• Adjust the brake pedal height. (2-19)
CLUTCH 7-9
CLUTCH RELEASE CAMSHAFT
REMOVAL
• Remove the magneto rotor and stator. (13-8)
• Loosen the clutch cable adjuster and unhook the clutch cable.
(5-6)
• Remove the clutch release camshaft 1.
INSPECTION
CLUTCH RELEASE CAMSHAFT
• Inspect the clutch release camshaft for abnormal deflection
and damage.
OIL SEAL AND BEARING
• Inspect the oil seal for damage and oil leakage.
• Inspect the bearings for abnormal noise, wear and damage.
OIL SEAL REMOVAL AND INSTALLATION (10-7)
BEARING REMOVAL AND INSTALLATION (10-9)
INSTALLATION
• Install the clutch release camshaft 1 and hook the clutch
cable.
• Reassemble the magneto rotor and stator. (13-9)
• Fit a new gasket and install the magneto cover.
• Inspect the clutch cable play. (2-12)
– MEMO –
8
KICK STARTER 8-1
CONTENTS
KICK STARTER
CONSTRUCTION ........................................................................................ 8- 2
REMOVAL ................................................................................................... 8- 3
INSPECTION ............................................................................................... 8- 4
OIL SEAL .............................................................................................. 8- 4
KICK STARTER .................................................................................... 8- 4
KICK STARTER IDLE GEAR ................................................................ 8- 4
REASSEMBLY ............................................................................................ 8- 5
INSPECTION AFTER REASSEMBLY .................................................. 8- 6
8-2 KICK STARTER
CONSTRUCTION
23 N.m
(2.3 kgf-m, 16.5 lb-ft)
10 N.m
(1.0 kgf-m, 7.0 lb-ft)
KICK STARTER 8-3
REMOVAL
• Drain transmission oil. (2-9)
• Drain engine coolant. (12-3)
• Remove the brake pedal. (5-5)
• Remove the kick starter lever.
• Disconnect the radiator hose 1.
• Remove the crankcase cover.
• Remove the clutch and primary driven gear assembly.
(7-3, -6)
• Remove the snap ring 2, washer 3 and kick starter idle gear
4.
 09900-06107: Snap ring pliers
• Unhook the kick return spring and remove the kick starter
assembly 5.
• Remove the kick starter guide 6.
• Disassemble the following parts from the kick starter shaft.
Spring 7
Kick starter 8
Spring guide 9
Kick return spring 0
Kick starter drive gear A
 09900-06107: Snap ring pliers
8-4 KICK STARTER
INSPECTION
OIL SEAL
• Inspect the oil seal for oil leakage and damage.
• Remove the oil seal using the special tool.
 09913-50121: Oil seal remover
• Install the oil seal using the special tool.
 09913-70210: Bearing installer set
KICK STARTER
• Inspect the return spring for damage.
• Inspect the kick starter drive gear teeth for wear and damage.
• Inspect the kick starter drive gear ratchet part for wear and
damage.
• Inspect the kick starter shaft and drive gear contact surface
for wear and damage.
KICK STARTER IDLE GEAR
• Inspect the kick starter idle gear teeth for wear and damage.
• Inspect the kick starter idle gear and driveshaft contact surface for wear and damage.
KICK STARTER 8-5
REASSEMBLY
Reassemble the kick starter assembly in the reverse order of
disassembly. Pay attention to the following points:
• Apply transmission oil to the kick starter shaft.
• Install the kick starter drive gear 1 and washer to the kick
starter shaft.
• Install new snap ring.
 09900-06107: Snap ring pliers
• Insert the return spring end 2 into the hole on the kick shaft.
• Install the spring guide 3 as its groove A engages with the
return spring hooked part.
• Install the kick starter 4 to the kick starter shaft.
NOTE:
Be sure to align the punch marks on the kick starter and kick
starter shaft when installing the kick starter.
8-6 KICK STARTER
• Install the kick starter assembly to the crankcase. Hook the
return spring 2.
• Reassemble the kick idle gear 5.
• Reassemble the primary driven gear assembly and clutch.
(7-5, -7)
• Install the crankcase cover.
 Crankcase cover bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft)
• Install the kick starter lever so the punch mark on the lever
aligns with the punch mark on the kick shaft.
 Kick starter lever bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
INSPECTION AFTER REASSEMBLY
After reinstalling the kick starter assembly, inspect the followings.
• Transmission oil level (2-9)
• Engine coolant level (2-10)
• Brake pedal height (2-19)
• Clutch lever play (2-12)
9
GEARSHIFTING 9-1
CONTENTS
GEARSHIFTING
CONSTRUCTION ........................................................................................ 9- 2
REMOVAL ................................................................................................... 9- 3
INSPECTION ............................................................................................... 9- 5
REASSEMBLY ............................................................................................ 9- 6
9-2 GEARSHIFTING
CONSTRUCTION
23 N.m
(2.3 kgf-m, 16.5 lb-ft)
24 N.m
(2.4 kgf-m, 17.5 lb-ft)
10 N.m
(1.0 kgf-m, 7.0 lb-ft)
GEARSHIFTING 9-3
REMOVAL
• Drain transmission oil. (2-9)
• Drain engine coolant. (12-3)
• Remove the gearshift lever 1.
NOTE:
Mark the gearshift shaft head at which the gearshift lever slit set
for correct reinstallation.
• Remove the right crankcase cover. (8-3)
• Remove the clutch assembly. (7-3, -6)
• Remove the gearshift shaft 2 and washer 3.
• Remove the pawl lifter 4.
• Remove the gearshift cam driven gear 5.
NOTE:
Be careful not to drop the pins and springs when removing the
gearshift cam driven gear.
• Remove the gearshift pawls 6, pins 7 and springs 8.
9-4 GEARSHIFTING
• Remove the gearshift cam bolt 9 and stopper plate 0.
• Remove the gearshift arm stopper bolt A and washer.
• Remove the gearshift cam stopper B and spring C.
• Remove the gearshift return spring D by removing the snap
ring.
 09900-06107: Snap ring pliers
GEARSHIFTING 9-5
INSPECTION
• Inspect the gearshift shaft 1 for bends and damage.
• Inspect the return spring 2 for damage.
• Inspect the pawls 3, pins 4 and springs 5 for damage.
9-6 GEARSHIFTING
REASSEMBLY
• Temporarily install the spring 1, washer 2 and gearshift cam
stopper 3.
• Hook the spring 1 to the projection A.
• Tighten the gearshift cam stopper bolt.
 Gearshift cam stopper bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
• Align the pin groove B with the pin C when installing the
stopper plate 4.
• Tighten the gearshift cam bolt 5.
 Gearshift cam bolt: 24 N·m (2.4 kgf-m, 17.5 lb-ft)
• Apply THREAD LOCK SUPER and tighten the gearshift arm
stopper bolt 6 to the specified torque.
 Gearshift arm stopper bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
99000-32030: THREAD LOCK SUPER “1303”
GEARSHIFTING 9-7
• Fit the springs 6, pins 7 and pawls 8 to the gearshift cam
driven gear 9. Wider side D of pawls should be positioned
outside.
• With the pawls held in pushed position, install the pawl lifter
0.
• Reassemble the gearshift cam driven gear and pawl lifter.
• Apply THREAD LOCK SUPER to the screws.
 Retainer screw: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
99000-32030: THREAD LOCK SUPER “1303”
• Reassemble the gearshift return spring A to the gearshift
shaft B properly.
 09900-06107: Snap ring pliers
9-8 GEARSHIFTING
• Align the center teeth on the gearshift shaft with the center
teeth on the gearshift cam shifter.
• Reassemble the clutch and crankcase cover.
(7-5, -7, 8-6)
• Install the gearshift lever.
 Gearshift lever bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
• Refill transmission oil. (2-9)
• Refill engine coolant. (2-10)
• Inspect the gearshift lever for smooth movement.
10
TRANSMISSION AND CRANKSHAFT 10-1
CONTENTS
TRANSMISSION AND CRANKSHAFT
CONSTRUCTION ...................................................................................... 10- 2
ENGINE BOTTOM END ............................................................................ 10- 3
PRIMARY DRIVE GEAR REMOVAL .................................................. 10- 3
CRANKCASE SEPARATION ............................................................. 10- 4
TRANSMISSION REMOVAL .............................................................. 10- 4
CRANKSHAFT REMOVAL ................................................................. 10- 5
TRANSMISSION INSPECTION .......................................................... 10- 5
CRANKSHAFT INSPECTION ............................................................. 10- 6
OIL SEAL INSPECTION, REMOVAL AND INSTALLATION ............. 10- 7
BEARING INSPECTION, REMOVAL AND INSTALLATION ............. 10- 9
CRANKSHAFT INSTALLATION ......................................................... 10-10
TRANSMISSION REASSEMBLY ....................................................... 10-11
CRANKCASE REASSEMBLY ............................................................ 10-12
PRIMARY DRIVE GEAR INSTALLATION .......................................... 10-13
10-2 TRANSMISSION AND CRANKSHAFT
CONSTRUCTION
70 N.m
(7.0 kgf-m, 50.5 lb-ft)
FW
D
TRANSMISSION AND CRANKSHAFT 10-3
ENGINE BOTTOM END
• Dismount the engine. (5-3)
NOTE:
The following parts must be removed before disassembling the
engine bottom side (crankcase).
• Remove the gearshift lever. (9-3)
• Remove the kick starter lever. (8-3)
• Remove the cylinder head, cylinder and piston. (6-3, -4)
• Remove the intake pipe and reed valve. (11-12)
• Remove the right crankcase cover and clutch assembly.
(8-3)
• Remove the kick starter idle gear and kick starter shaft.
(8-3)
• Remove the gearshift linkage. (9-3)
• Remove the exhaust valve governor. (6-12)
• Remove the engine sprocket 1.
 09900-06107: Snap ring pliers
PRIMARY DRIVE GEAR REMOVAL
• Holding the magneto rotor immovable with the special tool,
remove the primary drive gear bolt 2.
 09930-40113: Rotor holder
• Remove the washer 3 and primary drive gear 4.
• Remove the magneto rotor, stator and key. (13-8)
• Remove the clutch release camshaft. (7-9)
10-4 TRANSMISSION AND CRANKSHAFT
CRANKCASE SEPARATION
• Remove the engine sprocket spacer 1 and two O-rings 2.
• Remove the crankcase bolts.
• Separate the crankcase with the special tool.
 09920-13120: Crankcase separating tool
NOTE:
* Set the crankcase separating tool to the clutch side of the
crankcase.
* Separate the crankcase gradually while hitting the crankcase
boss and countershaft softly with a plastic hammer.
TRANSMISSION REMOVAL
• Remove the dowel pins 1 and gasket 2.
• Remove the gearshift fork shafts 3.
• Remove the gearshift cam 4.
• Remove the gearshift forks 5.
TRANSMISSION AND CRANKSHAFT 10-5
• Remove the driveshaft assembly 6 and countershaft assembly 7.
CRANKSHAFT REMOVAL
• Remove the crankshaft with the special tool.
 09920-13120: Crankcase separating tool
TRANSMISSION INSPECTION
• Inspect the gear teeth, dogs, and gearshift grooves for abnormal wear and damage.
• Inspect the bushings and splines for abnormal wear and discoloration.
• Inspect the gearshift cam groove for abnormal wear and damage.
• Inspect the gearshift forks and shafts for wear and damage.
CAUTION
Be careful not to damage the thread part of the crankshaft.
10-6 TRANSMISSION AND CRANKSHAFT
• Measure the gearshift fork thickness with a vernier calipers.
 Gearshift fork thickness
Standard: 4.80 – 4.90 mm (0.189 – 0.193 in)
 09900-20101: Vernier calipers
• Measure the gearshift fork groove width with a vernier calipers.
 Gearshift fork groove width
Standard: 4.95 – 5.05 mm (0.195 – 0.199 in)
 09900-20101: Vernier calipers
• Measure the gearshift fork to groove clearance with a thickness gauge.
 Gearshift fork to groove clearance
Service Limit: 0.45 mm (0.018 in)
 09900-20803: Thickness gauge
CRANKSHAFT INSPECTION
• Measure the conrod deflection with the special tools.
 Conrod deflection
Service Limit: 3.0 mm (0.12 in)
 09900-20607: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
09900-21304: V-block
CONROD SMALL END I.D. (6-8)
• Measure the conrod big end side clearance with the thickness
gauge.
 Conrod big end side clearance
Service Limit: 1.0 mm (0.04 in)
 09900-20803: Thickness gauge
TRANSMISSION AND CRANKSHAFT 10-7
• Measure the crankshaft runout with V-blocks and dial gauge.
 Crankshaft runout
Service Limit: 0.05 mm (0.002 in)
 09900-20607: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
09900-21304: V-block
NOTE:
* Place the crankshaft on to the V-blocks so that it becomes horizontally.
* Measure the runout from the tips of the crankshaft.
• Measure the crankshaft web to web width with a vernier calipers.
 Width between webs
Standard: 53.9 – 54.1 mm (2.122 – 2.130 in)
 09900-20101: Vernier calipers
OIL SEAL INSPECTION, REMOVAL AND
INSTALLATION
• Inspect oil seals for wear and damage.
10-8 TRANSMISSION AND CRANKSHAFT
• Remove the oil seal.
 09913-50121: Oil seal remover
• Install new oil seal using the special tool.
• Apply grease to each oil seal lip.
 09913-70210: Bearing installer set
 99000-25010: SUZUKI SUPER GREASE “A”
(or equivalent grease)
NOTE:
Be sure to check the direction of the crankshaft bearing oil seals
before fitting them.
OUT
SIDE
OUT
SIDE
Left Right
TRANSMISSION AND CRANKSHAFT 10-9
BEARING INSPECTION, REMOVAL AND
INSTALLATION
• Inspect the bearings for play, discoloration, wear and seizure.
• Move the inner race by finger and inspect for smooth movement.
• Remove the bearing retainers.
• Remove the bearings 1 to 4 by hitting out from the other
side using the special tool.
 09913-70210: Bearing installer set
• Remove the bearings 5 and 7 by hitting out from the other
side using the special tool.
 09913-70210: Bearing installer set
• Remove the bearing 6 using the special tool and suitable
bars.
• Remove the bearing 8 using the special tool.
 09921-20240: Bearing remover set
10-10 TRANSMISSION AND CRANKSHAFT
• Remove the bearings 9 and 0 using the special tool.
 09917-50410: Bearing remover
• Remove the bearing A using the special tools.
 09921-20200: Bearing remover
09930-30104: Sliding shaft
• Install the bearings with the special tool.
 09913-70210: Bearing installer set
• Apply THREAD LOCK SUPER to the shift cam bearing
retainer screws.
99000-32030: THREAD LOCK SUPER “1303”
CRANKSHAFT INSTALLATION
• Fit the crankshaft into the left crankcase half with the special
tool.
 09910-32812: Crankshaft installer
09910-32820: Crankshaft installer attachment
TRANSMISSION AND CRANKSHAFT 10-11
TRANSMISSION REASSEMBLY
NOTE:
Seat the circlip in the groove and locate its end as shown in the
illustration.
• Apply transmission oil to the following parts:
driveshaft, countershaft, transmission gears, bearings.
• Reassemble the driveshaft 1 and countershaft 2 with gears
installed.
Sharp edge
Thrust
10-12 TRANSMISSION AND CRANKSHAFT
• Apply transmission oil to the following parts:
gearshift forks, gearshift shafts, gearshift cam.
• Install the gearshift forks 3, 4, 5.
NOTE:
Each fork differs in shape.
• Install the gearshift cam 6 and gearshift shafts 7, 8.
NOTE:
Turn the gearshift cam to the neutral position and confirm that
the driveshaft and countershaft turn without resistance.
CRANKCASE REASSEMBLY
• Fit the dowel pins and new gasket.
• Fit the right crankcase half on the left crankcase half.
• Install the clamp to the bolt A and tighten the crankcase
bolts.
 Crankcase bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
NOTE:
If it is hard to tighten the bolts, separate the crankcase and confirm that the transmission parts are assembled correctly.
• Inspect the crankshaft, countershaft and driveshaft for smooth
movement.
• Apply grease to the oil seal lip and new O-rings.
• Fit the O-rings 1 and spacer 2 to the driveshaft.
 99000-25010: SUZUKI SUPER GREASE “A”
(or equivalent grease)
TRANSMISSION AND CRANKSHAFT 10-13
PRIMARY DRIVE GEAR INSTALLATION
• Reassemble the clutch release camshaft. (7-9)
• Reassemble the stator and magneto rotor. (13-9)
• Install the washer and primary drive gear.
NOTE:
The washer is directional. Assemble the washer 1 as shown in
the illustration.
• Hold the magneto rotor with the special tool and tighten the
primary drive gear bolt to the specified torque.
 09930-40113: Rotor holder
 Primary drive gear bolt: 70 N·m (7.0 kgf-m, 50.5 lb-ft)
• Reassemble the gearshift linkage. (9-6)
• Reassemble the kick idle gear and kick starter shaft.
(8-6)
• Reassemble the exhaust valve governor. (6-13)
• Reassemble the clutch and right crankcase cover.
(7-5, -7, 8-6)
• Reassemble the piston, cylinder and cylinder head.
(6-10)
• Reassemble the intake pipe and reed valve. (11-12)
• Reassemble the engine sprocket.
• Remount the engine. (5-7)
After mounting the engine, inspect the followings.
• Wire harness, cable and hose routing (18-12 to -14)
• Transmission oil level (2-9)
• Engine coolant level (2-10)
• Clutch cable play (2-12)
• Throttle cable play (2-12)
• Drive chain slack (2-16)
• Brake pedal height (2-19)
– MEMO –
11
FUEL SYSTEM 11-1
CONTENTS
FUEL SYSTEM
CARBURETOR .......................................................................................... 11- 2
CONSTRUCTION ................................................................................ 11- 2
REMOVAL AND DISASSEMBLY ....................................................... 11- 3
CLEANING .......................................................................................... 11- 7
INSPECTION ....................................................................................... 11- 7
REASSEMBLY AND REMOUNTING .................................................. 11- 8
CARBURETOR SOLENOID ...................................................................... 11-10
REMOVAL AND INSPECTION ........................................................... 11-10
REASSEMBLY .................................................................................... 11-10
THROTTLE POSITION SENSOR .............................................................. 11-11
INSPECTION ....................................................................................... 11-11
REED VALVE ............................................................................................ 11-12
REMOVAL ........................................................................................... 11-12
INSPECTION ....................................................................................... 11-12
REASSEMBLY .................................................................................... 11-12
11-2 FUEL SYSTEM
CARBURETOR
CONSTRUCTION
10 N.m
(1.0 kgf-m, 7.0 lb-ft)
FUEL SYSTEM 11-3
REMOVAL AND DISASSEMBLY
• Disconnect the throttle position sensor coupler and solenoid
coupler.
• Open the clamp.
• Disconnect the fuel hose. (5-3)
• Loosen the carburetor clamp screws and remove the carburetor.
• Drain fuel by removing the drain plug.
• Remove the carburetor top cap 1.
• Compressing the spring 2 with the coller 3, disconnect the
throttle cable from the throttle valve 4.
11-4 FUEL SYSTEM
• Remove the cable holder 5 and jet needle 6.
• Remove the fuel hose 7, air vent hoses 8 and overflow
hoses 9.
• Remove the float chamber.
• Remove the holder 0.
• Remove the floats A and needle valve B.
• Remove the needle valve seat C.
• Remove the main jet D and needle jet holder E.
• Remove the pilot jet F.
FUEL SYSTEM 11-5
• Remove the power jet G.
• Remove the starter knob H.
• Remove the lock-nut and throttle stop screw I.
• Remove the air screw J and spring.
• Remove the filter K.
• Remove the solenoid L.
NOTE:
Prior to disassembly, mark the sensor’s original position with a
paint or scribe for accurate reinstallation.
• Remove the throttle position sensor.
 09930-11960: Torx wrench, T20
• Unhook the return spring.
11-6 FUEL SYSTEM
• Flatten the plate M.
• Remove the throttle lever shaft bolt.
• Remove the dust seal N.
• Remove the throttle lever shaft O.
• Remove the throttle lever P, spacer Q and return spring R.
FUEL SYSTEM 11-7
CLEANING
• Clean all jets with a spray-type carburetor cleaner and dry
them using compressed air.
• Clean all circuits of the carburetor thoroughly, not just the perceived problem area. Clean the circuits in the carburetor body
with a spray-type cleaner and allow each circuit to soak if necessary to loosen dirt and varnish. Blow the body dry using
compressed air.
• After cleaning, reassemble the carburetor.
INSPECTION
Check the following parts for damage or clogging. If any damage
is found, replace the parts with a new one.
• Throttle valve
• Jet needle
• Hoses
• Floats
• Main jet
• Needle jet holder
• Pilot jet
• Power jet
• Starter knob
WARNING
Some carburetor cleaning chemicals, especially diptype soaking solutions, are very corrosive and must
be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and
storage.
CAUTION
Do not use a wire to clean the jets or passageways. A
wire can damage the jets and passageways. If the
components cannot be cleaned with a spray cleaner, it
may be necessary to use a dip-type cleaning solution
and allow them to soak. Always follow the chemical
manufacturer’s instructions for proper use and cleaning on the carburetor components.
CAUTION
Replace the removed O-rings with new ones.
11-8 FUEL SYSTEM
NEEDLE VALVE INSPECTION
If foreign matter is caught between the valve seat and the needle valve, the fuel will continue flowing and overflow. If the valve
seat and needle valve are worn beyond the permissible limits,
similar trouble will occur. Conversely, if the needle valve sticks,
the fuel will not flow into the float chamber. Clean the float chamber and float parts with gasoline. If the needle valve is worn, as
shown in the illustration, replace it along with a new valve seat.
Clean the fuel passage of the mixing chamber using compressed air.
FLOAT HIGHT ADJUSTMENT
• Measure the float height with the vernier calipers. To measure
the float height, tilt the carburetor until the float tip just contacts the needle valve.
 Standard float height A: 8.7 ± 1.0 mm (0.34 ± 0.04 in)
 09900-20101: Vernier calipers
REASSEMBLY AND REMOUNTING
Reassembly and remounting is in the reverse order of removal
and disassembly. Pay attention to the following points:
• Align the boss A on the throttle position sensor with the
recess B throttle lever shaft.
• Apply THREAD LOCK SUPER to the throttle position sensor
mounting screws.
99000-32110: THREAD LOCK SUPER “1322”
(or equivalent thread lock)
• Temporary tighten the throttle position sensor mounting
screws.
NOTE:
Fit the projection of throttle valve collar in the groove of cable
holder.
Good Worn
FUEL SYSTEM 11-9
• Fit the projection on the carburetor body to the depression of
the intake pipe.
After reinstalling the carburetor body assembly, inspect the followings.
• Throttle position sensor adjustment (11-11)
• Idle adjustment (4-5)
• Throttle cable play (2-12)
• Wire, cable and hose routing (18-12, -14)
11-10 FUEL SYSTEM
CARBURETOR SOLENOID
REMOVAL AND INSPECTION
• Remove the carburetor solenoid 1. Make sure the coupler 2
is connected.
• Connect the tachometer sensor.
• Shift the transmission into neutral.
• Start the engine.
• Inspect if the solenoid valve switches according to the following engine RPM.
OFF position: 9 000 – 11 000 r/min
ON position: Throttle grip opening 5 – 30%
If the solenoid valve operation is not correct, inspect the solenoid valve by following procedure.
• Remove the carburetor sorenoid.
• Connect 12 V battery as shown.
• Inspect if the valve moves each time the circuit is opened and
closed.
If the movement is not correct, replace the solenoid valve with a
new one.
If the movement is correct, inspect or replace following parts.
CDI unit
Stator coil (13-7)
Wiring harness for open circuit
Coupler connection
REASSEMBLY
Pay attention to the following point:
• Apply engine oil to the cross thread of the solenoid and the
new O-ring.
ONOFF
CAUTION
Replace the O-ring with a new one.
FUEL SYSTEM 11-11
THROTTLE POSITION SENSOR
INSPECTION
THROTTLE POSITION SENSOR INPUT VOLTAGE
• Disconnect the throttle position sensor coupler 1.
• Shift the transmission into neutral.
• Start the engine.
• Measure the throttle position sensor input voltage with the
multi circuit tester.
 B/G (+ probe) – B/Br (- probe):
4 – 6 V (Over 3 000 r/min)
 09900-25008: Multi circuit tester set
 Tester knob indication: Voltage ()
• If the voltage is not within the specified value, replace the CDI
unit.
THROTTLE POSITION SENSOR COIL RESISTANCE
• Measure the throttle position sensor coil resistance with the
multi circuit tester.
 Bl (+ probe) – B (- probe): 4 – 6 kΩ (Reference data)
 09900-25008: Multi circuit tester set
 Tester knob indication: Resistance (Ω)
 Y (+ probe) – B (- probe):
When the throttle is full closed:
0.4 – 0.6 kΩ (Reference data)
When the throttle is full opened:
2.7 – 4.04 kΩ (Reference data)
• If the resistance is correct, it is not necessary to replace the
throttle position sensor.
• If the resistance is not within the specified value, replace the
throttle position sensor assembly.
B/Br
B/G
B
Bl B
Y
11-12 FUEL SYSTEM
REED VALVE
REMOVAL
• Remove the carburetor. (11-3)
• Remove the intake pipe and reed valve.
INSPECTION
• Inspect the reeds for damage.
• Inspect the reed valve stoppers for damage.
• Inspect the valve seat rubber for damage.
NOTE:
Be careful not to damage the removed reed valve assembly.
• Inspect the reed valve clearance.
 Reed valve clearance
Service limit: 0.2 mm (0.008 in)
 09900-20803: Thickness gauge
REASSEMBLY
Reverse the sequence of removal.
• Tighten the intake pipe bolt to the specified torque.
 Intake pipe bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
12
COOLING SYSTEM 12-1
CONTENTS
COOLING SYSTEM
CONSTRUCTION ...................................................................................... 12- 2
COOLING CIRCUIT ................................................................................... 12- 3
INSPECTION ....................................................................................... 12- 3
ENGINE COOLANT ................................................................................... 12- 3
REPLACEMENT .................................................................................. 12- 3
RADIATOR ................................................................................................ 12- 4
REMOVAL ........................................................................................... 12- 4
INSPECTION ....................................................................................... 12- 4
INSTALLATION ................................................................................... 12- 4
WATER PUMP ........................................................................................... 12- 5
REMOVAL ........................................................................................... 12- 5
INSPECTION ....................................................................................... 12- 5
REASSEMBLY .................................................................................... 12- 6
12-2 COOLING SYSTEM
CONSTRUCTION
5.5 N.m
(0.55 kgf-m, 4.0 lb-ft)
10 N.m
(1.0 kgf-m, 7.0 lb-ft)
COOLING SYSTEM 12-3
COOLING CIRCUIT
INSPECTION
• Remove the radiator cap.
• Connect the tester 1 to the filler.
• Give a pressure of about 120 kPa (1.2 kgf/cm2, 17.1 psi) and
see if the system holds this pressure for 10 seconds.
• If the pressure should fall during this 10-second interval, it
means that there is a leaking point in the system. In such a
case, inspect the entire system and replace the leaking component or part.
ENGINE COOLANT
REPLACEMENT
• Place the motorcycle on a block.
• Remove the radiator cap.
• Remove the drain plug 1 and drain engine coolant.
• Tighten the drain plug 1.
• Pour specified coolant through the radiator inlet hole up to the
bottom of filler hole. (2-10)
 Engine coolant capacity: 1 100 ml (1.2/1.0 US/Imp qt)
• Tighten the radiator cap firmly.
• Run the engine a few minutes and inspect the coolant level.
 WARNING
Do not remove the radiator cap when the engine is
hot.
 WARNING
When removing the radiator cap tester, put a rag on
the filler to prevent spouting of engine coolant.
CAUTION
Do not allow the pressure to exceed the radiator cap
release pressure, or the radiator can be damaged.
 WARNING
You can be injured by scalding fluid or steam if you
open the radiator cap when the engine is hot.
Do not open the radiator cap when the engine is hot.
Wait until engine cools.
12-4 COOLING SYSTEM
RADIATOR
REMOVAL
• Remove the seat and fuel tank. (5-3)
• Drain engine coolant. (12-3)
• Remove the radiator covers 1. (LH & RH)
• Remove the hoses.
• Remove the radiators.
INSPECTION
RADIATOR
• Visually inspect the radiator for damage.
• Fins bent down or dented can be repaired by straightening
them with the blade of a small screwdriver.
RADIATOR CAP
• Inspect the radiator cap for function with a radiator cap pressure gauge.
 Radiator cap valve release pressure:
95 – 125 kPa (0.95 – 1.25 kgf/cm2, 13.5 – 17.8 psi)
NOTE:
Apply water to radiator cap seal before fitting the radiator cap to
the pressure gauge.
INSTALLATION
Reverse the sequence of removal.
• Rout the radiator hoses correctly. (18-14)
COOLING SYSTEM 12-5
WATER PUMP
REMOVAL
• Drain the engine coolant. (12-3)
• Drain the transmission oil. (2-9)
• Remove the kick starter lever. (8-3)
• Remove the brake pedal. (5-5)
• Disconnect the radiator hose 1.
• Remove the water pump cover 2.
• Remove the right crankcase cover and clutch cover.
• With the water pump shaft 3 held immovable, remove the
water pump impeller 4.
INSPECTION
IMPELLER AND GEAR SHAFT
• Inspect the impeller and gear shaft for damage.
WATER PUMP BEARING
Inspect the inner race play of the water pump bearing while it is
in the water pump housing. Rotate the inner race by finger to
inspect for abnormal noise and smooth rotation. If abnormal
noise occurs or if rough movement is noted, replace the water
pump bearing with a new one.
CAUTION
The impeller 4 has left-hand threads.
Play
Play
12-6 COOLING SYSTEM
• Remove the bearing with the special tool.
 09921-20240: Bearing remover set
OIL SEAL
• Inspect the oil seal for damage.
• Remove the oil seal with the suitable size socket wrench.
REASSEMBLY
• Apply THREAD LOCK SUPER to the outer surface of the oil
seal.
99000-32110: THREAD LOCK SUPER “1322”
(or equivalent thread lock)
• Press the oil seal with the suitable size socket wrench.
• Apply grease to the oil seal lip.
 99000-25010: SUZUKI SUPER GREASE “A”
(or equivalent grease)
COOLING SYSTEM 12-7
• Press the bearing with the special tool.
 09913-70210: Bearing installer set
NOTE:
When installing the bearing the stamped mark on the bearing
must face outside.
• Hold the water pump shaft with a wrench and tighten the
impeller to the specified torque.
 Impeller: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
• Install the dowel pins and a new gasket 1.
• Tighten the crankcase cover bolts to the specified torque.
 Crankcase cover bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft)
CAUTION
The impeller has left-hand threads.
CAUTION
Use a new gasket to prevent engine coolant leakage.
12-8 COOLING SYSTEM
• Reassemble the clutch cover and water pump cover.
After reinstalling the water pump, check the followings.
• Kick starter lever (8-6)
• Brake pedal (2-19, 5-7)
• Transmission oil level (2-9)
• Engine coolant level (2-10)
13
ELECTRICAL SYSTEM 13-1
CONTENTS
ELECTRICAL SYSTEM
CAUTIONS IN SERVICING ....................................................................... 13- 2
CONNECTOR ...................................................................................... 13- 2
COUPLER ........................................................................................... 13- 2
SEMI-CONDUCTOR EQUIPPED PART ............................................. 13- 2
USING THE MULTI-CIRCUIT TESTER .............................................. 13- 2
SWITCH ............................................................................................... 13- 2
LOCATION OF ELECTRICAL COMPONENTS ........................................ 13- 3
CONSTRUCTION ...................................................................................... 13- 4
ELECTRICAL CIRCUIT ............................................................................. 13- 4
TROUBLESHOOTING (No spark or poor spark) .................................... 13- 5
IGNITION SYSTEM .................................................................................... 13- 6
IGNITION SYSTEM PEAK VOLTAGE INSPECTION ......................... 13- 6
IGNITION COIL INSPECTION ............................................................ 13- 7
STATOR COIL INSPECTION .............................................................. 13- 7
MAGNETO ROTOR AND STATOR REMOVAL ................................. 13- 8
MAGNETO ROTOR AND STATOR REASSEMBLY .......................... 13- 9
13-2 ELECTRICAL SYSTEM
CAUTIONS IN SERVICING
CONNECTOR
• When connecting a connector, be sure to push it in until 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 when disconnecting, and push in fully to engage the lock when connecting.
• When disconnecting the coupler, be sure to hold the coupler
itself and do not pull the lead wires.
• Inspect each terminal on the coupler for being loose or bent.
• Inspect each terminal for corrosion and contamination.
SEMI-CONDUCTOR EQUIPPED PART
• Be careful not to drop the part with a semi-conductor built in
such as a CDI.
• When inspecting this part, follow inspection instruction strictly.
Neglecting proper procedure may cause damage to this part.
USING THE MULTI-CIRCUIT TESTER
• Properly use the multi-circuit tester + and - probes.
Improper use can cause damage to the motorcycle and
tester.
• If the voltage and current values are not known, begin measuring in the highest range.
• When measuring the resistance, make sure that no voltage is
applied. If voltage is applied, the tester will be damaged.
• After using the tester, be sure to turn the switch to the OFF
position.
 09900-25008: Multi-circuit tester set

SWITCH
• Never apply grease material to switch contact points to prevent damage.
Click
Click
Before using the multi-circuit tester, read its instruction manual.
Multi-circuit tester set
ELECTRICAL SYSTEM 13-3
LOCATION OF ELECTRICAL COMPONENTS
1 Engine stop switch 3 CDI unit
2 Ignition coil 4 Magneto, pick-up coil
13-4 ELECTRICAL SYSTEM
CONSTRUCTION
ELECTRICAL CIRCUIT
Wire color:
B: Black B/Bl: Black with Blue B/R: Black with Red tracer
G: Green B/Br: Black with Brown B/W: Black with White tracer
R: Red B/G: Black with Green tracer B/Y: Black with Yellow tracer
Y: Yellow B/O: Black with Orange tracer R/W: Red with White tracer
W/Bl: White with Blue tracer
35 N.m
(3.5 kgf-m, 25.5 lb-ft)
FW
D
Magneto
Engine stop switch
CDI unit
Ignition coil
Spark plug
Carburetor
solenoid
B/R
B/W
R
G
B
R
B/W
B/W
B/W
Y
B/Y
B/O
Throttle position sensor
B/G
B/Bl
B/Br
W/Bl
/
ELECTRICAL SYSTEM 13-5
TROUBLESHOOTING (No spark or poor spark)
Step 1
1) Check the ignition system couplers for poor connections.
Is there connection in the ignition system couplers?
Step 2
1) Measure the peak voltage of ignition coil. (13-6)
Is the peak voltage OK?
Step 3
1) Inspect the spark plug. (2-6)
Is the spark plug OK?
Step 4
1) Measure the ignition coil resistanace. (13-7)
Is the ignition coil resistanace OK?
Step 5
1) Measure the pick-up coil peak voltage. (13-6)
Is the peak voltage OK?
Step 6
1) Measure the pick-up coil resistance. (13-7)
Is the resistance OK?
Step 7
1) Measure the exciter coil and charge coil peak voltages. (13-6)
Are the peak voltages OK?
YES Go to Step 2.
NO Poor connection of couplers
YES Go to Step 3.
NO Go to Step 4.
YES • Poor connection of the spark plug
• Go to Step 4.
NO Faulty spark plug
YES Go to Step 5.
NO Faulty ignition coil
YES Go to Step 7.
NO Go to Step 6.
YES Go to Step 7.
NO
• Faulty pick-up coil
• Metal particles or foreign material being stuck on the pick-up coil and rotor tip
YES • Faulty CDI
• Faulty wire harness
• Faulty engine stop switch
NO Go to Step 8.
13-6 ELECTRICAL SYSTEM
Step 8
1) Measure the exciter coil and charge coil resistance. (13-7)
Is the exciter coil and charge coil OK?
IGNITION SYSTEM
IGNITION SYSTEM PEAK VOLTAGE
INSPECTION
• Remove the seat and fuel tank. (5-3)
• Remove the spark plug.
• Disconnect the magneto lead wire coupler 1.
Measure the ignition system peak voltage in the following procedure:
• Connect the multi circuit tester with peak volt adaptor as follows. (See table below.)
• Measure the highest peak voltage by depressing the kick
starter lever several times forcefully.

 09900-25008: Multi circuit tester set
 Tester knob indication: Voltage ()
• Connect the magneto lead wire coupler and disconnect the
ignition coil lead wire coupler 2.
• Connect the multi circuit tester with peak volt adaptor
between Black/White lead wire and White/Blue lead wire.
• Measure the highest peak voltage by depressing the kick
starter lever several times forcefully.

NOTE:
Be sure the Red probe pin to connected to the Black/White lead
wire and Black probe pin to the White/Blue lead wire.
YES Faulty CDI
NO Faulty magneto
Exciter + Black/Red – - Red/White 25 V and more
Pick-up + Red – - Green 2 V and more
Charge + Yellow – - Black/White 8 V and more R/W
G
R
B/RY
B/W
+ Black/White – - White/Blue 200 V and more
B/WW/BI
ELECTRICAL SYSTEM 13-7
IGNITION COIL INSPECTION
• Remove the seat and fuel tank. (5-3)
• Disconnect the ignition coil lead wire coupler 1.
Measure the ignition coil electrical resistance.

 09900-25008: Multi circuit tester set
 Tester knob indication: Resistance (Ω)
STATOR COIL INSPECTION
• Remove the seat and fuel tank. (5-3)
• Disconnect the magneto lead wire coupler 1.
Measure the stator coils electrical resistance.
 Reference data [20 °C, (68 ° F)]
 09900-25008: Multi circuit tester set
 Tester knob indication: Resistance (Ω)
NOTE:
The resistance of stator varies depending on the temperature.
(Stator and atmosphere)
Primary
White/Blue –
Black/White
0.17 – 0.70 Ω
Secondary
Plug cap –
White/Blue
13 – 20 kΩ
Exciter Black/Red – Red/White 24 – 40 Ω
Pick-up Red – Green 72 – 127 Ω
Charge Yellow – Black/White 1.6 – 2.6 Ω
13-8 ELECTRICAL SYSTEM
MAGNETO ROTOR AND STATOR REMOVAL
• Remove the seat and fuel tank. (5-3)
• Disconnect the magneto lead wire coupler and clamp.
• Remove the bolts and magneto cover 1.
• Remove the nut with a special tool.
 09930-40113: Rotor holder
• Remove the magneto rotor with the special tool.
 09930-30113: Flywheel rotor remover
• Remove the bolts and remove the stator.
ELECTRICAL SYSTEM 13-9
MAGNETO ROTOR AND STATOR
REASSEMBLY
• Fit the key 1 into the crankshaft.
• Align the line on the stator with the line on the crankcase to
set the ignition timing correctly.
• Install the magneto rotor.
• Tighten the nut to the specified torque with the special tool.
 Magneto rotor nut: 35 N·m (3.5 kgf-m, 25.5 lb-ft)
 09930-40113: Rotor holder
• Replace the gasket with a new one.
• Reassemble the magneto cover 2.
 Magneto cover bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft)
– MEMO –
14
FRONT AND REAR WHEELS 14-1
CONTENTS
FRONT AND REAR WHEELS
CONSTRUCTION ...................................................................................... 14- 2
FRONT WHEEL ......................................................................................... 14- 3
REMOVAL ........................................................................................... 14- 3
INSPECTION ....................................................................................... 14- 3
BEARING REPLACEMENT ................................................................ 14- 4
DISC PLATE REPLACEMENT ........................................................... 14- 5
INSTALLATION ................................................................................... 14- 5
REAR WHEEL ........................................................................................... 14- 6
REMOVAL ........................................................................................... 14- 6
INSPECTION ....................................................................................... 14- 6
BEARING REPLACEMENT ................................................................ 14- 7
DISC PLATE REPLACEMENT ........................................................... 14- 7
REAR SPROCKET REPLACEMENT ................................................. 14- 8
INSTALLATION ................................................................................... 14- 8
14-2 FRONT AND REAR WHEELS
CONSTRUCTION
100 N.m
(10.0 kgf-m, 72.5 lb-ft)
35 N.m
(3.5 kgf-m, 25.5 lb-ft)
10 N.m
(1.0 kgf-m, 7.0 lb-ft)
30 N.m
(3.0 kgf-m, 21.5 lb-ft)
10 N.m
(1.0 kgf-m, 7.0 lb-ft)
FW
D
FRONT AND REAR WHEELS 14-3
FRONT WHEEL
REMOVAL
• Place the motorcycle on a block to lift front wheel off the
ground.
• Remove the front axle nut 1.
• Loosen the left axle holder bolts 2.
• Loosen the right axle holder bolts 3.
• Remove the front axle shaft 4.
• Remove the front wheel.
INSPECTION
SPACER AND DUST SEAL
• Inspect the right and left wheel spacers 1 and dust seals 2
for wear and cracks.
• If any damage is found, replace the spacer together with the
dust seal.
NOTE:
Apply grease to the spacer and dust seal before reassembling.
AXLE SHAFT
• Support the axle shaft with the V-blocks and measure the axle
shaft runout.
 Axleshaft runout
Service Limit: 0.25 mm (0.010 in)
 09900-20607: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
09900-21304: V-block
14-4 FRONT AND REAR WHEELS
WHEEL RIM
• Measure the wheel rim runout with the dial gauge.
 Service Limit: 2.0 mm (0.08 in) ... axial and radial
 09900-20607: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
WHEEL BEARING
• Turn the inner race by finger and inspect it for smooth movement.
• Inspect for bearing damage.
BEARING REPLACEMENT
• Remove the dust seals with the special tool.
 09913-50121: Oil seal remover
• Remove the bearings with the special tools.
 09921-20240: Bearing remover set
• Remove the spacer.
FRONT AND REAR WHEELS 14-5
• Reassemble the bearings with the special tools.
• Fit the dust seals and apply grease to their lips.
 09941-34513: Steering race installer
09924-84521: Bearing installer set
 99000-25010: SUZUKI SUPER GREASE “A”
(or equivalent grease)
NOTE:
* Install the left side (disc side) bearing first and then the right
side bearing.
* After installing the bearings, inspect the bearings for smooth
movement.
* When installing the dust seal, place the manufacturer’s code
indicated side of the dust seal outside.
DISC PLATE REPLACEMENT
• Remove the disc plate.
• Apply THREAD LOCK SUPER to the bolts.
99000-32110: THREAD LOCK SUPER “1322”
(or equivalent thread lock)
• Tighten the bolts to the specified torque.
 Disc plate bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
INSTALLATION
• Hold the front axle shaft with the special tool and tighten the
front axle nut temporarily.
 09940-34581: Attachment (F)
• Remove the block from under the chassis tube and move the
front forks up and down several times.
• Tighten the front axle nut to the specified torque.
 Front axle nut: 35 N·m (3.5 kgf-m, 25.5 lb-ft)
• Tighten the left and right axle holder bolts to the specified
torque.
 Axle holder bolt: 18 N·m (1.8 kgf-m, 13.0 lb-ft)
Left Right
Left Right
Clearance
14-6 FRONT AND REAR WHEELS
REAR WHEEL
REMOVAL
• Place the motorcycle on a block to lift the rear wheel off the
ground.
• Remove rear axle nut 1 and washer 2.
• Remove the rear axle shaft 3 and chain adjuster washers 4.
• Disengage the drive chain.
• Remove the rear wheel.
INSPECTION
WHEEL SPACER
• Inspect the rear wheel spacers 1 and dust seals 2 for wear
and cracks.
• If any damage is found, replace the spacer together with the
dust seal.
NOTE:
Apply grease on the spacer and dust seal before reassembling.
AXLE SHAFT (14-3)
WHEEL RIM (14-4)
WHEEL BEARING (14-4)
FRONT AND REAR WHEELS 14-7
BEARING REPLACEMENT
• Remove the dust seals with the special tool.
 09913-50121: Oil seal remover
• Remove the bearings with the special tools.
 09921-20240: Bearing remover set
• Remove the spacer.
• Reassemble the bearings with the special tools.
• Fit the dust seals and apply grease to their lips.
 09941-34513: Steering race installer
09913-70210: Bearing installer set
 99000-25010: SUZUKI SUPER GREASE “A”
(or equivalent grease)
NOTE:
* Install the right side (disc side) bearing first and then the left
side bearing.
* After installing the bearings, inspect the bearings for smooth
movement.
* When installing the dust seal, place the manufacturer’s code
indicated side of the dust seal outside.
DISC PLATE REPLACEMENT
• Remove the disc plate.
• Apply THREAD LOCK SUPER to the bolts.
99000-32110: THREAD LOCK SUPER “1322”
(or equivalent thread lock)
• Tighten the bolts to the specified torque.
 Disc plate bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
Left
Clearance
Right
14-8 FRONT AND REAR WHEELS
REAR SPROCKET REPLACEMENT
• Remove the rear sprocket.
NOTE:
Install the rear sprocket as the letter on the sprocket surface
faces outside.
• Tighten the bolts/nuts to the specified torque.
 Rear sprocket bolt/nut: 30 N·m (3.0 kgf-m, 21.5 lb-ft)
INSTALLATION
• Install the rear wheel, chain adjuster washers and axle shaft.
• Adjust the drive chain slack. (2-16)
• Tighten the rear axle nut to the specified torque.
 Rear axle nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft)
FWD
Left Right
Chain adjuster washer
15
FRONT AND REAR BRAKES 15-1
CONTENTS
FRONT AND REAR BRAKES
CONSTRUCTION ...................................................................................... 15- 2
BRAKE FLUID AIR BLEEDING ................................................................ 15- 3
BRAKE FLUID REPLACEMENT ............................................................... 15- 4
BRAKE PADS REPLACEMENT ............................................................... 15- 5
FRONT BRAKE PADS ........................................................................ 15- 5
REAR BRAKE PADS .......................................................................... 15- 5
BRAKE DISC INSPECTION ...................................................................... 15- 7
CALIPER .................................................................................................... 15- 7
FRONT CALIPER REMOVAL AND DISASSEMBLY ......................... 15- 8
REAR CALIPER REMOVAL AND DISASSEMBLY ........................... 15- 9
CALIPER INSPECTION ...................................................................... 15-10
CALIPER CLEANING ......................................................................... 15-11
FRONT CALIPER REASSEMBLY ...................................................... 15-11
REAR CALIPER REASSEMBLY ........................................................ 15-12
MASTER CYLINDER ................................................................................. 15-13
FRONT MASTER CYLINDER REMOVAL AND DISASSEMBLY ...... 15-13
REAR MASTER CYLINDER REMOVAL AND DISASSEMBLY ........ 15-14
MASTER CYLINDER INSPECTION ................................................... 15-15
MASTER CYLINDER CLEANING ....................................................... 15-15
FRONT MASTER CYLINDER REASSEMBLY ................................... 15-15
REAR MASTER CYLINDER REASSEMBLY ..................................... 15-16
BRAKE LEVER .......................................................................................... 15-17
REMOVAL ........................................................................................... 15-17
INSTALLATION ................................................................................... 15-17
BRAKE PEDAL ......................................................................................... 15-18
REMOVAL ........................................................................................... 15-18
REASSEMBLY .................................................................................... 15-18
15-2 FRONT AND REAR BRAKES
CONSTRUCTION
FW
D
FW
D
23 N·m
(2.3 kgf-m, 16.5 lb-ft)
26 N·m
(2.6 kgf-m, 19.0 lb-ft)
29 N·m
(2.9 kgf-m, 21.0 lb-ft)
28 N·m
(2.8 kgf-m, 20.0 lb-ft)
18 N·m
(1.8 kgf-m, 13.0 lb-ft)
10 N·m
(1.0 kgf-m, 7.0 lb-ft)
23 N·m
(2.3 kgf-m,
16.5 lb-ft)
18 N·m
(1.8 kgf-m, 13.0 lb-ft)
6 N·m
(0.6 kgf-m, 4.4 lb-ft)
13 N·m
(1.3 kgf-m, 9.5 lb-ft)
23 N·m
(2.3 kgf-m,
16.5 lb-ft)
6 N·m
(0.6 kgf-m, 4.4 lb-ft)
23 N·m
(2.3 kgf-m,
16.5 lb-ft)
23 N·m
(2.3 kgf-m,
16.5 lb-ft)
23 N·m
(2.3 kgf-m,
16.5 lb-ft)
18 N·m
(1.8 kgf-m,
13.0 lb-ft)
10 N·m
(1.0 kgf-m, 7.0 lb-ft)
FW
D
Except for E-19
FRONT AND REAR BRAKES 15-3
BRAKE FLUID AIR BLEEDING
• Remove the reservoir cap.
• Connect a transparent tube to the bleeder valve and set the
other end into a receptacle.
• Pour brake fluid up to the UPPER line.
• Pump the brake lever/pedal until air bubbles stop coming out
from the reservoir.
• Hold the brake lever/pedal in the squeezed position.
• Open the bleeder valve and tighten the bleeder valve.
• Release the brake lever/pedal.
• Repeat this sequence until air bubbles stop coming out from
the bleeder valve.
WARNING
Brake fluid can be hazardous to humans and pets.
Brake fluid is harmful or fatal if swallowed, and harmful if it comes in contact with your skin or eyes.
Keep brake fluid away from children. Call your doctor
immediately if brake fluid is swallowed and induce
vomiting. Flush eyes or skin with water if brake fluid
gets in eyes or comes in contact with skin.
WARNING
The use of any fluid except DOT 4 brake fluid from a
sealed container can damage the brake system and
lead to an accident.
Use only DOT 4 brake fluid from sealed container.
Never use or mix different types of brake fluid.
CAUTION
Spilled brake fluid can damage painted surfaces and
plastic parts.
Be careful not to spill any brake fluid when servicing
brake fluid. Wipe spilled fluid up immediately.
15-4 FRONT AND REAR BRAKES
NOTE:
Do not release the brake lever/pedal while the bleeder valve is
opened.
• Replenish brake fluid to the UPPER line when the brake fluid
level drops below LOWER line.
• Tighten the air bleeder valve.
 Air bleeder valve: 6 N·m (0.6 kgf-m, 4.4 lb-ft)
• Pour brake fluid up to the UPPER line.
• Reassemble the reservoir cap.
BRAKE FLUID REPLACEMENT
• Remove the reservoir cap. (15-3)
• Suck up the brake fluid as much as possible.
• Pour fresh brake fluid into the reservoir.
• Connect a transparent tube to the bleeder valve and set the
other end into a receptacle. (above)
• Loosen the bleeder valve and pump the brake lever/pedal
until old brake fluid is completely out of the brake system.
• Bleed air from the brake system. (15-3)
FRONT AND REAR BRAKES 15-5
BRAKE PADS REPLACEMENT
FRONT BRAKE PADS
• Remove the cap 1 and pad mounting pin 2.
• Remove the brake pads.
NOTE:
Replace the two brake pads as a set.
• Fit the new brake pads into the caliper.
• Tighten the pad mounting pin to the specified torque.
 Brake pad mounting pin: 18 N·m (1.8 kgf-m, 13.0 lb-ft)
NOTE:
Pump the brake lever several times to seat the brake pads after
reassembling.
REAR BRAKE PADS
• Remove the pad mounting pin 1.
• Remove the brake pads.
NOTE:
Replace the two pads as a set.
15-6 FRONT AND REAR BRAKES
• Apply SUZUKI SILICONE GREASE to the O-ring.
 99000-25100: SUZUKI SILICONE GREASE
• Fit the new brake pads into the caliper.
• Tighten the brake pad mounting pin to the specified torque.
 Brake pad mounting pin: 18 N·m (1.8 kgf-m, 13.0 lb-ft)
NOTE:
* Inspect not to pinch the O-ring of brake pad mounting pin.
* Pump the brake pedal several times to seat the brake pads
after reassembling.
FRONT AND REAR BRAKES 15-7
BRAKE DISC INSPECTION
• Inspect the brake disc for damage.
• Measure the front and rear brake disc thickness.
 Brake disc thickness
Service limit (Front): 2.5 mm (0.10 in)
(Rear): 3.5 mm (0.14 in)
 09900-20205: Micrometer (0 – 25 mm)
• Measure the front and rear brake disc runout.
 Brake disc runout
Service limit: 0.3 mm (0.012 in)
 09900-20607: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
BRAKE DISC REPLACEMENT (14-5, -7)
CALIPER
WARNING
The use of any brake fluid except DOT 4 brake fluid
from a sealed container can damage the brake system
and lead to an accident.
Use only DOT 4 brake fluid from a sealed container.
Never use or mix different types of brake fluid.
WARNING
Brake fluid can be hazardous to humans and pets.
Brake fluid is harmful or fatal if swallowed, and harmful if it comes in contact with your skin or eyes.
Keep brake fluid away from children. Call your doctor
immediately if brake fluid is swallowed, and induce
vomiting. Flush eyes or skin with water if brake fluid
gets in eyes or comes in contact with skin.
CAUTION
Spilled brake fluid can damage painted surfaces and
plastic parts.
Be careful not to spill any fluid when servicing the caliper. Wipe spilled fluid up immediately.
15-8 FRONT AND REAR BRAKES
FRONT CALIPER REMOVAL AND
DISASSEMBLY
• Drain brake fluid. (15-4)
• Place a rag under the brake hose union bolt to catch spilled
brake fluid.
• Disconnect the brake hose.
• Remove the caliper mounting bolts 1.
• Remone the caliper.
• Remove the brake pads (15-5)
• Remove the spring 2.
• Remove the caliper bracket 3 from the caliper.
• Remove the boots 4.
• Remove the spring 5.
• Wrap the caliper with a rag to prevent brake fluid scatter and
piston pop-out.
• Apply low-pressure air into the caliper through the hole to
remove the pistons.
WARNING
Fingers can get caught between piston and caliper
body when removing the piston.
Do not place your fingers on the piston when removing the piston.
FRONT AND REAR BRAKES 15-9
• Remove the dust seals 6 and piston seals 7.
REAR CALIPER REMOVAL AND
DISASSEMBLY
• Remove the rear wheel. (14-6)
• Remove the disc cover 1 and caliper protector 2.
• Drain brake fluid. (15-4)
• Place a rag under the brake hose union bolt to catch spilled
brake fluid.
• Disconnect the brake hose.
• Remove the caliper.
• Remove the brake pad. (15-5)
• Remove the spring 3.
• Remove the caliper brakect 4 from the caliper.
• Remove the boots 5.
• Remove the spring 6.
15-10 FRONT AND REAR BRAKES
• Wrap the caliper with a rag to prevent brake fluid scatter and
piston pop-out.
• Apply low-pressure air into the caliper through the hole to
remove the piston.
• Remove the dust seal 7 and piston seal 8.
CALIPER INSPECTION
• Inspect the caliper cylinder for scuffing, wear and damage.
• Inspect the piston for scuffing, wear and damage.
WARNING
Fingers can get caught between piston and caliper
body when removing the piston.
Do not place your fingers on the piston when removing the piston.
FRONT AND REAR BRAKES 15-11
CALIPER CLEANING
• Flush the caliper ports with pressurized air.
• Wash the caliper piston and cylinder with fresh brake fluid.
NOTE:
Do not use gasoline or other cleaning solvents to wash the caliper parts.
FRONT CALIPER REASSEMBLY
Reassemble and remount the brake caliper in the reverse order
of removal. Pay attention to the following points:
• Apply brake fluid to the new piston seals, new dust seals and
pistons and fit the piston seals, dust seals and pistons.
 Specification and classification: DOT 4
• Install the springs and boots.
• Apply SUZUKI SILICONE GREASE to the caliper axles.
 99000-25100: SUZUKI SILICONE GREASE
• Install the caliper bracket.
• Install the brake pads and tighten the brake pad mounting pin
temporarily.
• Tighten the caliper mounting bolts 1 to the specified torque.
 Brake caliper mounting bolt: 26 N·m (2.6 kgf-m, 19.0 lb-ft)
• Tighten the brake pad mounting pin 2 to the specified torque.
 Brake pad mounting pin: 18 N·m (1.8 kgf-m, 13.0 lb-ft)
• Set the brake hose end between the hose stopper, then
tighten the brake hose union bolt 3 to the specified torque.
 Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
• Refill brake fluid and bleed air from the brake system.
(15-3)
15-12 FRONT AND REAR BRAKES
REAR CALIPER REASSEMBLY
Reassemble and remount the brake caliper in the reverse order
of removal. Pay attention to the following points:
• Apply brake fluid to the new piston seal, new dust seal andpiston fit the piston seal, dust seal and piston.
 Specification and classification: DOT 4
• Install the springs and boots.
• Apply SUZUKI SILICONE GREASE to the caliper axles.
 99000-25100: SUZUKI SILICONE GREASE
• Install the caliper bracket.
• Install the brake pads and tighten the brake pad mounting pin
temporarily. (15-6)
• Tighten the brake pad mounting pin 1 to the specified torque.
 Brake pad mounting pin: 18 N·m (1.8 kgf-m, 13.0 lb-ft)
NOTE:
* Inspect not to pinch the O-ring of brake pad mounting pin.
* Pump the brake pedal several times to seat the brake pads
after reassembling.
• Set the brake hose end between the hose stopper, then
tighten the brake hose union bolt 2 to the specified torque.
 Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
• Install the disc cover and caliper protector.
• Install the rear wheel. (14-8)
• Refill brake fluid and bleed air from the brake system.
(15-3)
FRONT AND REAR BRAKES 15-13
MASTER CYLINDER
FRONT MASTER CYLINDER REMOVAL AND
DISASSEMBLY
• Drain brake fluid. (15-4)
• Place a rag under the brake hose union bolt to catch spilled
brake fluid.
• Disconnect the brake hose.
• Remove the master cylinder holder bolts.
• Remove the master cylinder.
NOTE:
Mark the paint mark to the matching surface of master cylinder
holder and handlebars.
• Remove the bolt and brake lever.
WARNING
Brake fluid can be hazardous to humans and pets.
Brake fluid is harmful or fatal if swallowed, and harmful if it comes in contact with your skin or eyes.
Keep brake fluid away from children. Call your doctor
immediately if brake fluid is swallowed, and induce
vomiting. Flush eyes or skin with water if brake fluid
gets in eyes or comes in contact with skin.
WARNING
The use of any fluid except DOT 4 brake fluid from a
sealed container can damage the brake system and
lead to an accident.
Use only DOT 4 brake fluid from a sealed container.
Never use or mix different types of brake fluid.
CAUTION
Spilled brake fluid can damage painted surfaces and
plastic parts.
Be careful not to spill any fluid when filling the brake
fluid reservoir. Wipe spilled fluid up immediately.
15-14 FRONT AND REAR BRAKES
• Remove the master cylinder cap.
• Remove the diaphragm.
• Remove the dust boot 1.
• Remove the snap ring 2 with snap ring pliers.
• Remove the washer 3 and piston/cup set 4.
 09900-06108: Snap ring pliers
REAR MASTER CYLINDER REMOVAL AND
DISASSEMBLY
• Drain brake fluid. (15-4)
• Remove the cotter pin and then master cylinder rod pin.
• Remove the master cylinder mounting bolts.
• Place a rag under the brake hose union bolt to catch spilled
brake fluid.
• Disconnect the brake hose.
• Remove the master cylinder.
• Remove the master cylinder cap.
• Remove the diaphragm.
• Remove the dust boot 1.
• Remove the snap ring 2 with snap ring pliers.
• Remove the push rod 3.
• Remove the piston/cup set 4.
 09900-06108: Snap ring pliers
FRONT AND REAR BRAKES 15-15
MASTER CYLINDER INSPECTION
• Inspect the cylinder bore and piston for scuffing, wear and
damage.
• Inspect the piston rod and spring for damage.
MASTER CYLINDER CLEANING
• Flush the master cylinder ports with pressurized air.
• Wash the master cylinder bore and piston with fresh brake
fluid.
NOTE:
Do not use gasoline or other cleaning solvents to wash the master cylinder parts.
FRONT MASTER CYLINDER REASSEMBLY
Reassemble and remount the master cylinder in the reverse
order of removal and disassembly. Pay attention to the following
points:
• Install the brake lever. (15-17)
NOTE:
When remounting the master cylinder onto the handlebar, align
the master cylinder holder mating surface A with the paint mark
B on the handlebar and tighten the upper bolt first.
• Tighten the master cylinder mounting bolts 1 to the specified
torque.
 Master cylinder mounting bolt:
10 N·m (1.0 kgf-m, 7.0 lb-ft)
Clearance
Master
cylinder
Handlebars
Master
cylinder
holder
15-16 FRONT AND REAR BRAKES
• Set the brake hose end between the hose stopper, then
tighten the brake hose union bolt 2 to the specified torque.
 Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
• Refill brake fluid and bleed air from the brake system.
(15-3)
REAR MASTER CYLINDER REASSEMBLY
Reassemble and remount the master cylinder in the reverse
order of removal and disassembly. Pay attention to the following
points:
• Apply grease to the contact point between piston and push
rod.
 99000-25010: SUZUKI SUPER GREASE “A”
(or equivalent grease)
• Set the brake hose end between the hose stopper, then
tighten the brake hose union bolt 1 to the specified torque.
 Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
• Tighten the master cylinder mounting bolts 2 to the specified
torque.
 Master cylinder mounting bolt:
10 N·m (1.0 kgf-m, 7.0 lb-ft)
• Install the master cylinder rod pin.
• Refill brake fluid and bleed air from the brake system.
(15-3)
CAUTION
Improper brake hose routing can damage the brake
hose.
Set the brake hose so it touches the stopper and
tighten the union bolt. Ensure the brake hose has
enough clearance to the rear suspension spring.
FRONT AND REAR BRAKES 15-17
BRAKE LEVER
REMOVAL
• Remove the brake lever.
• Remove the brake lever adjuster return spring 1.
 09930-11960: Torx wrench, T20
INSTALLATION
• Apply grease to the brake lever adjuster return spring, pivot
bolt and contact point between piston and brake lever.
 99000-25010: SUZUKI SUPER GREASE “A”
(or equivalent grease)
• Tighten the pivot bolt and pivot nut to the specified torque.
 Pivot bolt: 6 N·m (0.6 kgf-m, 4.4 lb-ft)
Pivot nut: 6 N·m (0.6 kgf-m, 4.4 lb-ft)
15-18 FRONT AND REAR BRAKES
BRAKE PEDAL
REMOVAL
• Remove the cotter pin 1.
• Remove the cotter pin 2.
• Remove the washer and master cylinder rod pin 3.
• Remove the brake pedal pivot bolt 4.
REASSEMBLY
• Apply SUZUKI SUPER GREASE to the oil seal and brake
pedal pivot bolt.
 99000-25010: SUZUKI SUPER GREASE “A”
(or equivalent grease)
• Install the return spring properly. (18-15)
• Tighten the brake pedal pivot bolt to the specified torque.
 Brake pedal pivot bolt: 29 N·m (2.9 kgf-m, 21.0 lb-ft)
• Install new cotter pins.
• Adjust the brake pedal height. (2-19)
16
FRONT FORK AND STEERING 16-1
CONTENTS
FRONT FORK AND STEERING
CONSTRUCTION ...................................................................................... 16- 2
FRONT FORK, STEERING ................................................................. 16- 2
HANDLEBAR CONTROLS ................................................................. 16- 3
REMOVAL ........................................................................................... 16- 4
DISASSEMBLY ................................................................................... 16- 5
INSPECTION ....................................................................................... 16- 9
REASSEMBLY .................................................................................... 16-11
INSTALLATION ................................................................................... 16-17
STEERING ................................................................................................. 16-18
REMOVAL ........................................................................................... 16-18
INSPECTION ....................................................................................... 16-20
BEARING REPLACEMENT ................................................................ 16-20
INSTALLATION ................................................................................... 16-21
16-2 FRONT FORK AND STEERING
CONSTRUCTION
FRONT FORK, STEERING
30 N.m (3.0 kgf-m, 21.5 lb-ft)
35 N.m (3.5 kgf-m, 25.5 lb-ft)
70 N.m
(7.0 kgf-m, 50.5 lb-ft)
18 N.m
(1.8 kgf-m,
13.0 lb-ft)
18 N.m
(1.8 kgf-m, 13.0 lb-ft)
22 N.m
(2.2 kgf-m, 16.0 lb-ft)
100 N.m
(10.0 kgf-m, 72.5 lb-ft)
25 N.m
(2.5 kgf-m, 18.0 lb-ft)
23 N.m
(2.3 kgf-m, 16.5 lb-ft)
23 N.m
(2.3 kgf-m, 16.5 lb-ft)
45 N.m
(4.5 kgf-m, 32.5 lb-ft)
FRONT FORK AND STEERING 16-3
HANDLEBAR CONTROLS
6 N·m
(0.6 kgf-m, 4.4 lb-ft)
6 N·m
(0.6 kgf-m, 4.4 lb-ft)
Adhesive agent
Adhesive agent
25 N·m
(2.5 kgf-m, 18.0 lb-ft)
16-4 FRONT FORK AND STEERING
REMOVAL
• Place the motorcycle on a block to lift front wheel off the
ground.
• Remove the front wheel. (14-3)
• Remove the protector 1.
• Remove the front number plate band.
• Remove the handlebars. (16-18)
• Remove the brake hose guide 2 and fork protectors 3.
• Remove the front brake caliper 4.
• Loosen the front fork cap bolt 1 – 2 turns to facilitate later disassembly.
 09941-53630: Front fork top cap wrench
• Loosen the front fork upper clamp bolts 5.
• Hold the fork body and loosen the fork lower clamp bolts 6.
• Remove the front fork.
FRONT FORK AND STEERING 16-5
DISASSEMBLY
• Set rebound and compression damper settings to the minimum settings (softest) before disassembling. Record the setting before turning the adjuster.
• Thoroughly clean the fork before disassembly.
• Clamp the outer tube with a vise. Protect the outer tube with a
rag when using a vise.
• Loosen and remove the fork cap bolt (sub-tank) from the outer
tube and slowly slide down the outer tube.
 09941-53630: Front fork top cap wrench
• Place a drain pan under the front fork and drain fork oil.
NOTE:
Face the oil hole A on the sub-tank downward.
• Raise the outer tube and temporarily install the fork cap bolt
1 (sub-tank) to the outer tube.
CAUTION
Scratches or other damage on the inner tube or on the
oil seal lip will cause oil leak.
Avoid scratching or damaging the inner tube or the oil
seal. Use a mild detergent or car wash soap and
sponge out dirt with plenty of water.
 WARNING
Clamping the outer tube too tight can damage it which
will affect riding stability.
Do not clamp the outer tube too tight.
16-6 FRONT FORK AND STEERING
• Clamp the axle holder 2 with a vise. Protect the axle holder
with a rag when using a vise.
• Loosen the center bolt 3 completely with a 21 mm socket
wrench.
• Compress the outer tube by hands and install the conrod
holder (special tool) between the axle holder bottom 2 and
lock-nut 4.
 09910-20115: Conrod holder
• Hold the lock-nut with a wrench and remove the center bolt.
• Remove the push rod.
 WARNING
Clamping the axle holder too tight can damage it
which will affect riding stability.
Do not clamp the axle holder too tight.
FRONT FORK AND STEERING 16-7
• With the outer tube compressed by hands, remove the special
tool.
• Loosen the fork cap bolt 1 (sub-tank) and remove the subtank 5 along with the damper rod assembly 6.
• Remove the fork spring 7.
• Remove the dust seal 8 and the stopper ring 9.
CAUTION
Removing the lock-nut 4 and pushing the inner rod
thread into the damper rod will damage the inner rod
oil seal.
Do not remove the lock-nut 4 from the inner rod.
CAUTION
Disassembling the damper rod assembly can lead to
trouble.
Do not disassemble the damper rod assembly.
Do not separate the sub-tank and damper rod assembly.
CAUTION
Scratches on the inner tube could cause oil leaks.
Avoid scratching when removing.
16-8 FRONT FORK AND STEERING
INNER TUBE
• Separate the inner tube out of the outer tube.
• Remove the slide bushing from the inner tube.
• Remove the following parts from the inner tube.
Guide bushing 1
Seal retainer 2
Oil seal 3
Stopper ring 4
Dust seal 5
• Clamp the bottom (flat part) of the sub-tank with a monkey
wrench.
• Loosen the compression damper unit.
CAUTION
Do not clamp the sub-tank too tight.
FRONT FORK AND STEERING 16-9
• Remove the compression damper unit from the sub-tank.
NOTE:
Slowly compress the inner rod until it stops so that the compression damper unit can be removed easily.
• Drain the fork oil from the damper rod assembly by moving
the inner rod several strokes.
INSPECTION
CENTER BOLT
• Inspect the adjuster rod of the center bolt for damage. If it is
damaged, replace it with a new one.
• Replace the O-ring with a new one.
COMPRESSION DAMPER UNIT
• Inspect the compression damper unit for damage. If it is damaged, replace it with a new one.
• Replace the O-ring with a new one.
CAUTION
Disassembling the compression damper unit can lead
to trouble.
Do not disassemble the compression damper unit.
16-10 FRONT FORK AND STEERING
INNER TUBE AND OUTER TUBE
• Inspect the inner tube for scratches. If it has scratches,
replace it with a new one.
• Inspect the outer tube for dent. If it is dented all the way to the
inner side, replace it with a new one.
• Measure the inner tube runout using the V-blocks and dial
gauge.
 Inner tube runout
Service Limit: 0.4 mm (0.02 in)
 09900-20607: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
09900-21304: V-block
DAMPER ROD
• Inspect the damper rod assembly for scratches or bending. If
it has scratches or is bent, replace it with a new one.
FORK SPRING
• Measure the free length of front fork spring.
 Service Limit: 487 mm (19.17 in)
FRONT FORK AND STEERING 16-11
SLIDE BUSHING AND GUIDE BUSHING
Inspect the “teflon coating metals” (slide bushing and guide
bushing) for wear or damage. If they are worn or damaged,
replace them with new ones.
Inspect the metal particles on the “teflon coating metals”. If they
are not clean, clean them with a nylon brush and fork oil.
REASSEMBLY
NOTE:
* Clean all fork parts before reassembling.
* Replace the O-rings, oil seal and dust seal with the new ones.
* Apply specified front fork oil when installing the O-rings, slide
bushing, guide bushing, damper unit and other sliding parts.
INNER TUBE
• Apply front fork oil to the oil seal lip and the dust seal.
• Cover the inner tube with a plastic film.
• Install the following parts to the inner tube:
New dust seal 1
Stopper ring 2
New oil seal 3
NOTE:
The side of the oil seal that has a mark should face the dust
seal.
• Remove the plastic film and then install the seal retainer 4,
guide bushing 5 and slide bushing 6.
• Clean the parts and keep them free from dust.
NOTE:
Inspect the bushings for burrs. If there is a burr, remove it with a
knife, taking care not to peel off the teflon coating. If the bushings have a large crack or excessive play after installing them,
replace them with new ones.
• Insert the inner tube into the outer tube.
CAUTION
Scratches on the oil seal lip can cause oil leaks.
When installing the seals, place a plastic film over the
bushing attachment groove and edges of the inner
tube to avoid damaging the seals’ lip.
16-12 FRONT FORK AND STEERING
• Install the new oil seal 3 with the special tool until the stopper
ring groove of the outer tube can be seen.
 09940-52861: Front fork oil seal installer set
• Attach the stopper ring securely to the stopper ring groove of
the outer tube.
• Attach the dust seal 1.
NOTE:
After attaching the dust seal, make sure that there are no cracks
around the circumference of the seal. Cracks could allow water,
mud and the like to enter and cause an oil leak.
DAMPER ROD
• Clean each threaded part before installing.
• With the damper rod in fully extended position, pour the specified amount of fork oil.
 Fork oil quantity (Inside the damper rod):
193 ml (6.52/6.80 US/lmp oz)
 99000-99001-SS5: SUZUKI FORK OIL SS-05
(or equivalent fork oil)
CAUTION
Use of grease as a substitute fork oil when installing
the oil seal can result in an oil leak. Applying grease to
the dust seal and oil seal can cause dirt to accumulate
and damage the dust seal lip and oil seal lip.
Use only a thin coat of fork oil on the oil seal.
FRONT FORK AND STEERING 16-13
• Apply fork oil to the O-rings and bushing on the compression
damper unit.
• With the damper rod held immovable in fully extended position, gently install the compression damper unit to the subtank.
• Clamp the bottom (flat part) of the sub-tank with a monkey
wrench.
• Tighten the compression damper unit to the specified torque.
 Compression damper unit: 30 N·m (3.0 kgf-m, 21.5 lb-ft)
• With the damper rod held in vertical position, slowly move the
inner rod several strokes.
• Tighten the lock-nut by hand completely.
• With the damper rod held in vertical position, compress the
damper rod fully to discharge an excess of oil.
NOTE:
Set the compression damper setting to the softest.
CAUTION
Do not clamp the sub-tank too tight.
100 mm
(3.9 in)
CAUTION
Protect the inner rod end with a rag when compressing the damper rod.
16-14 FRONT FORK AND STEERING
• Force out the remaining oil (discharged oil) using compressed
air completely.
• With the damper rod in horizontal position, move the inner rod
by hand to inspect it if operating smoothly.
• If the inner rod is not extend, repeat the “COMPRESSION
DAMPER UNIT” procedures (Pour the specified amount fork
oil and discharge an excess of oil). (16-12)
• Make sure approx. 10 mm (0.39 in) of inner rod thread is
exposed on the end.
• Completely wipe off the fork oil from the spring and damper
rod assembly.
• Insert the spring and damper rod assembly into the fork.
• Temporarily tighten the fork cap bolt (sub-tank).
 09941-53630: Front fork top cap wrench
100 mm
(3.9 in)
Approx.10 mm
(0.39 in)
Lock-nut
FRONT FORK AND STEERING 16-15
• Clamp the axle holder with a vise. Protect the axle holder with
a rag when using a vise.
• Compress the outer tube by hands and install the conrod
holder (special tool) between the axle holder bottom and locknut.
 09910-20115: Conrod holder
• Insert the push rod into the inner rod.
• Insert the shaped projection of center bolt into the push
rod.
• Slowly turn the center bolt clockwise until resistance is felt
and check the clearance between the lock-nut and center bolt
to provide 1 mm (0.04 in) and more.
• Turn the lock-nut counterclockwise until it contacts with the
center bolt.
• With the lock-nut held immovable using a wrench, tighten the
lock-nut/center bolt to the specified torque.
 Lock-nut/center bolt: 22 N·m (2.2 kgf-m, 16.0 lb-ft)
• With the outer tube compressed by hands, remove the special
tool.
 WARNING
Clamping the axle holder too tight can damage it
which will affect riding stability.
Do not clamp the axle holder too tight.
1 mm and more
(0.04 in)
16-16 FRONT FORK AND STEERING
• Tighten the center bolt to the specified torque.
 Center bolt: 70 N·m (7.0 kgf-m, 50.5 lb-ft)
• Loosen and remove the fork cap bolt (sub-tank) from the outer
tube and slowly slide down the outer tube.
 09941-53630: Front fork top cap wrench
• Pour the specified amount of fork oil into the outer tube.
 Oil quantity (When standard fork spring is used):
357 ml (12.07/12.57 US/lmp oz)
 99000-99001-SS5: SUZUKI FORK OIL SS-05
(or equivaient fork oil)
• Raise the outer tube and temporarily tighten the fork cap bolt
(sub-tank).
 09941-53630: Front fork top cap wrench
FRONT FORK AND STEERING 16-17
INSTALLATION
• Install the front fork with the line T aligned with the upper surface of the upper bracket.
• Check that the air valve A is positioned at the front.
• Tighten the fork lower clamp bolts to the specified torque.
 Fork lower clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
• Tighten the fork upper clamp bolts to the specified torque.
 Fork upper clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
• Tighten the fork cap bolt (sub-tank) to the specified torque.
 Fork cap bolt: 35 N·m (3.5 kgf-m, 25.5 lb-ft)
 09941-53630 : Front fork top cap wrench
• Install the handlebars. (16-22)
• Install the front wheel. (14-5)
• Install the brake caliper. (15-11)
• Check that the front fork protectors move smoothly. If not,
loosen and adjust the protector guide.
INSPECTION AFTER INSTALLATION
• Front fork (2-20)
• Steering (2-22)
• Wire, cable and hose routing (18-12, -13, -17)
16-18 FRONT FORK AND STEERING
STEERING
REMOVAL
HANDLEBARS
• Place the motorcycle on a block to lift front wheel off the
ground.
• Remove the front number plate and protector.
(5-2, 16-4)
• Remove the clamps.
• Remove the clutch lever 1.
• Remove the engine stop switch 2.
• Remove the left handle grip 3.
NOTE:
Mark the paint mark to the matching surface of clutch lever
holder and handlebars, left handle grip and handlebars before
removing.
• Remove the front brake master cylinder.
NOTE:
Mark the paint mark to the matching surface of master cylinder
holder and handlebars before removing.
• Loosen the throttle assembly mounting bolts.
NOTE:
Mark the paint mark to the matching surface of throttle holder
and handlebars before removing.
• Remove the handlebar holder bolts and remove the handlebars.
NOTE:
Mark the paint mark to the matching surface of handlebar holder
and handlebars before removing.
FRONT FORK AND STEERING 16-19
STEERING STEM
• Remove the front wheel. (14-3)
• Remove the front forks. (16-4)
• Remove the front fender.
• Remove the steering stem head nut.
• Remove the steering stem upper bracket.
• Remove the steering stem nut with the special tools.
 09940-14911: Steering nut socket wrench
09940-14960: Attachment
• Remove the steering stem lower bracket.
• Remove the dust seal 1.
• Remove the upper bearing 2.
16-20 FRONT FORK AND STEERING
INSPECTION
STEERING STEM
• Inspect the needle bearings for wear.
• Inspect the steering stem for distortion.
• Inspect the bearing outer races for wear.
BEARING REPLACEMENT
NOTE:
Replace the outer race and bearing as a set.
• Remove the upper and lower outer races with the special
tools.
 09941-54911: Bearing outer race remover
09941-74911: Steering bearing installer
• Remove the lower bearing.
• Fit the lower bearing with the special tool.
 09925-18011: Steering bearing installer
FRONT FORK AND STEERING 16-21
• Fit the upper and lower outer races with the special tools.
 09941-34513: Steering race installer
09924-84510: Bearing installer set
INSTALLATION
STEERING STEM
• Apply grease to the bearings.
 99000-25010: SUZUKI SUPER GREASE “A”
(or equivalent grease)
• Fit the steering stem lower bracket, upper bearing and steering stem nut.
• Tighten the steering stem nut with the special tools.
 Steering stem nut: 45 N·m (4.5 kgf-m, 32.5 lb-ft)
 09940-14911: Steering nut socket wrench
09940-14960: Attachment
• Move the steering stem right and left several times to seat the
bearings.
• Turn back the steering stem nut by 1/4 to 1/2 turn.
• Fit the steering stem head nut and tighten it temporarily.
• Remount the front forks. (16-17)
• Tighten the steering stem head nut to the specified torque.
 Steering stem head nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft)
16-22 FRONT FORK AND STEERING
HANDLEBARS
• Apply adhesive agent to the left handlebar end and inside of
the left grip.
HANDLE GRIP BOND (commercial available)
• Align the “ ” mark on the left grip with the paint mark A on
the left handlebar end.
• Set the “ ” mark B on the handlebar holder forward.
• Align the paint mark C on the handlebars with the matching
surface of the handlebar holder.
• Tighten the handlebar holder bolts to the specified torque.
 Handlebar holder bolt: 25 N·m (2.5 kgf-m, 18.0 lb-ft)
NOTE:
When tightening the handlebar holder bolts, first tighten the bolts
1 then bolts 2.
Clearance
FWD
FRONT FORK AND STEERING 16-23
• Apply grease to the throttle cable and their hole.
 99000-25010: SUZUKI SUPER GREASE “A”
(or equivalent grease)
• Align the “ ” mark on the throttle grip with the hole on the
throttle rotor.
• Align the paint mark D on the handlebars with the throttle
holder matching surface.
• Align the paint mark E on the handlebars with the front brake
master cylinder holder matching surface. (15-15)
• Align the paint mark F on the handlebars with the clutch lever
holder matching surface. (18-16)
• Install the engine stop switch.
16-24 FRONT FORK AND STEERING
Inspect the following items.
• Front fork (2-20)
• Steering (2-22)
• Wire, cable and hose routing (18-12, -13, -17)
17
REAR SUSPENSION 17-1
CONTENTS
REAR SUSPENSION
CONSTRUCTION ...................................................................................... 17- 2
REAR SUSPENSION .......................................................................... 17- 2
REAR SHOCK ABSORBER ...................................................................... 17- 3
REMOVAL ........................................................................................... 17- 3
SPRING REPLACEMENT ................................................................... 17- 4
INSPECTION ....................................................................................... 17- 5
BEARING REPLACEMENT ................................................................ 17- 5
OIL REPLACEMENT ........................................................................... 17- 6
DISASSEMBLY AND INSPECTION ................................................... 17- 9
REASSEMBLY .................................................................................... 17-11
INSTALLATION ................................................................................... 17-11
DISPOSAL ........................................................................................... 17-12
SWINGARM ............................................................................................... 17-13
REMOVAL ........................................................................................... 17-13
INSPECTION ....................................................................................... 17-14
BEARING REPLACEMENT ................................................................ 17-15
INSTALLATION ................................................................................... 17-16
REAR SUSPENSION LINKAGE ............................................................... 17-17
REMOVAL ........................................................................................... 17-17
INSPECTION ....................................................................................... 17-18
BEARING REPLACEMENT ................................................................ 17-18
REASSEMBLY .................................................................................... 17-19
17-2 REAR SUSPENSION
CONSTRUCTION
REAR SUSPENSION
55 N.m
(5.5 kgf-m,
40.0 lb-ft)
80 N.m
(8.0 kgf-m,
58.0 lb-ft)
80 N.m (8.0 kgf-m, 58.0 lb-ft)
80 N.m
(8.0 kgf-m,
58.0 lb-ft)
55 N.m (5.5 kgf-m, 40.0 lb-ft)
70 N.m
(7.0 kgf-m, 50.5 lb-ft)
REAR SUSPENSION 17-3
REAR SHOCK ABSORBER
REMOVAL
• Place a block under chassis tube.
• Remove the seat. (5-3)
• Loosen the air cleaner clamp screw.
• Remove the right frame cover. (5-2)
• Remove the silencer and rear frame assembly.
• Remove the rear shock absorber upper mounting bolt and
nut.
(For E-19, 000)
17-4 REAR SUSPENSION
• Remove the rear shock absorber lower mounting bolt and nut.
• Remove the rear shock absorber.
NOTE:
If necessary, move the swingarm up or down to facilitate this
mounting bolt/nut removal.
SPRING REPLACEMENT
• Loosen the lock-nut 1 with the special tool and turn it fully to
the end of the thread.
• Turn the adjuster 2 as well as the lock-nut 1.
 09910-60611: Universal clamp wrench
• Depress the spring seat 3 and remove the stopper ring 4.
• Remove the spring seat 3 and the spring 5 from the rear
shock absorber.
• Install the lock-nut, adjuster, spring, spring seat and stopper
ring.
NOTE:
Install the spring as its painted side A or small diameter side
faces bottom.
• Adjust the spring set length and tighten the lock-nut.
 Standard spring set length:
3.7 mm (0.146 in) compressed from the free length
Spring set length adjustable range:
245 – 263 mm (9.646 – 10.354 in)
[at spring free length 265 mm (10.433 in)]
a: Hardest spring setting
b: Softest spring setting
 Spring adjuster lock-nut: 45 N·m (4.5 kgf-m, 32.5 lb-ft)
REAR SUSPENSION 17-5
INSPECTION
• Inspect the rear shock absorber for oil leakage.
• Inspect the damper rod for bends and smooth movement.
• Inspect the bump rubber for deterioration and damage.
• Inspect the damper rod hidden by the bump rubber by moving
the bump rubber.
• Inspect the spacers and dust seals for damage.
• Inspect the bearing for excessive play and smooth movement.
BEARING REPLACEMENT
• Remove the spacers.
• Remove the needle roller bearings 1.
• Remove the dust seals 2.
• Remove the needle roller bearing cage 3 with the special
tool.
 09921-20240: Bearing remover set
• Press the needle roller bearing cage with the special tool and
a suitable size socket wrench.
NOTE:
When installing the needle roller bearing cage, the stamped
mark on the bearing must face left side.
Position the needle roller bearing cage by refering to the illustration of page 17-20.
 09924-84521: Bearing installer set
17-6 REAR SUSPENSION
• Install the dust seals.
NOTE:
When installing the dust seal, the stamped mark A on the dust
seal must face inside.
• Apply grease to the needle roller bearings and install them.
• Apply grease to the dust seals and spacers.
• Install the spacers A and B.
A for Right side
B for Left side
 99000-25010: SUZUKI SUPER GREASE “A”
(or equivalent grease)
OIL REPLACEMENT
TOOLS AND EQUIPMENT
• Following tools and equipment are required to perform oil
replacement.
1 Screwdriver or small punch 7 Rags
2 Vise* 8 Nitrogen tank
3 Drain Pan 9 Filler Hose and Nozzle
4 Oilcan 0 Regulator Assembly
5 Beaker A Owner’s Service Manual
6 Specified Shock Oil (SS25)
* Not Shown in the illustration
125
REAR SUSPENSION 17-7
OIL REPLACEMENT PROCEDURE
• Remove the rear shock absorber unit from the frame
(17-4), clean and dry it.
• Remove the spring from the rear shock absorber unit.
(17-4)
NOTE:
Inspect the rear shock absorber unit for oil leak.
Turn the rebound damping force adjuster screw counterclockwise until it stops so that the rear suspension oil can be poured
easily.
• Remove the valve cap. Press the valve with a screwdriver to
bleed out nitrogen gas.
• Remove the compression adjuster assembly 1 from the rear
shock absorber.
• Place a drain pan under the rear shock absorber unit.
• Move the rod and drain the oil completely.
• Push the valve core again to equalize the bladder to atmospheric pressure.
WARNING
Releasing high pressure gas from the rear shock
absorber unit can be hazardous.
Never perform any servicing until the nitrogen gas
pressure has been released from the rear shock
absorber unit. When releasing the gas pressure, place
a rag over the gas valve and use the tip of a screwdriver etc. to press the valve. Do not use your finger to
depress the gas valve, and direct the valve away from
your face and body.
17-8 REAR SUSPENSION
• Pour the fresh specified rear suspension oil as shown while
moving the rod.
NOTE:
Be sure to extend the rod after filling the oil.
• Tilt the shock absorber unit as shown and pour the fresh rear
suspension oil fully into the reservoir tank.
99000-99001-S25: SUZUKI REAR SUSPENSION OIL
SS-25
(or equivalent rear suspension oil)
 Oil capacity: Approx. 380 ml (12.84/13.38 US/Imp oz)
• Cover the compression adjuster hole with the root of your
thumb.
• Tilt and shake the rear shock absorber unit to fill the reservoir
tank with the oil.
• Add the oil and repeat the above procedure until the reservoir
tank is filled with the oil completely.
• Replace the O-rings on the compression adjuster assembly
with new ones.
REAR SUSPENSION 17-9
• Reinstall the compression adjuster assembly 1.
 Compression adjuster assembly:
30 N·m (3.0 kgf-m, 21.5 lb-ft)
• Fill the rear shock absorber unit with nitrogen gas to 981 kPa
(9.8 kgf/cm2, 139.5 psi).
• Tighten the gas valve cap.
• Reinstall the spring. (17-4)
DISASSEMBLY AND INSPECTION
• Clean and dry the rear shock absorber.
• Remove the spring from the rear shock absorber. (17-4)
• Turn the rebound damping force adjuster to the softest position.
• Press the valve with a screwdriver to bleed out nitrogen gas.
(17-7)
• Remove the compression adjuster assembly and drain the oil.
(17-7)
WARNING
Use of flammable gas for pressuring the rear shock
absorber unit can be hazardous. Flammable gas such
as gas welding oxygen can cause a fire hazard.
Use nitrogen gas. If nitrogen gas is not available, compressed air free from water can be substituted.
WARNING
Applying too much pressure to the rear shock
absorber unit may rupture the rear shock absorber
unit.
Be sure to fill the rear shock absorber unit to the specified pressure.
CAUTION
Riding the motorcycle with abnormal gas pressure
can damage the rear shock absorber unit. Low gas
pressure can result in oil leakage. Abnormal gas pressure cannot provide normal rear shock absorber unit
performance.
Be sure to fill the rear shock absorber unit to the specified pressure.
17-10 REAR SUSPENSION
• Vise the rear shock absorber unit in inverted position.
• Depress the bump rubber fully to protect the damper rod.
• Evenly hammer the stopper 1 with a screwdriver or equivalent and remove it from the rear shock absorber body.
• Depress the seal case 2 with a screwdriver until the circlip 3
is fully exposed.
• Remove the circlip 4.
NOTE:
Do not scratch the inner surface of the shock absorber body to
avoid oil leaks.
• Extract the damper rod assembly from the shock absorber
body.
• Inspect the oil seal and O-rings.
• Inspect the damper rod for bends and scratches.
• Inspect the inner surface of the body.
• Inspect the “teflon coating metal” on the piston.
• Replace O-rings with new ones.
• Replace the “teflon coating metal” by cutting off the old one
and putting a new one onto the piston if necessary.
REAR SUSPENSION 17-11
REASSEMBLY
• Apply the rear suspension oil to the O-rings and the “teflon
coating metal”.
• Insert the damper rod assembly 1 and fit a new circlip 2.
• Pull up the damper rod assembly 1 until it is stopped by the
circlip 2.
• Fit the stopper to the shock absorber body.
• Fill the specified rear suspension oil in the rear shock
absorber. (17-8)
99000-99001-S25: SUZUKI REAR SUSPENSION OIL
SS-25
(or equivalent rear suspension oil)
 Oil capacity: Approx. 380 ml (12.84/13.38 US/Imp oz)
• Reinstall the compression adjuster assembly. (17-9)
• Pressure the rear shock absorber unit with nitrogen gas to
981 kPa (9.8 kgf/cm2, 139.5 psi). (17-9)
• Reassemble the spring and adjust the spring set length.
(17-4)
• Tighten the valve cap.
INSTALLATION
Install the rear shock absorber in the reverse order of removal.
Pay attention to the following points:
• Tighten the rear shock absorber lower mounting bolt and nut
to the specified torque.
NOTE:
If necessary, move the swingarm up or down to facilitate this
mounting bolt/nut tightening.
 Rear shock absorber lower mounting nut:
55 N·m (5.5 kgf-m, 40.0 lb-ft)
• Tighten the upper mounting bolt and nut to the specified
torque.
 Rear shock absorber upper mounting nut:
55 N·m (5.5 kgf-m, 40.0 lb-ft)
NOTE:
Replace the self-locking nuts with new ones.
17-12 REAR SUSPENSION
DISPOSAL
High pressure nitrogen gas is sealed in the rear shock absorber
unit. Be sure to release gas before disposing the rear shock
absorber unit.
• Remove the valve cap.
• Press the valve with a screwdriver.
WARNING
Releasing high pressure gas from the rear shock
absorber unit can be hazardous.
Place a rag over the valve and push the valve with a
screwdriver to release nitrogen gas. Do not use your
finger to push the valve, and direct the valve away
from your face and body.
REAR SUSPENSION 17-13
SWINGARM
REMOVAL
• Place the motorcycle on a block to lift rear wheel off the
ground.
• Remove the rear wheel. (14-6)
• Remove the chain guide.
• Remove the rear brake hose guide.
• Remove the rear brake caliper from the swingarm.
• Remove the rear cushion rod bolt and nut.
• Remove the rear cushion lever bolt and nut.
• Remove the swingarm pivot nut and shaft.
• Remove the swingarm.
17-14 REAR SUSPENSION
• Remove the chain buffer.
• Remove the plates.
• Remove the following parts from the swingarm.
Spacer 1
Oil seal 2
Washer 3
Thrust bearing 4
Dust seal 5
Spacer 6
INSPECTION
PIVOT SHAFT
• Measure the pivot shaft runout with the dial gauge and
V-blocks.
 Swingarm pivot shaft runout
Service Limit: 0.3 mm (0.01 in)
 09900-20607: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
09900-21304: V-block
CHAIN BUFFER AND CHAIN GUIDE
• Inspect the chain buffer and chain guide for damage and
excessive wear.
REAR SUSPENSION 17-15
SWINGARM
• Inspect the swingarm for cracks and damage.
BEARING, SPACER, DUST SEAL, OIL SEAL
• Inspect the bearings, spacers, dust seals and oil seals for
damage.
• Insert the spacer into the bearings and inspect them for play
and smooth movement.
BEARING REPLACEMENT
• Remove the bearings with the special tool.
 09921-20240: Bearing remover set
• Press fit the bearings with the special tool.
 09913-70210: Bearing installer set
17-16 REAR SUSPENSION
• Apply grease to the bearings.
 99000-25010: SUZUKI SUPER GREASE “A”
(or equivalent grease)
INSTALLATION
• Reassemble the following parts into the swingarm.
1 Oil seal 5 Washer
2 Spacer 6 Dust seal
3 Washer 7 Spacer
4 Thrust bearing
• Apply grease to the dust seals, bearings, spacers and oil
seals.
 99000-25010: SUZUKI SUPER GREASE “A”
(or equivalent grease)
• Reassemble the plates and chain buffer.
• Tighten the swingarm pivot nut to the specified torque.
 Swingarm pivot nut: 70 N·m (7.0 kgf-m, 50.5 lb-ft)
• Tighten the rear cushion lever nut and rear cushion rod nut to
the specified torque.
 Rear cushion lever nut: 80 N·m (8.0 kgf-m, 58.0 lb-ft)
Rear cushion rod nut: 80 N·m (8.0 kgf-m, 58.0 lb-ft)
• Install the rear brake caliper.
• Reassemble the chain guide.
• Install the rear wheel. (14-8)
• Adjust the drive chain slack. (2-16)
REAR SUSPENSION 17-17
REAR SUSPENSION LINKAGE
REMOVAL
• Place a block under the chassis tubes.
• Remove the lower drive chain control roller 1.
• Remove the rear cushion rod bolt and nut.
• Remove the cushion lever bolt and nut.
• Remove the shock absorber lower bolt and nut.
• Remove the cushion rod from the cushion lever.
• Remove the collars and spacers.
17-18 REAR SUSPENSION
INSPECTION
• Inspect the cushion rod and cushion lever for damage.
• Inspect the dust seals and spacers for damage.
• Insert the spacers into the bearings and inspect them for
excessive play and smooth movement.
BEARING REPLACEMENT
• Remove the spacers and dust seals.
• Remove the needle roller bearings.
• Remove the needle roller bearing cages 1 with the special
tool.
 09921-20240: Bearing remover set
REAR SUSPENSION 17-19
• Press fit the needle roller bearing cages with the special tool.
 09913-70210: Bearing installer set
NOTE:
When installing the needle roller bearing cages, the stamped
mark on the bearing must face outside.
• Apply grease to the needle roller bearings and install them.
 99000-25010: SUZUKI SUPER GREASE “A”
(or equivalent grease)
• Press fit the needle roller bearing cages with the special tool
and a suitable size socket wrench.
 09924-84521: Bearing installer set
NOTE:
* When installing the needle roller bearing cages 2, the
stamped mark on the bearing must face outside. (3: right side)
* Position the needle roller bearing cages by refering to the illustration of page 17-20.
• Apply grease to the needle roller bearings and install them.
 99000-25010: SUZUKI SUPER GREASE “A”
(or equivalent grease)
REASSEMBLY
Reassemble and remount the rear suspension linkage in the
reverse order of removal and disassembly. Pay attention to the
following points:
• Position the dust seals 1 so that the manufacturer’s code
indicated side of the seals face outside. (2: inside)
• Apply grease to the spacers and dust seals.
 99000-25010: SUZUKI SUPER GREASE “A”
(or equivalent grease)
17-20 REAR SUSPENSION
• Tighten the cushion lever, cushion rod and swingarm nuts to the specified torque.
 Tightening torque:
A: 55 N·m (5.5 kgf-m, 40.0 lb-ft)
B: 55 N·m (5.5 kgf-m, 40.0 lb-ft)
C: 80 N·m (8.0 kgf-m, 58.0 lb-ft)
D: 80 N·m (8.0 kgf-m, 58.0 lb-ft)
E: 80 N·m (8.0 kgf-m, 58.0 lb-ft)
F: 70 N·m (7.0 kgf-m, 50.5 lb-ft)
5 mm
4 mm
4 mm
4 mm
Left Right
REAR SUSPENSION 17-21
• Tighten the lower drive chain control roller bolt to the specified
torque.
 Drive chain control roller bolt:
31 N·m (3.1 kgf-m, 22.5 lb-ft)
CAUTION
Improperly reassembled rear suspension linkage bolts can interfere with suspension movement and damage the rear suspension linkage.
* Make sure that the rear shock absorber rebound damping adjuster on the bottom bracket of
the rear shock absorber is located to the right side.
* Insert the rear suspension linkage bolt 1 from the left side. Make sure that the nut B is in the
recess of the rear shock absorber bottom bracket.
Left Right
– MEMO –
18
SERVICING INFORMATION 18-1
CONTENTS
SERVICING INFORMATION
SERVICE DATA ......................................................................................... 18- 2
CYLINDER + PISTON + PISTON RING............................................... 18- 2
CONROD + CRANKSHAFT................................................................. 18- 2
CLUTCH ............................................................................................... 18- 2
RADIATOR .......................................................................................... 18- 3
TRANSMISSION .................................................................................. 18- 3
DRIVE CHAIN....................................................................................... 18- 3
CARBURETOR .................................................................................... 18- 3
ELECTRICAL ....................................................................................... 18- 4
BRAKE + WHEEL ................................................................................ 18- 4
SUSPENSION ...................................................................................... 18- 5
TIRE ..................................................................................................... 18- 6
FUEL + OIL + COOLANT .................................................................... 18- 6
TIGHTENING TORQUE ............................................................................. 18- 7
SPECIAL TOOLS ...................................................................................... 18- 9
WIRING DIAGRAM .................................................................................... 18-11
WIRE, CABLE AND HOSE ROUTING ...................................................... 18-12
SPECIFICATIONS ..................................................................................... 18-20
DIMENSIONS AND DRY MASS ......................................................... 18-20
ENGINE ............................................................................................... 18-20
TRANSMISSION ................................................................................. 18-20
CHASSIS ............................................................................................. 18-21
ELECTRICAL ...................................................................................... 18-21
CAPACITIES ....................................................................................... 18-21
SPARE PARTS LIST ................................................................................. 18-22
OPTIONAL PARTS .................................................................................... 18-22
SETTING DATA ......................................................................................... 18-23
18-2 SERVICING INFORMATION
SERVICE DATA
CYLINDER + PISTON + PISTON RING Unit: mm (in)
CONROD + CRANKSHAFT Unit: mm (in)
CLUTCH Unit: mm (in)
ITEM STANDARD LIMIT
Piston to cylinder clearance 0.030 – 0.040
(0.0012 – 0.0016)
0.120
(0.0047)
Cylinder bore 54.000 – 54.015
(2.1260 – 2.1266)
Measure 20 (0.79) from the top surface.
Nicks or
Scratches
Piston diam. 53.965 – 53.980
(2.1246 – 2.1252)
Measure 19 (0.75) from the skirt end.
53.880
(2.1213)
Cylinder distortion — 0.05(0.002)
Cylinder head distortion — 0.05(0.002)
Piston ring free end gap Approx. 4.3 (0.17) 3.4(0.13)
Piston ring end gap 0.45 – 0.60
(0.018 – 0.024)
0.80
(0.031)
Piston ring to groove clearance 0.020 – 0.060
(0.0008 – 0.0024) —
Piston pin bore 15.002 – 15.008
(0.5905 – 0.5907)
15.030
(0.5917)
Piston pin O.D. 14.995 – 15.000
(0.5904 – 0.5906)
14.980
(0.5898)
ITEM STANDARD LIMIT
Conrod small end I.D. 19.003 – 19.011
(0.7481 – 0.7485)
19.040
(0.7496)
Conrod deflection — 3.0(0.12)
Conrod big end side clearance — 1.0 (0.04)
Crank web to web width 53.9 – 54.1
(2.12 – 2.13) —
Crankshaft runout — 0.05(0.002)
ITEM STANDARD LIMIT
Clutch lever play 10 – 15
(0.40 – 0.60) —
Drive plate thickness No. 1, 2 2.72 – 2.88(0.107 – 0.113)
2.42
(0.094)
Drive plate claw width No. 1, 2 13.85 – 13.96(0.545 – 0.550)
13.35
(0.526)
Driven plate distortion — 0.10(0.004)
Clutch spring free length 39.78
(1.57)
37.8
(1.50)
SERVICING INFORMATION 18-3
RADIATOR
TRANSMISSION Unit: mm (in) Except ratio
DRIVE CHAIN Unit: mm (in)
CARBURETOR
ITEM STANDARD LIMIT
Radiator cap valve release
pressure
95 – 125 kPa
(0.95 – 1.25 kgf/cm2, 13.5 – 17.8 psi)

ITEM STANDARD LIMIT
Primary reduction ratio 3.368 (64/19) —
Final reduction ratio 4.250 (51/12) —
Gear ratios Low 2.071 (29/14) —
2nd 1.687 (27/16) —
3rd 1.444 (26/18) —
4th 1.200 (24/20) —
5th 1.052 (20/19) —
Top 0.950 (19/20) —
Shift fork to groove clearance No. 1, 2 & 3 0.05 – 0.25(0.002 – 0.010)
0.45
(0.018)
Shift fork groove width No. 1, 2 & 3 4.95 – 5.05(0.195 – 0.200) —
Shift fork thickness No. 1, 2 & 3 4.80 – 4.90(0.190 – 0.193) —
ITEM STANDARD LIMIT
Drive chain Type D.I.D 520DMA2 —
Links 114 —
20-pitch length — 323.8(12.7)
Drive chain slack 40 – 50
(1.6 – 2.0) —
ITEM SPECIFICATION
Carburetor type TMX38SS
Bore size 38 mm (1.5 in)
I.D. No. 36F8
Float height 8.7 ± 1.0 mm (0.34 ± 0.04 in)
Main jet (M.J.) #370
Jet needle (J.N.) 6CHY17-65-3rd
Pilot jet (P.J.) #42.5
Cut-away (C.A.) #5.0
Air screw (A.S.) 2 turns out
Throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) at the throttle grip
18-4 SERVICING INFORMATION
ELECTRICAL Unit: mm (in)
BRAKE + WHEEL Unit: mm (in)
ITEM SPECIFICATION NOTE
Ignition timing 5° B.T.D.C. at 1 000 r/min.
Spark plug Type NGK: R6918B-8
Gap 0.55 – 0.65 (0.022 – 0.026)
Spark performance Over 8 (0.3) at 1 atm.
Pick-up coil resistance
(Reference data) 72 – 127 Ω at 20 °C (68 °F) R – G
Exciter coil resistance
(Reference data) 24 – 40 Ω at 20 °C (68 °F) B/R – R/W
Charge coil resistance
(Reference data) 1.6 – 2.6 Ω at 20 °C (68 °F) Y – B/W
Pick-up peak voltage 2 V and more + R – - G
Exciter peak voltage 25 V and more + B/R – - R/W
Charge peak voltage 8 V and more + Y – - B/W
Ignition coil resistance Primary 0.17 – 0.70 Ω W/Bl – B/W
Secondary 13 – 20 kΩ Plug cap – W/Bl
Ignition coil primary peak voltage 200 V and more + B/W – - W/Bl
ITEM STANDARD LIMIT
Brake lever adjuster length 11 – 15
(0.4 – 0.6) —
Rear brake pedal height 0 – 10
(0 – 0.4) —
Brake disc thickness Front 3.0 ± 0.2(0.118 ± 0.008)
2.5
(0.10)
Rear 4.0 ± 0.2(0.157 ± 0.008)
3.5
(0.14)
Brake disc runout Front &
Rear —
0.3
(0.012)
Master cylinder bore Front 11.000 – 11.043(0.4331 – 0.4348) —
Rear 12.700 – 12.743(0.5000 – 0.5017) —
Master cylinder piston diam. Front 10.957 – 10.984(0.4314 – 0.4324) —
Rear 12.657 – 12.684(0.4983 – 0.4994) —
Brake caliper cylinder bore Front 27.000 – 27.050(1.0630 – 1.0650) —
Rear 27.000 – 27.050(1.0630 – 1.0650) —
Brake caliper piston diam. Front 26.900 – 26.950(1.0591 – 1.0610) —
Rear 26.900 – 26.950(1.0598 – 1.0617) —
Brake fluid type DOT4
Wheel rim runout Axial — 2.0(0.08)
Radial — 2.0(0.08)
SERVICING INFORMATION 18-5
SUSPENSION Unit: mm (in)
ITEM STANDARD LIMIT
Wheel rim size Front 1.60 × 21
Rear 1.85 × 19
Wheel axle runout Front — 0.25(0.010)
Rear — 0.25(0.010)
ITEM STANDARD LIMIT NOTE
Front fork stroke 310
(12.2) —
Front fork inner tube
O.D.
47 mm
(1.85 in) —
Front fork spring free
length
494 ± 2.5
(19.45 ± 0.10) 487 (19.17)
Front fork damping
force adjuster Rebound
MAX-10 clicks
turn back —
Compression
MAX-11 clicks
turn back —
Front fork air pressure 0 kPa
(0 kgf/cm2, 0 psi) —
Front fork spring rate 4.2 N/mm
(0.42 kgf/mm) —
Rear shock absorber gas pressure 981 kPa
(9.8 kgf/cm2, 139.5 psi) —
Rear shock absorber spring set
length 3.7 (0.146) —
3.7 mm compressed
from spring free length
Rear shock absorber spring rate 51 N/mm
(5.1 kgf/mm) —
Rear shock absorber
damping force adjuster Rebound
MAX-12 clicks
turn back —
Compression (High
speed)
MAX-2
turns back —
Compression (Low
speed)
MAX-10 clicks
turn back —
Rear wheel travel 310
(12.2) —
Swingarm pivot shaft runout — 0.3(0.01)
18-6 SERVICING INFORMATION
TIRE
FUEL + OIL + COOLANT
ITEM STD/SPEC. LIMIT
Cold inflation tire pressure Front&Rear 70 – 110 kPa(0.7 – 1.1 kgf/cm2, 10 – 16 psi) —
Tire size Front 80/100-21 51M —
Rear 100/90-19 57M —
Tire type Front
(E-03) DUNLOP: SPORTS D742F —
Front
(The others) DUNLOP: SPORTS D756F —
Rear DUNLOP: SPORTS D756 —
Tire tread depth
(Recommend depth)
Front&Rear — 4.0 mm (0.16 in)
ITEM SPECIFICATION NOTE
Fuel type Use only unleaded gasoline of at least 90 pump
octane (R/2 + M/2 method). E-03, 28
Use only unleaded gasoline of at least 95 octane.
(Research method) The others
Fuel tank capacity 8.0 L
(2.1/1.8 US/Imp gal)
Engine oil type SUZUKI CCI SUPER 2-CYCLE MOTOR LUBURICANT
or equivalent Two Cycle Racing Lubricant E-03
MOTUL 800 2T
FACTORY LINE OFF ROAD
or equivalent Two Cycle Racing Lubricant
The others
Air cleaner element oil type MOTUL AIR FILTER OIL or equivalent filter oil
Fuel and engine oil mixture ratio 30 : 1
Transmission oil type SAE 10W-40, API SF/SG or SH/SJ with JASO MA
Transmission oil capacity Change 750 ml(0.8/0.7 US/Imp qt)
Overhaul 800 ml(0.8/0.7 US/Imp qt)
Front fork oil type SUZUKI fork oil SS-05 or equivalent fork oil
Front fork oil capacity
(each leg)
357 ml
(12.07/12.57 US/Imp oz)
Outer tube oil
quantity
193 ml
(6.52/6.80 US/lmp oz)
Damper rod
oil quantity
Engine coolant type Use an anti-freeze&summer engine coolant
compatible with aluminum radiator, mixed with
distilled water only, at the ratio of 50 : 50.
Engine coolant capacity 1 100 ml
(1.2/1.0 US/Imp qt)
Rear shock absorber oil type SUZUKI rear suspension oil SS-25
or equivalent suspension oil
Rear shock absorber oil capacity 380 ml
(12.84/13.38 US/Imp oz)
SERVICING INFORMATION 18-7
TIGHTENING TORQUE
PART N·m kgf-m lb-ft
Cylinder head nut 25 2.5 18.0
Magneto rotor nut 35 3.5 25.5
Cylinder nut 25 2.5 18.0
Crankcase bolt 10 1.0 7.0
Clutch sleeve hub nut 70 7.0 50.5
Primary drive gear bolt 70 7.0 50.5
Spark plug 17.5 1.75 12.5
Transmission oil drain plug 21 2.1 14.5
Transmission oil level bolt 5.5 0.55 4.0
Water pump drain plug 5.5 0.55 4.0
Handlebar holder bolt 25 2.5 18.0
Front fork upper clamp bolt (right and left) 23 2.3 16.5
Front fork lower clamp bolt (right and left) 23 2.3 16.5
Steering stem head nut 100 10.0 72.5
Front fork center bolt 70 7.0 50.5
Fork cylinder inner rod lock-nut 22 2.2 16.0
Front fork cap bolt 35 3.5 25.5
Fork cylinder compression damper unit 30 3.0 21.5
Master cylinder mounting bolt (front) 10 1.0 7.0
Master cylinder mounting bolt (rear) 10 1.0 7.0
Brake hose union bolt (front and rear) 23 2.3 16.5
Brake caliper mounting bolt (front) 26 2.6 19.0
Brake pad mounting bolt (front and rear) 18 1.8 13.0
Brake caliper axle bolt (For bracket: rear) 13 1.3 9.5
Brake caliper axle bolt (For bracket and caliper: front) 23 2.3 16.5
Brake air bleeder valve (front and rear) 6 0.6 4.4
Brake pedal boss bolt 29 2.9 21.0
Disc plate bolt 10 1.0 7.0
Front axle holder bolt 18 1.8 13.0
Front axle nut 35 3.5 25.5
Engine plate nut 43 4.3 31.0
Engine mounting nut (upper) 45 4.5 32.5
Engine mounting nut (front) 45 4.5 32.5
Engine mounting nut (lower) 45 4.5 32.5
Rear axle nut 100 10.0 72.5
Rear sprocket nut 30 3.0 21.5
Drive chain tensioner roller bolt 31 3.1 22.5
Spoke nipple 4 0.4 3.0
Rear swingarm pivot nut (engine mounting) 70 7.0 50.5
Rear shock absorber mounting nut (upper) 55 5.5 40.0
Rear shock absorber mounting nut (lower) 55 5.5 40.0
Rear cushion lever nut 80 8.0 58.0
Rear cushion rod nut 80 8.0 58.0
18-8 SERVICING INFORMATION
For other bolts and nuts not listed in the table, refer to this chart.
PART N·m kgf-m lb-ft
Handlebar holder set nut 15 1.5 11.0
Seat rail nut (upper) 23 2.3 16.5
Seat rail bolt (lower) 23 2.3 16.5
Brake lever pivot bolt 6 0.6 4.4
Brake lever pivot nut 6 0.6 4.4
Bolt Diameter
A (mm)
Conventional or “4” marked bolt “7” marked or crown headed bolt
N·m kgf-m lb-ft N·m kgf-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
A
SERVICING INFORMATION 18-9
SPECIAL TOOLS
09900-00410
Hexagon wrench set
09900-06107
Snap ring pliers
09900-06108
Snap ring pliers
09900-09003
Impact driver set
09900-20101
Vernier calipers
(150 mm)
09900-20203
Micrometer
(50 – 75 mm)
09900-20205
Micrometer
(0 – 25 mm)
09900-20508
Cylinder gauge set
09900-20605
Dial gauge
(1/100, 10 – 34 mm)
09900-20607
Dial gauge
(1/100, 10 mm)
09900-20701
Magnetic stand
09900-20803
Thickness gauge
09900-21304
V-block (100 mm)
09900-25008
Multi circuit tester
09910-20115
Conrod holder
09910-32812
Crankshaft installer
09910-32820
Attachment
09910-34510
Piston pin puller
09910-60611
Universal clamp
wrench
09913-50121
Oil seal remover
09913-70210
Bearing installer set
09917-50410
Bearing remover
09920-13120
Crankcase
separating tool
09920-20310
Spring hook
09920-53740
Clutch sleeve hub
holder
18-10 SERVICING INFORMATION
09921-20200
Bearing remover
09921-20240
Bearing remover set
09924-84510
Bearing installer set
09924-84521
Bearing installer set
09925-18011
Steering bearing
installer
09930-10121
Spark pulg wrench
set
09930-11960
Torx wernch (T20)
09930-30104
Rotor remover slide
shaft
09930-30113
Flywheel rotor
remover
09930-40113
Rotor holder
09940-14911
09940-14960
Steering nut socket
wrench
09940-34581
Attachment F
09940-52861
Front fork oil seal
installer set
09941-34513
Steering race
installer
09941-53630
Front fork top cap
wrench
09941-54911
Bearing outer race
remover
09941-74911
Steering bearing
installer
SERVICING INFORMATION 18-11
WIRING DIAGRAM
WIRE COLOR
B: Black
Bl: Blue
G: Green
R: Red
W: White
Y: Yellow
B/Bl: Black with Blue tracer
B/Br: Black with Brown tracer
B/G: Black with Green tracer
B/O: Black with Orange tracer
B/R: Black with Red tracer
B/W: Black with White tracer
B/Y: Black with Yellow tracer
R/W: Red with White tracer
W/Bl: White with Blue tracer
ENGINE
STOP
SWITCH
CDI UNIT
THROTTLE
POSITION
SENSOR
MAGNETO
IGNITION COIL
CARBURETOR
SOLENOID
RUN
OFF
: Pickup
coil
B
/W Y R G B
/R
R
/W
B
/W Y R G B
/R
R
/W
B
/G
B
/B
l B
/B
r B
/G
B
/B
l B
/B
r B
/W Y R G B
/R
R
/W
B
/W Y R G B
/R
R
/W
R G B
/G
B
/B
l B
/B
r R G B
/G
B
/B
l B
/B
r W YW Y B
/W
B
/Y
B
/W
B
/Y
B
/W
B
/Y
B
/W
B
/Y
W
/B
l W
/B
l B
/W
W
/B
l B
/W
W
/B
l B
/W
W
/B
l B
/W
W
/B
l W
/B
l B
/W BW
/B
l B
/W B B
lO BB
/O BB
/Y
B
/R
R
/W
B
/O YB
/Y
B
/R
R
/W
B
/O Y
B
l Y BB
l Y B
18-12 SERVICING INFORMATION
WIRE, CABLE AND HOSE ROUTING
Clutch cable
Clutch cableThrottle cable
Clutch cable
Throttle cable
Throttle cable
Clamp Pass through the clutch cable
under the radiator breather hose.
Pass through the clutch
cable between the engine
mounting plates.
SERVICING INFORMATION 18-13
Throttle position sensor lead wire
Engine stop switch lead wire
Engine stop switch lead wire
Throttle cable
Clamp
Clamp
Clamp
Clamp
Clamp
Clamp
Clamp
Frame
CDI unit
Wiring harness
Engine stop switch lead wire
Wiring harness
Clamp
Engine stop switch lead wire
Wiring harness
Engine stop switch lead wire
Wiring harness
Throttle cable
Carburetor solenoid lead wire
Cylinder breather hose
Magneto lead wire
Exhaust valve breather hose
Radiator breather hose
Ignition coil couplerFRONT
18-14 SERVICING INFORMATION
C
la m p th e en d of h os e se cu re ly .
In se rt th e ho se s ec ur el y. up pe r si de ba ck s id e M
at ch in g m ar k is le ft si de .
rig
ht s id e 25
m m 25
m m M
at ch in g m ar k is r ig ht s id e rig
ht s id e P
as s th ro ug h th e w at er h os e be hi nd th e fr am e. : T
he c la m p bo lt he ad fa ce s. ..
ba ck s id e C
ar bu re to r ov er flo
w h os e C
ar bu re to r C
ar bu re to r ai r ve nt h os e E
ng in e sp ro ck et C
la m p D
on ’t
be nd th e ho se s. Fr am e 2.
5
N
·m
(0
.2
5
kg fm , 1
.8
lb -f t) P
as s th e fu el ho se o ut si de o f cl ut ch c ab le .
2.
5
N
·m
(0
.2
5
kg fm , 1
.8
lb -f t) 45
˚
C
la m p C
la m p 30
˚
SERVICING INFORMATION 18-15
Clamp
NOTE:
Face each clamp end to the downward.
Clamp
Clamp
Fuel tank
cushion rubber
Fuel tank
cushion rubber
10 mm
(0.4 in)
A
A
SECT AA
Protector
18-16 SERVICING INFORMATION
Adjustable
range
Do not apply grease to the rubber covers.
Fit the cover positively.
Adjuster
Quick adjuster
Turn to loosen
the clutch cable tension.
Turn to tighten
the clutch cable tension.
When the movement is felt heavier,
clean this and apply grease.
Align the paint mark on the handlebars with the
mating surface of the left handlebar holder.
Apply adhesive
to inner of grip
and handlebars.
36 mm (1.4 in)
Position of magic tape : rearward
66˚
Upper side
Align the master cylinder holder
mating surface with the paint mark
on the handlebars.
190 mm (7.5 in)
Align the throttle holder
mating surface with the
paint mark on the
handlebars.
15˚
Install the throttle grip
so the “ ”mark on it aligns
with the hole throttle cable
end hooked.
30˚
55˚
Upper side
Align the clutch lever holder mating surface
with the paint mark on the handlebars.
175 m
m (6.
9 in)
121 m
m (4.
8 in)
Align the “ ” mark on the left grip
with the paint mark on the handlebars.
Upper side
Upper side
151 mm (5.9 in)
SERVICING INFORMATION 18-17
Front brake master cylinder
Washer
Hose guide
Front brake hose
Front brake hose
Clamp
Front fork protector
Clamp the upper
difference portion in
brake hose diameter.
Washer
After touching the brake hose
union to the stopper, tighten the
union bolt to the specified torque.
Caliper
Set the brake hose end between the hose stopper,
then tighten the brake hose union bolt to the specified torque.
18-18 SERVICING INFORMATION
S
to pp er R
ea r br ak e ca lip
er S
to pp er R
ea r br ak e flu
id re se rv oi r G
ui de M
as te r cy lin
de r S
et th e br ak e ho se e nd b et w ee n th e ho se s to pp er ,
th en ti gh te n th e br ak e ho se u ni on b ol t t
o th e sp ec ifi
ed to rq ue .
O
ut si de S
et th e br ak e ho se e nd b et w ee n th e ho se s to pp er ,
th en ti gh te n th e br ak e ho se u ni on b ol t t
o th e sp ec ifi
ed to rq ue .
SERVICING INFORMATION 18-19
10
N
. m
(1
.0
k gf . m
, 7
.3
lb -f t) 10
N
·m
(1
.0
k gf -m , 7
.0
lb -f t) C
us hi on Fr am e S
ile
nc er 10
N
. m
(1
.0
k gf . m
, 7
.3
lb -f t) 10
N
·m
(1
.0
k gf -m , 7
.0
lb -f t) C
us hi on 1s t m
uf fle
r Fr am e M
uf fle
r m ou nt in g pl at e 10
N
. m
(1
.0
k gf -m , 7
.3
lb -f t) 10
N
. m
(1
.0
k gf . m
, 7
.3
lb -f t) 10
N
·m
(1
.0
k gf -m , 7
.0
lb -f t) D
am pe r Fr am e 1s t m
uf fle
r 10
N
. m
(1
.0
k gf -m , 7
.0
lb -f t) S
ile
nc er S
ea t r
ai l 10
N
. m
(1
.0
k gf . m
, 7
.3
lb -f t) 10
N
·m
(1
.0
k gf -m , 7
.0
lb -f t) C
us hi on N
ut R
ea r fe nd er N
ut W
as he r S
pa ce r W
as he r W
as he r S
pa ce r S
pa ce r W
as he r S
ile
nc er (
E
-1
9,
0
00
)
S
ile
nc er (
E
-0
3,
2
8)
18-20 SERVICING INFORMATION
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length....................................................... 2 145 mm (84.4 in)
Overall width ........................................................ 830 mm (32.7 in)
Overall height ...................................................... 1 275 mm (50.2 in)
Wheelbase........................................................... 1 450 mm (57.1 in)
Ground clearance ................................................ 350 mm (13.8 in)
Seat height........................................................... 950 mm (37.4 in)
Dry mass.............................................................. 87 kg (192 lbs)
ENGINE
Type ..................................................................... Two-stroke, liquid-cooled
Intake system....................................................... Crankcase reed valve
Number of cylinders ............................................. 1
Bore ..................................................................... 54.0 mm (2.126 in)
Stroke................................................................... 54.5 mm (2.146 in)
Piston displacement............................................. 124 cm3 (7.6 cu. in)
Corrected compression ratio................................ 8.3/9.9 : 1 (Ex valve open/Ex valve close)
Carburetor............................................................ MIKUNI TMX38SS single
Air cleaner............................................................ Polyurethane foam element
Starter system...................................................... Primary kick
Lubrication system............................................... Fuel/oil premixture of 30 : 1
TRANSMISSION
Clutch................................................................... Wet multi-plate type
Transmission ........................................................ 6-speed constant mesh
Gearshift pattern .................................................. 1-down, 5-up
Primary reduction ratio......................................... 3.368 (64/19)
Final reduction ..................................................... 4.250 (51/12)
Gear ratios, Low................................................... 2.071 (29/14)
2nd.................................................... 1.687 (27/16)
3rd .................................................... 1.444 (26/18)
4th..................................................... 1.200 (24/20)
5th..................................................... 1.052 (20/19)
Top.................................................... 0.950 (19/20)
Drive chain ........................................................... D.I.D 520DMA2, 114 links
SERVICING INFORMATION 18-21
CHASSIS
Front suspension................................................. Telescopic, pneumatic/coil spring, oil damped
Rear suspension ................................................. Link type
Steering angle ..................................................... 45° (right & left)
Caster.................................................................. 27° 30’
Trail...................................................................... 115 mm (4.53 in)
Turning radius...................................................... 2.3 m (7.5 ft)
Front brake .......................................................... Disc brake, hydraulically operated
Rear brake........................................................... Disc brake, hydraulically operated
Front tire size....................................................... 80/100-21 51M
Rear tire size ....................................................... 100/90-19 57M
Front fork stroke .................................................. 310 mm (12.2 in)
Rear wheel travel ................................................ 310 mm (12.2 in)
ELECTRICAL
Ignition type......................................................... Electronic Ignition (CDI)
Ignition timing ...................................................... 5° B.T.D.C. at 1 000 r/min
Spark plug ........................................................... NGK R6918B-8
CAPACITIES
Fuel tank ............................................................. 8.0 L (2.1/1.8 US/Imp gal)
Transmission oil (change)................................... 750 ml (0.8/0.7 US/Imp qt)
(overhaul) ................................. 800 ml (0.8/0.7 US/Imp qt)
Coolant................................................................ 1 100 ml (1.2/1.0 US/Imp qt)
18-22 SERVICING INFORMATION
SPARE PARTS LIST
OPTIONAL PARTS
Carburetor: 4-2
Front fork spring: 4-13
Rear suspension spring: 4-18
ITEM PART NAME PART NUMBER Q’TY
1 PARTS SET, SPARE 19900-36F70 1
1 O-RING, CYLINDER HEAD No. 1 11147-27C11 2
2 O-RING, CYLINDER HEAD No. 2 11148-27C11 2
3 GASKET, CYL COVER, No. 1 11233-27C34 2
4 GASKET, CYL COVER, No. 2 11238-36E01 1
5 GASKET, CYLINDER 11241-36F00 2
6 GASKET, CRANKCASE 11481-36F20 1
7 GASKET, CLUTCH COVER 11482-36F00 1
8 GASKET, MAGNETO COVER 11483-36E11 1
9 O-RING, CLUTCH COVER OUTER 11484-36E10 1
0 PISTON COMP 12110-36F10-0F0 1
0-A PISTON 12111-36F10 1
0-B PIN, KNOCK 09207-01014 1
A RING, PISTON 12141-36F00 2
B PIN, PISTON 12151-01B41 1
C O-RING, EXHAUST PIPE 14171-36E00 2
D LEVER, BRAKE 57310-37F00 1
E LEVER, CLUTCH 57621-28C40 1
F BEARING, PISTON PIN 09263-15040 1
G O-RING, SPROCKET SPACER 09280-20006 2
H CIRCLIP, PISTON PIN 09381-15001 2
PARTS No.
NUMBER OF
TEETH
COMMENTS
REAR SPROCKET
64511-14D60 48 112 L
64511-28E00 49 112 L or 114 L
64511-36E00 50 114 L
64511-40266 52 116 L
FRONT WHEEL RIM 55311-37F00 — 20 × 1.85
FRONT WHEEL SPOKE SET 55320-37F20 — 20 inch
FRONT BRAKE DISC COVER 59231-36E20 — —
RIM LOCK 65270-43D00 — 1.85
SERVICING INFORMATION 18-23
SETTING DATA
*MAKE COPIES.
DATE / / / / / /
RACE/COURSE / / /
TEMP./HUMIDITY / / /
WHETHER
COURSE COUDITION
MAIN JET
JET NEEDLE / / /
PILOT JET
AIR SCREW
FLOAT LEVEL
SPARK PLUG
OIL LEVEL mm mm mm
COMP. ADJ. POSITION
RE-BOUND ADJ. POSITION
SPRING
SPRING
SPRING SET LENGTH mm mm mm
SUG mm mm mm
COMP. ADJ. POSITION LOW
COMP. ADJ. POSITION HIGH
RE-BOUND ADJ. POSITION
FINAL REDUCTION RATIO / / /
MAKER/SIZE
PRESSURE kPa kPa kPa
MAKER/SIZE
PRESSURE kPa kPa kPa
COMMENT:
E
V
E
N
T
D
A
T
E
/
LO
C
A
T
IO
N
E
N
G
IN
E
C
A
R
B
U
R
E
T
O
R
C
H
A
S
S
IS
F
R
O
N
T
F
O
R
K
R
E
A
R
S
U
S
P
E
N
T
IO
N
F
R
O
N
T
T
IR
E
R
E
A
R
T
IR
E
– MEMO –
Printed in Japan300 TAKATSUKA, HAMAMATSU, JAPANK7
Failure to follow these safety precautions may increase your
risk of injury:
! Wear a helmet, eye protection, and bright protective clothing.
! Don’t ride after consuming alcohol or other drugs.
! This owner’s service manual contains important safety
information. Please read it carefully.

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