Suzuki FA50 Page 56 Service Manual Download

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TROUBLESHOOTING

HARD E N G I N E STARTING OR NO ENG I N E STARTING

E N G I N E

1 . Compression leakage from crank chamber

•

Leakage from cylinder base gasket

•

Damaged or improperly tightened reed valve

•

Leakage due to defective crankshaft oil seal

•

Leakage from crankcase mating surface

2. Compression leakage from combustion chamber

•

Loose spark plug mounting

•

Damaged cylinder head gasket

•

Loose cylinder head tightening nut

•

Worn or sticking piston ring

•

Piston seizure, wear or holed piston

•

Defective or warped cylinder head mating surface

FUEL CI RCUIT

1 .

Fuel line

•

Clogged fuel hose

•

Damaged fuel cock diaphram

Air passage

•

Air intake due to defective fuel cock vacuum hose

•

Air intake due to damaged reed valve gasket

•

Air intake due to loose carburetor inlet mounting

•

Clogged tank cap breather hole

Carburetor

•

Poor return of choke plunger

•

Clogged air jet or pilot jet

•

Clogged needle valve

ELECTRICAL CI RCUIT

1 .

No sparking at spark plug

•

Bridged, carbon fouled or wet spark plug

•

Poor contact between spark plug cap and high tension cord

•

Broken or improperly connected engine ground wire

•

Defective engine kill switch

•

Poor contact of ignition switch

•

Broken or short circuited igni tion coil

•

Defective wiring among stator, PE I unit and ignitin coil

•

Defective P E I unit

2. Sparking at spark plug

•

I mproperly timed ignition

•

Loose mounting part of stator or rotor

•

Check engine unit or fuel circuit

•

Summary of Contents for FA50

Page 1: ......

Page 2: ...uch as PEI ignition and automatic clutch The FASO fits the needs of a wide variety of motorcycle users Those who will be servicing this motorcycle should carefully review this manual before performing any repairs or services II SUZUKI MOTOR CO LTD Service Department Overseas Operations Division All specifications and construction details contained in this manual were correct at time of issue Suzuk...

Page 3: ... FO MA I O _ N _ __ _ a IN_S_P_s _c_Ti _ l O_N_ A _ N _ D _ A_D _ u _ s _ Ti_M_E _N _ T _ _ I 1 11 __ _ ____ _ _ ___ _ _ _ _ _ _Iii SERVICIN G P RO CEDURE ___ S _ E _ R _ v1 _c_1N_G_ l _N _ F_ O _ R _ M _ _ T1_ o _N _ _ __ll ...

Page 4: ... GENERAL INFORMAJ TON 1 1 GENERAL INFO RMAT I O N CONTENTS MODEL IDENTI FICATION 1 2 SPECIFICATIONS 1 3 FUEL AND OIL RECOM MENDATION 1 5 GEN ERAL NOTES AND PR ECAUTIONS 1 6 TECHNICAL FEATURES 1 7 II ...

Page 5: ... The frame serial number is stamped on the right side of the steering head pipe LEFT SIDE VIEW ENGI N E NUMBER The engine serial number is located on the left side of the crankcase 7 These numbers are requi red especially for registering the machine and ordering the spare parts ...

Page 6: ...cation system TRANSMISSION Clutch Transmission Gearshift pattern Primary reduction F inal reduction D rive chain chain gear 1 585 mm 62 4 in 670 mm 26 4 in 970 mm 38 2 in 1 040 mm 40 2 in 1 20 mm 4 7 in 45 kg 99 lbs Two stroke air cooled Reed valve 4 1 0 mm 1 6 1 4 in 37 4 mm 1 472 in 49 cm3 3 0 cu in 6 5 1 MI KUNI VM1 2SH single Polyurethane foam element Primary kick SUZU K I CCI Wet shoe automat...

Page 7: ...serve reserve Engine oil tank Transmission oil I Telescopic Swinging arm oil dampened 45 right left 65 00 70 mm 2 76 in 1 4 m 4 6 ft Internal expanding I nternal expanding 2 25 14 4PR 2 25 1 4 4PR 1 50 kPa 1 50 kg cm2 2 1 psi Normal solo riding 200 kPa 2 00 kg cm2 28 psi Normal solo riding SUZUK I PE I 25 B T D C at 4 000 rpm NGK BP4HA or NIPPON D ENSO W 1 4 F P UL 6V 7 2 kC 2 Ah 1 0 H R Flywheel ...

Page 8: ...95 pump octane R M method or 89 octane or higher rated by the Research method ENGINE OIL For the SUZUKI CCI system use of SUZUKI CCI SUPER 2 CYCLE MOTOR LUB RI CANT is highly recommended but if it is not available a good qual ity synthetic based 2 cycle oil should be used TRANSMISSION OIL Use a good quality SAE 20W 40 multi grade motor oil Engine oil tank cap Fuel tank cap Oil filler cap Drain plu...

Page 9: ...e safety of each other After the reassembly check parts for tightening condition and operation Treat gasoli ne which is extremely flammable and highly explosive with greatest care Never use gasoline as cleaning solvent Warning caution and note are included in this manual occasional ly describing the following contents WARNtN 3 1 When personal safety of the rider is involved disregard of the inform...

Page 10: ... simple construction and rational design of the engine has minimized the number of inspection items thus allowing easy inspection and almost maintenance free operation This provides a unique motorcycle with a long enjoyable l ife free from troubles Drive axle shaft Final drive shaft Kick starter shaft Countershaft ...

Page 11: ...d close The reed valve timing and opening vary depending on the engine speed and throttle opening I n other words it can be said that the intake timing is ideally matched to the operating condition of the engine R eed valve 0 ENGINE LUBRICATION Engine oil is supplied by means of an oil pump which is driven by the crankshaft through the oil pump driven shaft and oil pump drive gear mounted on the c...

Page 12: ...d for better durability 0 Jr c J Sectiona I form of piston ring Both 1st and 2nd rings are sloped at the top side Automatic centrifugal shoe type clutch is secured to the crankshaft This clutch has simple construction When the clutch drive shoes which are thrown apart by centrifugal force varying with the crankshaft speed come in contact with the clutch driven wheel engine power is trans mitted to...

Page 13: ... countershaft is transmitted to the final drive shaft IQ by means of the drive chain s Power of the final drive shaft is transmitted to the drive axle shaft 13 and at the same time the rear wheel 14 is rotated 1 Crankshaft 2 Clutch drive shoes i I Clutch 41 Primary drive gear 5 Primary driven gear 6 Countershaft 7 Drive sprocket B Drive chain 91 Driven sprocket 1_0 Final drive shaft fl Final drive...

Page 14: ... tensioner Final drive gear Power transmitted to the final drive shaft through the drive chain The driven sprocket and final drive gear are press fitted to the final drive shaft The speed is reduced by the final drive gear and the final driven gear mounted on the drive axle shaft The drive axle shaft is integrated with the final driven gear and it rotates at a speed reduced finally by the final dr...

Page 15: ..._ the kick starter is turned by the kick starter drive gear 4 As a result the kick starter moves to the left side of the kick idle gear 51 while being turned by the kick starter gear and meshes with the kick idle gear The kick idle gear rotates and makes the cran kshaft turn The one way clutch as shown in the figure below is incorporated in the kick idle gear When the engine is started up the engi...

Page 16: ...occurs at the spark plug gap The PEI magneto has no breaker points and therefore it is free from mechanical trouble This ensures a stabler secondary high voltage and better spark performance Features of PEI System Ignition coil Magneto o o U o Q0 n 0 U c s 1 Spark plug deposits are minimized as high voltage spark is produced Spark plug 2 Disuse of contact points means no dust trouble Contact point...

Page 17: ...he rotor turns 1 80 the polarity of the red black terminal becomes positive and the generated voltage which is divided by R1 is applied through R2 to the SCR gate When this voltage arrives at the SC R gate it makes SC R conduct turned on 3 When SCR closes the circuit the electrical charge stored in the condenser is rapidly discharged through the following ci rcuit Condenser C SCR __ Ignition coil ...

Page 18: ... L INSJ EC J JON AND ADJUSTMENT 2 1 INSP EC TI O N AN D ADJUS TM EN T CONTENTS PERIODIC MAINTENANCE SCHEDULE 2 2 MAINTENANCE PROCEDURE 2 4 ...

Page 19: ...kes Brake shoes _ Carburetor I I I l I nitial II 1 000 I Every 3 000 I 600 2 Check specific gravity and service electrolyte solution Ad1ust play t 2 000 _L ___ 6 Wash and clean Check S G and service electrolyte solution 1 Adjust play Every 6 000 4 000 12 Adjust idle rpm Adjust idle rpm Overhaul and clean Cylinder head and cylinder _ _ ___ __ t Check wear i R etorque head nuts and 1 Retorque head n...

Page 20: ...eedometer gear Speedometer cable Throttle cable WARNING Every 3 000 2 000 6 Motor oil Motor oil I Motor oil Every 6 000 4 000 12 Grease Grease Grease Be carefulnottoapplytoomuchgreasetothebrakecamshafts Ifgreasegetsonthelinings brake slippage will result Lubricate exposed parts which are subject to rust with either motor oil or grease whenever the motorcycle has been operated under wet or rainy co...

Page 21: ...to be sure that the vent pipe is secure and routed properly Add distilled water as necessary to keep the surface of the electrolyte above the LOWE R level line but not above the UPPER level line j r l Battery UPPER 2___LOWER YuAsA I I 6N2 2A 4 YUASA 6ATTlRY 0 LTD 1 MAOE IN JAPAN If the electrolyte surface falls rapidly and requires frequent addition of distilled water check the charging system for...

Page 22: ...ifter lever play is 1 mm 0 04 in 1 OIP l0 c Adjusting nut L Rear brake camlever Kick starter lifter lever 1 mm 0 04 in I Adjust by turning the brake cable adjust ing nut so that the clearance between lever and grip is 20 30 mm 0 8 1 2 in r 0 JNSPEC ION AND 11DjUSTMl iNT 2 5 BRAKE SHOE WEAR Checkevery3 000km 2 000miles L__ When applying the front brake if the ex tended line of the brake cam lever e...

Page 23: ...ows Idle rpm 1 500 150rpm Throttle stop screw Finally adjust the throttle cable play I 0 5 1 0 mm Throttlecable playI 0 02 _ 0_04 in THROTTLE CABLE Loosen the lock nut and adjust the cable slack by turning adjuster in or out to ob tain the following slack After adjusting slack tighten the lock nut Cable slack 0 5 1 0mm 0 02 0 04 in I 0 5 1 0mm 0 02 0 04in Lock nut Adjuster CARBURETOR OVERHAUL AND ...

Page 24: ...r overheating Carbon deposited at the ex haust port of the cylinder wi l l prevent the flow of exhaust reducing the output Re move carbon deposits periodically INSPEC 10N l lND ADJUS fMENT 2 7 FUEL LI N E l _ eplace everytwo years Replace the fuel line every two years OIL PUM P pectatinitial1000km 600m I a eve _3 000km 2 000mile Air bleeding Whenever evidence is noted of some air having leaked int...

Page 25: ...l 0 033 0 039 US oz at 2000rpmfor 6minutes SPARK PLUG Checkatinitial 1000km 600miles andevery3000km 2 000miles 1 Replaceevery6000km 4000miles J _J Neglecting the spark plug eventually leads to difficult starting and poor performance If the spark plug is used for a long period the electrode gradually burns away and carbon builds up along the inside part In ac cordance with the Periodic Inspection C...

Page 26: ...h manipulation of handlebars and too loose steering will cause the handlebars to vibrate Check to see that there is no play in the front fork fitting If any play can be found adjust the steering as follows Support the motorcycle body and jack up the front wheel Loosen the steering stem nut securing nut tighten the steering stem nut CV using the special tool so that the front fork moves smoothly St...

Page 27: ...read condition Operating the motorcycle with the excessive ly worn tires will decrease riding stability and consequently invite a dangerous situ ation It is highly recommended to replace the tire when the remaining depth of tire tread reaches the following specifications FRONT and REAR 1 6mm 0 06in I _J Changeatinitial 1000km 600miles andevery3 000km 2000miles L After a long period of use the tran...

Page 28: ...ith a torque wrench No Description 0 ty kg m lb ft Front brake cam lever 0 3 0 6 2 0 4 5 nut I Rear shock absorber 2 0 3 0 14 5 21 5 upper nut 3 Rear shock absorber 1 J 2 0 3 o 14 5 21 5 lower nut 4 Rear brake cam lever 0 3 0 6 2 0 4 5 nut 2 11 No Description O ty kg m lb ft 5 Rear axle nut 3 6 5 2 26 5 37 5 6 Engine mouting nut 1 2 5 4 0 18 5 28 5 7 Footrest nut 6 0 4 0 7 3 0 5 0 B Handlebar set ...

Page 29: ... INSTALLATION 3 2 CYLINDER HEAD CYLIN DER PISTON 3 3 KICK STARTER LEFT COVER 3 5 POWER TRANSM ISSION 3 6 LEFT CRANKCASE 3 9 CRAN KSHAFT 3 10 CARBURETOR 3 12 FLYWHEEL MAGNETO 3 13 CHASSIS ELECTRICAL 3 16 SWITCHES 3 20 STEERING 3 22 FRONT SUSPENSION 3 23 WHEELS AND BRAKES 3 24 ...

Page 30: ...ap Loosen the engine mounting nut 3 2 5 4 0 kg m 18 5 28 5lb ft Left side 7 Remove the fuel line and the vacuum line with the fuel cock set to ON Remove the oil pump cover and oil hose Remove the carburetor top cover 110 Remove the carburetor choke cable from the carburetor side 1J Remove the rear brake cable 1J Loosen and remove the rear shock ab sorber lower bolt 1 Pull out the engine mounting b...

Page 31: ...1 5 2 0 kg m 11 0 1 4 0 lb ft Remove carbon of the exhaust port and apply oil on the cylinder wall Arrow mark on the piston crown faces exhaust side J Remove carbon and apply oil Top mark R or T indicates up side on rings 9 Replace with new circlips l J r 1 Smm 0 Apply thread lock cement ff _ 1363C 111111111111111 Mark fi 16mm Expander ring ...

Page 32: ...508 41 065 mm 1 6167 in PISTON DIAM ETER Micrometer 09900 20202 40 880 mm Service Limit I 1 6094 in RING E N D GAP Thickness gauge Service Limit 09900 20803 0 75 mm 0 030 in RING FREE END GAP ernier caliper 09900 20101 Service Limit Rmarked Tmarked 3 6mm 0 14 in 4 0mm 0 16 in NOTE IR pl ce _ the iston rings as _ set _ ...

Page 33: ...ng shaft I 09921 20210 r 09930 30102 Sliding shaft 0 5 0 8 kg m 4 0 5 5 lb ft When installing the kick starter return spring install and then insta l l Apply Suzuki Super Grease A to the oil seal lip and the kick starter spring Replace the gasket Install two dowel pins 11 ...

Page 34: ...der 09920 30220 Apply thread lock cement I 2 0 J o kg m J 14 5 21 5 lb ft I _ Key Q o O rnITJ 0 oj Lookw h W h W h W h W h W ave washer One way clutch ij Circlip opener 09900 06107 Replace all circlips Adjust shim t o reduce th final drive and driven gear noise J ...

Page 35: ...tachometer to the engine Seated on the motorcycle with the motor cycle on level ground increase the engine RPMs slowly nd note the RPM at which the motorcycle egins to move forward ENGAG EMENT RPM STD Tolerance 2 400 rpm 200 rpm Sl U VICING PROCEDURE 3 7 2 C LUTCH LOCK UP INSPECTION Perform this inspection to determine if the clutch is engaging fully and not slipping Warm the engine to normal oper...

Page 36: ...ernier calipers NOTE Clutch shoes or springs must be changed as a set_ _ eve i idually Clutch wheel inspect visually the con dition of the inner clutch wheel surface for scoring cracks or uneven wear Measure the inside diameter of the clutch wheel with inside calipers Measure the diameter at several points to check for an out of round condition as well as normal wear Item Clutch wheel 1 0 Clutch s...

Page 37: ... 5 5 lb ft J ri_ Brcathcr J cover Bearing remover Push out as shown in the figure I NOTE Remove the rear brake shoe and slide out the cam to the right Be sure to mark the cam lever position before re moval I Brake lining wear indicator 0 3 0 6 kg m 2 0 4 5 lb ft ...

Page 38: ... to set the spacer when installing the oil pump Match the projecting part of oil pump and the groove Check the oil seal and the bearing for damage or excessive clearance Apply grease to the oil seal Apply oil to the bearing Check for damage and bent reeds Be careful not to bend the reed valve stopper Reed valve Use a crankshaft remover to prevent damage to the crankshaft bearing and crankshaft Cra...

Page 39: ...f Dl RE 3 11 CRANKSHAFT DEFLECTION Service limit 0 05 mm 0 002 in SMALL END DEFLECTION Service limit 3 0 mm 0 12 in SMALL E N D BORE DIA Service limit 16 040 mm 0 6315 in PISTON PIN 0 D Service limit 1 1 980 mm 0 4717 in ...

Page 40: ...1 YG T Rocr n1 1u CARBURETOR Clean each passage of air and fuel with an air gun Idle 1 22 4 0 1 mm 0 88 0 02 in Be sure to clean it when overhauling __J Leaner I 3rd j Richer 3F13 3 Check for damage and replace if any ...

Page 41: ...at correct ignition timing is assured Timing advance Timing retard Using a timing l ight check whether the ig nition timing is correct by running the engine at 4 000 rpm and noting that the marks are al igned properly Flywheel holder Sliding shaft Attachment C 09930 401 1 3 09930 30102 09930 30161 Wipe off oil on the taper thoroughly 3 0 4 0 kg m 22 0 28 5 lb ft Timing advance Timing retard ...

Page 42: ... 20 c o o 15 c 2 f9 10 9 8 u 7 x u 0 g 6 _ cu o c 5 E C O t J 4 c u en c 3 i3 c u 2 Ci _ I I v __ L v v r _ 2 sparks per crankshaft rotation 5 5 V or more at 2 300 rpm 8 7 V or less at 8 000 rpm 2 5 A or less at 8 000 rpm 1 2 kV or more at 500 8 000 rpm Primary Approx 0 5 Q Secondary 1 6 1 8 kn Secondary voltage Ignition timing r u Battery capacit I y Lighting capacity Charging capacity j 0 2 3 4 ...

Page 43: ...lCJNG PROCEDURli 3 15 STATOR Pocket tester 09900 25002 Select the knob to RX x 1 Make a following continuity test Unit n B W W R Y R B R I B W _ W R 0 1 Y R 0 1 0 1 B R OFF OFF OFF R B 90 110 OFF OFF i 90 110 ...

Page 44: ...ion coil Core B Y Core High tension B Y High tension Electro tester Resistance Knob position o rn x 1n 16 18 kii x kn 16 18 kii x kn 09900 28106 Wire as shown in the figure and turn the main switch to ON If a bluish white spark occurs continuous ly for about ten minutes it is in good condition When a red spark a poor spark or no spark is found replace it Red ...

Page 45: ...d for FA50 09900 28607 Wire as shown in the figure and turn the main switch to ON It is in good condition if the indicator I ight comes on and remains Iit If the l ight stays off replace it Indicator light M w t h ON L c z Electro tester PE I test lead ...

Page 46: ... I OFF I The pocket tester s selector knob should be set at X 1 n or X 1 kn range referring to the chart The two testing probes and are to be placed on terminals of the P E I unit referring to the chart The probe or pointer is to be placed on one of the terminals listed in the top horizontal row and the probe or pointer on the corresponding terminal listed in the vertical column NOTE L Whether or ...

Page 47: ...ther case replace it If the sound volume is insufficient turn the adjusting screw while con necting the horn directly to the battery till the maxi mum volume is found and set it there After turning the adjusting screw if no sound is heard or the sound volume is in sufficient replace it Connect the lead wire in the headlight housing and the ground wire to the pocket tester set knob range to R and p...

Page 48: ...chart below If contir iui ty is found it is in good condition If not replace it OFF ON B WlB R 0 0 Gr I Y ol o 0 R Set it to high beam position and check continuity between gray and yellow If continuity is found it is in good con dition Set it to low beam position and check continuity between gray and white If continuity is found it is in good con dition If not replace it ...

Page 49: ... ground wire to the pocket tester and check continuity If continuity is found it is in good con dition When the kill switch is set to R U N posi tion if no continuity is found it is in good condition Place the pocket tester between orange lead wire and W B lead wire with the red tube and squeeze the brake lever If con tinuity is found it is in good condition If not replace it ...

Page 50: ...PJ CEVl I STEERING Lock nut Sp Jcer Steering stem nut _ Check inner or outer races for wear Steel balls GREAS _ Ej Check inner or outer races for wear I GREASE Steel balls Number of steel balls Upper 25 pcs Lower 25 pcs ...

Page 51: ... SER VICING PROCEDURE 3 23 FRONT SUSPENSION REASE __ Check the rubber stopper for cracks or damage 2 5 3 5 kg m 18 5 25 5 lb ft ...

Page 52: ... 1 0 lb ft When applying grease be sure to apply it thin to avoid damaging the brake shoe and braking effeciency REAR Tire pressure 200 kPa 2 0 kg cm2 28 PSI 0 3 0 6 kg m 2 0 4 5 lb ft _ Tire pressure I 1 5 cm2 21psi 0 3 0 6 kg m 2 0 4 5 lb ft 36 52N m 3 6 5 2kg m 26 5 37 5 lb ft Cotter pin ...

Page 53: ...ar wheel bearing both sides are sealed If noise or excessive clearance is found between the inner race and the outer race or rotation is not smooth replace it FRONT AXLE SHAFT Measure the front axle shaft deflection Service limit I 0 25 mm 0 01 in BRAKE DRUM Measure inner diameter of both front and rear drums Service limit j Front and Rear 80 5 mm 3 17 in BRAKE LINING THICKNESS Service limit 1 5 m...

Page 54: ... TIRE Measure both front and rear tire tread depth Service limit 1 1 6 mm 0 06 in Front and Rear SPOKE N IPPLE Check to be sure that all nipples are tight and retighten them as necessary using special tool Loose spoke nipples are l ikely to result in spoke damage or in rim distortion 09940 601 1 2 I Spoke nipple wrench I 0 25 0 3 kg m Tightening torque 1 8 _2 1 lb ft ...

Page 55: ... V CJNG INFORt 1 A TJON 4 1 SERVICING INFORMAT ION CONTENTS TROUBLESHOOTING 4 2 SPECIAL MATERIALS 4 5 SPECIAL TOOLS 4 6 WIRE AND CABLE ROUTING 4 8 WIRING DIAGRAM 4 10 TIGHTENING TORQUE 4 11 SERVICE DATA 4 12 ...

Page 56: ... fuel cock diaphram 2 Air passage Air intake due to defective fuel cock vacuum hose Air intake due to damaged reed valve gasket Air intake due to loose carburetor inlet mounting Clogged tank cap breather hole 3 Carburetor Poor return of choke plunger Clogged air jet or pilot jet Clogged needle valve ELECTRICAL CI RCUIT 1 No sparking at spark plug Bridged carbon fouled or wet spark plug Poor contac...

Page 57: ...tch slippage 7 Sticking piston ring 8 Worn cylinder piston or piston rings POOR ENGINE PERFORMANCE AT LOW SPEED 1 Carburetor adjustment Air screw adjustment Incorrect fuel level Idling rpm out of adjustment 2 Ignition system Incorrect spark plug gap SER J ICJNC f ORAL l J JON 4 3 Improperly timed ignition improper stator mounting position 3 Air cleaner element ripped or leaking 4 Air intake throug...

Page 58: ...bon deposit Cylinder head piston crown exhaust port spark plug 4 Dragging brake 5 Defective oil pump DEFECTIVE CLUTCH 1 Slipping clutch Worn or burnt clutch shoe 2 Disengaged clutch Poor operation of clutch drive shoe 3 Incorrect clutch engagement rpm Defective clutch spring Worn or burnt clutch drive shoe 4 Not smooth idling Defective clutch spring Too high idling rpm ...

Page 59: ...er gears o Crankcase mating surface 1 201 99104 3 1 1 0 I o Muffler fitting bolt c0 Suzuki lock super 1 363C 991 04 32050 Thread lock cement 99000 32040 o Screws securing read valve o Crankshaft RH oil seal to outer surface of oil seal o Magneto rotor nut o Crankshaft left end nut o Muffler clamp bolt o Horn adjusting screw I o Cylinder stud bolts USE OF GENUINE SUZUKI PARTS To replace any part of...

Page 60: ...8607 Universal clamp wrench 0991 0 6061 1 SPECIAL TOOLS Shock driver set 09900 09002 l I Cylinder gauge set 09900 20508 Torque wrench 09009 21 102 0 1 20 kg cm 09900 21 1 03 1 00 900 kg cm j I _ y I i Electro tester 09900 28106 Stud bolt installer 099 10 1 0 1 1 0 Bearing installer 09913 75820 Dial gauge 09900 20606 0 10 mm 160 mm CCI oil gauge 09900 21602 Hydrometer 09900 28403 n p n pull 09910 3...

Page 61: ...m baring installer 09941 34 51 1 Bearing remover 09921 20210 Attachment C 27 mm screw 09930 30161 Spoke nipple wrench 09940 601 1 3 SJ iR I ICING l1 l OR1 unJON 4 7 Spark plug wrench 09930 101 1 1 f J Rotor holder 09930 401 1 3 1 Steering race installer 09940 53 1 1 1 _ ___ _ _ _ _ _ _ _ _ _ _ _ _ __ Tire pressure gauge 96200 4 1 330 ...

Page 62: ... I 8 SF R I JCJ IG INFOl M TTON WIRE AND CABLE ROUTING WIRING ROUTING u a I 5 u c 0 e c en ...

Page 63: ...r r r r r Rear brake cable Front brake cable Throttle cable Choke cable Rear brake cable Front brake cable Rear brake cable co r m lJ 0 c z C c Q c c c 0 f ...

Page 64: ... Kl l llill I C WI U tt Ij mill d nmr Off O N IGNITIO I SWITCH I I I l L t I t AC ETO W I R E COLOR G Green B R Black with Red tracer Gr Gray B W Black with White tracer 0 Orange B Y Black with Yellow tracer R Red R B Red with Black tracer w White W B White with Black tracer Y Yellow W R White with Red tracer Y R Yellow with Red tracer t c v Q e c z G c G c s ...

Page 65: ...0 5 0 8 4 0 5 5 Flywheel magneto nut 3 0 4 0 22 0 28 5 CHASSIS Front brake cam lever nut 1 0 3 0 6 I 2 0 4 5 Rear shock absorber upper nut 1 2 0 3 0 14 5 2 1 5 Rear shock absorber lower bolt 1 2 0 3 0 14 5 2 1 5 Rear brake cam lever nut 1 0 3 0 6 2 0 4 5 Rear axle nut 1 3 6 5 2 26 5 37 5 Engine mounting nut 1 2 5 4 0 18 5 28 5 Footrest bolt 6 0 4 0 7 3 0 5 0 Handlebar set nut 1 9 5 1 2 0 68 5 86 5...

Page 66: ...rtion Cylinder head distortion Piston ring free end gap R Approx 4 5 0 1 8 1 St T Approx 5 0 0 20 R Approx 4 5 0 1 8 2nd T Approx 5 0 0 20 Piston ring end gap 0 1 0 0 25 0 004 0 0 10 Piston ring to groove clearance 1 st 0 020 0 060 0 0008 0 0024 2nd 0 020 0 060 0 0008 0 0024 Piston pin bore 1 1 998 1 2 006 0 4724 0 4727 Piston pin 0 D 1 1 996 1 2 000 0 4723 0 4724 Unit mm in L I M IT 0 1 20 0 0047...

Page 67: ...ary drive to driven gear backlash i R l C NG INl ORM ITION 4 13 STAN DARD 16 003 1 6 01 1 0 6300 0 6304 40 0 1 57 I 0 1 t 0 004 SPECI F I CATI O N 7 00 1 4 I 2 0 97 1 1 4 U n i t m m i n I L I M IT 1 6 040 I 0 631 5 I 3 0 I 0 1 2 I I 0 05 0 002 ml 0 033 I 0 034 0 039 I 0 040 US Imp oz for 6 minutes at 2000 rpm U n i t mm in STANDARD L I M I T 87 00 87 1 5 87 40 3 425 3 43 1 3 441 86 9 87 0 No groo...

Page 68: ... m in ITEM STANDARD LIMIT Primary reduction ratio 1 000 Final reduction ratio 5 564 Gear ratios Chain 2 384 3 1 I 1 3 Gear 2 333 56 I 24 DRIVE CHAIN Unit mm in ITEM STANDARD LIMIT Drive chain Type 0 1 D 270H Links 64 I 1 70 0 1 73 7 20 pitch length 6 69 6 84 ...

Page 69: ... N Needle jet N J Cut away C A Pilot jet P J Pilot outlet P 0 Air screw A S Valve seat V S Starter jet G S Throttle cable play loR l ICING 11 FORMATION 4 1 5 Unit mm in SPECI F ICATION M I KUMI V M 1 2SH 1 2 02340 1 500 1 50 rpm 22 4 1 0 0 88 0 04 rt 77 5 25 3 F 1 3 3 E 6 2 0 1 5 0 7 1 y 1 5 30 0 5 1 0 0 02 0 04 ...

Page 70: ...J Plug cap Ground I Secondary Approx 1 6 1 8 kn 1 Unit mm in NOTE 1 M a g n _ e _ t _ o _ c _ o il re s is ta _ n _ c _ e L 1 Y R W R l I Appr _ _ o _ __ _ 1 _ _ _ n _1 1 I W R B W I Approx 0 1 n I y R Sii 1 Approx 0 1 n R B B W I 1_ App _o __ JQ_9_ l I I R B B R _ _1 Approx 90 1 1 O n Charging r e_ i i Below 5A 8000 m Lighting coil output I Above 5 5 V at 2300 rpm Below 8 7 V at 8000 rpm Battery ...

Page 71: ... depth Front Rear SUSP ENSION ITEM Frant fork stroke Frant fork spring free length Rear wheel travel Engine mounting pivot shaft runout SER VJCLNG INFORJ lfA TJON 4 1 7 Unit mm in STANDARD LIMIT 20 30 0 8 1 2 20 30 0 8 1 2 80 5 3 1 7 80 5 3 1 7 1 5 0 06 2 0 0 08 2 0 0 08 2 25 1 4 4PR 2 25 1 4 4PR 1 6 0 06 1 6 0 06 Unit mm in STANDARD L IM I T NOTE 40 1 57 80 2 3 1 6 60 2 36 0 6 0 02 ...

Page 72: ...y the R esearch method i I 2 5 L 1 0 66 I 0 55 US Imp gal 0 4 L 0 42 I 0 35 US Imp qt _l t Use SUZU K I CCI SUPER 2 CYCLE MOTOR LUBR ICANT or an equivalent good quality I synthetic based 2 cycle oil 0 7 L l 0 74 I 0 62 US Imp qt SAE 20W 40 I 1 500 ml I I 0 53 I 0 44 US Imp qt NOTE _J L___ 550 ml 1 _ _ _ _ _ 0 _ 5 _ 8 _ _ 0 _ 4 _ 8 _ U _ S _ l _ m _ p _ q _ t _ l_ _ _ _ I _ _ _ _ _ __ T I R E P R E...

Page 73: ..._ I Tail Brake l ight Turn signal l ight _ Tachometer light Speedometer light _ Turn signal indicator light High beam indicator light Neutral indicator light __ Oil level warning light Charging ind icator l ight r Parking or city light SPEC I F ICATION 20 20 5 3 1 7 1 5 1 7 ...

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