manualshive.com logo in svg

Suzuki FD 110 XC, Service Manual, Page: 1 / 193

Share
Download
Suzuki FD 110 XC Service Manual Download Page 1

FD110

FD
110

6(59,&(0$18$/

 

6(59,&(0$18$/

 

'$7(

Summary of Contents for FD 110 XC

Page 1: ...FD110 FD110 6 59 0 18 6 59 0 18 7...

Page 2: ...and service This man ual will help you now the vehicle better so that you can assure your customers of your optimum and quick service COPYRIGHT SUZUKI MOTOR CORPORATION 2012 This manual has been prepa...

Page 3: ...are looking for belong 3 Holding the manual as shown as the right will allow 4 On the first page of each section its contents are listed Find the item and page you need COMPONENT PARTS AND WORK TO BE...

Page 4: ...ER 1303 99000 32030 Apply oil Use engine oil unless otherwise specified Apply THREAD LOCK 1342 99000 32050 Apply SUZUKI SUPER GREASE A 99000 25010 Apply or use brake fluid Apply SUZUKI SILICONE GREASE...

Page 5: ......

Page 6: ...N CONTENTS 1 WARNING CAUTION NOTE 1 2 GENERAL PRECAUTIONS 1 2 SUZUKI FD 110 XC XCS XCD XCSD 1 4 SERIAL NUMBER LOCATION 1 4 FUEL AND OIL RECOMMENDATIONS 1 4 FUEL 1 4 ENGINE OIL 1 5 FRONT FORK OIL 1 5 B...

Page 7: ...NS stated you must use good judgement and basic mechanical safety principles If you are unsure about how to perform a particular service operation ask a more experienced mechanic for advice GENERAL PR...

Page 8: ...head case bolts and nuts beginning with larger diameter and ending with smaller diameter from inside to outside diagonally to the specified tightening torque Whenever you remove oil seals gaskets pac...

Page 9: ...Vehicle Identification Number is stamped on the left side of the steering head tube The engine serial number is located on the upper right side of the crankcase These numbers are required especially f...

Page 10: ...nd reliability of the engine depends on the care and restraint exercised during its early life The general rules are as follows Keep to this break in throttle position Initial 500 km less than throttl...

Page 11: ...cement 109 6 cm3 Compression ration 9 6 1 Carburetor MIKUNI VM17 Air cleaner Paper Starter system Electric starter Kick starter starter Lubrication system Wet sump Valve clearance IN 0 04 0 07 mm EX 0...

Page 12: ...ze 2 50 17 NR72 38L Front fork stroke 90 mm Rear wheel travel 79 mm ELECTRICAL Ignition type DC CDI Spark plug ND U20FS U NGK C6HS Batter 12 V 5AH 10HR Fuse 10 A Headlight 12 V 35 35 W Turn signal lig...

Page 13: ...1 8 GENERAL INFORMATION...

Page 14: ...DURES 2 4 BATTERY 2 4 EXHAUST PIPE BOLTS 2 5 AIR CLEANER 2 5 VALVE CLEARANCE 2 6 SPARK PLUG 2 8 ENGINE OIL 2 9 OIL FILTER 2 9 FUEL HOSE 2 10 FUEL FILTER 2 10 CARBURETOR 2 10 DRIVE CHAIN 2 11 BRAKE 2 1...

Page 15: ...cessary C Clean R Replace T Tighten Interval Km 1 000 4 000 8 000 12 000 16 000 20 000 24 000 Item Months 1 6 12 18 24 30 36 Battery I I I I I I I Exhaust pipe bolts T T T T T T T Air cleaner C C R C...

Page 16: ...oil dirt or grime Lubricate exposed parts which are subject to rust with a rust preventative spry whenever the motorcycle has been operated under wet or rainy condition SPEEDOMETER GEARBOX FRONT WHEE...

Page 17: ...PER Level line For checking specific gravity use a hydrometer to determine the charged condition 09900 28403 Hydrometer Battery type GM3 3B Battery type YB5L B An S G reading of 1 22 YB5L B 1 20 GM 3...

Page 18: ...m AIR CLEANER If the air cleaner is clogged with dust intake resistance will be increased with a resultant decrease in output and an increase the fuel consumption Check and clean the element in the f...

Page 19: ...Remove the center leg shield Remove the leg shields left and right Remove the carburetor by loosening the screws The procedure for adjusting the valve clearance is as follows NOTE The piston must be...

Page 20: ...nter of hole on the magneto cover Insert the thickness gauge to the clearance between the valve stem end and the adjusting screw on the rocker arm 09900 20803 Thickness gauge If clearance is off the s...

Page 21: ...t condition If abnormal replace the plug as indicated below Tighten the spark plug in the cylinder head with the specified torque by using special tool Spark plug 1 1 kg m 9930 10121 Spark plug socket...

Page 22: ...en L Low and F Full lines Oil viscosity and classification SAE 40 API SF SG Oil drain plug 1 8 kg m NOTE To check the oil level holding the motorcycle vertically reinsert the dipstick until the thread...

Page 23: ...screws Engine idle speed 1 500 100 r min 09900 26006 Tachometer THROTTLE CABLE PLAY Throttle cable play A should be 2 4 mm as measured at throttle grip when turning the throttle grip lightly If the pl...

Page 24: ...measure the distance between the two If the distance exceed following limit the chain must be replaced Drive chain 20 pitch length 259 mm After the adjustment is completed check that handlebar movern...

Page 25: ...ned high speeds the drive chain should be cleaned and lubricated more often ADJUSTING Loosen the nut 1 Loosen or tighten the adjusters 2 until the chain has 15 25 mm of slag at the middle between engi...

Page 26: ...r to page 5 12 BRAKE Inspect Initially at 1 000 km 1 month and Every 4 000 km 6 months thereafter BRAKE HOSE AND BRAKE FLUID Inspect Every 4 000 km 6 month Replace houses Every 4 years Replace Fluid E...

Page 27: ...der valve Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it Loosen the bleeder valve by turning it a quarter of a turn so that the...

Page 28: ...ne of the index mark on the brake camshaft should be within the range embossed on the brake panel with brake on To check wear of the brake lining perform the following steps First check if the brake s...

Page 29: ...eer ing should be adjusted properly for smooth turning of handlebars and safe running Over tight steering prevents smooth fuming of the handlebars and too loose steering will cause poor stability Chec...

Page 30: ...tches on the outer surface of the inner tubes Replace any defective parts if necessary Refer to page 5 19 REAR SUSPENSION Inspect the rear shock absorber for oil leakage and damage Replace any defecti...

Page 31: ...nth and Every 4 000 km 6 months thereafter ITEM kPa kg cm3 1 Front axle nut 30 0 47 0 3 0 4 0 2 Steering stem lock nut 25 0 35 0 8 0 3 Handlebars clamp bolt 50 0 60 0 8 3 4 5 Front fork cap bolt 23 2...

Page 32: ...PERIODIC MAINTENANCE 2 19 1 5 9 13 14 6 11 8 7 10 12 2 3...

Page 33: ...PRESSION TEST PROCEDURE NOTE Before testing the engine for compression pressure make sure that the cylinder head nuts are tightened to the specified torque values and valves are properly adjusted Have...

Page 34: ...s too high viscosity Clogged oil passage way Combination of above items OIL PRESSURE TEST PROCEDURE Check the oil pressure in the following manner Support the motorcycle with the center stand Install...

Page 35: ...he engine to normal operating temperature Connect an electric tachometer Seated on the motorcycle with the motorcycle on level ground increase the engine RPM slowly and note the RPM at which the motor...

Page 36: ...NGINE COMPONENTS INSPECTION AND SERVICE 3 15 FIRST CLUTCH 3 15 GEAR SHIFTING CLUTCH 3 16 GEAR SHIFT FORK 3 17 CRANKCASE BEARING AND OIL SEAL 3 18 CYLINDER HEAD RELATED PARTS 3 19 ROCKER ARM AND SHAFT...

Page 37: ...tion instructions ENGINE CENTER Exhaust pipe Carburetor Cam chain tensioned adjuster Cylinder head Piston Cylinder Camshaft ENGINE LEFT SIDE Engine sprocket Magneto cover Rotor Gearshift switch Starte...

Page 38: ...d Remove the oil drain plug 1 to drain out engine oil See page 2 8 Open the seat and disconnect the battery lead wire See page 6 2 and 6 6 Remove the leg shields left and right See page 5 1 Remove the...

Page 39: ...re coupler 4 Engine ground coupler Disconnect the engine breather pipe Disconnect the spark plug cap 5 Disconnect the starter motor lead coupler Disconnect the fuel hose 6 Disconnect the fuel tap vacu...

Page 40: ...cable Page 2 9 Drive chain Page 2 10 Rear brake pedal Page 2 12 Idling speed Page 2 9 Pour 1 000 ml of engine oil SAE 40 graded SF or SG into the engine after overhauling engine Start up the engine an...

Page 41: ...tarter lever Remove the cam pocket cover Remove the cap and insert the screwdriver into the slotted end of the cam chain tension adjuster and turn it clockwise to lock the spring tension NOTE When rem...

Page 42: ...er Place a clean rag over the cylinder base to prevent piston pin circlip from dropping into the crankcase and then remove the piston pin circlip with a long nose pliers Remove the piston pin and pist...

Page 43: ...circlip and primary drive gear Remove the clutch bearing Loosen the nut by using the special tool 09930 40113 Rotor holder Loosen the spring mousing bolt by using the special tool Remove the clutch pr...

Page 44: ...hift cam stopper bolt 1 Remove the shift cam pin bolt 2 Remove the shift cam stopper plate shift cam pin guide and pins Remove the outer bearing clutch bearing and gearshift shaft and plate shift cam...

Page 45: ...special tool 09930 34951 Rotor remover Loosen the screw and remove the starter clutch plate Remove the starter driven gear Remove the starter driven idle gear by removing the circlip 1 and washer 099...

Page 46: ...ate the right and left crankcase by using the special tool 09920 13120 Crankcase crank shaft separator Remove the kick starter shaft by turning it Remove the gearshift fork shaft gearshift fork and ge...

Page 47: ...914 79610 Bearing installer 09921 20210 Bearing puller 09930 30102 Sliding shaft 09913 76010 Bearing installer 09925 98221 Bearing installer 09913 75520 Bearing installer 09913 75821 Bearing installer...

Page 48: ...pring valve by compress the valve springs with the special tools 09916 14510 Valve spring compressor 09916 14521 Attachment Remove the two valve cotter halves from the valve stem by using the special...

Page 49: ...e out the spring seat 2 For installing the valve spring seat and valve stem seal refer to pages 3 21 and 22 Remove the valve guide by using the special tool 09916 44310 Valve guide remover For servici...

Page 50: ...ut ENGINE COMPONENTS INSPECTION AND SERVICE FIRST CLUTCH CLUTCH SHOE INSPECTION Inspect the linings for crack uneven wear or burning Measure the lining thickness with a venire calipers If any defects...

Page 51: ...way clutch roller 4 One way clutch retainer 5 One way clutch inner race GEAR SHIFTING CLUTCH DRIVE PLATE AND DRIVEN PLATES Clutch plates in service remain in oily condition as if they were lubricated...

Page 52: ...k has its prongs fitted into the annular groove provided in its gear in operation there is sliding contact between fork and gear axially too much a clearance is therefore liable to clearance check is...

Page 53: ...ding shaft 09913 76010 Bearing installer 09921 20210 Bearing puller 09925 98221 Bearing installer NOTE If abnormal noise does not occur it is necessary to remove the bearing LEFT CRANKCASE BEARING REA...

Page 54: ...930 30102 Sliding shaft RIGHT CRANKCASE BEARING REASSEMBLY Install the right crankcase bearing into the crankcase by using the special tool 09913 70122 Bearing installer 09914 79610 Bearing installer...

Page 55: ...n installing it Reassembly the spring rocker arm exhaust only VALVE AND VALVE SPRING DISASSEMBLY Compress the valve springs with the valve spring compressor Remove the valve cotters from the valve ste...

Page 56: ...If it measures more than limit replace the valve Service Limit 0 03 mm VALVE STEM DEFLECTION Lift the valve about 10 mm 0 39 in from the valve seat Mea sure the valve stem deflection in two direction...

Page 57: ...drive the guide into the guide hole using the valve guide installer 09916 44310 Valve guide installer NOTE Only oversized valve guides are available as replacement parts After fitting the valve guides...

Page 58: ...sualized seat width must be within the following specification Standard Valve seat width W 0 9 1 1 mm If either requirement is not met correct the seat by servicing it as follows VALVE SEAT SERVICE Th...

Page 59: ...n the contact area After the desired seat posi tion and width is achieved use the 45 cutter very lightly to clean up any burrs caused by the previous cutting operations Clean and assemble the head and...

Page 60: ...the free length reading or if the measured force does not fail within the range specified replace both the inner and outer springs as a set Valve spring free length Service Limit 30 09 mm 09900 20201...

Page 61: ...it worn down to the limit Cam height H Intake cam 27 66 mm Exhaust cam 27 47 mm 09900 20202 Micrometer 25 50 mm CAMSHAFT BEARING Rotate the camshaft bearing outer race by finger to inspect for abnorm...

Page 62: ...a straightedge and thickness gauge taking a clearance reading at several places as indicated If the largest reading at any position of the straightedge exceeds the limit replace the cylinder Service l...

Page 63: ...th piston and piston rings Piston ring groove clearance Service limit 1 st 0 180 mm 2nd 0 150 mm Piston ring groove width standard 1 st 1 01 1 03 mm 2 nd 1 01 1 03 mm Oil 2 01 2 03 mm Piston ring thic...

Page 64: ...mark or numbers on it PISTON PIN PIN BORE Using a caliper gauge measure the piston pin bore inside diam eter and using a micrometer measure the piston pin outside diameter If the difference between th...

Page 65: ...hown and rotate the crankshaft slowly to read the run out Cor rect or replace the crankshaft if the run out is greater than the limit Service Limit 0 08 mm STARTER CLUTCH AND STARTER DRIVEN GEAR BEARI...

Page 66: ...referring to the figure below when rebuilding the crankshaft Standard width between webs 42 0 0 1 mm When installing the crankshaft into the crankcase it is necessary to pull its left end into the lef...

Page 67: ...0 Crankcase separator Measure the width of compressed plastic gauge with the envelope scale Standard Thrust clearance 0 01 0 07 mm If the thrust clearance is not within specification select the proper...

Page 68: ...K STARTER Align the punch mark 1 of kick starter shaft with punch mark 2 of kick starter Turn the kick starter shaft counter clockwise and then lock the kick starter with kick starter guide A THREAD L...

Page 69: ...Seat the circlip in the groove and its ends A should be located as shown in the photo When mounting circlip pay attention to the direc tion of the circlip Fit it to the rounded side against the gear s...

Page 70: ...ins on to the left half of the crankcase Apply engine oil to con rod big end and T M gears Apply BOND NO 1215 to the mating surface of the left crankcase E 99000 31110 SUZUKI BOND NO 1215 Assemble the...

Page 71: ...D LOCK SUPER 1303 to the starter clutch bolts and tighten them to the specified toque by holding the crankshaft G 99000 32030 THREAD LOCK SUPER 1303 Starter clutch boil 10 Nm 1 0 kg m install the star...

Page 72: ...Install the key to the crankshaft Install the rotor assembly after resembling the rotor and starter gear Apply THREAD LOCK SUPER 1303 to the thread and tighten the nut by using the special tool 99000...

Page 73: ...as shown in the photograph When install the shift cam pin bolt apply THREAD LOCK SUPER 1322 to thread H 99000 32110 THREAD LOCK SUPER 1322 When install the shift cam stopper bolt apply THREAD LOCK SUP...

Page 74: ...mp use dowel pin and new O rings Apply THREAD LOCK 1342 to the oil pump securing screws J 99000 32050 THREAD LOCK SUPER 1342 GEAR SHIFTING CLUTCH Install the gear shifting clutch by using the circlip...

Page 75: ...en installing the clutch shoe in the clutch housing align the boss 1 of one way clutch inner with slit 2 of clutch shoes Fix the primary drive gear to clutch housing circlip by using a special tool 99...

Page 76: ...groove first Then install both side rails 2 one on each side of the spacer The spacer and side rails do not have a specific top or bottom when they are new When reassembling used parts install them i...

Page 77: ...located The following are reminders for piston installation Rub a small quantity of SUZUKI MOLY PASTE on to the pis ton pin Place a clean rag over the cylinder base to prevent piston pin circlip from...

Page 78: ...after attaching camshaft drive chain keep the camshaft drive chain taut The camshaft drive chain must not be caught between cam drive chain sprocket and crankcase when crankshaft is rotated NOTE There...

Page 79: ...ng the camshaft drive chain pulled up ward NOTE If crankshaft is turned without drawing the camshaft drive chain upward the chain will be caught between crankcase and cam chain drive sprocket Engage t...

Page 80: ...haft normal direction to remove the cam chain slack between the crank sprocket and exhaust sprocket After installing the cam chain tension adjuster turn a screwdriver counter clockwise As the slotted...

Page 81: ...3 46 ENGINE...

Page 82: ...G 4 4 CARBURETOR 4 5 SPECIFICATIONS 4 5 I D NO LOCATION 4 5 CARBURETOR 4 6 SLOW SYSTEM 4 7 MAIN SYSTEM 4 7 STARTER SYSTEM 4 8 FLOAT SYSTEM 4 8 TRANSIENT ENRICHMENT SYSTEM 4 9 CARBURETOR REMOVAL 4 10 C...

Page 83: ...y in the carburetor intake pipe and vac uum hose Due to this the negative pressure increases behind the fuel tap diaphragm until it is higher than the valve spring pressure The fuel valve in the fuel...

Page 84: ...3 left and right Disconnect the fuel hose 4 and vacuum hose 5 from the fuel valve 6 Remove the fuel valve mounting bolt Disconnect the fuel level gauge lead wire 8 Remove the fuel tank along with the...

Page 85: ...is dirty with sediment or rust fuel will not flow smoothly and loss in engine power may result Clean the fuel fil ter with a compressed air FUEL VALVE Connect the vacuum pump gauge to the vacuum port...

Page 86: ...ts specifications ITEM SERVICE LIMIT Carburetor type MIKUNI VM 17 Bore size 17 mm I D No 09GF Idle r min 1 500 f 100 r min Float height 16 f 1 0 mm Main jet M J 92 5 Main air jet M A J 1 65 mm Jet nee...

Page 87: ...ON SYSTEM CARBURETOR 1 JET NEEDLE 2 THROTTLE VALVE 3 NEEDLE JET 4 MAIN JET 5 PILOT JET 6 FLOAT 7 NEEDLE VALVE 8 FLOAT PIN 9 THROTTLE VALVE ADJUSTER SCREW 10 PLUNGER 11 OVERFLOW PIPE 12 PILOT AIR SCREW...

Page 88: ...ilot air screw 4 The mixture is discharged into the pilot air passage MAIN SYSTEM This system supplies fuel during engine operation when the piston valve is full open The fuel passes through the main...

Page 89: ...outlet 5 into the main bore FLOAT SYSTEM The floats 1 and needle valve 2 are associated with the same mechanism so that as the floats move up and down the needle valve 2 too moves likewise When the f...

Page 90: ...valve is closed suddenly large negative pressure generated on cylinder side works on to a dia phragm 2 The ball 0 held by the diaphragm 2 closes the air passage 3 therefore the fuel air mixture become...

Page 91: ...ake pipe 1 Disconnect the fuel hose 2 and 3 vacuum hose Remove the starter plunger 4 from the carburetor body Loosen the belt 5 Remove the throttle cable assembly 6 CARBURETOR DISASSEMBLY Remove the c...

Page 92: ...rter jet Pilot screw Gasket and o ring Needle jet air bleeding hole Pilot outlet and by pass holes NEEDLE VALVE INSPECTION If foreign matter is caught between the valve seat and the needle the gasolin...

Page 93: ...essary to bring the height A to this value Float height A 16 1 0 mm 09900 20101 Vernier calipers JET NEEDLE ADJUSTMENT Remove the throttle cable Remove the jet needle locker by screwdriver Remove the...

Page 94: ...e 2 18 OIL FILTER Refer to page 2 8 OIL SUMP FILTER When you replace the engine oil check to be sure that the oil sump filter is free from any sign of rupture also wash the oil sump filter clean perio...

Page 95: ...ADN CAM DRIVE CHAIN PISTON AND PISTON PIN BY PASS OIL SUMP FILTER OIL PAN OIL PUMP OIL FILTER OIL ORIFICE CYLINDER OIL COOLER CYLINDER HEAD CONROD SMALL END CYLINDER WALL CONROD BIG END BEARING CRANK...

Page 96: ...FUEL AND LUBRICATION SYSTEM 4 15 LUBRICATION SYSTEM...

Page 97: ...ASSEMBLY 5 14 CALIPER INSPECTION 5 15 CALIPER REASSEMBLY AND REMOUNTING 5 15 MASTER CYLINDER INSPECTION 5 17 MASTER CYLINDER REASSEMBLY AND REMOUNTING 5 17 HANDLEBAR 5 19 REMOVAL 5 19 REASSEMBLY 5 20...

Page 98: ...FI SYSTEM DIAGNOSIS 5 2...

Page 99: ...5 3 CHASSIS EXTERIOR PARTS CENTER LEG SHIELD REAR FRAME COVER UPPER COVER LEFT FRAME COVER REAR FENDER BATTERY BOX LEFT LEG SHIELD FRONT FENDER FRAME HEAD COVER RIGHT LEG SHIELD...

Page 100: ...CHASSIS 5 4 FRONT HANDLEBAR S COVER REAR HANDLEBAR S COVER...

Page 101: ...move the frame head cover REAR VIEW MIRROR Remove the rear view mirrors left and right by loosening the lock nuts HANDLEBAR S COVER Remove the handlebar s cover screws Remove the screw and unhook the...

Page 102: ...the rear side of the handlebar s cover along with the speedometer by disconnecting the speedometer cable and speedometer lead wire couplers REINSTALLATION Reinstall the removed parts in the reverse o...

Page 103: ...speedometer cable 2 Disconnect the front brake cable 3 Remove the axle and front wheel FRONT BRAKE Remove the front brake panel from the wheel Remove the brake shoes from the brake panel Remove the o...

Page 104: ...ingers to inspect for abnormal play noise and smooth rotation while the bearings are in the wheel Replace the bearing in the following procedure if there is anything unusual Insert the adapter 1 of be...

Page 105: ...e the wheel SPOKE NIPPLE Check to be sure that all nipples are tight and retighten them as necessary using a spoke nipple wrench Spoke nipple 2 0 N m 0 2 kg m BRAKE DRUM Measure the brake drum I D to...

Page 106: ...A to the bearings before installing X 99000 25010 SUZUKI SUPER GREASE A Using the bearing installer set 1 press fit the bearing to the wheel First install the left wheel bearing then right wheel beari...

Page 107: ...earbox apply SUZUKI SUPER GREASE A to its dust seal lip Align the drive lugs A to the recesses B of the wheel hub and attach the speedometer gearbox to the wheel hub X 99000 25010 SUZUKI SUPER GREASE...

Page 108: ...oving its bolts INSPECTION AND DISASSEMNBLY SPEEDOMETER GEARBOX Refer to page 5 6 WHEEL BEARING Refer to page 5 6 AXLE SHAFT Refer to page 5 7 FRONT WHEEL Refer to page 5 7 SPOKE NIPPLE Refer to page...

Page 109: ...stand REASSEMBLY AND REMOUNTING WHEEL BEARING Refer to page 5 8 BRAKE DISC Make sure that the brake disc is clean and free of any greasy matter Tighten the disc mounting bolts to the specified torque...

Page 110: ...union bolt and catch the brake fluid in a suitable receptacle Remove the caliper mounting bolts 2 Remove the caliper Remove the brake pad pins 3 Remove the brake pads 4 Remove the brake pad spring 5 H...

Page 111: ...The removed rubber parts should be replaced with new ones CALIPER REASSEMBLY AND REMOUNTING Reassemble the caliper in the reverse order of removal and disassembly Pay attention to the following points...

Page 112: ...TER CYLINDER REMOVAL AND DISASSEMBLY The procedure of master cylinder removal is as follows Rear view mirrors Handlebar s cover See page 5 3 Break light switch lead 1 Break hose union bolt 2 Master cy...

Page 113: ...ton surface for any scratches or other damage Inspect the piston cup and dust seal for wear or damage MASTER CYLINDER REASSEMBLY AND REMOUNTING Reassembly the master cylinder in the reverse order of r...

Page 114: ...n the handlebar align the master cylinder holder s mating surface A with punched mark B on the handlebar and tighten the upper clamp bolt first as shown Tightening torque 10 N m 1 0 kg m NOTE Be sure...

Page 115: ...ter lead wire couplers Disconnect the brake light switch lead Remove the left handlebar parts Refer to above illustration Remove the brake master cylinder For disc brake Refer to page 5 14 Remove the...

Page 116: ...For drum brake X 99000 25010 SUZUKI SUPER GREASE A Apply an adhesive agent onto the left handlebar then install the left handle grip 3 Install the throttle cable 4 Connect the throttle cable end 5 to...

Page 117: ...5 21 CHASSIS Connect each lead wire Connect the speedometer cable Install the front and rear handlebar s covers FRONT FORK AND STEERING...

Page 118: ...ove the rear view mirror See page 5 3 Remove the left and right leg shields See page 5 1 Remove the handle bar Remove the front fender 1 Remove the front fender by remove the screw 2 Remove the front...

Page 119: ...ch 09910 60611 Universal clamp wrench Remove the washer Remove the steering stem nut 3 9910 60611 Universal clamp wrench Remove the dust seal 4 and outer upper race Remove the steering stem bracket Re...

Page 120: ...the dust seal 2 and stopper ring 3 Remove the damper rod bolt with the special tools Remove the inner tube from the outer tube 09940 34520 T handle 09940 34561 Attachment D 09900 00410 Hexagon wrench...

Page 121: ...race lower race and balls for corrosion dents or damage DAMPER ROD RING Inspect the damper rod ring 1 for wear or damage FRONT FORK SPRING Measure the fork spring free length If it is shorter than the...

Page 122: ...m H 99000 32110 THREAD LOCK SUPER 1322 1322 09900 00410 Hexagon wrench set 09940 34520 T handle 09940 34561 Attachment D Install the oil seal with the special tool NOTE Before installing the oil seal...

Page 123: ...l tool 09943 74111 Fork oil level gauge Oil level 116 mm NOTE When adjusting the oil level remove the fork spring and com press the inner tube fully Be sure to bring the close pitch side of fork sprin...

Page 124: ...s smoothly and easily left to right Install the washer Tighten the steering stem lock nut 4 with the special tool 09940 14920 Steering stem nut wrench Steering stem lock nut 30 N m 3 0 kg m NOTE After...

Page 125: ...REAR BRAKE REMOVAL AND DISASSEMBLY REAR WHEEL Support the motorcycle with the center stand Remove the rear brake adjusting nut 1 Remove the cotter pin and torque link nut 2 Remove the chain case 1 by...

Page 126: ...usting nuts 2 left and right Draw out the axle shaft Disengage the drive chain from the rear sprocket Remove the rear wheel REAR SPROCKET Remove the rear sprocket along with its mounting drum out of t...

Page 127: ...the special tool 09913 50121 Oil seal remover Remove the rear sprocket drum bearing in the same manner of the front wheel bearing Refer to page 5 6 09941 50111 Bearing remover REAR BRAKE Remove the re...

Page 128: ...5 7 WHEEL Refer to page 5 7 SPOKE NIPPLE Refer to page 5 7 BRAKE DRUM Refer to page 5 7 REAR SPROCKET DRUM BEARING Refer to page 5 6 The inspection of the rear sprocket drum bearing in the same manner...

Page 129: ...lling X 99000 25010 SUZUKI SUPER GREASE A Using the bearing installer set press fit the bearing to the wheel First install the right wheel bearing then left wheel bearings 09924 84521 Bearing installe...

Page 130: ...the brake cam shaft and pin before installing the brake shoes X 99000 25010 SUZUKI SUPER GREASE A BRAKE CAM LEVER When installing the brake cam lever and brake lining wear indicator align the groove...

Page 131: ...5 35 CHASSIS REAR SUSPENSION SWING ARM AND SHOCK ABSORBER REMOVAL Remove the rear wheel see page 5 27 Remove the shock absorber mounting lower bolts 1 left and right...

Page 132: ...buffer for wear or damage If any defects are found replace the chain buffer with a new one SWINGARM PIVOT SHAFT Using a dial gauge check the pivot shaft run out and replace it if the run out exceeds...

Page 133: ...nt the swing arm and shock absorber in the reverse order of removal and disassembly and also carry out the following steps SWINGARM BUSHING Press the bushing into swing arm pivot by using the special...

Page 134: ...6 11 STARTER MOTOR REASSEMBLY 6 12 STARTER RELAY INSPECTION 6 13 IGNITION SYSTEM 6 14 DESCRIPTION 6 14 TROUBLESHOOTING 6 15 INSPECTION 6 16 FUEL METER 6 21 FUEL METER CIRCUIT 6 21 INSPECTION 6 21 COM...

Page 135: ...e wire harness at such positions as indicated in WIRE HARNESS ROUTING Refer to page 7 10 Bend the clamp properly so that the wire harness is clamped securely In clamping the wire harness use care not...

Page 136: ...RE Route the wire harness properly according to WIRE HAR NESS ROUTING Refer to page 7 10 ADJUSTUSING POCKET TESTER Be sure to use positive and negative probes of the tester properly Their false use ma...

Page 137: ...CTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS 1 Battery 7 Ignition coil 2 Fuse 8 Generator 3 Fuel level gauge 9 Starter motor 4 Turn signal relay 10 Horn 5 Regulator rectifier 11 CDI unit 6 Starter...

Page 138: ...unit and battery The AC current generated from AC generator is converted by rectifier and is turned into DC current then it charges the battery On the other hand lighting coil supplies A current to th...

Page 139: ...nuity generator Coils Refer to page 6 7 Correct Inspect regulator rectifier Coils Refer to page 6 8 Correct Inspect wirings Correct Installed leak Correct No continuity Incorrect Incorrect Incorrect I...

Page 140: ...itch turned ON Measure the DC voltage between the batter with a pocket tester If the tester reads under the specified value inspect the generator coil and regulator rectifier NOTE When making this tes...

Page 141: ...W Yellow with white tracer GENERATOR NO LOAD PERFORMANCE INSPECTION Remove the center leg shield leg shields and leg side shields frame covers See page 5 1 Disconnect the regulator rectifier coupler...

Page 142: ...side this rectifier the resistance values will differ between testers STARTER SYSTEM DESCRIPTION The starter system is shown in the diagram below namely the starter motor starter relay starter switch...

Page 143: ...n is pushed Measure he starter relay voltage at the starter relay connectors between Y B and B W when the starter button is pushed Check the CDI unit ignition coil and generator Refer to opages 6 15 a...

Page 144: ...al wear crack or smoothness in the brush holder In the brush holder If the brush has failed replace the brush sub assy COMMUTATOR Inspect the commutator for discoloration abnormal wear A or undercut I...

Page 145: ...one OIL SEAL INSPECTION Check the seal lip for damage or leakage If any damage is found replace the bracket STARTER MOTOR REASSEMBLY Reassemble the starter motor in the reverse order of disassem bly P...

Page 146: ...minals inspect the continuity between the terminals 3 and 4 If the starter relay is in sound condition continuity is found 09900 25002 Pocket tester V Tester knob indication X1 range Check the coil fo...

Page 147: ...volt age signal is sent to SCR gate allowing the electric energy stored in the capacitor C to discharge instantly to the ignition primary coil This then causes a high voltage to be induced in the sec...

Page 148: ...ance of charging coil W R and Ground Refer to page 6 7 Incorrect Correct Inspect the resistance of charging coil G W and L Y Refer to page 6 16 Incorrect Poor contact of coupler Faulty charging coil F...

Page 149: ...nition coil lead wires 09900 25008 Multi circuit tester set Digital Turn the ignition switch to the on position Press the starter button and allow the engine to crank for a few seconds and then measur...

Page 150: ...re connected properly and the battery is fully charged Disconnect the CDI unit coil coupler Measure the pickup coil peak voltage in the following procedure Connect the multi circuit tester DM 200 with...

Page 151: ...y peak voltage More then 4 V Multi circuit tester set DM 200 If the peak voltage on the pickup coil coupler is within specifica tion but on the CDI unit coupler is not within specification replace the...

Page 152: ...ester is used 09900 25002 Pocket tester V Tester knob indication X1 k range Unit Approx K CON When the capacitor is discharged state the needle of tester swings first then return to infinity NOTE If n...

Page 153: ...t is extremely worn or burnt replace the plug Also replace the plug if it has broken insulator damaged thread etc Heat Range NGK C 6 HS should be used as the standard However the heat range of the spa...

Page 154: ...is incorrect replace the fuel gauge assembly with new one The relation between the position of the fuel gauge float and resistance is shown in the following table 09900 25002 Pocket tester V Tester k...

Page 155: ...on when the specified resistance is applied to the circuit and if its pointer indicates the F full position when the resistor is changed to 4 10 ohms If either one or both indicator are abnor mal repl...

Page 156: ...indication X 1 range NOTE When making this test it is not necessary to remove the combination meter U G L GREEN WITH BLUE TRACER Y L YELLOW WITH BLUE TRACER W WHITE Y W YELLOW WITH WHITE TRACER Y B Y...

Page 157: ...er Push in on the bulb socket turn it to the left and pull it out Remove the headlight bulb TURN SIGNAL LIGHT BULB REPLACEMENT Remove the turn signal light lenses Pull out each bulb When replacing the...

Page 158: ...e left and pull it out TURN SIGNAL RELAY The turn signal relay 1 is located the front stem side If the turn signal light does not light Inspect the bulb or repair the circuit connection If the bulb an...

Page 159: ...W B OFF ON Color Position GRO UND L W L R B G L Y L N 1 2 3 4 B Black L Blue G Green Gr Gray Sb Light blue B W Black with White tracer R B Red with Black tracer W Y White with Yellow tracer Y W Yello...

Page 160: ...by the number of months that have elapsed since the date of manufacture Confirmation for date of manufacture Date of manufacture is indicated by a three part number 1 as shown in the photograph each i...

Page 161: ...to permit the electrolyte temperature to exceed 45 C at any time during the recharging operation Interrupt the operation as necessary to let the electrolyte cool down Recharge the battery to the spec...

Page 162: ...ole plates and will deteriorate the performance suifation Replace the battery with new one in such a case When a battery is left for a long tem without using it is apt to subject to sulfation When the...

Page 163: ...6 30 ELECTRICAL SYSTEM...

Page 164: ...ATTERY 7 9 WIRING DIAGRAM FD 110 XB517QSC XB517QD 7 10 WIRE HARNESS CABLE AND HOSE ROUTING 7 11 WIRE HARNESS ROUTING 7 11 CABLE ROUTING 7 13 FRONT BRAKE HOSE ROUTING 7 14 FUEL HOSE ROUTING 7 15 FRONT...

Page 165: ...st Replace Replace or rebore See electrical section Retighten Clean Clean and dry Replace Replace Replace Clean Clean or replace Replace Clean or replace Engine stalls easily 1 Fouled spark plug 2 Def...

Page 166: ...lutch 2 Slipping gear shifting clutch Replace clutch shoe Adjust or replace Transmission will not Shift 1 Broken gearshift cam 2 Distorted gearshift forks 3 Worn gearshift pawl Replace Replace Replace...

Page 167: ...5 Worn valves or stems 6 Defective stem seals 7 Worn oil ring side rails Drain out excess oil Replace Replace Rebore or replace Replace Replace Replace Engine lacks power 1 Loss of valves clearance 2...

Page 168: ...ine runs but motorcy cle will not start or run 1 Damaged first clutch 2 Gear shifting clutch out of adjustment 3 Seized gears 4 Damaged countershaft and driveshaft Replace clutch shoe Adjust Replace R...

Page 169: ...pressure in tires Adjust Replace Replace Adjust Wobbly handlebars 1 Loss of balance between right and left front forks 2 Distorted front fork 3 Distorted front axle or crooked tire Replace Repair or...

Page 170: ...rear wheel axle 5 Worn pads 6 Foreign material in brake fluid 7 Clogged return port of master cylinder 8 Brake shoe surface glazed 9 Worn shoe Repair surface with sand paper Modify pad fitting or rep...

Page 171: ...Repair or replace or retighten Replace Replace Generator does charge but charging rate is below the specification 1 Lead wires tend to get shorted or open circuited or loosely connected at terminals 2...

Page 172: ...o low 5 Contaminated electrolyte 6 Battery is too old Check the generator regulator rectifier and circuit connections and make necessary adjustments to obtain specified charging operation Replace the...

Page 173: ...GROUND BATTERY FUSE REGULATOR RECTIFIER MAGNET GEAR POSITION SWITCH IGNITION SWITCH FRONT TURN SIGNAL LIGHT L HEAD LIGHT FRONT TURN SIGNAL LIGHT R DIMMER SWITCH TURN SIGNAL SWITCH LIGHTING SWITCH HORN...

Page 174: ...AMP IGNITION S WITCH THE FUE L HOS E CLAMP R E AR BR AKE LIGHT S WITCH FUE L GAUGE FUS E BOX BATTE R Y TE R MINAL COVE R BATTE R Y TE R MINAL S TAR TE R R E LAY BATTE R Y BR E ATHE R PIPE S TOP LAMP S...

Page 175: ...7 12 SERVICING INFORMATION MAGNETO LEAD WIRE ROUTING PICK UP COIL MAGNETO LEAD WIRE MAGNETO STATOR GROMMET ENGINE GROUND WIRE GEAR POSITION INDICATOR GROMMET 8 0 KG M CLAMP...

Page 176: ...ICING INFORMATION 7 13 CABLE ROUTING S TAR TE R CABLE S TAR TE R LE VE R S TAR TE R CABLE CLAMP CLAMP FR ONT BR AKE CABLE FR ONT BR AKE CABLE S PE E DOME TE R CABLE S PE E DOME TE R CABLE VIEW B VIEW...

Page 177: ...7 14 SERVICING INFORMATION FRONT BRAKE HOSE ROUTING S TAR TE R CABLE THR OTTLE CABLE S TAR TE R CABLE CLAMP S PE E DOME TE R CABLE CLAMP FR ONT BR AKE CABLE S TAR TE R CABLE CLAMP CAR BUR E TOR...

Page 178: ...SERVICING INFORMATION 7 15 FUEL HOSE ROUTING FUEL TANK CLAMP...

Page 179: ...7 16 SERVICING INFORMATION BATTERY BATTERY BREATHER HOSE FUEL TANK...

Page 180: ...SERVICING INFORMATION 7 17 FRONT WHEEL SET UP DRUM TYPE 4 0 K 0 8 KG M mm 7 86 14 O...

Page 181: ...7 18 SERVICING INFORMATION FRONT WHEEL SET UP DISK TYPE 2 3 K G M 2 6 K G M 2 3 K G M 4 0 K G M...

Page 182: ...SERVICING INFORMATION 7 19 REAR WHEEL SET UP 5 4 KG M 0 8 KG M 114 8 mm...

Page 183: ...V block set 100 mm 0900 22302 Plastigauge 09900 25002 Pocket tester 0900 26006 Tacho meter 0900 28108 Electro tester 09900 28403 Hydrometer 09910 20115 Con rod holder 09910 32812 Crankshaft installer...

Page 184: ...570 Valve guide reamer 5 0 mm 09916 44310 Valve guide remover installer 09916 34580 Valve guide reamer 10 8 mm 09916 84511 Tweezers 09917 14910 Vale clearance adjusting driver 099 17 47910 Vacuum pump...

Page 185: ...1 Bearing remover 09941 74910 Steering bearing installer 09943 74111 Front fork oil level gauge 09951 16080 Bearing installer 09940 14920 Steering stem nut wrench 09940 52860 Front fork oil seal insta...

Page 186: ...rance inspection cap bolt 10 1 0 Cylinder head right cover bolt 8 0 12 0 0 8 1 2 Cylinder head left cover bolt 8 0 12 0 0 8 1 2 Cam chain guide bolt 8 0 12 0 0 8 1 2 First clutch nut 40 0 60 0 4 0 6 0...

Page 187: ...0 12 0 0 8 1 2 Front brake hose union bolt 23 2 3 Front brake caliper mounting bolt 18 0 28 0 1 8 2 8 Front brake air bleeder valve 8 0 8 Rear axle nut 42 0 66 0 4 2 6 6 Engine mounting nut bolt 50 0...

Page 188: ...m Conventional or W4W marked bolt 7 marked bolt N m Kg m N m Kg m 4 1 5 0 15 2 0 2 5 3 0 3 5 0 5 6 6 0 6 10 1 0 8 13 1 3 23 2 3 10 29 2 9 50 5 0 12 45 4 5 85 8 5 14 65 6 5 135 13 5 16 105 10 5 210 21...

Page 189: ...end length In EX 2 400 Valve seat width In EX 1 0 Valve head radial run out In EX 0 030 Valve spring free length In EX 30 090 Valve spring tension In EX 14 7 N at length 25 8 mm ITEM STANDARD LIMIT Ca...

Page 190: ...006 14 014 14 040 Conrod deflection 3 000 Conrod big end side clearance 0 10 0 45 1 0 Crank web to web width 42 0 0 1 Crankshaft thrust bearing thickness 0 60 1 35 Crankshaft thrust clearance 0 00 0 0...

Page 191: ...Type DID428 Links 98 links 20 pitch length 259 Drive chain slack 15 25 ITEM STANDARD Carburetor type MIKUNI 17 Bore size 17 mm I D No 09GF1 Idle r min 1 500 100 r min Float height 16 Main jet M J 92 5...

Page 192: ...0 V at 5 000 r min Night time Battery Capacity 12V 5Ah 10HR FD 110 Standard Electrolytes S G 1 28 at 20 C Fuse side Main 10A ITEM STANDARD Headlight HI 32 LO 32 Tail Brake light 5 18 Turn signal light...

Page 193: ...pth Front 1 6 Rear 1 6 ITEM STANDARD LIMIT NOTE Front fork stroke 90 Rear wheel travel 77 9 Swing arm pivot shaft run out 0 6 COLD INFLATION NORMAL AND DUAL RIDING TIRE PRESSURE Psi Kg cm2 FRONT 25 1...

Reviews:

No comments