Suzuki FZ50 1979 Service Manual Download Page 57 | Manualshive

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3-26

SER

VICING

PROCEDURE

Radiai

WHEE

L RUNOUT

Measure

axial and radial wheel

rim

runout of

front an

d rear wheels.

ce

li mit

Servi

(Axia

I

and Radial)

TIRE

2.0

mm

(0.08 i n )

Measure

both f ront and rear tire tread depth.

ce

limit

Servi

( Fron

t and R ear)

1.6

mm

(0.063 i n )

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Summary of Contents for FZ50 1979

Page 1: ......

Page 2: ... as PEI ignition automatic transmission and clutch The FZ50 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 SUZUKI MOTOR CO LTD Service Department Overseas Operations Division All specifications and construction details contained in this manual were correct at time of issu...

Page 3: ... I GROUP INDEX GENERAL INFORMATION INSPECTION AND ADJUSTMENT SERVICING PROCEDURE SERVICING INFORMATION ...

Page 4: ...CE ERJIL INFORMATIO r 1 1 GENERAL INFORMATION CONTENTS MODEL IDENTIFICATION 1 2 SPECIFICATIONS 1 3 FUEL AND OIL RECOMMENDATION 1 5 GENERAL NOTES AND PRECAUTIONS 1 6 TECHNICAL FEATURES 1 7 j a ...

Page 5: ...ER The frame serial number is stamped on the right side of the steeri ng head pipe LEFT SIDE VIEW ENGINE NUMBER The engine serial number is located on the left side crankcase I These numbers a re required especially for registering the mach i ne and orderi ng the spare parts ...

Page 6: ...SION Clutch Transmission Gearshift pattern Primary reduction Final reduction Gear ratios Low 2nd Drive cha i n chain gear 1 650 mm 65 0 in 665 mm 26 2 in 990 mm 39 0 in 1 120 mm 44 1 in 120 mm 4 7 in 59 kg 130 lbs Two stroke air cooled Reed valve 41 0 mm 1 614 in 37 4 mm 1 472 in 49 cm3 3 0 cu in 6 1 1 M I KU N I VM14SH si ngle Polyurethane foam element Primary k ick SUZUKI CCI Wet shoe automatic ...

Page 7: ...ngine oil tank Transmission oil Leading l ink oil dampened Swinging arm 45 right left 63 00 81 mm 3 19 in 1 7 m 5 6 ft I nternal expand ing I nternal expanding 3 00 12 4PR 3 00 12 4PR 125 kPa 1 25 kg cm2 18 psi N ormal solo riding 150 kPa 1 50 kg cm2 21 psi Normal solo riding SUZUKI PE I 20 B T D C at 4 000 r mi n NGK BP4HA or N I PPON DENSO W 14FP U L 6V 14 4 kC 4 Ah 10 HR F lywheel magneto 10A 6...

Page 8: ...UEL Gasol ine used shou ld be unleaded or low lead where they are avai lable ENGINE OIL For the SUZU KI CCI system use of S UZUKI CCI SUPE R 2 O I L is h igh ly recommended but if it is not available a good quality two stroke oil non diluent type shou l d be used TRANSMISSION 01 L Use a good qual ity SAE 20W 40 mu lti grade motor oil Drain plug ...

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

Page 10: ...ith a reed valve The simple constructi on and rational design of the engine has mini mized the number of inspection items thus allowing easy inspection and almost maintenance free operation This provides a unique motorcycle with a long enjoyable life free from troubles Kick starter shaft Counter shaft ...

Page 11: ...ry depending on the engine speed and throttle opening In other words it can be said that the intake timing is ideal ly matched to the operating condition of the engine ENGINE LUBRICATION Engine oil is supplied by means of an oil pump which is driven by the cran kshaft through the oi l pump driven shaft and oil pump drive gear mounted on the crankshaft The supply of the oi l is controlled by the oi...

Page 12: ...durability 70 Sectiona 1 form of piston ring Both 1 st and 2nd rings are sloped at the top side Automatic centrifugal shoe type clutches are secured to the crankshaft and counter shaft These clutches have simple construction When the clutch drive shoes wh ich are thrown apart by cen trifugal force varying with the crankshaft speed come in contact with the clutch driven wheel engine power is transm...

Page 13: ...nd driven gear 3 Clutch drive shoes 16 Clutch No 2 4 Clutch N o 1 17 Clutch drive shoes 5 1st drive gear 6 1st driven gear 7 Counter shaft _ _______ _ ___ ___ 8 Drive sprocket 9 Drive chain 10 Driven sprocket 11 Final drive gear 12 Final driven gear 13 Drive axle shaft 14 Rear wheel One way clutch ...

Page 14: ... to also rotate Splined to the inner counter shaft is the chain drive sprocket When the engine r min increases clutch No 2 engages for 2nd gear power transmission As the clutch begins to engage it forces the counter shaft to turn faster than the r min produced by the drive of the 1 st driven gear set This is accomplished by the use of a one way or free wheel ing clutch inside of the 1 st driven ge...

Page 15: ... transmitted to the final d rive 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 d rive gear The shaft is i nstalle...

Page 16: ... the kick starter lifter the kick starter guide is pushed and the guide end is raised Keeping this condition when the kick lever is depressed the kick starter is turned by the kick starter d rive gear As a result the kick starter moves to the left side of the kick idle gear whi le being turned by the kick starter gear a nd meshes with the kick idle gear The kick idle gear rotates and makes the cra...

Page 17: ...rk plug gap The PE I magneto has no breaker points and therefore it is free from mechanical trouble This ensures a stabler secondary high voltage and better spark performance PEI unit PEI Features of PEI System Ignition coil Magneto 0 0 0 1 Spark plug deposits are minimized as high voltage spark is produced Spark plug 2 Disuse of contact points means no dust trouble Contact points become worn by d...

Page 18: ...ontacts the i nside of the head pipe and is fixed there Tighten bolt FRONT FORK Front suspension of leading link type assures soft and comfortable riding Road snocks are transmitted to the a rm by way of the front axle shaft and absorbed i n the shoc k absorber On the contrary when the shock absorber extends the a rm contacts the damper rubber and thus shocks are dampened Shock absorber ...

Page 19: ...INSPiiC J OJ AND ADJUSTME 1 2 1 INSPECTION AND ADJUSTMENT PERIODIC MAINTENANCE SCHEDULE 2 2 MAINTENANCE PROCEDURE 2 3 ...

Page 20: ...th 2 6 12 Air cleaner element Wash and clean Wash and clean Battery Check specific gravity Check S G and service and service electrolyte electrolyte solution solution Brakes Adjust play Adjust play Brake shoes Check wear Carburetor Adjust idle r min Adjust idle r min Overhaul and clean Cylinder head and cylinder Retorque head nuts and Retorque head nuts and Remove carbon exhaust pipe bolts exhaust...

Page 21: ...rease Choke cable Motor oil Front suspension arm shaft Grease Oil pump cable Motor oil Speedometer gear Grease Speedometer cable Grease Throttle cable Motor oil WARNING Be careful not to apply too much grease to the brake cam shafts If grease gets on the linings brake slippage will result Lubricate exposed parts which are subject to rust with either motor oil or grease whenever the motorcycle has ...

Page 22: ...y Add distilled water as necessary to keep the surface of the electrolyte above the LOWER level line but not above the UPPE R level line CAUTION MISC H GARDE aa1tt1r autrr e emu b1eath 1 piH Renilbr de hlterie YUASA 6N4 2A NAX N JJ P4 If the electrolyte surface fal ls rapidly and requires frequent addition of distilled water check the charging system for proper charging rate A S G reading of 1 220...

Page 23: ...t the lifter lever play is 1 mm 0 04 in 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 Adjusting nut I rsJ ECnON AND tlD srMENT 2 5 BRAKE SHOE WEAR Check every 3 000 km When applying the front brake if the ex tended line of the brake cam lever exceeds the range on the brake panel replace the brake shoes Remove inspection cap on ...

Page 24: ...mm 0 02 0 04 in This adjustment will affect the oil pump lever adjustment Therefore re adjust the oil pump lever cable as necessary CARBURETOR OVERHAUL AND CLEANING Overhaul and clean every 6 000 km Wash the carburetor and component parts in cleaning solvent after disassembly Before reassembly inspect the float level and needle valve Adjust and replace parts when necessary Refer to page 3 11 Then ...

Page 25: ...n at initial 1 000 km and every 6 000 km If the fuel strainer cup is dirty with sediment or water gasoline will not flow smoothly and a loss in engine power ma y resu lt Clean the strainer cup leaving the cock lever in ON position 0 Cup 0 ring Filter OIL PUMP Adjust at initial 1 000 km and every 3 000 km Cable adjustment mesh The engin e oil is fed by the oil pump to the eng ine The amount of oil ...

Page 26: ...ine not running condition loosen screw CD to let out the air and after making sure that the trapped air has all been bled tighten the screw good and hard Checking oil pump capacity Use the special tool check the pump for capacity by measuring the amount of oil the pump draws during the specified interval Engine oil discharge amount measuring tool 09900 21602 Have the tool fil led with SUZUK I CCI ...

Page 27: ...ion If abnormal replace the plug as indicated below NGK Nippon Remarks Denso If the standard plug BP 2HA I W9FP UL is apt to get wet re place with this plug BP 4HA W14FP UL Standard If the standard plug BP 5HA W16FP UL is apt to overheat re place with this plug Tighten the spark plug in the cylinder head with the specified torque Spark plug tightening torque STEERING STEM 2 5 3 0 kg m 18 0 21 5 lb...

Page 28: ...i tion If abnormal replace the plug as indicated below NGK N ippon Remarks Denso If the standard plug BP 2HA W9FP UL is apt to get wet re place with this plug BP 4HA W14FP UL Standard If the standard plug BP SHA W1 6FP U L is apt to overheat re place with this plug Tighten the spark plug i n the cylinder head with the specified torque Spark plug tightening torque STEERING STEM 2 5 3 0 kg m 18 0 21...

Page 29: ...damage of steel balls Number of steel bal ls upper 22 pcs lower 25 pcs Distortion of steering stem 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 CAUTION 0 5 1 0 mm 0 02 0 04 in Locknut This adjustment will affect the oil pump control lever adjustment Re adjust the oil...

Page 30: ...ssive ly worn tires will decrease riding stabi lity and consequently invite a dangerous situ ation It is highly recommended to replace the tire when the remaining depth of tire tread reaches the fol lowing specifications FRONT and REAR 1 6 mm 0 06 in Ji SPiiCTJO A D ADJ STMENT 2 11 TRANSMISSION OIL Change at initial 1 000 km and every 3 000 km After a long period of use the transmission oil qualit...

Page 31: ...sorber 2 1 0 1 5 7 5 10 5 lowor nut Front suspension arm 2 2 0 3 0 14 5 21 5 rear nut Front suspension arm 2 1 0 1 5 7 5 10 5 damper nut Front shock absorber 2 1 5 2 0 11 0 14 0 upper bolt Roar shock 3bsorber 1 2 0 3 0 14 5 21 5 upper nut Q Ro3r shock 3bsorber 1 2 0 3 0 14 5 21 5 lower nut Rear brake cam lever 1 0 5 0 8 4 0 5 5 nut Description Q ty kg m lb ft Rear axle nut 1 3 6 5 2 26 5 37 5 Engi...

Page 32: ...NSTALLATION 3 2 CYLINDER HEAD CYLINDER PISTON KICK STARTER LEFT COVER POWER TRANSMISSION 3 3 3 5 3 6 LEFT CRANKCASE 3 10 CRANKSHAFT 3 11 CARBURETOR 3 13 FLYWHEEL MAGNETO CHASSIS ELECTRICAL SWITCHES STEERING FRONT SUSPENSION WHEELS AND BRAKES 3 14 3 16 3 20 3 22 3 23 3 24 m ...

Page 33: ... the carburetor side Remove the carburetor top cover Loosen the engine mou nting nut Right Left CD Remove the spark plug cap Remove the oil pump control cable Remove the oil hose Remove the rear brake cable Loosen and remove the rear shock ab sorber lower bolt Remove the engine ground wire from the ignition coi l side Pul l out the engine mounting bolt Lift the body 2 5 4 0 kg m 18 5 28 5 lb ft 2 ...

Page 34: ...on Replace gasket 2 0 kg m 14 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 0 Remove carbon and apply oi I Top mark R or T indicates up side on rings R eplace with new circlips Apply thread lock cement 1342 ...

Page 35: ...41 060 mm 1 6165 in PISTON DIAMETER Micrometer Service Limit RING END GAP Thickness gauge Service Limit 09900 20202 40 880 mm 1 6094 in 09900 20804 0 75 mm 0 030 in RING FREE END GAP Vernier caliper 09900 20101 R marked T marked Service 3 6mm 4 0mm Limit 0 14 in 0 16in NOTE Replace the piston rings as a set ...

Page 36: ...0210 Sliding shaft 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 install Apply Suzuki Super Grease A to the oil seal l ip and the kick starter spring Replace the gasket Insta l l two dowel pins CD Remover ...

Page 37: ...ly thread lock cement 2 0 3 0 kg m 14 5 21 5 lb ft Rubber Rubber Adjust so that there is no clutch thrust play 0 Wave Washer Plastic ring To prevent chain noise To wheel Circl ip opener 09900 06107 Replace all circlips Adjust shim to reduce the final drive and driven gear noise ...

Page 38: ...onnect an electric tachometer to the engine Seated on the motorcycle with the m otor cycle on level ground increase the engine RPMs slowly and note the RPM at which the motorcycle begins to move forward ENGAGEMENT R M I N STD I Tolerance I 2 500 r min _200 r min SER VICING PROCEDURE 3 7 2 C LUTCH LOCK UP INSPECTION C LUTC H NO 1 Perform this inspection to determine if the clutch is engaging fully ...

Page 39: ...he free length of the springs with vernier calipers NOT E Clutch shoes or springs must be changed as a set and never individually 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 wel l a...

Page 40: ... indications of slipping or grabbing If the shift point does not coinside with the standard MPH range then Clutch No 2 com ponents should be inspected in the same manner as was Clutch No 1 in the fol lowing areas Clutch shoes Clutch springs Clutch wheel Unit mm in Item Service limit Clutch wheel l D 1 05 50 4 1 54 Clutch shoe surface No groove Clutch spring free 33 0 1 30 length Sci VICI G PROCl D...

Page 41: ...e out the clutch and remove the countershaft Removing countershaft Pull out by using the bearing pu ller and sliding shaft Push out as shown in the figure 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 0 ring I 0 5 0 8 kg m 4 0 5 5 lb ft Brake cam shaft G R EASE ...

Page 42: ...p Match the projecting part of oil pump and the groove Check the oi l seal and the bearing for damage or excessive clearance Apply grease to the oil seal Apply oil to the bearing I nstall the engi ne ground wire Check for damage and bent reeds Be careful not to bend the reed valve stopper Ground wire Oil pump control cable guide Oil pump U se a crankshaft remover to prevent damage to the crankshaf...

Page 43: ...ROCED R E I I CRANKSHAFT DEFLECTION Service limit 0 0 mm 0 002 in SMALL END DEFLECTION Service limit 3 0 mm 0 12 in SMALL END BORE DIA Service limit 1 6 040 mm 0 631 5 in PISTON PlN 0 D Service limit 1 1 980 mm 0 4717 in ...

Page 44: ... VICI C l ROCED RE 3 13 CARBURETOR Clean each passage of air and fuel with an air gun Idle I 20 0 0 1 mm 0 88 0 02 in Be sure to clean it when overhauling Richer 301 3 3 Check for damage and replace if any ...

Page 45: ...timing is assured Timing advance Timing retard Using a timing light check whether the ig nition timing is correct by running the engine at 4 000 RPM and noting that the marks are aligned properly Flywheel holder 09930 401 13 Sliding shaft 09930 301 02 Attachment C 09930 301 6 1 Wipe off oil o n the taper thoroughly Timing advance 3 0 4 0 kg m 22 0 28 5 lb ft Timing retard ...

Page 46: ...en c 3 J u c 0 2 6 I SER VIC 1 C PR OCED RE 3 15 2 sparks per crankshaft rotation 5 2 V or more a 2 500 r min 8 5 V or less at 8 000 r min 0 7 A or more at 4 000 r min 3 0 A or less at 8 000 r min 12 kV or more at 500 8 000 r min Primary Approx 0 5 n Secondary Approx 15 kn r __ I I I c Secondary voltage r ____1 Ignition timing I I I I I I I I Battery capacitY I I I Lighting capacity I I I Charging...

Page 47: ...a fol lowing continuity test R B OFF OFF OFF Unit lnl 180 220 CHASSIS ELECTRICAL IGNITION COIL High tension cord B Y Using the pocket tester check the ignition coil _t Res istance Kn ob position Core B Y 0 1S1 x 1il 1 Core High tension Approx 1 5 kil x kil B V High tension Approx 1 5 kn x kil ...

Page 48: ... 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 PE I test lead for FZ50 I 09900 28605 Wire as shown in the figure and turn the main switch to ON It is in good condition if the indicator l ight comes on and remains lit I f the light stays off replace it Indicator light PE I test lead ...

Page 49: ...robes and are to be pl ced 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 p robe or pointer on the corresponding terminal listed in the vertical column NOTE CON means a momentary continuity The indicating hand should deflect once and then swing back to the end of the scale infinity Be sure ...

Page 50: ...ither case rep lace it If the sound volume is insufficient turn the adjusting screw while connecting 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 su fficient replace it Connect the lead wire in the headlight housing and the ground wire to the pocket tester set knob range to R and...

Page 51: ...t 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 Set the ki ll switch to O F F position con nect B R wire and ground wire to the pocket tester and check continuity If continuity is found it is i...

Page 52: ...on t Brake Rear Brake 0 SER VICI1 C PROCEDURE 3 21 Place the pocket tester between orange lead wire and white 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 53: ...3 22 SER VICI re PROCF D RF STEERING 0 A 1 IGREASEI Check inner or outer races for wear Check inner or outer we IGREASEI V o Number of steel bal ls Upper 22 pcs Lower 25 pcs ...

Page 54: ... FRONT SUSPENSION Check the shock absorber for oil leakage GR EASE 1 5 2 0 kg m 1 1 0 14 0 lb ft 1 0 1 5 kg m 7 5 1 1 0 lb ft Check the bushing for 1 0 1 5 kg m 7 5 1 1 0 lb ft wear or damage ac c 2 0 3 0 kg m 1 4 5 2 1 5 lb ft ...

Page 55: ...A N D BRAKES WHEELS FRONT CAUTION When applying grease be sure to apply it thin to avoid damaging the brake shoe and braking effeciency REAR Tire pressure 1 i X g cm 2 2 1 psi 1 5 2 0 kg m 1 1 0 14 5 lb ft 1 5 2 0 kg m 1 1 0 14 5 1b ft ...

Page 56: ... 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 0 25 mm 0 01 in BRAKE DRUM Measure inner diameter of both front and rear drums Service limit Front and Rear 100 7 mm 3 95 in BRAKE LINING THICKNESS Service limit 1 5 mm 0 06 in NOTE As an indicator is attached to the rea...

Page 57: ...ai WHEEL RUNOUT Measure axial and radial wheel rim runout of front and rear wheels ce limit Servi AxiaI and Radial TIRE 2 0 mm 0 08 in Measure both front and rear tire tread depth ce limit Servi Front and Rear 1 6 mm 0 063 in I I I ...

Page 58: ...lt C Ji FOJ MA TION 4 1 SERVICING INFORMATION CO NTENTS __ TROUBLESHOOTING 4 2 SPECIAL MATERIALS 4 5 SPECIAL TOOLS 4 6 WIRE AND CABLE ROUTING 4 8 WIRING DIAGRAM 4 1 0 TIGHTENING TORQUE 4 1 1 SERVICE DATA 4 1 2 ...

Page 59: ... cock diaphram Clogged fuel hose 2 Air passage Clogged tank cap b reather hole Air intake due to defective fuel cock vacuum hose Air i ntake due to damaged reed valve gasket Air intake due to loose carbu retor inlet mou nting 3 Carburetor Clogged needle valve Clogged air jet or pilot jet Poor return of choke plunger ELECTRICAL CIRCUIT 1 No sparking at spark plug Bridged carbon fouled or wet spark ...

Page 60: ...fuel level 6 Clogged air cleaner 7 Clogged exhaust muffler 8 Sl ipping clutch see clutch slippage POOR ENGINE PERFORMANCE AT LOW SPEED 1 Carburetor adjustment Air screw adjustment I dling r min out of adjustment I ncorrect fuel level 2 Ignition system I mproperly timed ignition improper stator mounting posit ion I ncorrect spark plug gap 3 Air cleaner element ripped or leaking 4 Air intake through...

Page 61: ...e oil pump 4 Lean fuel air mixture Carburetor float level Clogged carburetor jet 5 Dragging brake DEFECTIVE CLUTCH 1 Slippi ng clutch Worn or burnt clutch shoe 2 Disengaged clutch Poor operation of clutch drive shoe 3 I ncorrect clutch engagement r min Defective clutch spring Worn or burnt clutch drive shoe 4 Not smooth idling Defective clutch spring Too high idling r min ...

Page 62: ...ometer o Brake cam shaft o Speedometer gears o Front shock absorber arm and arm shaft o Crankcase mating surface o Muffler fitting bolt 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 o Cyli nder stud bolts USE OF GENUINE SUZUKI PARTS To replac...

Page 63: ... 21 1 01 Electro tester SS I I 09900 281 06 SPECIAL TOOLS Clutch holder 09920 30220 Shock d river set 09900 09002 CCI oil measuring tool 09900 21 602 6mm stud bolt installer 09910 1 01 1 0 Bearing remover I D 1 2mm 0992 1 202 1 0 Thickness gauge 09900 20804 Pocket tester 09900 25002 Con rod stopper 0991 0 201 1 5 ...

Page 64: ...0 401 1 3 Steering race installer 09941 3451 1 Bearing installer 0991 3 75820 Rotor remover shaft 09930 30102 Steering stem lock nut wrench 09940 101 22 SHR VJCJ C I FORMA TIO 4 7 Crankshaft remover 09920 131 1 1 Attachment C Screw 27mm 09930 301 61 Steering race installer 09940 531 1 1 ...

Page 65: ...4 8 SER VICI re Ii FORMll no WIRE AND CABLE ROUTI NG WIRING ROUTING ...

Page 66: ...Front brake cable Rear brake cable Speedometer cable Choke cable Front brake cable Horn clamp Speedometer cable 0 m r m n 0 c f z C c s Q 0 ...

Page 67: ...IGHTJ i t p l 7W B W a i DIMMER SWITCH HORN SWITCH ENGINE KILL SWITCH HORN OFF ON IGNITION SWITCH a i ifc SE RECTIFIER BATTERY SV 4Ah WIR E COLOR W White Y Yellow R Red O Orange G Groon Gr Gray 8 W Black with White tracer W R White with Red tracer B Y Black with Yellow tracer 8 R Black with Red tracer R B Red with Blac k tracer e l J z G c G IJ s 0 l l s Ci 2 2 0 ...

Page 68: ... lever nut 1 0 5 0 8 4 0 5 5 Front suspension arm lower nut 2 1 0 1 5 7 5 1 0 5 Front suspension arm rear nut 2 2 0 3 0 1 4 5 21 5 Front suspension arm damper nut 2 1 0 1 5 7 5 1 0 5 F ront shock absorber upper bolt 2 1 5 2 0 1 1 0 1 4 0 Rear shock absorber upper nut 1 2 0 3 0 1 4 5 21 5 Rear shock absorber lower bolt 1 2 0 3 0 1 4 5 2 1 5 Rear brake cam lever nut 1 0 5 0 8 4 0 5 5 Rear axle nut 1...

Page 69: ...0 1 0 0 00 4 0 010 Pi ton ring width 1st 1 7 1 9 10 067 0 0 75 2nd 1 5 1 7 0 0 59 0 067 Piston pin Pin bore clearance 0 002 tight 0 0 1 0 0 0001 0 0004 Piston pin bore 1 0 1 1 998 1 2 006 0 4724 0 4727 Piston pin 0 0 1 1 996 1 2 000 0 4723 0 4724 CRANKSHAFT ITEM STANDA R D Con rod small end bore 16 003 1 6 01 1 0 6300 0 6304 Con rod deflection small end Con rod big end wear Crankshaft runout OIL P...

Page 70: ...pitch length STANDAR D Low 87 00 87 1 5 3 425 3 431 2nd 105 00 1 05 1 5 4 134 4 140 Low 2nd Low 2nd 2 500 200 r min 3 800 200 r min 21 t2 km h 1 3 1 mph 0 0 03 0 0 00 1 2 STAN DAR D 1 000 8 696 31 13 x 62 1 7 2 1 37 62 29 1 421 54 38 0 05 0 1 0 0 002 0 004 D l D 270 H 64 links 1 70 0 6 69 SER VICING I FORM ITIO 4 t3 Unit mm in LIMIT 87 40 3 441 1 05 50 4 1 54 No groove at any part No groove at any...

Page 71: ...CATION Ignition timing 20 B T D C at 4 000 r min Spark plug NGK BP 4HA or ND W14FP U L Spark plug gap 0 6 0 8 0 024 0 03 1 Ignition coil resistance primary Approx 0 5 n Ignition coil resistance secondary Approx 15 k Q Magneto coil resistance charge Y R W R Approx 0 4 Q Magneto coil resistance lighting Y R Ground Approx 0 2 i1 Magneto coil resistance primary B R R B Approx 200 n Battery capacity YU...

Page 72: ...psi SUSPENSION ITEM Front wheel travel Rear wheel travel Engine mounting pivot shaft runout CAPACITY ITEM Fuel tank including reserve reserve Engine oil tank Transmis sion oil Fuel type Engine oil type Transmission oil type STANDARD 78 3 1 82 3 2 SPECI F I CATION 4 5 L 1 2 1 0 US Imp gal 0 9 L 0 24 0 20 US Imp gal 1 2 L l 27 1 06 US Imp qt Change Overhaul 800 ml 850 m l 800 cc 0 85 0 70 US Imp 850...

Page 73: ... Prepared by SUZUKI MOTOR CO LTD Service Department OverSeas Operations Division April 1 979 SR 0560 Printed in Japan ...

Page 74: ...SUZUKI MOTOR 1CO LTD ...

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