Suzuki GN125F Service Manual Download Page 32

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REMOVING ENGINE PARTS WITH ENGINE IN PLACE

E N G I N E

3-1

UPPER SIDE OF ENGINE

RIGHT SIDE OF ENGINE

LEFT SIDE OF ENGINE

Chain tensioner

Cam shaft

Cylinder head cover

Cylinder head
Cylinder
Piston

Oil filter
Clutch cover
Clutch
Oil pump
Gear shifting shaft

Sprocket cover
Starting motor
Generator rotor
Starting clutch
Generator stator
Trigger coil

3-6
3-6
3-7
3-7

3-17
3-17

3-21
3-21
3-22
3-25
3-26

3-27
3-27
3-27
3-28
3-28
3-28

Summary of Contents for GN125F

Page 1: ...GN125F 99500H3030DE001...

Page 2: ...ion If modifications have been made since then differ ences may exist between the content of this manual and the actual motorcycle Illustrations in this manual are used to show the basic principles of...

Page 3: ...Roller bearing Spacer ITEM 9 10 Front tire Front wheel rim Speedometer gear driver Oil seal HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR 1 The text of this manual is divided into 7 secti...

Page 4: ...99000 25140 Apply or use the absorber oil Apply THREAD LOCK 1342 99000 32050 Apply THREAD LOCK 1303 99000 32030 Apply or use the brake fluid Measure voltage Apply sealant 1215 99000 31110 Apply seala...

Page 5: ...low with White tracer B Bl B Br B G B R B W B Y Bl W Bl Y Br Y G Y O B Black with Blue tracer Black with Brown tracer Black with Green tracer Black with Red tracer Black with White tracer Black with Y...

Page 6: ...GENERAL INFORMATION 1 CONTENTS 1 1 1 1 1 1 2 1 2 1 2 1 3 WARNING CAUTION NOTE GENERAL PRECAUTIONS SERIAL NUMBER LOCATION FUEL AND OIL RECOMMENDATION BREAK IN PROCEDURE SPECIFICATIONS...

Page 7: ...AUTION stated you must use good judgment and basic mechanical safety principles If you are unsure about how to perform a particular service operation ask a more experienced technician for advice Prope...

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

Page 9: ...ring the manufacture only the best ossible are used and all machined parts are finished to a very high standard allow the moving part to BREAK IN subjecting the engine to maximum stresses s the care a...

Page 10: ...troke 1 57 mm 48 8 mm 124 ml 9 2 1 BS type P Wet sump olyurethane foam element Electric Type Number of cylinders Bore Stroke Piston displacement Compression ratio Carburetor Air cleaner Starter system...

Page 11: ...teering angle Caster Trail Turning diameter Front brake Rear brake Front tire size Rear tire size Front absorber stroke Telescopic coil spring oil damped Swingarm type 5 level adjustable coil spring o...

Page 12: ...AIR FILTER MUFFLER NUT AND BOLT CYLINDER HEAD CYLINDER BOLTS AND NUTS VALVE CLEARANCE SPARK PLUG ENGINE OIL ENGINE OIL FILTER OIL SUMP FILTER CLUTCH CABLE PLAY CARBURETOR IDLING THROTTLE CABLE PLAY FU...

Page 13: ...km Muffler bolts 2 5 Tighten Tighten Clutch 2 8 Throttle cable clearance Inspect 2 8 Fuel strainer Inspect 2 9 Inspect Drive chain Inspect clean and lubricate every 1 000 km 2 10 Tighten Tighten 2 5...

Page 14: ...l not to apply too much grease to the brake cam shafts If grease gets on the linings break slippage will result Interval Item Month Km 6 12 Speedometer cable Speedometer gear box Grease Grease Lubrica...

Page 15: ...off the machine take it off and charge it from a recharger Charging the battery in place can lead to failure of the regulator rectifier O To install the battery reverse the procedure described above...

Page 16: ...e in output and an increase in fuel consumption Remove the plug and drain water and oil at the periodic maintenance interval Remove the left frame cover Remove the screws and take off the air filter c...

Page 17: ...ances indicated above check and adjust the valve clearance to the following specification Remove the spark plug and valve inspection caps Remove the generator cover cap and rotate the generator rotor...

Page 18: ...ial 1 000 km and every 5 000 km replace every 10 000 km TYPE Hot type Standard Cold type NGK CR7E CR8E CR9E Remove the carbon deposits with a wire of pin and adjust the spark plug gap to 0 7 0 8 mm me...

Page 19: ...with an oil viscosity of SAW 10W 40 engine Required amount of engine oil Oil change 850 ml Oil filter change 950 ml Overhaul 1 300 ml ENGINE OIL FILTER Clean initial 1 000 km and every 5 000 km Repla...

Page 20: ...play Use the adjuster for minor adjustment Tighten lock nut while holding the adjuster in position CARBURETOR Inspect initial 1 000 km and every 5 000 km IDLING ADJUSTMENT Make this adjustment when th...

Page 21: ...rior to its exterior The fuel strainer should be inspected and cleaned periodically If the fuel strainer is damaged replace it immediately THROTTLE CABLE PLAY 0 5 1 0mm After adjustment is completed c...

Page 22: ...lubricate the drive chain with chain lube or new engine oil Adjust the drive chain slack to the proper specification The drive chain may require more frequent adjustment than periodic maintenance sche...

Page 23: ...the thickness of front brake disc replace the front brake disc with new one if the thickness is less than 3 5mm The extent of brake pad wear can be checked by observing the grooved limit line on the...

Page 24: ...brake fluid circuit be purged of air in the following manner Fill up the master cylinder reservoir to the upper line Replace the reservoir cap to prevent entry of dirt Attach a pipe to the caliper ble...

Page 25: ...25 mm Adjust rear brake light switch so that brake light will come on just before a pressure is felt when the brake pedal is stepped REAR BRAKE LIGHT SWITCH REAR BRAKE LINING WEAR LIMIT The motorcycle...

Page 26: ...initial 1 000 Km and every 5 000 Km Steering stem bearings should be adjusted properly for smooth turning of the handlebars and safe running Steering which is too stiff prevents smooth movement of ha...

Page 27: ...s and they must be in good condition for safety They must be re tightened as necessary to the specified torque with a torque wrench ITEM N m Kg m 1 Front axle nut Front brake caliper mounting bolts 2...

Page 28: ...PERIODIC MAINTENANCE 2 16...

Page 29: ...14 kg cm 2 When the compression pressure noted is down to or below the limit indicated above the engine must be disassembled inspected and repaired as required 2 1 1 2 17 Cylinder compression is an in...

Page 30: ...cally inspect oil pressure of engine so as to ascertain the state of moving parts Oil pressure specification Above 10 kPa 0 1kg cm Below 30 kPa 0 3kg cm 2 2 at 3 000rpm Oil temperature 60 Engine strai...

Page 31: ...GINE IN PLACE ENGINE REMOVAL AND REMOUNTING CYLINDER HEAD AND VALVE CYLINDER AND PISTON CLUTCH OIL PUMP GEAR SHIFTING SHAFT GENERATOR AND STARTING CLUTCH CRANKSHAFT TRANSMISSION AND KICK STARTER DEVIC...

Page 32: ...INE Chain tensioner Cam shaft Cylinder head cover Cylinder head Cylinder Piston Oil filter Clutch cover Clutch Oil pump Gear shifting shaft Sprocket cover Starting motor Generator rotor Starting clutc...

Page 33: ...motorcycle with main stand Drain the engine oil Remove the left and right seat mounting bolts and left rear shock absorber nut then take off the seat Remove the left and right side cover Remove the ba...

Page 34: ...ake off the engine sprocket cover Disconnect the ground wire from the crankcase Take off the drive chain by removing the clip Remove the crankcase breather pipe Remove the speedometer cable mounting s...

Page 35: ...engine upper mounting bolt and rear lower mounting bolt Remove the rear swing arm shaft nut draw out the rear swing arm shaft take out the engine from the right side Be careful not to draw out the swi...

Page 36: ...engine mounting nuts are self lock nuts Once the nut has been removed it is no longer of any use Be sure to use new nuts and tighten them to the specified torque Temporarily fasten the engine mountin...

Page 37: ...L Drain the engine oil take off the engine Refer to page 3 2 Remove the generator cover cap and valve timing inspect ing plug Bring the piston to top dead center Remove the camshaft chain tensioner Lo...

Page 38: ...the cylinder head side nuts and cylinder side nuts Loosen the cylinder head cover nuts diagonally then detach the cylinder head Remove the rocker arm shaft set bolts Pull out the rocker arm shafts wit...

Page 39: ...the cylinder head cover on a plain plate and check for distortion with a thickness gauge Check points are shown in Fig If the distortion exceeds the limit replace the cylinder head cover Measure the...

Page 40: ...limit or not by measuring camshaft journal oil clearance with the camshaft installed Use the plastigage to read the clearance at the widest portion install the cylinder head cover and tighten the cyl...

Page 41: ...r abnormal wear Measure the valve stem O D CYLINDER HEAD 09900 20803 Thickness gauge VALVE STEM 09900 20205 Micrometer 0 25 mm Visually inspect each valve for wear of its seating face Replace any valv...

Page 42: ...e valve face in a rotating manner in order to obtain a clear impression contact The ring like dye impression left on the valve face must be continuous without any break The impression contact can be u...

Page 43: ...45 o Contact surface is too low Contact surface is too high 30o 60o Using the 45 reamer descale and cleanup the seat with one or two turns o The valve seat position will affect the contact surface of...

Page 44: ...nder head and valve Check the valve seat contact surface again If the lapping pressure is too big valve seat will be possibly distorted or damaged Change the lapping tool angel frequently to prevent v...

Page 45: ...140 MOLY PASTE M NOTE When a valve spring is mounted the seal ring side should face the combustion chamber In order to avoid oil seal damage the valve oil seal should be mounted while the valve is rot...

Page 46: ...hly with detergent Lubricate the rocker arm shaft with engine oil Mount the rocker arm rocker spring flexuous washer and rocker arm to the cylinder head cover Tighten the rocker arm shaft set bolts to...

Page 47: ...and cam sprocket Align the marks on the camshaft so it is parallel with the surface of the cylinder head Apply Thread lock to the bolts 99000 32030 Thread lock 1303 99000 31110 Bond No 1215 Wipe up t...

Page 48: ...ken down Remove the cylinder head Refer to page 3 7 Remove the gasket dowel pins and guide rod Remove the cylinder Clean the remaining gasket on the cylinder surface Check the gasketed surface of the...

Page 49: ...to the suitable position with marked side upward Measure the clearance between the piston ring and groove with a thickness gauge Measure the piston outside diameter at the place 8mm from the skirt en...

Page 50: ...piston rings should be staggered at 120 Carefully fit the piston rings to the piston with marked side to the top Clean the top skirt or groove of the piston Install the piston and cylinder in the reve...

Page 51: ...the piston pin circlip with long nose pliers Replace with a new piston pin circlip to prevent circlip slipping from position End gap of the circlip should not be aligned with the cutaway in the pisto...

Page 52: ...ilter cover Remove the oil filter Remove the clutch cover screws diagonally take off the clutch cover Remove the gasket and dowel pins REMOVAL Remove the clutch spring bolts diagonally Remove clutch p...

Page 53: ...ve the clutch hub and washer Remove the primary driven gear spacer and washer Measure the thickness and claw width of each drive plate with vernier calipers Replace the drive plates found to have worn...

Page 54: ...00 20103 Vernier calipers Clutch spring free length limit 29 45 mm Inspect the clutch release bearing for any abnormality parti cularly cracks to decide whether it can be reused or should be replaced...

Page 55: ...ive hub Install the lock washer tighten the clutch sleeve hub nut to the specified torque Set the marked side of clutch spring faces outside Install the clutch push rod push piece bearing washer and p...

Page 56: ...lock 1342 to the oil pump mounting bolts and tighten the bolts 99000 32050 Thread lock 1342 REMOVAL OIL PUMP Remove the clip oil pump driven gear and oil pump driven gear pin Remove the oil pump Rotat...

Page 57: ...gear shifting cam guide plate and Remove the gear shifting driven gear pawl gear shifting pawl pin and return spring Remove gear shifting lever Remove the clutch Refer to page 3 20 INSPECTION REASSEMB...

Page 58: ...r rotor nut while holding the generator rotor with the special tool Remove the generator cover Remove the gasket and dowel pins Remove the starting motor by removing the bolts Remove the engine sprock...

Page 59: ...ush piece and spring from the starting clutch Remove the starter clutch gear Remove the generator rotor and key with the special tool 11F14 003 M16 screw 11F14 001 Rotor holder 11F14 005 Generator rot...

Page 60: ...y moving Install the stator cable pressure plate apply the Thread lock to the bolt and tighten it Install the trigger coil apply Thread lock to the screw head and tighten it Apply bond to the grommet...

Page 61: ...lling the rotor align the rotor key slot with the key on the crankshaft Install the generator nut tighten the nut to the specified torque When installing the key take care not to damage the key slot a...

Page 62: ...neutral locating screw plug inner hexagon when drain the engine oil Remove the gear shifting cam guide Remove the gear shifting cam driven gear assembly Remove the gear switch position screws take of...

Page 63: ...Crankcase separator 09920 13120 09920 13120 Crankcase separator The crankshaft and transmission components must remain in the left crankcase half This is necessary because the gear shifting cam stopp...

Page 64: ...g fork thickness Using a thickness gauge check the shifting fork clearance in the groove of its gear If the clearance limit exceeds by any gear determine whether the gear or the gear shifting fork sho...

Page 65: ...n Remove the bearing locating plates on left and right crankcase Rotate the inner race by hand to inspect for an abnormal noise and a smooth rotation and inspect to see if the outer race is movable in...

Page 66: ...attention to the following points REASSMEBLY 09913 70210 Bearing installer BEARING CRANKSHAFT Decide the width between the webs when rebuilding the crankshaft Width between webs Standard 52 9 53 1 mm...

Page 67: ...d TRANSMISSION Never reuse a circlip After a circlip has been removed from a shaft it should be discarded and a new circlip must be installed When installing a new circlip care must be taken not to ex...

Page 68: ...install it so that the length as shown in Fig A A 99000 32030 Thread lock super 1303 The procedure may be performed only twice before shaft replacement is required GEAR SHIFITNG HUB AND FORKS Counters...

Page 69: ...alf 99000 31110 Bond No 1215 99000 25010 Super grease A A After the driven gear guide shifting shaft and neutral stopper have been fitted confirm that gear change is normal while turning the countersh...

Page 70: ...FUEL AND LUBRICATION CONTENTS FUEL COCK CARBURETOR LUBRICATION SYSTEM 4 1 4 3 4 7 4...

Page 71: ...ove the fuel filter Remove the fuel cock Clean filter with compressed air and inspect for cracks Rust from the fuel tank tends to build up in the filter which when the filter has been neglected for a...

Page 72: ...everse order of removal Pay attention to the following points Install the fuel cock Install the fuel filter Gasket must be replaced with a new one to prevent leakage Gasket Do not miss to install the...

Page 73: ...ONSTRUCTION A E B C D ITEM SPECIFICATION ITEM SPECIFICATION Carburetor type I D No Main jet Bubbling jet Needle Needle jet Idle jet Idle air screw Idle air jet 12 5 0 390 P 4DH41 2 3 110 054G BS26 140...

Page 74: ...Disconnect the carburetor balance pipe Remove the carburetor clamp screw Remove the throttle cable Remove the fuel hose Remove the carburetor Remove the carburetor diaphragm cover Remove the spring di...

Page 75: ...ll continue flowing and cause it to overflow Clean the float chamber and float parts with gasoline if the needle is worn as shown in the illustration replace it together with a valve seat Clean the fu...

Page 76: ...der idle running condition Adjust the idle speed by means of the pilot screw IDLING ADJUSTMENT A A Throttle cable play 0 5 1 0 mm If engine running is needed in work be sure to keep the work area well...

Page 77: ...nal and cam face Camshaft Conrod small end bearing Cylinder wall Conrod big end bearing Driveshaft bearing Drive shaft and gears Clutch plates Primary driven gear spacer Countershaft and gears Counter...

Page 78: ...CHASSIS CONTENTS FRONT WHEEL FRONT ABSORBER STEERING STEM FRONT BRAKE REAR WHEEL AND REAR BRAKE REAR ABSORBER AND REAR SWING ARM 5 1 5 6 5 12 5 18 5 24 5 30 5...

Page 79: ...36 52 3 6 5 2 18 28 1 8 2 8 B B Front axle Front axle nut Oil seal Brake disc bolt Spacer Dust seal Washer Brake disc Roller bearing Spacer Front tire Front rim Speedometer gear driver Oil seal Speedo...

Page 80: ...the front wheel Remove the speedometer gearbox assembly Remove the front axle spacer and front wheel assembly dust seal Flatten the lock washer remove the brake disc bolts take off the brake disc Rem...

Page 81: ...304 V block 100mm WHEEL RIM Wheel rim runout Service limit 2 0 mm Wheel axle runout Service limit 0 25 mm Make sure that the wheel rim runout does not exceed the service limit when checked as shown An...

Page 82: ...e outside 09924 84521 Bearing installer a B A Left bearing Spacer Right bearing Removed wheel bearing LH RH Clearance Install left wheel bearing first then install the spacer and right wheel bearing w...

Page 83: ...the front wheel and front axle tighten the front axle nut to the specified torque N m Front axle nut 36 52 SPEEDOMETER GEAR BOX 99000 25010 Super grease A Before installing the speedometer gear box ap...

Page 84: ...ring Plug Tube Oil lock piece Oil seal ITEM N m kgf m A 4 5 6 12 13 Washer Rebound spring Ring Oil seal Outer tube 7 8 14 A B Damper rod Inner tube Front axle pinch bolt Oil seal stopper ring Seal ri...

Page 85: ...cap bolt and draw out the spacer and absorber spring 1 Remove the four bolts and take off the front fender Remove the four handlebar holder clamp bolts take off the handle bar then remove the two fro...

Page 86: ...damper rod bolt by using the special tools and hexagon wrench Remove the oil lock piece and damper rod with rebound spring Separate the inner tube from the outer tube Remove the stopper ring Remove th...

Page 87: ...eplace it Apply Bond No 4 and Thread Lock Cement to the damper rod bolt and tighten the bolt by using the hexagon wrench and special tools Remounting the front fork in the reverse order of removal pay...

Page 88: ...side FRONT ABSORBER INNER SCREW PLUG Install the front absorber inner screw plug and tighten it CAUTION ABSORBER OIL Absorber oil type 32 Pour the specified absorber oil into the inner tube Front abso...

Page 89: ...ghten the front absorber lower bracket clamp bolts to the specified torque Lower bracket clamp bolt 25 35 N m Install the front absorbers to the upper and lower bracket tighten the front absorber cap...

Page 90: ...Dust seal Handlebar clamp bolt Lower bracket clamp bolt 8 9 B C Upper bearing outer race 10 Steering stem bolt Washer Ball Upper bearing inner race Lower bearing inner race Ball Lower bracket 1 2 3 4...

Page 91: ...e the two bolts and take off the headlight housing Remove the two nuts and take off the turn signal lights right and left Loosen the lower bracket bolts Remove the tachometer cable Remove the front wh...

Page 92: ...f the handlebar Remove the front absorber cap bolts and steering stem nut take off the upper bracket Take off the front absorbers 1 1 Remove the steering stem nut and draw out steering stem 09940 1491...

Page 93: ...steel balls Remove the outer race fitted on the steering stem This can be down with a chisel Draw out the two inner races fitted to the top and bottom ends of the head pipe with the special tool Insp...

Page 94: ...a special tool Apply grease to the upper and lower inner races when installing the steel balls Apply grease on the new lower oil seal Press in the lower outer race with the special tool 99000 25010 Su...

Page 95: ...teer stem bolt 35 55 N m After performing the adjustment and installing the steering stem upper bracket rock the front wheel assembly forward and backward to ensure that there is no play and that the...

Page 96: ...STRUCTION 1 B 2 C 3 4 5 A Brake lever Piston cup set Brake light switch Brake hose Pad set Master cylinder clamping bolt Brake hose union bolt Air bleeder valve ITEM N m kgf m A B 8 12 0 8 1 2 20 25 2...

Page 97: ...brake disc or brake pad reduces braking performance Discard contaminated pads and clean the disc with high quality brake cleaner or neutral detergent Immediately and completely wipe off any brake flu...

Page 98: ...piston to prevent popping up Force out the piston by using air gun Remove the piston piston boot and piston seal Inspect the master cliper bore for any scratches or other damage Do not use high press...

Page 99: ...Reassemble the cliper in the reverse orders of disassembly and removal and also carry out the following steps RUBBER PARTS BRAKE DISC 09900 20205 Micrometer 0 25 mm Wash the master cylinder component...

Page 100: ...underneath the union bolt on the master cylinder to catch spilled drops of brake fluid Unscrew the union bolt and disconnect the brake hose from the master cylinder joint Remove two clamp bolts and ta...

Page 101: ...erse orders of disassembly and removal and also carry out the following steps REASSEMBLY Brake fluid specification Suzuki brake fluid When washing the components use the specified brake fluid Never us...

Page 102: ...al Roller bearing Rear sprocket drum retainer Rear sprocket drum Brake rod Brake shoe Rear break anchor panel Brake cam lever Rear wheel Roller bearing Spacer Rear axle nut ITEM N m kgf m A B 50 80 5...

Page 103: ...axle nut Loosen the chain adjuster lock nut and adjuster bolt right and left Draw out the axle shaft and take off the chain from rear sprocket Take off the rear wheel and separate the brake panel from...

Page 104: ...nd Rotate the inner race by hand to inspect whether abnormal noise occurs and it rotates smoothly Replace the bearing if there are any defects INSPECTION WHEEL BEARING Play Play Remove the cushion fro...

Page 105: ...s indicated inside the drum Check the brake shoes and decide whether is should be replaced or not from the thickness of the brake shoe linings Inspect the cushion for wear and damage 09900 20606 Dial...

Page 106: ...sing the special tool Insert the bearing by using the special tool Apply grease to the mounting drum as shown 99000 25010 Super grease A 99000 25010 Super grease A First install the bearing for right...

Page 107: ...se A Be careful not to apply too much grease to the brake cam If the grease gets on the lining the brake slippage will result WARNING BRAKE CAM LEVER Install the brake cam lever and tighten the cam le...

Page 108: ...haft Dust seal Thrust washer Oil seal Spacer Spacer Washer Rear torque link Rear swing arm Lock washer Bolt Chain buffer Rear swing arm pivot nut Rear torque link nut ITEM N m kgf m A B 50 80 5 0 8 0...

Page 109: ...hain case mounting screws take off the chain case Remove the swing arm pivot nut and draw out the shaft Remove the swing arm Pull off the cotter pin and remove the nut and bolt Remove the torque link...

Page 110: ...and remount the swing arm in the reverse order of disassembly and removal and also carry out the following steps Force fit the bushings into the swing arm by using the special tool Apply grease to th...

Page 111: ...E L E C T R I C A L CONTENTS STARTER SYSTEM IGNITION SYSTEM CHARGING SYSTEM DASHBOARD LIGHTS SWITCHES BATTERY 6 1 6 5 6 7 6 11 6 12 6 12 6 15 6 6...

Page 112: ...er relay Starter motor Fuse Clutch switch Battery TROUBLESHOOTING Starter motor will not run Check whether to hear the click noise from the starter relay when the starter button is pushed Check whethe...

Page 113: ...ween Y G and W B when the starter button is pushed Voltage measured Faulty ignition switch Faulty front brake light switch Faulty rear brake light switch Faulty starter button Poor contact of connecto...

Page 114: ...ase to the groove 2 of the housing end out side Align the match mark on the starter motor case with the match mark on the housing end inside STARTER RELAY INSPECTION Remove the left frame cover Remove...

Page 115: ...stance between the terminals using the multi circuit tester If the resistance is not within the specified value replace the starter relay with a new one 09900 25008 Pocker tester Starter relay resista...

Page 116: ...tion coil resulting in strong spark between the spark plug cap TROUBLINGSHOOTING No spark at plug Inspect the battery voltage Recharge the battery or replace the battery Less than 12V Check the igniti...

Page 117: ...p Tester knob indication X1 range Trigger coil Measure resistance between lead wires using multi circuit tester If resistance is out of specified values replace with new trigger coil 09900 25008 Pocke...

Page 118: ...Faulty generator rotor Inspect battery leak current Inspect charging voltage between battery terminals Inspect continuity of generator coils Inspect generator no load voltage Incorrect Correct Leak In...

Page 119: ...ng an ammeter Do not turn the ignition switch to the ON position when measuring current GENERATOR COIL INSPECTION Remove the right side cover Disconnect generator coupler Measure the resistence betwee...

Page 120: ...is during the removal the generator coil Regulator rectifier inspection If the resistance checked is incorrect replace the regulator rectifier Battery DC Pocket tester CHARGING OUTPUT INSPECTION Remov...

Page 121: ...amaged FUEL METER Disconnect fuel level gauge coupler Refer to page 4 2 To test the fuel meter two different checks may be used The first connect a jumper wire between B W and Y B wires coming from th...

Page 122: ...ty measured is incorrect replace the respective parts DASHBOARD INSPECTION When making this test it is not necessary to remove the dashboard 09900 25008 Multi circuit tester Tester knob indication Con...

Page 123: ...TAIL LIGHT BRAKE LIGHT SWITCHES Inspect each switch for continuity with the pocket tester If any abnormality is found replace the respective switch assemblies with new ones 09900 25008 Pocket tester T...

Page 124: ...ELECTRICAL 6 13 STARTER SWITCH FRONT BRAKE LIGHT SWITCH OFF ON OFF B B Y G O W 2 ENGINE STOP SWITCH O B O W DIMMER SWITCH TURN SIGNAL LIGHT SWITCH HORN SWITCH B L B W OFF Y W W Y B Sb Lg 1 1 2 3 4 5 3...

Page 125: ...RICAL 6 14 REAR BREAK LIGHT SWITCH O W B OFF ON GEAR POSITION INDICATION LIGHT SWITCH Neutral Low 2nd 3rd 4th Top Y L Br R G L W Y R B L Ground CLUTCH SWITCH B Y B W PASS SWITCH Y O FREE PUSH PUSH 10...

Page 126: ...low o o o o Standard Charging current 0 7 A In fitting the battery to the motorcycle connect the breather tube to the battery vent Servicing CHARGING TIME Months after manufacturing 6 12 Over 12 Neces...

Page 127: ...with chart to determine the recharging time in hours by constant current charging at a charging rate of 0 7A Be careful not to permit the electrolyte temperature to exceed 45 C at any time during the...

Page 128: ...SERVICING INFORMATION CONTENTS TROUBLESHOOTING SPECIAL TOOLS TIGHTENING TORQUE SERVICE DATA WIRE AND CABLE ROUTING WIRING DIAGRAM 7 1 7 7 7 9 7 11 7 16 7 18 7...

Page 129: ...an or replace Clean and dry Replace Replace Replace Clean Clean or replace Replace Clean or replace Clean or replace 1 Fouled spark plug 2 Defective trigger coil 3 Defective ignitor unit 4 Clogged fue...

Page 130: ...or replace Replace Clean 1 Valve springs weakened 2 Valve timing out of limit 3 Worn cams or rocker arms 4 Spark plug gap too narrow 5 Defective ignition coil 6 Clogged air cleaner element 7 Clogged...

Page 131: ...lace Replace Check and adjust Clean BRAKES Complaint Poor braking Brake squeaking Excessive brake lever free stroke Leakage of brake fluid Symptom and possible causes Remedy 1 Not enough brake fluid i...

Page 132: ...e 4 Loose nut on axle 1 Weakened springs 2 Not enough absorber oil 1 Absorber oil too viscous 2 Too much oil absorber 1 Not enough oil 2 Loose nuts on absorbers absorbers 1 Distorted wheel rim 2 Worn...

Page 133: ...plug Adjust Replace Tighten Adjust carburetor 1 Opened or shorted in lead wires or loose lead connections 2 Shorted grounded or opened generator coils 3 Shorted or destroyed regulator rectifier Repai...

Page 134: ...umulation of sediments caused by the high electrolyte S G 4 Electrolyte S G is too low 5 Contaminated electrolyte 6 Battery is too old Check the generator regulator rectifier and circuit connections a...

Page 135: ...16 Conrod holder 09900 20508 cylinder bore gauge kit 1 100mm 40 80mm 09900 21304 V block set 100mm 09910 34510 Piston pin puller 09923 73210 Bearing remover 15 17 mm 09900 20103 Vernier calipers 1 50m...

Page 136: ...14 010 Front absorber tools 09941 74910 Bearing installer 11F14 018 Valve spring tools 11F14 001 Rotor holder 11F14 017 Valve adjust spring 09941 34513 Bearing installer 11F14 019 T valve adjust wrenc...

Page 137: ...olt Tensioner bolt Camshaft sprocket bolt Generator rotor nut Starter clutch bolt Engine mounting bolt Engine hanging bolt 0 9 1 0 2 1 2 5 1 0 1 3 0 8 1 2 2 0 2 5 4 0 6 0 3 0 5 0 2 5 3 5 0 8 10 1 1 1...

Page 138: ...wing arm pivot bolt 12 20 20 30 35 55 25 35 36 52 18 28 6 9 18 28 20 25 8 12 50 80 22 35 50 80 6 8 10 16 18 28 34 50 1 2 2 0 2 0 3 0 3 5 5 5 2 5 3 5 3 6 5 2 1 8 2 8 0 6 0 9 1 8 2 8 2 0 2 5 0 8 1 2 5 0...

Page 139: ...0 9 1 1 Unit mm LIMIT 0 35 0 05 0 5 0 03 31 24 33 58 CAMSHAFT CYLINDER HEAD ITEM Cam height Camshaft journal oil clearance Rocker arm I D Rocker arm shaft O D Cylinder head distortion Cylinder head co...

Page 140: ...h STANDARD 1st 1st 1st 1st 1st 2nd 2nd 2nd 2nd 2nd Oil 1 000 1 400 kPa 0 030 0 051 57 010 57 015 56 964 56 970 Measure at 8 mm from the skirt end Approx 7 2 Approx 5 8 0 10 0 25 0 10 0 25 1 01 1 03 1...

Page 141: ...T 259 0 mm STANDARD 10 15 2 9 3 1 11 8 12 0 31 STANDARD Low 2nd 3rd 4th Top Type Links 20 pitch length 3 470 59 17 2 867 43 15 3 000 33 11 1 857 26 14 1 368 26 19 1 095 23 21 0 957 22 23 KMC428HG 116...

Page 142: ...4 6 15 4V at 5 000 r min 12N7 4A 12 V7Ah 1 28 0 01 20 o C 15 A Approx 110 Headlight HI LO Tail Brake light Turn signal light Position light ITEM LIGHT ITEM Spark plug Ignition coil resistance Generato...

Page 143: ...Wheel axle runout Brake drum I D Brake lining thickness ITEM FUEL OIL Fuel type Fuel tank capacity Engine oil type and grade STANDARD LIMIT 130 385 5 168 3 ml 0 6 2nd STANDARD LIMIT Front Front Front...

Page 144: ...WIRE ROUTING SERVICING INFORMATION 7 16...

Page 145: ...SERVICING INFORMATION 7 17...

Page 146: ...B Y B B W Y B B W OW W G L L W O W B W Y Y Y B B B R B W B R B W O O W B W B O Sb R R R B W B W L Gr Y G R Y Y Y L G B W L G L G L Br R Br R Y L Y L G L G L R B R B W Y W Y L L B B R Y W Y W O O Y Y...

Page 147: ...JIANG MEN DACHANGJIANG GROUP CO LTD Customer service department 1st Ed DEC 2014 Printed in China...

Page 148: ...SUZUKI MOTOR CORPORATION JIANGMEN DACHANGJIANG GROUP CO LTD...

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