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Suzuki GZ250 Marauder, Service Manual

The Suzuki GZ250 Marauder Owner's Manual is a comprehensive guide that provides essential information and instructions for owners of this powerful motorcycle. Accessible for free download at manualshive.com, this manual equips riders with the necessary knowledge to safely operate and maintain their GZ250 Marauder, ensuring an optimal riding experience.

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GENERAL INFORMATION     1-2 

CAUTION

 

*  If  parts  replacement  is  necessary,  replace  the  parts  with  Suzuki  Genuine  Parts  or  their  

equivalent.

 

*  When  removing  parts  that  are  to  be  reused,  keep  them  arranged  in  an  orderly  manner  

so that they may be reinstalled in the proper order.

 

*  Be sure to use special tools when instructed. 
*  Make sure that all parts used in reassembly are clean. Lubricate them when spec ified. 
*  Use the specified lubricant, bond, or sealant. 
*  When  removing  the  battery,  disconnect  the  negative  cable  first  and  then  the  positive 

cable. 

 

*  When  reconnecting  the  battery,  connect  the  positive  cable  first  and  then  the  negative 

cable, and cover the positive terminal with the terminal cover. 

*  When performing service to electrical parts, disconnect the battery negative cable un less 

the service procedure requires the battery power. 

*  When  tightening  cylinder  head  and  crankcase  bolts  and  nuts,  tighten  the  larger  sizes 

first.  Always  tighten  the  bolts  and  nuts  from  the  inside  working  out,  in  a  crisscross 
pattern and to the specified tightening torque.

 

*  Whenever  you  remove  oil  seals,  gaskets,  packing,  O-rings,  self-locking  nuts,  locking 

washers, cotter pins, circlips, and certain other parts as specified, be sure to replace them 
with  new  ones.  Also,  before  installing  these  new  parts,  be  sure  to  remove  any  left  over 
material from the mating surfaces. 

*  Never reuse a circlip. When installing a new circlip, take care not to expand the  end gap 

larger than required to slip the circlip over the shaft. After installing a circlip, always ensure 
that it is completely seated in its groove and securely fitted.  

*  Use  a  torque  wrench  to  tighten  fasteners  to  the  specified  torque.  Wipe  off  grease  and 

oil if a thread is smeared with them.

 

*  After reassembling, check parts for tightness and proper operation.

 

CAUTION

 

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Summary of Contents for GZ250 Marauder

Page 1: ...Downloaded from www Manualslib com manuals search engine ...

Page 2: ...trations in this manual are used to show the basic principles of operation and work procedures They may not represent the ac tual motorcycle exactly in detail This manual is written for persons who have enough knowledge skills and tools includ ing special tools for servicing SUZUKI mo torcycles If you do not have the proper knowledge and tools ask your authorized SUZUKI motorcycle dealer to help y...

Page 3: ...page of the section easily 4 The contents are listed on the first page of eachsec tion to help you find the item and page you need COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit is its exploded view Work instructions and other service information such as the tightening torque lubricating points and locking agent points are provided Example Front wheel Downloaded from www...

Page 4: ...se brake fluid Apply molybdenum oil solution mix ture of engine oil and SUZUKI MOLY PASTE in a ratio of 1 1 Measure in voltage range Apply SUZUKI SUPER GREASE A 99000 25010 Measure in resistance range Apply SUZUKI SILICONE GREASE 99000 25100 Measure in current range Apply SUZUKI MOLY PASTE 99000 25140 Measure in diode test range Apply SUZUKI BOND 1215 99000 31110 Measure in continuity test range A...

Page 5: ... GZ250X 99 MODEL 1 3 SERIAL NUMBER LOCATION 1 3 FUEL AND OIL RECOMMENDATIONS 1 3 FUEL 1 3 ENGINE OIL 1 4 BRAKE FLUID 1 4 FRONT FORK OIL 1 4 BREAK IN PROCEDURES 1 4 INFORMATION LABELS 1 5 SPECIFICATIONS 1 6 COUNTRYAND AREA CODES 1 8 Downloaded from www Manualslib com manuals search engine ...

Page 6: ...gement and basic mechanical safety prin ciples If you are unsure about how to perform a particular service operation ask a more experienced mechanic for advice GENERAL PRECAUTIONS WARNING Proper service and repair procedures are important for the safety of the service me chanic and the safety and reliability of the motorcycle When 2 or more persons work together pay attention to the safety of each...

Page 7: ...ower When tightening cylinder head and crankcase bolts and nuts tighten the larger sizes first Always tighten the bolts and nuts from the inside working out in a crisscross pattern and to the specified tightening torque Whenever you remove oil seals gaskets packing O rings self locking nuts locking washers cotter pins circlips and certain other parts as specified be sure to replace them with new o...

Page 8: ... do not unlawfully dispose of used motor oil and all other fluids batteries and tires To protect the earth s natural resouces properly dispose of used motorcycles and parts Downloaded from www Manualslib com manuals search engine ...

Page 9: ...the right side of the steering head pipe The engine serial number is located on the left side of the crankcase These numbers are required especially for registering the machine and ordering spare parts FUEL AND OIL RECOMMENDATIONS FUEL Use unleaded gasoline that is graded 91 octane or higher Downloaded from www Manualslib com manuals search engine ...

Page 10: ...t servicing or which has been stored for a long period of time FRONT FORK OIL Use SUZUKI fork oil SS 08 10 BREAK IN PROCEDURES During manufacturing only the best possible materials are used and all machined parts are finished to a very high standard It is still necessary to allow the moving parts to BREAK IN before subjecting the engine to maximum stresses The future performance and reliability of...

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Page 12: ...n ratio Final reduction ratio Gear ratios Low 2nd 3rd 4th Top Drive chain 2 160 mm 85 0 in 815 mm 32 1 in 1 090 mm 42 9 in 1 450 mm 57 1 in 125 mm 4 9 in 680 mm 27 8 in 137 kg 302 lbs Four stroke air cooled OHC 1 72 0 mm 2 835 in 61 2 mm 2 409 in 249 cm 3 15 2 cu in 9 0 1 MIKUNI BSR32SS single Non woven fabric element Electric Wet sump Wet multi plate type 5 speed constant mesh 1 down 4 up 3 238 6...

Page 13: ...suspension Telescopic coil spring oil damped Rear suspension Swingarm type coil spring oil damped spring preload 5 way adjustable Front fork stroke 120 mm 4 7 in Rear wheel travel 90 mm 3 5 in Steering angle 40 right and left Caster 32 30 Trail 140 mm 5 5 in Turning radius 2 6 m 8 5 ft Front brake Disc brake Rear brake Internal expanding Front tire size 110 90 16 59P Rear tire size 130 90 15M C 66...

Page 14: ...ea s CODE COUNTRY OR AREA E 01 General E 02 UK E 03 U S A Except for California E 04 France E 17 Sweden Finland E 15 Norway E 16 Denmark E 26 E 22 Germany E 24 Australia E 25 Netherlands E 28 Canada E 33 California U S A E 34 Italy Belgium E 21 Spain E 53 Downloaded from www Manualslib com manuals search engine ...

Page 15: ...R CLEANER 2 3 VALVECLEARANCE 2 4 SPARK PLUG 2 6 FUEL HOSE 2 7 ENGINE IDLE SPEED 2 7 THROTTLE CABLE PLAY 2 7 STARTER PLUNGER CABLE PLAY 2 9 CLUTCH 2 9 ENGINE OIL AND OIL FILTER 2 9 DRIVE CHAIN 2 70 BRAKES 2 12 TIRE 2 15 STEERING 2 15 FRONT FORK 2 16 REAR SUSPENSION 2 16 CHASSIS BOLTS AND NUTS 2 16 COMPRESSION PRESSURE CHECK 2 18 OIL PRESSURE CHECK 2 19 Downloaded from www Manualslib com manuals sea...

Page 16: ...6 000 9 500 months 3 15 30 45 Exhaust pipe bolts and muffler mounting bolts T T T Air cleaner element Clean every 3 000 km 2 000 miles Valve clearance I I I I Spark plug I R I Fuel hose I I I Replace every 4 years Engine idle speed I I I I Throttle cable play I I I I Clutch I I I Engine oil R R R R Engine oil filter R R Drive chain I I I I Clean and lubricate every 1 000 km 600 miles Brakes I I I ...

Page 17: ...vot Drive chain and spring hook Brake pedal pivot NOTE Before lubricating each part clean off any rusty spots and wipe off any grease oil dirt or grime Lubricate exposed parts which are subject to rust with a rust preventative spray especially whenever the motorcycle has been operated under wet or rainy condition Clutch lever holder Brake lever holder Downloaded from www Manualslib com manuals sea...

Page 18: ...fied torque Exhaust pipe bolt 14 N m 1 4 kg m 10 0 Ib ft Mufflermounting bolt 29N m 2 9 kg m 21 0Ib ft AIR CLEANER Clean every 3 000 km 2 000 miles If the air cleaner is clogged with dust intake resistance will increase resulting in a decrease in engine output and an increase in fuel consumption Check and clean the air cleaner element in the following manner Remove the front seat See p 5 1 Remove ...

Page 19: ...der dusty conditions clean the air cleaner element more frequently The surest way to accelerate engine wear is to operate the engine without the element or to use a torn element Make sure that the air cleaner is in good condition at all times The life of the engine depends largely on this component NOTE When cleaning the air cleaner element remove the plug and drain any water from the air cleaner ...

Page 20: ...n order to check or adjust the valve clearance The valve clearance should only be checked when the engine is cold Remove the valve timing inspection plug and generator cover cap Rotate the crankshaft with a box wrench to set the piston at top dead center TDC on the compression stroke Rotate the crankshaft until the T line on the generator rotor is aligned with the triangle mark on the generator co...

Page 21: ... spark plug eventually leads to difficult start ing and poor engine performance If the spark plug is used for a long period the electrode gradually bums away and carbon builds up along the inside part of the spark plug In accordance with the Periodic Maintenance chart the spark plug should be inspected cleaned and regapped at the rec ommended intervals Remove the cylinder head cover left cap Disco...

Page 22: ... may result CAUTION Before using a spark plug wrench carefully turn the spark plug by finger into the threads of the cylinder head to prevent damage Tighten the spark plug to the specified torque using the special tool Spark plug 18 N m 1 8 kg m 13 0 Ib ft 09930 10121 Spark plug socket wrench set FUEL HOSE Inspect every 5 000 km 3 000 miles 15 months Replace every 4 years ENGINE IDLE SPEED Inspect...

Page 23: ...lling cable Turn the adjuster in or out until the throttle cable play should be 2 0 4 0 mm 0 08 0 16 in at the throttle grip Tighten the lock nut while holding the adjuster Third step While holding the throttle grip at the fully closed position slowly turn out the adjuster of the throttle returning cable to feel resistance Tighten the lock nut while holding the adjuster Throttle cable play 2 0 4 0...

Page 24: ...miles 15 months there after OIL FILTER Replace initially at 1 000 km 600 miles 3 months and every 10 000 km 6 000 miles 30 months thereafter The engine oil should be changed while the engine is warm Oil filter replacement at the above intervals should be done together with the engine oil change ENGINE OIL REPLACEMENT Keep the motorcycle upright Place an oil pan below the engine and drain the engin...

Page 25: ... AMOUNT OF ENGINE OIL Oil change 1 300 ml 1 4 1 1 US Imp qt Oil and filter change 1 400 ml 1 5 1 2 US Imp qt Engine overhaul 1 700 ml 1 8 1 5 US Imp qt DRIVE CHAIN Inspect initially at 1 000 km 600 miles 3 months andevery 5 000 km 3 000 miles 15 months there after Clean and lubricate every 1 000 km 600 miles Visually inspect the drive chain for the possible defects listed below Support the motorcy...

Page 26: ...replacement Downloaded from www Manualslib com manuals search engine ...

Page 27: ... at the same position on the scale to ensure that the front and rear wheels are correctly aligned Drive chain slack 5 15 mm 0 2 0 6 in After adjusting the drive chain tighten the rear axle nut to the specified torque Rear axle nut 65 N m 6 5 kg m 47 0 Ib ft For E 03 28 33 78 N m 7 8 kg m 56 5 Ib ft For the others Recheck the chain slack after tightening the axle nut and readjust if necessary Tight...

Page 28: ...ng the lower limit line on the front brake fluid reservoir When the brake fluid level is below the lower limit line replenish with brake fluid thatmeets the following specifi cation Specification and classification DOT 4 WARNING The brake system of this motorcycle is filled with a glycol based brake fluid Do not use or mix different types of fluid such as silicone based and petroleum based fluids ...

Page 29: ...lace the reservoir cap to prevent dirt from entering Attach a hose to the air bleeder valve and insert the free end of the hose into a receptacle Bleed air from the brake system Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without re leasing it Loosen the bleeder valve by turning it a quar ter of a turn so that the brake fluid runs into the rece...

Page 30: ...ar perform the following steps Make sure that the rear brake is properly adjusted Depress the rear brake pedal Make sure that the index mark is within the range embossed on the brake panel If the index mark goes beyond the range the brake shoe assembly should be replaced with a new set of shoes The extension line of the index mark is within the range The extension line of the index mark is out of ...

Page 31: ...cm 2 psi kPa kg cm 2 psi FRONT 175 1 75 25 175 1 75 25 REAR 200 2 00 29 225 2 25 33 CAUTION The standard tire fitted on this motorcycle is a 110 90 16 59P for the front and a 130 90 15M C 66P for the rear The use of tires other than those speci fied may cause instability It is highly recommended to use the specified tires STEERING Inspect initially at 1 000 km 600 miles 3 months and every 10 000 k...

Page 32: ...11 5 Handlebar holder nut 45 4 5 32 5 Steering stem head bolt 65 6 5 47 0 Front fork upper clamp bolt 23 2 3 16 5 Front fork lower clamp bolt 33 3 3 24 0 Front fork cap bolt 23 2 3 16 5 Front fork damper rod bolt 23 2 3 16 5 Front axle 65 6 5 47 0 Front axle pinch bolt 23 2 3 16 5 Front brake caliper mounting bolt 39 3 9 28 0 Front brake hose union bolt 23 2 3 16 5 Front brake caliper air bleeder ...

Page 33: ...2 17 PERIODIC MAINTENANCE Downloaded from www Manualslib com manuals search engine ...

Page 34: ...oves Poor valve seating Ruptured or otherwise defective cylinder head gasket COMPRESSION 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 ad justed Have the engine warmed up before testing Make sure that the battery is fully charged Remove the related parts and test the ...

Page 35: ...il leakage from the oil passage Damaged O ring Defective oil pump Combination of the above items HIGH OIL PRESSURE Engine oil viscosity is too high Clogged oil passage Combination of the above items OIL PRESSURE TEST PROCEDURE Check the oil pressure in the following manner o Install the oil pressure gauge in the position shown Connect an electric tachometer Warm up the engine as follows Summer 10 ...

Page 36: ...ING GENERATOR STATOR AND PICK UP COIL 3 39 3 40 __ 3 41 TRANSMISSION __3 42 PRIMARY DRIVEN GEAR __3 44 CLUTCH __3 45 CLUTCH COVER __3 46 OIL FILTER 3 46 OIL SUMP FILTER 3 47 ENGINE REASSEMBLY 3 48 CRANKSHAFT 3 48 BALANCER SHAFT 3 48 TRANSMISSION 3 48 GEARSHIFT CAM AND GEARSHIFT FORKS 3 49 CRANKCASE 3 50 GENERATOR ROTOR __3 52 DRIVESHAFT RETAINER __3 52 PRIMARY DRIVE GEAR 3 52 BALANCER SHAFT BOLT 3...

Page 37: ...t 3 10 and 62 Cylinder head 3 10 and 61 Cylinder 3 10 and 60 Piston 3 11 and 59 Starter motor 3 11 and 58 Oil sump filter 3 47 ENGINE LEFT SIDE ENGINE RIGHT SIDE See page See page Gearshift link arm 3 2 Oil filter 3 46 Engine sprocket cover 3 3 Clutch cover 3 12 and 57 Engine sprocket 3 3 and 7 Clutch 3 12 and 55 Generator cover 3 12 and 57 Oil pump 3 14 and 54 Generator rotor 3 16 and 52 Gearshif...

Page 38: ...ove the right frame cover See p 5 1 Disconnect the battery lead wire Drain the engine oil See p 2 9 Remove the right footrest bracket Remove the exhaust pipe bolts Remove the exhaust pipe by removing the bolt Remove the muffler mounting bolt Remove the gearshift link arm Downloaded from www Manualslib com manuals search engine ...

Page 39: ...e brake pedal Remove the engine sprocket NOTE If it is difficult to remove the engine sprocket loosen the rear axle nut and chain adjuster nuts to provide additional chain slack Remove the clutch release arm Loosen the clutch cable adjuster lock nut and remove the clutch cable Remove the left and right cylinder head cover caps Disconnect the spark plug cap Downloaded from www Manualslib com manual...

Page 40: ... explosive Extreme care must be taken Disconnect the engine ground wire Disconnect the crankcase breather hose Disconnect the starter motor lead wire Disconnect the side stand switch coupler Disconnect the generator couplers Disconnect the neutral switch coupler Downloaded from www Manualslib com manuals search engine ...

Page 41: ...e upper engine mounting bolt and nut NOTE When removing the upper mounting bolt support the en gine with a jack Remove the left and right swingarm pivot end caps Remove the swingarm pivot nut and washer Partially remove the swingarm pivot shaft so that the engine can be removed NOTE Be careful not to draw out the pivot shaft Gradually lower the engine Downloaded from www Manualslib com manuals sea...

Page 42: ...longer of any use ITEM N m kg m Ib ft 41 4 1 29 5 41 4 1 29 5 41 4 1 29 5 BOLTLENGTH 50 mm 2 0 in 67 mm 2 6 in 100 mm 3 9in Tighten the swingarm pivot nut to the specified torque Swingarm pivot nut 72 N m 7 2 kg m 52 0 Ib ft Tighten the frame down tube mounting bolts and nuts to the specified torque Frame down tube mounting bolt nut 23 N m 2 3 kg m 16 5 Ib ft NOTE Apply a small quantity of THREAD ...

Page 43: ...ion NOTE Align the release arm slit surface with the notch mark on the release camshaft Loosen the rear axle nut and drive chain adjuster nuts Install the engine sprocket as shown Install the drive chain Tighten the engine sprocket nut to the specified torque Engine sprocket nut 90 N m 9 0 kg m 65 0 Ib ft NOTE When tightening the engine sprocket nut depress the rear brake pedal Bend the lock washe...

Page 44: ...djustments are necessary Engine idling speed See p 2 7 Throttle cable play See p 2 8 Starter plunger cable play See p 2 9 Clutch lever play See p 2 9 Drive chain slack See p 2 11 Rear brake pedal height and free travel See p 2 14 Pour 1 700 ml 1 8 1 5 US Imp qt of SAE 10W 40 en gine oil graded SF or SG into the engine after overhaul ing it Start up the engine and allow it run for several minutes a...

Page 45: ...the cylinder head cover NOTE If the cylinder head cover does not come off lightly tap on the finless portion of it with a plastic mallet to make the gasketed joint loose Remove the rubber cap and then turn the slotted end of cam chain tension adjuster with the flat head screwdriver in the clockwise direction and lock the push rod Remove the cam chain tension adjuster by removing the mounting bolts...

Page 46: ... removing the cylinder head nuts NOTE If the cylinder head does not come off lightly tap on the finless portion of it with a plastic mallet Remove the cylinder head gasket and dowel pins Remove the cam chain guide Remove the cylinder by removing the nuts NOTE If the cylinder does not come off lightly tap on the Unless portion of it with a plastic mallet to make the gasketed joint loose Downloaded ...

Page 47: ... pin circlip with a long nose pliers Remove the piston pin using the special tool 09910 34510 Piston pin puller Remove the piston Remove the starter motor Flatten the lock portion of the oil seal retainer Remove the oil seal retainer Remove the spacer Remove the neutral switch Remove the neutralswitch contact spring and O ring Downloaded from www Manualslib com manuals search engine ...

Page 48: ...er Remove the gasket and dowel pins While holding the generator rotor using the special tool remove the clutch spring mounting bolts in a crisscross pattern and remove the clutch springs and clutch pres sure plate 09930 44913 Rotor holder Downloaded from www Manualslib com manuals search engine ...

Page 49: ...drive and driven plates Remove the spring washer and washer seat Flatten the lock washer of the clutch sleeve hub nut Remove the clutch sleeve hub nut using thespecial tool 09920 53740 Clutch sleeve hub holder Remove the clutch sleeve hub Downloaded from www Manualslib com manuals search engine ...

Page 50: ... Remove the oil pump A CAUTION Do not attempt to disassemble the oil pump as sembly Remove the gearshift shaft Remove the pawl lifter and cam guide by removing the screws Remove the gearshift cam driven gear NOTE When removing the cam driven gear do not lose the pawls pins and springs Remove the gearshift shaft stopper Downloaded from www Manualslib com manuals search engine ...

Page 51: ...cam chain Remove the primary drive gear nut using the special tool 09930 44913 Rotor holder A CAUTION The primary drive gear nut has left hand threads Remove the spring washer Remove the primary drive gear Remove the keys Remove the cam chain sprocket Remove the circlip and washer Downloaded from www Manualslib com manuals search engine ...

Page 52: ...r nut using the special tool 09930 44913 Rotor holder Remove the generator rotor using the special tool 09930 34960 Rotor remover Remove the generator rotor key Remove the starter driven gear Remove the bearing and washer Downloaded from www Manualslib com manuals search engine ...

Page 53: ... separator so that the tool arms are in parallel with the side of crankcase The crankshaft and transmissioncomponents should re main in the left crankcase half Whenseparating thecrankcase tap the end of the coun tershaft with a plastic mallet Remove the O ring Remove the shim washer and balancer shaft driv en gear Remove the washer Downloaded from www Manualslib com manuals search engine ...

Page 54: ...ork shafts and gearshift forks Remove the gearshift cam Remove the transmission Remove the balancer shaft Remove the balancer shaft drive gear Remove the crankshaft using the special tool 09920 13120 Crankcase separator Downloaded from www Manualslib com manuals search engine ...

Page 55: ...rmali ties the bearing is defective and must be replaced as fol lows BEARING REMOVAL Remove the bearing retainers NOTE Remove the driveshaft bearing retainer along with the driveshaft bearing Remove the oil seals using the special tool 09913 50121 Oil seal remover CAUTION The removed oil seals should be replaced with new ones Remove the bearings CAUTION The removed bearings should be replaced with...

Page 56: ... 09913 75520 Bearing remover installer For 09913 75830 Bearing remover installer For 09913 84510 Bearing remover installer For 09913 85210 Bearing remover installer For Install the oil seal into the left crankcase using the special tool 09913 85210 Bearing remover installer Apply grease to the oil seal lip 99000 25010 SUZUKI SUPER GREASE A Place the washer so that the convex of it faces towards th...

Page 57: ...ring with the bearing retainer Install the bearing retainers NOTE Apply a small quantity of THREAD LOCK 1342 to the bearing retainer screws 99000 32050 THREAD LOCK 1342 Apply grease to the oil seal lip 99000 25010 SUZUKI SUPER GREASE A Install the driveshaft oil seals as shown CAUTION When installing the oil seal Do not block the oil passage Downloaded from www Manualslib com manuals search engine...

Page 58: ...d clutch cable guide Remove the oil seal Remove the clutch release cam shaft REASSEMBLY Apply engine oil to the clutch release camshaft as shown in the illustration Install the clutch release camshaft washer and oil seal Downloaded from www Manualslib com manuals search engine ...

Page 59: ...r place the cylinder head cover on a surface plate and check for distortion with a thickness gauge Check points are shown in Fig 09900 20803 Thickness gauge Service Limit 0 05 mm 0 002 in If the distortion exceeds the limit replace the cylinder head cover ROCKER ARM SHAFT O D Measure the diameter of the rocker arm shafts 09900 20205 Micrometer 0 25 mm Standard IN EX 11 966 11 984 mm 0 4711 0 4718 ...

Page 60: ...gs to prevent oil leakage Tighten the rocker arm shaft bolts to the specified torque Rocker arm shaft bolt 10 Nm 1 0 kg m 7 0 Ib ft CYLINDER HEAD I ACAUTION Identify the position of each removed part Orga nize the parts in their respective groups i e in take or exhaust so that they can be installed in their original locations DISASSEMBLY Remove the cam chain tensioner Remove the intake pipe Downlo...

Page 61: ...alve lifter attachment Remove the valve cotters from the valve stem 09916 84511 Tweezers Remove the valve spring retainer and valve spring Remove the valve from the combustion chamber side Remove the valve stem seal Remove the valve spring seat Downloaded from www Manualslib com manuals search engine ...

Page 62: ... the runout exceeds the limit replace the valve 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block 100 mm Service Limit 0 05 mm 0 002 in VALVE HEAD RADIAL RUNOUT Place the dial gauge at a right angle to the valve head face and measure the valve head radial runout If it measures more than the service limit replace the valve 09900 20606 Dial gauge 1 100 mm 09900 20701 Mag...

Page 63: ...CE Remove the valve guide using the special tool 09916 44910 Valve guide remover installer NOTE Discard the removed valve guide subassemblies Only oversized valve guides are available as replace ment parts Re finish the valve guide holes in the cylinder head using the special tools 09916 34561 Valve guide reamer 11 3 mm 09916 34542 Handle NOTE Insert the reamer from the combustion chamber side and...

Page 64: ...inuous without any breaks In addition the width of the dye ring which is the valve seat width must be within the following specification Standard Valve seat width 0 9 1 1 mm 0 035 0 043 in If the valve seat is out of specification re cut the seat VALVE SEAT SERVICE The valve seats for both intake and exhaust valves are ma chined to two different angles The seat contact surface is cut 45 INTAKESIDE...

Page 65: ...eat position and width is achieved use the 45 cutter very lightly to clean up any burrs caused by the previous cutting operations CAUTION Contactarea too high and too wide on face of valve DO NOT use lapping compound after the final cut is made The finished valve seat should have a velvety smooth finish and not a highly polished or shiny finish This will provide a soft surface for the final seatin...

Page 66: ...Contactarea too low and too narrow on face of valve Downloaded from www Manualslib com manuals search engine ...

Page 67: ... free length IN EX 40 1 mm 1 58 in Standard Valve spring tension IN EX 18 4 21 6 kg 35 0 mm 40 56 47 62 lbs 1 38 in 18 4 21 6 kg 40 56 47 62 lbs REASSEMBLY Reassemble the cylinder head in the reverse order of dis assembly Pay attention to the following points Install each valve spring seat Apply molybdenum oil solution to the valve stem seal and press fit the seal into position by hand A CAUTION D...

Page 68: ...e the valve lifter to allow the cotter to wedge between the retainer and the valve stem Be sure that the rounded lip of the cotter fits snugly into the groove in the stem end 09916 14510 Valve lifter 09916 14910 Valve lifter attachment 09916 84511 Tweezers CAUTION Be sure to install all of the parts in their original positions INTAKE PIPE When installing the intake pipe apply grease to the CD ring...

Page 69: ...als for wear or damage CAM WEAR Worn down cams are often the cause of mistimed valve operation resulting in reduced power output Measure the cam height using the micrometer Replace a camshaft if the cams are worn to the service limit 09900 20202 Micrometer 25 50 mm Service Limit Cam height IN 34 690 mm 1 3657 in EX 34 730 mm 1 3673 in CAMSHAFT JOURNAL WEAR Determine whether or not each journal is ...

Page 70: ... inside diameter of the camshaft journal holder and outside diameter of the camshaft journal Replace the camshaft or the cylinder head depending upon which one exceeds the specification 09900 22403 Small bore gauge Standard Camshaft journal holder I D Right side 25 012 25 025 mm 0 9847 0 9852 in Left side 20 012 20 025 mm 0 7879 0 7884 in 09900 20205 Micrometer 0 25 mm Standard Camshaft journal O ...

Page 71: ... gauge Service Limit 0 05 mm 0 002 in CYLINDER BORE Measure the cylinder bore diameter at six places If any one of themeasurements exceed the limit overhaul the cylinder and replace the piston with an oversize piston or replace the cylinder PISTON AND PISTON PIN DIAMETER Measure the piston diameter using the micrometer at 15 mm 0 6 in from the skirt end If the piston diameter is less than the serv...

Page 72: ...st 0 975 0 990 mm 0 0384 0 0390 in 2nd 1 170 1 190 mm 0 0461 0 0469 in NOTE Remove any carbon from the piston crown and ring grooves using a soft metal scraper PISTON RING FREE END GAP AND PISTON RING END GAP Measure the piston ring free end gap using a vernier cali pers Next fit the piston ring squarely into the cylinder and measure the piston ring end gap using a thickness gauge If the piston ri...

Page 73: ...e the outside diameter to identify the side 0 5mmO S I OmmO S Oil ring spacer PIN BORE Measure the piston pin bore inside diameter using the cali per gauge and measure the piston pin outside diameter using the micrometer If either is out of specification or the difference between these two measurements is more than the limits replace both piston and piston pin 09900 20605 Dial calipers 09900 20205...

Page 74: ...NROD SMALL END I D Measure the conrod small end inside diameter using the dial calipers If the conrod small end inside diameter ex ceeds the service limit replace the conrod 09900 20605 Dial calipers Service Limit 18 040 mm 0 7102 in Downloaded from www Manualslib com manuals search engine ...

Page 75: ...rvice limit is exceeded replace crankshaft assembly or bring the deflection and side clearance into specification by replacing the worn parts e g conrod big end bearing and crank pin CRANKSHAFT RUNOUT Support the crankshaft with V blocks as shown Position the dial gauge as shown and rotate the crankshaft slowly to read the runout Correct the runout or replace the crank shaft assembly if the runout...

Page 76: ...ce the defective part Measure the free length of each balancer spring using ver nier calipers If any spring is not within the service limit replace all of the spring 09900 20101 Vernier calipers Service Limit 10 0 mm 0 39 in REASSEMBLY Reassemble the balancer shaft driven gear in the reverse order of disassembly Pay attention to the following points Make sure that the punch mark on the inner race ...

Page 77: ... clutch Also inspect the surface of the starter driven gear which contacts the starter clutch for wear or damage If any wear or damage is found replace the defective part s STARTER DRIVEN GEAR BEARING Install the starter driven gear bearing and gear onto the crankshaft and turn the starter driven gear by hand Inspect the starter driven gear bearing for smooth rotation and any abnormal noise If the...

Page 78: ...nd tighten them to the specified torque while holding the rotor holder 99000 32030 THREAD LOCK SUPER 1303 09930 44913 Rotor holder Starter clutch bolt 18 N m 1 8 kg m 13 0 Ib ft GENERATOR STATOR AND PICK UP COIL When replacing the generator stator or pick up coil apply THREAD LOCK 1342 to the generator stator set bolts and pick up coil set bolts and tighten them 99000 32050 THREAD LOCK 1342 Downlo...

Page 79: ...__________ 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 do not expand the end gap larger than required to slip the circlip over the shaft After installing a circlip make sure that it is completely seated in its groove and securely fitted 1 1st driven gear 2 5th driven gear 3 3rd driven g...

Page 80: ...o the side where the thrust is as shown in the illustration The rounded side should be against the gear surface Thrust Sharp edge Washers and circlips thickness 1 2 mm 0 05 in 1 0 mm 0 04 in 1 0 mm 0 04 in 1 0 mm 0 04 in 2 0 mm 0 08 in 0 5 mm 0 02 in Downloaded from www Manualslib com manuals search engine ...

Page 81: ...e meshed gears may slip apart If the clearance exceeds the specification replace the fork its respective gear or both 09900 20803 Thickness gauge Service Limit Gearshift fork to groove clearance 0 60 mm 0 024 in Standard Gearshift fork groove width No 1 No 2 No 3 4 25 4 35 mm 0 167 0 171 in Standard Shift fork thickness No 1 No 2 No 3 3 95 4 05 mm 0 156 0 159 in PRIMARY DRIVEN GEAR Remove the stop...

Page 82: ... service limit replace the clutch plates as a set 09900 20803 Thickness gauge Service Limit 0 10 mm 0 004 in CLUTCH SPRING FREE LENGTH Measure the free length of each clutch spring using vernier calipers If any spring is not within the service limit replace all of the spring 09900 20101 Vernier calipers Service Limit 40 9 mm 1 61 in CLUTCH RELEASE BEARING Inspect the clutch release bearing for any...

Page 83: ...ner NOTE Apply a small quantity of THREAD LOCK 1342 to the oil seal retainer screws 99000 32050 THREAD LOCK 1342 OIL FILTER Remove the oil filter cap Remove the oil filter and install a new one NOTE Before installing the new oil filter and oil filter cap make sure that the spring and newO rings are installed correctly Install the oil filter cap Downloaded from www Manualslib com manuals search eng...

Page 84: ...emove the oil sump filter cap Remove the oil sump filter INSPECTION Check the oil sump filter for any damage or clogs CLEANING Clean the oil sump filter with a compressed air Downloaded from www Manualslib com manuals search engine ...

Page 85: ...ecial tools 09910 32812 Crankshaft installer 09910 32840 Attachment 09910 20116 Conrod holder CAUTION Never install the crankshaft into the crankcase by striking it with a plastic hammer Always use the spe cial tool otherwise crankshaft may be misaligned Apply engine oil to the crankshaft bearings Install the balancer shaft drive gear NOTE Makesure that the hole in the drive gear is aligned with t...

Page 86: ...ancer shaft driven gear with the punch mark on the balancer shaft drive gear GEARSHIFT CAM AND GEARSHIFT FORKS Align the pin groove of gearshift cam stopper plate with the pin on the gearshift cam Install the gearshift forks to their respective gears Install the gearshift cam stopper Install the gearshift cam into the crankcase Downloaded from www Manualslib com manuals search engine ...

Page 87: ...nstalled easily Install the the gearshift cam stopper spring CRANKCASE Wipe both crankcase mating surfaces with a cleaning solvent Apply SUZUKI BOND 1215 uniformly to the mating surface of the right crankcase and assemble the cases within a few minutes 99000 31110 SUZUKI BOND 1215 Downloaded from www Manualslib com manuals search engine ...

Page 88: ... to the specified torque Crankcase bolt 11 N m 1 1 kg m 8 0 Ib ft NOTE Install the clamp to the bolt NOTE After the crankcase bolts have been tightened make sure that the crankshaft countershaft and driveshaft ro tate smoothly If these shafts do not rotate smoothly try to free it by tapping with a plastic hammer Install the the gearshift cam stopper Downloaded from www Manualslib com manuals searc...

Page 89: ...ely Apply a small quantity of THREAD LOCK 1303 to the generator rotor nut 99000 32030 THREAD LOCK SUPER 1303 Tighten the generator rotor nut to the specified torque using the special tool 09930 44913 Rotor holder Generator rotor nut 160N m 16 0 kg m 115 5 Ib ft DRIVESHAFT RETAINER Install the washer and circlip to the driveshaft CAUTION Use a new circlip PRIMARY DRIVE GEAR Install the cam chain sp...

Page 90: ...4913 Rotor holder Balancer shaft bolt 39 N m 3 9 kg m 28 0 Ib ft GEARSHIFT CAM DRIVEN GEAR Install each pawl into the gearshift cam driven gear Gearshift pawl Pin Spring Gearshift cam driven gear NOTE The large shoulder must face to the outside Apply a small quantity of THREAD LOCK 1303 to the gearshift shaft stopper 99000 32030 THREAD LOCK SUPER 1303 Tighten the gearshift shaft stopper to the spe...

Page 91: ...on the gearshift shaft with the center teeth on the gearshift cam driven gear OIL PUMP Apply engine oil to the sliding surfaces of the oil pump case outer rotor inner rotor and shaft before mounting the oil pump Apply a small quantity of THREAD LOCK 1342 to the oil pump mounting screws and tighten them 99000 32050 THREAD LOCK 1342 Install the washer and pin Install the oil pump driven gear and cir...

Page 92: ...nto the countershaft NOTE When engaging the primary drive and driven gears turn the primary driven gear assembly to the counterclockwise Clutch pressure plate Push piece Clutch drive plate No 1 T 3 00 Clutch driven plate Clutch drive plate No 2 T 3 50 Clutch push rod Concaved washer Washer seat Clutch sleeve hub Clutch housing Oil pump drive gear Downloaded from www Manualslib com manuals search e...

Page 93: ...e clutch push rod Install the push piece bearing and washer Install the clutch pressure plate clutch springs and clutch spring mounting bolts Hold the generator rotor using the special tool and tight en the clutch spring mounting bolts to the specified torque in a crisscross pattern 09930 44913 Rotor holder Clutch spring mounting bolt 10N m 1 0kg m 7 0 Ib ft NOTE Make sure that the clutch pressure...

Page 94: ... washer to the bolt STARTER IDLE GEAR Install the starter idle gear A CAUTION Apply engine oil to the starter idle gear GENERATOR COVER Install the dowel pins and a new gasket Install the generator cover and tighten the bolts securely NOTE Install the wire harness clamp with the bolt Downloaded from www Manualslib com manuals search engine ...

Page 95: ...eshaft NOTE The oil hole on the spacer should be on the engine side Be careful that the oil seal lip does not turn in Install the oil seal retainer Bend the tabs on the oil seal retainer to lock the bolts Pass through the neutral switch lead wire inside of the guide Clamp the neutral switch lead wire and generator lead wire with the clamp STARTER MOTOR Install the starter motor A CAUTION Use a new...

Page 96: ...verlap in the piston ring groove INCORRECT Same way in which to distinguish the 1st and 2nd piston rings 1 Their ring face shapes are different 2 The 1st piston ring s face is chrome plated 3 The 2nd piston ring appears darker in color The 1st and 2nd piston should be installed with their marks facing up Position the piston ring gaps as shown NOTE Before inserting the piston into the cylinder chec...

Page 97: ...rrow mark facing towards the exhaust side CYLINDER Before installing the cylinder apply engine oil to the sliding surface of the piston Install the dowel pins into the crankcase and then Install the cylinder gasket A CAUTION Use a new gasket to prevent oil leakage Make sure that the piston rings are properly positioned and insert the piston into the cylinder NOTE When mounting the cylinder keep th...

Page 98: ...ashers must be installed cor rectly as shown Copper washer Steel washer Tighten the cylinder head nuts 10 mm to the specified torque in a crisscross pattern Cylinder head nut 10 mm 38N m 3 8 kg m 27 5 Ib ft Tighten the cylinder base nuts 2 and cylinder head nuts 6 mm D to the specified torque H Cylinder base nut 10 N m 1 0 kg m 7 0 Ib ft Cylinder head nut 6 mm 10 N m 1 0 kg m 7 0 Ib ft Downloaded ...

Page 99: ...the cam chain Install the camshaft and camshaft sprocket Face the notch on the camshaft towards the intake side Align the engraved line marks on the camshaft so it is parallel with mating surface of the cylinder head and cyl inder head cover Engage the cam chain on the camshaft sprocket with the locating pin hole at one o clock position NOTE Do not rotate thecrankshaft while installing the camshaf...

Page 100: ...t and the cam chain tension adjuster onto the cylinder with the two bolts and tighten them to the specified torque Cam chain tension adjuster bolt 7 N m 0 7 kg m 5 0 Ib ft After installing the cam chain tension adjuster turn the screwdriver counterclockwise As the slot in the cam chain tension adjuster turns the tension rod advances under the spring force and pushes the cam chain tension adjuster ...

Page 101: ...uniformly to the mating surface of the cylinder head cover and install it within a few minutes 99000 31110 SUZUKI BOND N0 1215 Tighten the cylinder head cover bolts to the specified torque Cylinderhead coverbolt 10 N m 1 0 kg m 7 0 Ib ft I A CAUTION Install the new gasket washer to the bolt A CAUTION Be sure to check the valve clearance See pp 2 3 and 4 Install the valve timing inspection caps CAU...

Page 102: ...ECIFICATIONS 4 2 I D NO LOCATION 4 2 CONSTRUCTION 4 3 REMOVAL 4 4 DISASSEMBLY 4 4 CLEANING 4 8 INSPECTION AND ADJUSTMENT 4 8 REASSEMBLY 4 9 REMOUNTING 4 9 LUBRICATION SYSTEM 4 10 OIL PRESSURE 4 10 OIL FILTER 4 10 OIL SUMP FILTER 4 10 ENGINE LUBRICATION SYSTEM CHART 4 11 Downloaded from www Manualslib com manuals search engine ...

Page 103: ... Remove the fuel tank Remove the fuel valve INSPECTION FUEL VALVE If the fuel filter is dirty with sediment or rust fuel will not flow smoothly and loss in engine power may result Clean the fuel filter with compressed air Also check the fuel filter for cracks AWARNING Gaskets and O rings must be replaced with new ones to prevent fuel leakage REMOUNTING Remount the fuel tank and fuel valve in the r...

Page 104: ...lay 2 4 mm 0 08 0 16 in Starter plunger cable play 0 5 1 0 mm 0 02 0 04 in ITEM SPECIFICATION E 03 28 E 33 Carburetor type MIKUNI BSR32SS Bore size 32 mm I D No 13F3 13F4 Idle r min 1 300 50 r min Float height 13 0 0 5 mm Main jet M J Jet needle J N 5C65 Needle jet N J Pilot jet P J Pilot air jet No 1 P A J 1 87 5 Pilot air jet No 2 P A J 2 120 Throttle valve Th V 110 Pilot screw PS PRE SET Thrott...

Page 105: ...le holder Washer Spacer Jet needle Piston valve diaphragm Diaphragm Starter plunger Pilotjet Jet holder Main jet Pilotscrew Starter jet Throttle stop screw Float Gasket Needle valve seat Needle valve Float chamber Downloaded from www Manualslib com manuals search engine ...

Page 106: ...r plunger Loosen the lock nuts and disconnect the throttle cables Remove the overflow hose and air vent hose Loosen the clampscrews Remove the carburetor DISASSEMBLY Remove the fuel hose and vacuum hose Remove the throttle stop screw Downloaded from www Manualslib com manuals search engine ...

Page 107: ...SYSTEM Remove the diaphragm cover Remove the diaphragm Remove the carburetor top cap Remove the spring and piston valve along with diaphragm Remove the jet needle holder Downloaded from www Manualslib com manuals search engine ...

Page 108: ...ve the screw and needle valve seat Remove the main jet and jet holder Remove the pilot jet Remove the starter jet Remove the pilot screw NOTE Before removing the pilot screw its setting must be de termined Slowly turn the pilot screwclockwise and count the number of turns until it is lightly seated When reassembling the pilot screw you will want to set it to its original position A CAUTION Do not ...

Page 109: ...he plug Pull on the screw head with pliers to remove the plug Carefully clean any metal shavings from the area Slowly turn the pilot screw clockwise and count the num ber of turns until the screw is lightly seated Make a note of how many turns were made so the screw can be reset correctly after cleaning Remove the pilot screw along with the spring washer and O ring After cleaning reinstall the pil...

Page 110: ... to soak Al ways follow the chemical manufacturer s instruc tions for proper use and cleaning of the carbure tor components After cleaning reassemble the carburetor with newseals and gaskets INSPECTION AND ADJUSTMENT Check the following items for any damage or clogging Pilot jet Needle jet air bleeding hole Main jet Float Starter jet Needle valve Diaphragm Gasket and O ring Pilot screw Pilot outle...

Page 111: ...ttle stop screw until the throttle valve s bottom end is aligned with the foremost by pass port NOTE When removing the throttle valve applying a small quantity of THREAD LOCK 1342 to the throttle valve mounting screws and tighten them 99000 32050 THREAD LOCK 1342 Face the stamped side of the throttle valve out Install the needle jet as shown Large diameter side Bore side Small diameter side Main j...

Page 112: ...0 OIL SUMP FILTER When replacing the engine oil make sure that the oil sump filter has no tears or damage Also be sure to clean the oil sump filter periodically See pp 3 16 47 and 51 FUEL AND LUBRICATION SYSTEM 4 10 Downloaded from www Manualslib com manuals search engine ...

Page 113: ...4 11 FUEL AND LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM CHART Downloaded from www Manualslib com manuals search engine ...

Page 114: ...MOVAL AND DISASSEMBLY 5 11 MASTER CYLINDER INSPECTION 5 13 MASTER CYLINDER REASSEMBLY AND REMOUNTING 5 13 FRONT FORK 5 15 CONSTRUCTION 5 15 REMOVAL AND DISASSEMBLY 5 15 INSPECTION 5 17 REASSEMBLY AND REMOUNTING 5 18 STEERING 5 22 CONSTRUCTION 5 22 REMOVAL AND DISASSEMBLY 5 22 INSPECTION 5 25 REASSEMBLY AND REMOUNTING 5 26 REAR WHEEL AND REAR BRAKE 5 29 CONSTRUCTION 5 29 REMOVAL 5 30 INSPECTION AND...

Page 115: ...right frame cover LEFT FRAME COVER Remove the screw Remove the left frame cover Remove the seat lock hooked part hooked part REAR SEAT Remove the rear seat by removing the bolts REMOUNTING Remount the seats frame covers front and rear fenders in the reverse order of removal Downloaded from www Manualslib com manuals search engine ...

Page 116: ...TEM N m kg m Ib ft 65 6 5 47 0 23 2 3 16 5 23 2 3 16 5 Dust cover Spacer Bearing Front w heel Spacer Bearing Brake disc Speedometer gearbox Front axle Axle pinch bolt Brake disc bolt Downloaded from www Manualslib com manuals search engine ...

Page 117: ...Left Right Downloaded from www Manualslib com manuals search engine ...

Page 118: ...10 Hexagon wrench set INSPECTION AND DISASSEMBLY SPEEDOMETER GEARBOX Turn thespeedometer gear and check to see that the gear turns smoothly together with the speedometer pinion WHEEL BEARINGS Inspect the play of the wheel bearings by hand while they are in the wheel Rotate the inner race by hand to inspect it for abnormal noise and smooth rotation Replace the wheel bearings if there is anything un...

Page 119: ...900 20701 Magnetic stand 09900 21304 V block set 100 mm Service Limit 0 25 mm 0 010 in WHEEL Make sure that the wheel runout axial and radial does not exceed the service limit when checked as shown An ex cessive amount of runout is usually due to worn or loose wheel bearings and can be corrected by replacing the bearings If bearing replacement fails to reduce the runout replace the wheel Service L...

Page 120: ... install the left wheel bearing then install the right wheel bearing The sealed cover on the bearings must face to the outside Leftside Rightside Leftside Rightside Spacer BRAKE DISC Make sure that the brake disc is clean and free of any grease Apply THREAD LOCK SUPER 1360 to the brake disc bolts and tighten them to the specified torque 99000 32130 THREAD LOCK SUPER 1360 Brake disc bolt 23 N m 2 3...

Page 121: ...ER GREASE A Align the lugs on the speedometer gearbox with the recesses on the front wheel Set the speedometer gearbox with cable as shown in the illustration Tighten the front axle to the specified torque Front axle 65 N m 6 5 kg m 47 0 Ib ft Tighten the axle pinch bolt to the specified torque Axle pinch bolt 23 N m 2 3 kg m 16 5 Ib ft Downloaded from www Manualslib com manuals search engine ...

Page 122: ...dren When replenishing brake fluid take care not to get dust into the fluid When washing brake components use new brake fluid Never use cleaning solvent A contaminated brake disc or brake pad reduces braking performance Discard contaminated pads and clean the disc with high quality brake cleaner or a neutral detergent A CAUTION Handle brake fluid with care the fluid reacts chemically with paint pl...

Page 123: ...brake lever a fewtimes to operate the brake correctly and then check the brake fluid level BRAKE FLUID REPLACEMENT Place the motorcycle on a level surface and keep the handlebars straight Remove the master cylinder reservoir cap and dia phragm Suck up the old brake fluid as much as possible Fill the reservoir with new brake fluid Specification and Classification DOT 4 Connect a cleaner hose to the...

Page 124: ...RNING Brake fluid if it leaks will interfere with safe running and discolor painted surfaces Check the brake hose and hose joints for cracks and oil leakage Remove the brake pads See p 5 8 Remove the brake caliper holder Remove the spring Place a rag over the brake caliper piston to prevent it from popping out and then force out the piston using compressed air A CAUTION Do not use high pressure ai...

Page 125: ...seal groove Specification and Classification DOT 4 A CAUTION Wash the brake caliper components with new brake fluid before reassembly Do not wipe the brake fluid off after washing the components When washing the components use the speci fied brake fluid Never use different types of fluid or cleaning solvents such as gasoline ker osine etc Replace the piston seal and dust seal with new ones Apply b...

Page 126: ...eck the brake disc for damage or cracks Measure the thickness using the micrometer Replace the brake disc if the thickness is less than the service limit or if damage is found 09900 20205 Micrometer 0 25 mm Service Limit Brake disc thickness 4 5 mm 0 18 in Measure the runout using the dial gauge Replace the brake disc if the runout exceeds the service limit 09900 20606 Dial gauge 1 100 mm 09900 20...

Page 127: ...part of the motorcycle The brake fluid reacts chemically with paint plastics and rubber materi als etc and will damage them severely Remove the master cylinder assembly Remove the front brake light switch Remove the reservoir cap and diaphragm Drain the brake fluid Remove the dust boot Remove the circlip using the special tool 09900 06108 Snap ring pliers Downloaded from www Manualslib com manuals...

Page 128: ... master cylinder components with new brake fluid before reassembly Do not wipe the brake fluid off after washing the components When washing the components use the speci fied brake fluid Never use different types of fluid or cleaning solvents such as gasoline ker osine etc Apply brake fluid to the master cylinder bore and all of the master cylinder components be fore reassembly Specification and C...

Page 129: ...st Master cylinder bolt 10 N m 1 0 kg m 7 0 Ib ft Master cylinder Clearance Install the brake hose union as shown and tighten the union bolt to the specified torque Brake hose union bolt 23 N m 2 3 kg m 16 5 Ib ft A CAUTION Bleed air from the brake system after reassem bling the master cylinder See p 2 13 Upper clamp bolt Handlebars Downloaded from www Manualslib com manuals search engine ...

Page 130: ...etc taking care not to bend the brake hose Remove the speedometer cable guide from the left fork leg Remove the front fender and brake hose guide O ring Spacer Washer Front fork spring Damper rod ring Damper rod Rebound spring Inner tube Dust seal Oil seal stopper ring Oil seal Washer Slide metal Guide bushing Oil lock piece Outer tube Gasket Front fork cap bolt Damper rod bolt Downloaded from www...

Page 131: ...front fork cap bolt spacer washer and spring Invert the front fork and stroke it several times to drain out the fork oil Hold the front fork in the inverted position for a few min utes to allow the fork oil to fully drain Remove the dust seal and oil seal stopper ring Remove the damper rod bolt 09900 00410 Hexagon wrench set Downloaded from www Manualslib com manuals search engine ...

Page 132: ... slide metals should be replaced with new ones Remove the oil lock piece from the outer tube INSPECTION DAMPER ROD RING Inspect the damper rod ring for wear or damage If it is worn or damaged replace it with a new one FRONT FORK SPRING Measure the fork spring free length If it is shorter than the service limit replace it with a new one Service Limit 301 mm 11 9 in A CAUTION Downloaded from www Man...

Page 133: ...ce the oil seal and dust seal with new ones during reassembly Hold the inner tube vertically clean themetal groove and install the slide metal by hand I A CAUTION Do not damage the Teflon coated surface of the inner tube s slide metal when mounting it Install the outer tube metal washer and oil seal to the inner tube IA CAUTION When installing the oil seal onto the inner tube protect their seal li...

Page 134: ...a new damper rod gasket to prevent oil leakage Install the oil seal stopper ring and dust seal A CAUTION Make sure that the oil seal stopper ring is fitted securely NOTE Before installing the dust seal apply a small quantity of SUZUKI SUPER GREASE A to the lip of dust seal 99000 25010 SUZUKI SUPER GREASE A Downloaded from www Manualslib com manuals search engine ...

Page 135: ...on Front fork oil level 105 mm 4 1 in NOTE When adjusting the oil level remove the fork spring and compress the inner tube fully Install the fork spring as shown NOTE The end of the fork spring with the smaller pitch should be at the bottom of the front fork Install the front fork cap bolt to the inner tube A CAUTION Use a new O ring to prevent oil leakage Install the front fork to the motorcycle ...

Page 136: ... m 16 5 Ib ft Front fork lower clamp bolt 33 N m 3 3 kg m 24 0 Ib ft Front fork cap bolt 23 N m 2 3 kg m 16 5 Ib ft Install the front fender and tighten the mounting bolts temporarily Install the front brake caliper See p 5 10 Install the front wheel See p 5 8 Move the front fork up and down several times Tighten the front fender mounting bolts securely Downloaded from www Manualslib com manuals s...

Page 137: ...t Handlebar clamp Handlebar holder Steering stem nut Dust seal Bearing upper Bearing low er Steering stem Steering stem low er cover Handlebars Handlebar balancer Steering stem head bolt Handlebar clamp bolt Handlebar holder nut Front fork upper clamp bolt Front fork low er clamp bolt Downloaded from www Manualslib com manuals search engine ...

Page 138: ... p 5 15 Disconnect the front brake light switch lead wires Remove the front brake master cylinder Remove the right handlebar balancer Remove the handlebar right switch Disconnect the throttle cables and remove the throttle grip Downloaded from www Manualslib com manuals search engine ...

Page 139: ... rear view mirror Disconnect the clutch cable Remove the handlebar clamp bolt caps Remove the handlebars by removing the handlebar clamp bolts Remove the headlight Disconnect the headlight coupler Disconnect the lead wire couplers Remove the headlight housing by removing the mounting nut Downloaded from www Manualslib com manuals search engine ...

Page 140: ...ont brake hose speedometercable guide Disconnect the speedometer cable Remove the speedometer Remove the front turn signal light brackets Remove the handlebar holders Remove the steering stem head bolt 5 TJ E Downloaded from www Manualslib com manuals search engine ...

Page 141: ...d upper bearing Remove the lower bearing Remove the ignition switch using the special tool 09930 11920 Torx bit JT40H 09930 11940 Bit holder INSPECTION Inspect the removed parts for the following abnormalities Handlebar distortion Handlebar clamp wear Race wear and brinelling Bearing wear or damage Abnormal bearing noise Distortion of the steering stem Remove the lower bearing outer race using a c...

Page 142: ...ion to the fol lowing points Press in the upper and lower outer races using the spe cial tool 09941 34513 Steering race installer Press n the steering stem lower race using the spe cial tool 09941 74910 Steering bearing installer Apply grease to the upper and lower bearings 99000 25010 SUZUKI SUPER GREASE A Tighten the steering stem nut using the special tool 09940 14911 Steering stem nut wrench S...

Page 143: ...ube with the upper surface of the steering stem upper bracket Tighten the upper and lower front fork clamp bolts to the specified torque _ Front fork clamp bolt upper 23 N m 2 3 kg m 16 5 Ib ft lower 33 N m 3 3 kg m 24 0 Ib ft Install the handlebar holders and tighten their nuts temporarily Install the handlebars with the punch mark aligned with the handlebar clamp as shown Tighten the handlebar c...

Page 144: ...aster cylinder See p 5 13 Install the front brake caliper See p 5 10 Install the front fender and front wheel See pp 5 6 and 21 NOTE Hold the front fork legs move them back and forth and make sure that the steering is not loose A CAUTION After performing the adjustment and installing the handlebars rock the front wheel assembly for ward and backward to ensure that there is no play and that the pro...

Page 145: ...ing Bearing Spacer Brake camshaft Rear w heel Bearing Damper Drive chain guide Rear sprocket mounting drum Retainer Bearing Dust seal Spacer Rear sprocket Rear axle Rear axle nut Rear brake cam lever nut Rear sprocket mounting nut Downloaded from www Manualslib com manuals search engine ...

Page 146: ...ITEM N m kg m kg m 78 7 8 56 5 10 1 0 7 0 50 5 0 36 0 Downloaded from www Manualslib com manuals search engine ...

Page 147: ...Disengage the drive chain from the rear sprocket Remove the rear wheel Remove the rear brake panel Remove the rear sprocket with mounting drum from the rear wheel NOTE Before separating the rear sprocket and mounting drum slightly loosen the rear sprocket bolts Remove the rear sprocket damper Remove the drive chain guide and rear sprocket from the rear sprocket mounting drum Remove the brake shoes...

Page 148: ...f the rear sprocket mounting drum bearing in the same manner as the wheel bearing Remove the rear sprocket mounting drum bearing as fol lows Remove the dust seal using the special tool 09913 50121 Oil seal remover A CAUTION The removed dust seal should be replaced with a new one Remove the rear sprocket mounting drum bearing using the special tool 09941 50111 Bearing remover A CAUTION The removed ...

Page 149: ...d decide whether it should be replaced or not from the thickness of the brake shoe lining Service Limit 1 5 mm 0 06 in A CAUTION Replace the brake shoes as a set otherwise braking performance will be adversely affected REAR SPROCKET DAMPER Inspect the rear sprocket damper for wear and damage Replace the rear sprocket damper if there is anything un usual REAR SPROCKET Inspect the sprocket s teeth f...

Page 150: ... set 09924 84521 Bearing installer set A CAUTION First install the right wheel bearing then left wheel bearing The sealed cover on the bearing must face out Rightside Rightside Rightbearing Leftbearing Clearance Spacer REAR SPROCKET MOUNTING DRUM BEARING Install the rear sprocketmounting drum bearing and dust seal using the special tool 09913 76010 Bearing installer NOTE Apply grease to the bearin...

Page 151: ...AFT When installing the brake camshaft apply SUZUKI SU PER GREASE A to the camshaft 99000 25010 SUZUKI SUPER GREASE A BRAKE CAM LEVER Install the new O ring and washer Align the notch on the brake camshaft with the slit in the brake cam lever as shown Tighten the brake cam lever nut to the specified torque Brake cam lever nut 10 N m 1 0 kg m 7 0 Ib fl Downloaded from www Manualslib com manuals sea...

Page 152: ...AR WHEEL Tighten the rear torque link nut to the specified torque and install the new cotter pin Rear torque link nut 13 N m 1 3 kg m 9 5 Ib ft Adjust the drive chain slack after installing the rear wheel See p 2 11 Tighten the rear axle nut to the specified torque Rear axle nut 78 N m 7 8 kg m 56 5 Ib ft Tighten both chain adjusting nuts securely Adjust the rear brake pedal free travel See p 2 14...

Page 153: ...72 7 2 52 0 Rightside Rear shock absorber Rear torque link Sw ingarm Spacer Dust seal Dust seal Spacer Drive chain buffer Sw ingarm pivot shaft Rear shock absorber nut Rear torque link nut Rear shock absorber bolt Sw ingarm pivot nut Leftside Downloaded from www Manualslib com manuals search engine ...

Page 154: ...Downloaded from www Manualslib com manuals search engine ...

Page 155: ...e the rear brake cable holder Remove the rear brake cable from the swingarm Remove the shock absorbers Remove the swingarm pivot shaft end caps Remove the swingarm pivot nut and washer Remove the swingarm by removing the pivot shaft Downloaded from www Manualslib com manuals search engine ...

Page 156: ...D DUST SEALS Inspect the swingarm pivot spacers and dust seals for damage If any defects are found replace the spacer with a new one SWINGARM NEEDLE BEARINGS Insert the spacers into the needle bearings move the spacer up and down and check for any play If there is excessive play replace the bearing s with a new one Downloaded from www Manualslib com manuals search engine ...

Page 157: ...lace the chain buffer with a new one SWINGARM PIVOT SHAFT Measure the pivot shaft runout using the dial gauge If the pivot shaft exceeds the service limit replace it with a new one 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block 100 mm Service Limit 0 3 mm 0 01 in REAR SHOCK ABSORBER Inspect the rear shock absorber for damage and oil leak age If any defects are found...

Page 158: ... set NOTE Install the needle bearings with the stampedmark facing out Apply grease to the spacers dust seals and needle bearings 99000 25010 SUZUKI SUPER GREASE A Install the rear torque link to the swingarm Tighten the rear torque link nut to the specified torque Rear torque link nut 13 N m 1 3 kg m 9 5 Ib ft Install the new cotter pin Install the swingarm and tighten the swingarm pivot nut to th...

Page 159: ...the spring tension ad justing holes facing out Install the rear wheel and rear brake See p 5 35 Adjust the rear shock absorber spring pre load Spring pre load STD 3 5 position After installing the rear suspension and rear wheel adjust the following before riding Drive chain slack See p 2 11 Rear brake pedal free travel See p 2 14 Tire pressure See p 2 15 Downloaded from www Manualslib com manuals ...

Page 160: ...CTION 6 12 STARTER MOTOR REASSEMBLY 6 13 STARTER RELAY INSPECTION 6 14 SIDE STAND IGNITION INTERLOCK SYSTEM PART INSPECTION 6 15 IGNITION SYSTEM 6 18 DESCRIPTION 6 18 TROUBLESHOOTING 6 19 INSPECTION 6 20 SPEEDOMETER 6 24 REMOVAL AND DISASSEMBLY 6 24 INSPECTION 6 25 LAMPS 6 26 HEADLIGHT AND POSITION LIGHT 6 26 BRAKE LIGHT TAILLIGHT 6 27 TURN SIGNAL LIGHTS 6 28 RELAYS 6 29 STARTER RELAY 6 29 TURN SI...

Page 161: ...corrosion and contamination CLAMPS Refer to WIRE CABLE AND HOSE ROUTING See pp 7 11 to 18 for proper clamping procedures Bend the clamp properly as shown in the illustration When clamping the wire harness do not allow it to hang down Do not use wire or any other substitute for the band type clamp CORRECT INCORRECT FUSES When a fuse blows always investigate the cause cor rect the problem and then r...

Page 162: ...st When connecting the battery lead wires be sure to con nect the battery lead wire first If the terminal is corroded remove the battery pour warm water over it and clean it using a wire brush After connecting the battery apply a light coat of grease to the battery terminals Reinstall the cover over the battery terminal WIRING PROCEDURE Properly route the wire harness according to WIRE CABLE AND H...

Page 163: ...ELECTRICAL COMPONENTS Clutch lever position switch Ignitor Turn signal side stand relay Fuse box Ignition coil Horn Generator Neutral switch Side stand switch Regulator rectifier Downloaded from www Manualslib com manuals search engine ...

Page 164: ...ELECTRI CA LSY STEM 6 4 Front brake light switch Rear brake light switch Starter motor Starter relay Main fuse Battery Downloaded from www Manualslib com manuals search engine ...

Page 165: ... is indicated in the figure which is composed of an AC generator regulator rectifier 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 Downloaded from www Manualslib com manuals search engine ...

Page 166: ...e or disconnected wires Faulty battery Faulty battery Abnormal driving condition Incorrect Measure the continuity of the stator coil See p 6 8 No continuity Faulty stator coils or disconnected coupler Continuity Inspect generator no load voltage See p 6 8 No good Faulty generator rotor or stator coil Inspect regulator rectifier See p 6 9 Faulty regulator rectifier Good Inspect the wirings Good No ...

Page 167: ...Battery overcharges Faulty regulator rectifier Faulty battery Poor contact of stator coil coupler Downloaded from www Manualslib com manuals search engine ...

Page 168: ...ectors one by one checking each part CHARGING OUTPUT INSPECTION Remove the front seat and right frame cover See p 5 1 Start the engine turn the lighting switch to ON and the dimmer switch to HI and run the engine at 5 000 r min Measure the DC voltage between the and battery terminals with a tester If the tester reads under 13 5V or over 15 0V inspect the stator coil and regulator rectifier A CAUTI...

Page 169: ...coil resistance GENERATORNO LOAD PERFORMANCE INSPECTION Remove the front seat See p 5 1 Remove the fuel tank See p 4 1 Disconnect the stator coil coupler Start the engine and keep it running at 5 000 r min Measure the voltage between the three lead wires using a tester If the tester reads under the specified value replace the stator coil and pick up coil or the generator rotor with a new one Gener...

Page 170: ...ation Diode test Unit V Probe of tester to Probe of tester to R B W Y2 Y3 R 0 5 1 0 0 3 0 7 0 3 0 7 0 3 0 7 B W 1 2 1 5 1 2 1 5 1 2 1 5 1 2 1 5 1 2 1 5 0 3 0 7 1 2 1 5 1 2 1 5 1 2 1 5 0 3 0 7 1 2 1 5 1 2 1 5 1 2 1 5 0 3 0 7 1 2 1 5 1 2 1 5 WIRE COLOR R Red Y Yellow B W Black with White tracer NOTE If the tester lead under 1 4V replace the battery of multi circuit tester when do not connecting the ...

Page 171: ...e SIDE STAND IGNITION INTERLOCK SYSTEM DESCRIPTION This side stand ignition interlock system prevents the motorcycle from being started with the side stand down The system is operated by an electric circuit provided between the battery and ignition coil Engine stop switch Ignition switch Clutch lever position switch Fuse Starter motor Neutral switch Starter relay Starter button Side stand relay Si...

Page 172: ...rs be tween Y B and B W when the starter button is pushed No voltage Faulty ignition switch Faulty engine stop switch Faulty clutch lever position switch Faulty neutral switch Faulty side stand relay Faulty starter button Poor contact of connector Open circuit in wire harness Check the starter relay See pp 6 14 and 15 No good Faulty starter relay OK Poor contact of the starter relay The starter mo...

Page 173: ... Faulty starter clutch Downloaded from www Manualslib com manuals search engine ...

Page 174: ...ation STARTER MOTOR INSPECTION CARBON BRUSH Inspect the brushes for abnormal wear crack or smooth ness in the brush holder If either carbon brush is defective replace the brush as sembly Housing end Outside O ring Brush spring Brush holder Starter motor case Armature O ring Housing end Inside O ring O ring 2 pcs Oil seal Downloaded from www Manualslib com manuals search engine ...

Page 175: ...segment and the armature shaft If there is no continuity between the segments or there is continuity between the segments and shaft replace the ar mature with a new one OIL SEAL INSPECTION Check the seal lip for damage or leakage If any damage is found replace the housing end inside STARTER MOTOR REASSEMBLY Reassemble the starter motor in the reverse order of disas sembly Pay attention to the foll...

Page 176: ... relay cover Disconnect the starter motor lead wires and starter relay lead wire coupler Remove the starter relay Apply 12 volts to terminals and and measure for continuity between the positive and negative terminals If the starter relay clicks and continuity is found the relay is ok 09900 25008 Multi circuit tester set Tester knob indication Continuity test A CAUTION To starter motor To battery D...

Page 177: ...uity between Blue and Ground with the transmis sion in neutral Blue Ground ON in neutral OFF not in neutral SIDE STAND SWITCH The side stand switch coupler is located under the fuel tank Remove the front seat See p 5 1 Remove the fuel tank See p 4 1 Disconnect the side stand switch lead wire coupler and measure the voltage between Green and Black White lead wires 09900 25008 Multi circuit tester s...

Page 178: ...ay It is located under the luggage box Remove the front seat See p 5 1 Remove the luggage box SIDE STAND RELAY INSPECTION First check the insulation between and terminals with tester Then apply 12 volts to and terminals to and to and check the continuity between and If there is no continuity replace turn signal side stand relay with a new one Downloaded from www Manualslib com manuals search engin...

Page 179: ...owing table Unit V Probe of tester to Probe c tester to i 1 4 1 5 0 4 0 6 09900 25008 Multi circuit tester set Tester knob indication Diode test NOTE If the tester read under 1 4V replace the battery of multi circuit tester when do not connecting the tester probes Downloaded from www Manualslib com manuals search engine ...

Page 180: ...lculates the best ignition timing The CPU outputs the signal to the transistor of the ignition coil output circuit which is connected to the primary windings of the ignition coil which is turned off and on accordingly Thus it induces the secondary current in the ignition coil s secondary winding and produces the spark between the spark plug gap Side stand relay Engine stop switch Fuse Ignitor Igni...

Page 181: ...y with the multi circuit tester and the peak volt adaptor Inspect the ignition coil See p 6 21 Faulty ignition switch Faulty turn signal side stand relay Faulty engine stop switch Broken wire harness or poor connection of related circuit couplers Inspect the spark plug See p p 2 4 and 5 Incorrect Correct Faulty igniter unit Faulty spark plug Poor conne ction of the spark plug cap Faulty ignition c...

Page 182: ... Open circuit in wiring harness Poor connection of ignition couplers Downloaded from www Manualslib com manuals search engine ...

Page 183: ...g the multi circuit tester and peak volt adaptor referto the appropriate instruction manual Shift the transmission into neutral turn the ignition switch to the ON position and grasp the clutch lever Press the starter button and allow the engine to crank for a few seconds and then measure the Ignition coll prima ry peak voltage Repeat the above procedure a few times and measure the highest ignition...

Page 184: ...terminals in the following table 09900 25008 Multi circuit tester set Tester knob indication Diode test i Probe of tester to Probe of tester to 1 2 1 5 1 2 1 5 1 2 1 5 1 2 1 5 1 2 1 5 1 2 1 5 1 2 1 5 1 2 1 5 1 1 1 5 1 1 1 5 1 2 1 5 1 2 1 5 1 2 1 5 1 1 1 5 0 9 1 4 1 1 1 5 0 1 2 1 5 1 2 1 5 1 2 1 5 0 5 0 8 0 9 1 4 1 1 1 5 0 1 2 1 5 1 2 1 5 1 2 1 5 0 5 0 8 1 1 1 5 1 1 1 5 0 3 0 6 0 3 0 6 1 2 1 5 1 2 ...

Page 185: ... and peak volt adaptor refer to the appropriate instruction manual Shift the transmission into neutral turn the ignition switch to the ON position and grasp the clutch lever Press the starter button and allow the engine to crank for a few seconds and then measure the pick up coil peak voltage Repeat the above procedure a few times and measure the highest pick up coil peak voltage Tester knob indic...

Page 186: ...l lead wire coupler is ok but on the ignitor coupler is out of specification the wire harness must be replaced If both peak voltages are out of specification the generator must be replaced and re checked PICK UP COIL RESISTANCE Remove the seat and fuel tank and disconnect the pick up coil coupler Measure the resistance between the lead wires and ground If the resistance is not within the specified...

Page 187: ... 24 SPEEDOMETER REMOVAL AND DISASSEMBLY Remove the speedometer Disassemble the speedometer as follows Speedometer Speedometer bracket Speedometer cover Socket assy Downloaded from www Manualslib com manuals search engine ...

Page 188: ...ontinuity it is not necessary to remove the speedometer WIRE COLOR B Black B W Black with White tracer Gr Gray Bl B Blue with Black tracer Lg Light green O G Orange with Green tracer Y Yellow Bl B Neutral B Turn signal L Y High beam Lg Turn signal Gr Illumination Neutral B W High beam illumination Downloaded from www Manualslib com manuals search engine ...

Page 189: ...Disconnect the socket Remove the rubber cap Remove the bulb by removing the bulb holder spring Remove the position light bulb Reassemble the bulb in the reverse order of removal A CAUTION If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure Downloaded from www Manualslib com manuals search engine ...

Page 190: ...sh in on the bulb socket turn it counterclockwise and pull it out Remove the brake light taillight bulb A CAUTION If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure Reassemble the bulb in the reverse order of removal Downloaded from www Manualslib com manuals search engine ...

Page 191: ...e the lens by removing the screws Remove the bulb CAUTION________________________________ If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure Reassemble the bulb in the reverse order of removal CAUTION Do not overtighten the lens fitting screws Downloaded from www Manualslib com manuals search engine ...

Page 192: ...der the luggage box Remove the front seat See p 5 1 Remove the luggage box INSPECTION Before removing the turn signal side stand relay check the operation of the turn signal light If the turn signal light does not light inspect the bulb turn signal switch and circuit connection If the bulb turn signal switch and circuit connection checked are all right the turn signal relay may be faulty replace i...

Page 193: ...AL SWITCH ENGINE STOP SWITCH WIRE COLOR B Black O Orange Br Brown R Red Gr Gray Y Yellow Lbl Light blue W White Lg Light green B W Black with White tracer B Y Black with Yellow tracer B R Black with Red tracer O B Orange with Black tracer O BI Orange with Blue tracer O R Orange with Red tracer O W Orange with White tracer O Y Orange with Yellow tracer W B White with Black tracer Y W Yellow with Wh...

Page 194: ...y filling the battery with electrolyte use the caps from the electrolyte container to seal the battery filler holes Insert the nozzles of the electrolyte container into the battery s electrolyte filler holes Hold the electrolyte con tainer firmly so that it does not fall Do not allow any of the electrolyte to spill Make sure that the air bubbles rise to the top of each electrolyte container and le...

Page 195: ...y use the specified MF battery Do not remove the caps once they are installed in the battery CORRECT INCORRECT Measure the battery voltage using a tester The tester should indicate more than 12 5 12 6V DC as shown If the battery voltage is lower than specification charge the battery with a battery charger NOTE Initial charging for a new battery is recommended if two years have elapsed since the da...

Page 196: ... careful not to permit the charging current to exceed 3Aat any time After recharging wait at least 30 minutes and then mea sure the battery voltage using a tester If the battery voltage is less than 12 5V recharge the battery again If the battery voltage is still less than 12 5V after recharg ing replace the battery with a new one When a battery is left unused for a long time its voltage needs to ...

Page 197: ...ONTENTS TROUBLESHOOTING 7 1 WIRING DIAGRAM 7 8 WIRE CABLE AND HOSE ROUTING 7 11 FRAME REAR COVER SET UP 7 19 SPECIAL TOOLS 7 20 TIGHTENING TORQUE 7 23 SERVICEDATA 7 26 Downloaded from www Manualslib com manuals search engine ...

Page 198: ... tension cord 7 Defective pick up coil or ignitor unit No fuel reaching the carburetor 1 Clogged or defective fuel valve 2 Defective carburetor needle valve 3 Clogged fuel hose 4 Clogged fuel filter Rebore or replace Replace Repair or replace Tighten Replace See electrical section Adjust Adjust Replace Replace Clean or replace Clean and dry or replace Replace Replace Replace Clean or replace Repla...

Page 199: ...lutch plate 4 Distorted clutch plate Replace 5 Worn clutch release bearing Replace 6 Weak clutch damper Replace primary driven gear 7 Weak clutch spring Noise seems to come from the crankshaft Replace 1 Rattling bearing Replace 2 Worn or burnt crank pin bearing Replace 3 Worn or burnt ball bearing Noise seems to come from the transmission Replace 1 Worn or rubbing gear Replace 2 Worn countershaft ...

Page 200: ... 6 Defective ignition coll 7 Defective pick up coil or ignitor unit 8 Low float chamber fuel level 9 Clogged air cleaner element 10 Clogged fuel hose resulting in inadequate fuel supply to carburetor Replace Replace Regap or replace Adjust Replace ignitor unit Replace Replace Adjust float height Clean or replace Clean and prime Exhaust smoke is dirty or thick 1 Excessive amount of engine oil 2 Wor...

Page 201: ...ged bypass port 5 Starter plunger not fully closed Clean or tighten Tighten or replace defective part Clean Clean Adjust Medium or high speed trouble 1 Clogged main jet 2 Clogged needle jet 3 Improperly working throttle valve 4 Clogged fuel filter Clean Clean Adjust Clean or replace Overflow and fuel level fluctuations 1 Worn or damaged needle valve 2 Broken needle valve spring 3 Improperly workin...

Page 202: ...t 6 Loosen wheel spokes 7 Loosen rear suspension fastener Replace Replace Replace Replace Tighten Tighten Tighten Rear suspension too soft 1 Weak rear shock absorber spring 2 Rear shock absorber leaks oil 3 Improper suspension setting Replace Replace Adjust Rear suspension too stiff 1 Improperly adjusted rear suspension 2 Bent swingarm 3 Worn swingarm and rear suspension related bearings Adjust Re...

Page 203: ...r poor sparking 1 Defective ignition coil 2 Defective spark plug 3 Defective pick up coil 1 Defective ignitor unit Replace Replace Replace Replace Spark plug is wet or quickly becomes fouled with carbon 1 Excessively rich air fuel mixture 2 Excessively high idling speed 3 Incorrect gasoline 4 Clogged air cleaner element 5 Incorrect spark plug cold type Adjust carburetor Adjust carburetor Change Cl...

Page 204: ...the commutator in the starter motor 4 Defective starter relay Recharge or replace Replace Repair or replace Replace BATTERY Complaint Symptom and possible causes Remedy Sulfation or spots on surfaces of cell plates 1 Cracked battery case 2 Battery has been left In a run down condition for a long time Replace battery Replace Battery runs down quickly 1 Incorrect charging method 2 Battery cell plate...

Page 205: ...WIRING DIAGRAM FOR E 03 28 and 33 SERVICING INFORMATION 7 8 Downloaded from www Manualslib com manuals search engine ...

Page 206: ...7 9 SERVICING INFORMATION FOR E 24 Downloaded from www Manualslib com manuals search engine ...

Page 207: ...FOR THE OTHERS SERVICING INFORMATION 7 10 Downloaded from www Manualslib com manuals search engine ...

Page 208: ...g harness Wiring harness Starter motor Clamp Clamp Starter motor lead w ire Clamp Rear fender Turn signal side stand relay Air cleaner Generator Ignitor Neutral sw itch Side stand switch Clamp Handlebar switch L R Handlebar sw itch L R Starter motor Clamp Side stand switch Clamp Regulator rectifier Neutral sw itch Side stand switch Downloaded from www Manualslib com manuals search engine ...

Page 209: ...re under the brake hose Clamp Clamp Clamp Clamp Battery terminal Rear turn signal light R Rear turn signal light L Battery Brake light Taillight Starter relay Engine ground Starter motor Clamp Rear brake switch Wiring harness Handlebar switch L R Starter motor Generator Wiring harness Clamp Starter motor Clamp Downloaded from www Manualslib com manuals search engine ...

Page 210: ...re Neutral sw itch Pick up coil Clamp Engine ground wire Side stand switch lead w ire Clamp Generator rolor Neutral switch lead wire Side stand switch leadw ire Neutral sw itch lead w ire Downloaded from www Manualslib com manuals search engine ...

Page 211: ...Stator coil Downloaded from www Manualslib com manuals search engine ...

Page 212: ...Throttle cable returning cable Throttle cable pulling cable Clamp Throttle cables Starter cable Pass the throttle cables outside of the brake hose Starter cable Clamp Wiring harness Clamp Brake hose Handlebar sw itch R Clutch cable Clutch cable Starter cable Handlebar sw itch L Starter cable Clamp Clamp Clamp Clamp Clamp Clutch cable Downloaded from www Manualslib com manuals search engine ...

Page 213: ...ng Guide Speedometer cable Guide Pass the speedometer cable outside of the brake hose Brake hose Clamp 100 mm 4 0 in Max 10 mm 0 4 in 4 Do not contact the guide to the caliper rubber bushing Downloaded from www Manualslib com manuals search engine ...

Page 214: ...ORMATION 7 16 Clamp Seatlock cable Rear brake switch cable Clamp Rear brake cable Rear brake cable clip Clamp Rear brake cable Clamp Rear brake switch cable Downloaded from www Manualslib com manuals search engine ...

Page 215: ...der Clamp Clamp the brake hose securely Brake hose Clamp Speedometer cable Clamp Clamp the brake hose securely Brake caliper After touching the brake hose union to the stopper tighten the union bolt to the specified torque Stopper Downloaded from www Manualslib com manuals search engine ...

Page 216: ...eft Right Left Right Engine side Air cleaner side Carburetor clamp position VIEW A Air cleaner Carburetor Carburetor air vent hose Battery case Clamp Air cleaner drain hose Carburetor overflow hose Downloaded from www Manualslib com manuals search engine ...

Page 217: ...7 19 SERVICINGINFORMATION FRAME REAR COVER SET UP Rear fender brace Rear fender Frame rear cover Cushion Nut Frame Spacer Downloaded from www Manualslib com manuals search engine ...

Page 218: ...100 mm 10 mm 09900 20701 Magnetic stand 09900 20803 Thickness gauge 09900 20805 Tire depth gauge 09900 21304 V block set 100 mm 09900 22301 09900 22302 Plastigauge 09900 22401 09900 22403 Small bore gauge 09900 25008 Multi circuit tester set 09900 26006 Tachometer 09910 20116 Conrod holder 09910 32812 Crankshaft installer 09910 32840 Attachment 09910 34510 Piston pin puller 09913 50121 Oil seal re...

Page 219: ...16 84511 Tw eezers 09917 14920 Valve adjuster wrench 09918 03810 Adaptor 09920 13120 Crankcase separator 09920 53740 Clutch sleeve hub holder 09923 74510 Bearing remover 09924 84510 Bearing installer set 09924 84521 Bearing installer set 09930 10121 Spark plug socket wrench set 09930 11920 Torx bit JT40H 09930 11940 Bit holder 09930 30102 Sliding shaft 09930 34960 Rotor remover 09930 44913 Rotor h...

Page 220: ...r 09941 54911 Bearing outer race remover 09941 74910 Steering bearing installer 09943 74111 Front fork oil level gauge NOTE When ordering a special tool please confirm whether it is available or not Downloaded from www Manualslib com manuals search engine ...

Page 221: ... 3 9 28 0 Front brake pad mounting bolt 18 1 8 13 0 Front brake hose union bolt 23 2 3 16 5 Front brake caliper air bleeder valve 7 5 0 75 5 5 Front brake master cylinder mounting bolt 10 1 0 7 0 Front brake disc bolt 23 2 3 16 5 Front footrest bolt 26 2 6 19 0 Swingarm pivot nut 72 7 2 52 0 Rear axle nut E 03 28 33 65 6 5 47 0 The others 78 7 8 56 5 Rear torque link nut front and rear 13 1 3 9 5 ...

Page 222: ...N m kg m Ib ft N m kg m Ib ft 4 1 5 0 15 1 0 2 0 2 1 5 5 3 0 3 2 0 5 0 5 3 5 6 6 0 6 4 5 10 1 0 7 0 8 13 1 3 9 5 23 2 3 16 5 10 29 2 9 21 0 50 5 0 36 0 12 45 4 5 32 5 85 8 5 61 5 14 65 6 5 47 0 135 13 5 97 5 16 105 10 5 76 0 210 21 0 152 0 18 160 16 0 115 5 240 24 0 173 5 Conventional bolt 4 marked bolt 7 marked bolt Downloaded from www Manualslib com manuals search engine ...

Page 223: ...N EX 0 35 0 014 Valve guide I D IN EX 5 500 5 512 0 2165 0 2170 Valve stem O D IN 5 460 5 475 0 2150 0 2156 EX 5 445 5 460 0 2144 0 2150 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve stem end length IN EX 3 6 0 14 Valve seat width IN EX 0 9 1 1 0 035 0 043 Valve head radial runout IN EX 0 03 0 001 Valve spring free length IN EX 40 1 1 58 Valve spring tension IN EX 18...

Page 224: ...718 Cylinder head distortion 0 05 0 002 Cylinder head cover distortion 0 05 0 002 CYLINDER PISTON PISTON RING Unit mm in ITEM STANDARD LIMIT Compression pressure 1 000 1 400 kPa 10 0 14 0 kg cm 2 142 199 psi 800 kPa 8 kg cm 2 114 psi j Piston to cylinder clearance 0 045 0 055 0 0018 0 0022 0 120 0 0047 Cylinder bore 72 000 72 015 2 8346 2 8352 72 085 2 8380 Piston diam 71 950 71 965 2 8327 2 8333 ...

Page 225: ...6 1 0 0 04 Conrod big end width 20 95 21 00 0 825 0 827 Crankshaft web to web width 60 0 0 1 2 362 0 004 Crankshaft runout 0 05 0 002 Balancer spring free length 10 0 0 39 OIL PUMP ITEM STANDARD LIMIT Oil pump reduction ratio 2 812 68 21 x 33 38 Oil pressure at 60 C 140 F Above 30 kPa 0 3 kg cm 2 4 3 psi Below 70 kPa 0 7 kg cm 2 10 0 psi at 3 000 r min CLUTCH Unit mm in ITEM STANDARD LIMIT Clutch ...

Page 226: ... chain Type DID520VC5 Links 110 20 pitch length 319 4 12 57 Drive chain slack 5 15 0 2 0 6 CARBURETOR ITEM SPECIFICATION E 01 02 04 25 34 E 17 22 24 Carburetor type MIKUNI BSR32SS Bore size 32 mm I D No 13F0 13F2 Idle r min 1 300 100 r min Float height 13 0 0 5 mm Main jet M J 115 Jet needle J N 5C60 3rd Needle jet N J P 0 Pilot jet P J 17 5 Pilot air jet No 1 P A J 1 87 5 Pilot air jet No 2 P A J...

Page 227: ...n Spark plug Type NGK DR8EA DENSO X24ESR U Gap 0 6 0 7 0 024 0 028 Spark performance Over 8 0 3 at 1 atm Ignition coil resistance Primary 3 5 terminal terminal Secondary 17 28 terminal Plug cap Ignition coil primary peak voltage More than 200 V Generator coil resistance Pick up 400 650 Bl G Charging 0 1 1 5 Y Y Pick up coil peak voltage More than 5 0 V Generator Max output 210Wat5 000r min Generat...

Page 228: ... pedal height 50 2 0 Brake disc thickness Front 5 0 0 2 0 20 0 01 4 5 0 18 Brake disc runout Front 0 30 0 012 Master cylinder bore 12 700 12 743 0 4999 0 5017 Master cylinder piston diam 12 657 12 684 0 4983 0 4994 Brake caliper cylinder bore 33 960 34 036 1 3370 1 3400 Brake caliper piston diam 33 884 33 934 1 3340 1 3360 Brake drum I D Rear 130 7 5 15 Brake lining thickness Rear 1 5 0 06 Wheel r...

Page 229: ...e containing MTBE Methyl Tertiary Butyl Ether less than 10 ethanol or less than 5 methanol with appropriate cosolvents and corrosion inhibitor is permissible E 03 33 Use only unleaded gasoline of at least 87 pump octane method or 91 octane or higher rated by the Research Method E 28 Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended The others Fuel tank includin...

Page 230: ...Prepared by SUZUKI MOTORCORPORATION Motorcycle Service Department June 1998 PartNo 99500 32100 01E Printed in Japan 224 Downloaded from www Manualslib com manuals search engine ...

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