Suzuki LT-A50 Service Manual Download

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SERVICING INFORMATION

7-5

Complaint

Symptom and possible causes

Remedy

Suspension too stiff.

1. Worn suspension arms and related bushings.

Replace.

Suspension too noisy.

1. Loose suspension system bolts.

Tighten.

2. Worn suspension arms and related bushings.

Replace.

Rear wheels wobble.

1. Distorted rear wheel rims.

Replace.

2. Damage or worn rear wheel hub bearings.

Replace.

3. Defective or incorrect rear tires.

Replace.

4. Loose rear wheel hub nuts.

Tighten.

5. Improper rear brake sdjustment.

Adjust.

6. Damaged or worn rear swingarm and related bushings.

Replace.

7. Rear shock absorber leaks oil.

Replace.

8. Loose rear suspension arm unit.

Tighten.

BRAKES

Complaint

Symptom and possible causes

Remedy

Poor braking.

1. Worn shoe linings.

Replace.

2. Too much play on brake pedal.

Adjust.

Insufficient brake power.

1. Worn lining.

Replace.

2. Worn brake drum.

Replace.

Brake squeaks.

1. Carbon adhesion on lining surface.

Repair surface with emery
paper.

2. Loose front wheel axle or rear wheel axle.

Tighten to specified torqoe.

3. Worn linings.

Replace.

4. Wrongly fixed spring.

Set correctly.

Excessive brake lever

1. Worn brake lever cam.

Replace brake cam.

stroke.

ELECTRICAL

Complaint

Symptom and possible causes

Remedy

No sparking or poor

1. Defective CDI/Ignition coil unit.

Replace.

sparking.

2. Defective spark plug.

Replace.

3. Defective generator coil.

Replace.

4. Loose connection of lead wire.

Connect/tighten.

Spark plug is wet or

1. Excessively rich air/fuel mixture.

Adjust carburetor.

quickly becomes fouled

2. Excessively high idling speed.

Adjust carburetor.

with carbon.

3. Incorrect gasoline.

Change.

4. Clogged air cleaner element.

Clean or replace.

5. Incorrect spark plug.

Replace.

Spark plug quickly

1. Worn piston ring.

Replace.

becomes fouled with oil or

2. Worn piston.

Replace.

carbon.

3. Worn cylinder.

Rebore or replace.

Spark plug electrodes

1. Incorrect spark plug.

Replace.

overheat or burn.

2. Overheated engine.

Tune-up.

3. Loose spark plug.

Tighten.

4. Excessively lean air/fuel mixture.

Adjust carburetor.

Summary of Contents for LT-A50

Page 1: ...9 9 5 0 0 2 0 2 1 2 0 1 E LT A50 ...

Page 2: ...in injury to the mechanic and may ren der the vehicle unsafe for the rider 2 3 4 5 GENERAL INFORMATION This manual has been prepared on the basis of the latest specifications at the time of pub lication If modifications have been made since then differences may exist between the con tent of this manual and the actual vehicle Illustrations in this manual are used to show the basic principles of ope...

Page 3: ...MPONENT 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 and rear wheel 1 Oil seal 2 Bearing 3 Spacer 4 Front wheel hub 5 Bearing 6 Oil seal 7 Front wheel 8 Front wheel center cap 9 Rear wheel hub 0 Rear wheel A Rea...

Page 4: ...ly SUZUKI SUPER GREASE A 99000 25030 Apply THREAD LOCK 1342 99000 32050 Apply THREAD LOCK SUPER 1360 99000 32130 Apply SUZUKI BOND 1207B 99104 31140 Apply THREAD LOCK SUPER 1303 99000 32030 Measure in voltage range Measure in current range Measure in diode test range Measure in continuity test range Use special tool SYMBOL DEFINITION SYMBOL DEFINITION Indication of service data Apply SUZUKI MOLY P...

Page 5: ...SUPER GREASE A 99000 25010 Apply THREAD LOCK 1342 99000 32050 Apply THREAD LOCK SUPER 1360 99000 32130 Apply SUZUKI BOND 1207B 99000 31140 Apply THREAD LOCK SUPER 1303 99000 32030 Measure in voltage range Measure in current range Measure in diode test range Measure in continuity test range Use special tool SYMBOL DEFINITION SYMBOL DEFINITION Indication of service data Apply SUZUKI MOLY PASTE 99000...

Page 6: ...E 1 2 GENERAL PRECAUTIONS 1 2 SUZUKI LT A50K2 2002 MODEL 1 4 SERIAL NUMBER LOCATION 1 4 FUEL AND OIL RECOMMENDATIONS 1 4 FUEL 1 5 ENGINE OIL 1 5 TRANSMISSION OIL 1 5 BREAK IN PROCEDURES 1 5 INFORMATION LABELS 1 6 SPECIFICATIONS 1 7 COUNTRY OR AREA CODES 1 8 CONTENTS ...

Page 7: ...must use good judgement and basic mechanical safety principles If you are unsure about how to perform a particular service operation ask a more experienced mechanic for advice GENERAL PRECAUTIONS Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the vehicle When 2 or more persons work together pay attention to the safety of ...

Page 8: ...oil seals gaskets packing O rings locking washers self locking nuts 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 ov...

Page 9: ...h method 2 Suzuki recommends that customers use alcohol free unleaded gasoline whenever possible 3 Use of blended gasoline containing MTBE Methyl Tertiary Butyl Ether is permitted 4 Use of blended gasoline alcohol fuel is permitted provided that the fuel contains not more than 10 ethanol Gasoline alcohol fuel may contain up to 5 methanol if appropriate cosolvents and corrosion inhibitors are prese...

Page 10: ...oke engine oil rated FC under the JASO classification TRANSMISSION OIL Use a good quality SAE 10W 40 multi grade motor oil 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 an...

Page 11: ...nce label 3 Manual notice label 4 Parking brake label E 5 Parking brake label F 6 Tire pressure label E 7 Tire pressure label F 8 General warning label E 9 General warning label F 10 No passenger label 11 Age 6 label E 12 Age 6 label F 13 Approval label 14 EC mark label 15 ICES Canada label 16 Fuel caution label E English F French ...

Page 12: ... Idle speed 1 800 100 r min TRANSMISSION Transmission 2 416 29 12 Primary reduction 2 650 53 20 Final reduction 3 700 37 10 Drive chain D I D 420 CHASSIS Front suspension Independent swing axle coil spring oil damped Rear suspension Swingarm coil spring oil damped Front wheel travel 52 mm 2 0 in Rear wheel travel 51 mm 2 0 in Caster 3 Trail 10 mm 0 39 in Camber 0 Steering angle 35 Turning radius 2...

Page 13: ...1 8 GENERAL INFORMATION COUNTRY OR AREA CODES The following codes stand for the applicable country ies and area s CODE COUNTRY or AREA P 02 UK P 03 USA P 28 Canada ...

Page 14: ...YLINDER HEAD AND CYLINDER 2 5 SPARK PLUG 2 6 THROTTLE CABLE PLAY 2 7 ENGINE IDLE SPEED 2 7 FUEL HOSE 2 7 TRANSMISSION OIL 2 8 DRIVE CHAIN 2 8 BRAKES 2 10 TIRES 2 11 SUSPENSION 2 12 STEERING 2 12 EXHAUST PIPE BOLT AND MUFFLER BOLT 2 13 SPARK ARRESTER 2 13 CHASSIS BOLTS AND NUTS 2 14 INITIAL ENGAGEMENT AND CLUTCH LOCK UP INSPECTION 2 16 INITIAL ENGAGEMENT INSPECTION 2 16 CLUTCH LOCK UP INSPECTION 2 ...

Page 15: ...bolt and muffler bolt T T T Spark arrester C Chassis bolts and nuts T T T PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the vehicle operating at peak performance and economy Maintenance intervals are expressed in terms of kilometers miles and months and are dependent on whichever comes first NOTE More freq...

Page 16: ...eration and long life of each working part of the vehicle Major lubrication points are indicated below 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 vehicle has been operated under wet or rainy condition ...

Page 17: ...the element or it will develop tears Immerse the element in motor oil and squeeze the oil out of the element leaving it slightly wet with oil Inspect the air cleaner element for tears A torn element must be replaced A Non flammable cleaning solvent B Motor oil SAE 30 AIR CLEANER Clean every 3 months If the air cleaner is clogged with dust intake resistance will be increase resulting in a decrease ...

Page 18: ...der bore is of ten caused by a defective or poorly fitted element If driving under 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 de pends largely on this component CYLINDER HEAD AND CY...

Page 19: ...d sparking and may cause the engine to misfire Be sure to clean the car bon deposits off periodically If the center electrode is fairly worn down the spark plug should be replaced and the spark plug gap set to the specification us ing a thickness gauge 09900 20804 Thickness gauge Spark plug gap 0 5 0 6 mm 0 020 0 024 in Check the spark plug for burns If any abnormalities are found replace the spar...

Page 20: ...ereaf ter Throttle cable play A should be 3 5 mm 0 12 0 20 in as measured at throttle when turning the throttle lightly If the play A is incorrect adjust it as follows Loosen the locknut 1 and turn the adjuster 2 in or out until the specified play is obtained Tighten the locknut 1 while holding the adjuster 2 Throttle cable play A 3 5 mm 0 12 0 20 in After the adjustment is completed check that ha...

Page 21: ... plug 2 Remove the oil level screw 3 Pour new oil through the oil filler hole until the oil reaches the oil level hole Tighten the oil level screw 3 and reinstall the oil filler cap 1 Transmission oil capacity 500 ml 0 5 0 4 US Imp qt DRIVE CHAIN Clean lubricate and inspect each time the vehicle is rid den Visually inspect the drive chain for the possible defects listed be low Loose pins Twisted o...

Page 22: ... the chain between the engine and rear sprockets as shown Drive chain slack 20 30 mm 0 8 1 2 in After adjusting the drive chain tighten the bolts 2 to the se curely Recheck the chain slack after tightening the bolts 2 NOTE After drive chain adjustment adjust the rear brake Rear brake adjustment 2 10 CLEANING AND LUBRICATING Clean the drive chain with kerosine If the drive chain tends to rust quick...

Page 23: ... brake lever play B 4 6 mm 0 16 0 24 in NOTE After rear brake adjustment adjust the recoil srarter Recoil starter adjustment 2 11 FRONT AND REAR BRAKE SHOE WEAR This vehicle is equipped with brake wear limit indicators for the front and rear brake Check brake lining wear as follows Make sure the brake play is properly adjusted While fully applying the brake check to see that the extension line of ...

Page 24: ...cified tire RECOIL STARTER ADJUSTMENT NOTE Check the rear brake cable play Loosen the adjuster lock nut 4 and turn the recoil adjuster 3 clockwise as far as it will go Set the parking brake 2 and make sure that the rear wheels and locked Turn the recoil adjuster 3 counter clockwise by a half turn and pull the starter grip 1 Slowly to see if the retchet engages and engine can be cranked If the reco...

Page 25: ...and Rear 4 0 mm 0 16 in 09900 20805 Tire depth gauge STEERING Inspect initial 1 month and every 3 months thereafter Steering system should be adjusted properly for smooth manipu lation of the handlebars and safe running TOE IN Place the vehicle on level ground Make sure the tire pressure for both tire is the same and set to the proper specification Set the front wheels in the forward position Plac...

Page 26: ... engine and replace the drain bolts 1 EXHAUST PIPE BOLT AND MUFFLER BOLT Tighten initial 1 month and every 3 months thereafter Remove the frame cover 5 2 Tighten the exhaust pipe bolts 1 and muffler mounting bolt 2 to the specified torque Exhaust pipe bolts 10 N m 1 0 kgf m 7 0 lb ft Muffler mounting bolt 23 N m 2 3 kgf m 16 5 lb ft Only clean the spark arrester in an open area away from combustib...

Page 27: ... 2 8 20 5 3 Steering shaft holder bolt 23 2 3 16 5 4 Steering shaft lower nut 29 2 9 21 0 5 Handlebar clamp bolt 13 1 3 9 5 6 Footrest bolt 23 2 3 16 5 7 Rear hab nut 75 7 5 55 0 8 Swing arm pivot nut 102 10 2 74 0 9 Tie rod lock nut 29 2 9 21 0 0 Rear shock absorber 29 2 9 21 0 A Front brake cam lever nut 3 3 0 33 2 43 B Rear brake cam lever nut 7 7 0 77 5 3 C Front suspension arm bolt 50 5 0 36 ...

Page 28: ...PERIODIC MAINTENANCE 2 15 ...

Page 29: ...o inspection checks must be performed to thoroughly check the operation of the drive train Perform the following Check the oil level 2 8 Warm up the engine INITIAL ENGAGEMENT INSPECTION Connect the tachometer onto the spark plug lead Start the engine Slowly open the throttle and note the engine speed r min when the vehicle begins to move forward Engagement speed 2 200 2 600 r min If the engagement...

Page 30: ...rear brakes as firmly as possible Fully open the throttle for a brief period and note the maximum engine speed sustained during the test cycle Lock up speed 2 500 2 900 r min Do not apply full power for more than 10 seconds or dam age to the clutch or engine may occur If the lock up speed r min does not coincide with the standard range inspect the following items for any abnormalities Clutch shoes...

Page 31: ...TE 3 8 ENGINE DISASSEMBLY 3 9 ENGINE COMPONENTS INSPECTION AND SERVICE 3 13 CYLINDER HEAD 3 13 CYLINDER 3 13 PISTON 3 14 CRANKSHAFT 3 16 CLUTCH 3 17 OIL SEALS AND BEARINGS 3 18 ENGINE REASSEMBLY 3 20 CRANKSHAFT 3 20 CRANKCASE 3 20 GENERATOR ROTOR 3 21 OIL GUIDE BEARING RETAINER PLATE 3 21 CLUTCH 3 22 PISTON RING AND PISTON 3 24 CYLINDER 3 25 CYLINDER HEAD 3 25 RECOIL STARTER 3 25 ...

Page 32: ...listed in each section for removal and reinstallation instructions ENGINE LEFT SIDE Engine sprocket 3 9 Generator rotor 3 10 and 21 Recoil stater 3 25 ENGINE CENTER Exhaust pipe 3 3 Cylinder 3 9 and 25 Piston 3 9 and 24 Cylinder head 3 9 and 25 Carburetor 4 4 and 7 ENGINE RIGHT SIDE Oil pump 4 11 Clutch cover 3 10 and 24 Clutch assembly 3 10 and 22 Primary driven gear 3 10 and 22 ...

Page 33: ...e frame wash the engine using a steam cleaner Engine removal is sequentially explained in the following steps Drain the transmission oil 2 8 Remove the seat 5 2 Remove the frame cover 5 2 Remove the fuel tank 4 2 Remove the exhaust pipe cover Remove the exhaust pipe bolts Remove the muffler ...

Page 34: ...3 4 ENGINE Remove the clamp Remove the recoil starter bolt Loosen the screw Remove the carburetor assembly Remove the oil tank 1 Disconnect the generator lead wire and remove the spark plug cap 2 ...

Page 35: ...ENGINE 3 5 Remove the engine sprcket cover 1 Remove the drive chain 2 Remove the engine mounting bolts ...

Page 36: ...t B and C 99000 32050 THREAD LOCK 1342 Tighten the engine mounting nuts to the specified torque Engine mounting nut A 31 N m 3 1 kgf m 22 5 lb ft Engine mounting nut B 41 N m 4 1 kgf m 29 5 lb ft Engine mounting nut C 31 N m 3 1 kgf m 22 5 lb ft ITEM N m kgf m lb ft A Engine mounting nut 31 3 1 22 5 B Engine mounting nut 41 4 1 29 5 C Engine mounting nut 31 3 1 22 5 ...

Page 37: ... transmission oil in to the crank case 2 8 Oil change 500 ml 0 53 0 44 US Imp qt Overhaul 550 ml 0 58 0 48 US Imp qt After remounting the engine the following adjustments are nec essary Engine idle speed 2 7 Throttle cable play 2 7 Rear brake cable play 2 10 Drive chain slack 2 8 Oil pump air bleeding 4 13 Recoil starter 2 11 Check the wire and cable routing Direction of travel ...

Page 38: ... inside the exhaust flange as shown in the illustrations Do not remove the power reduction plate until the rider develops sufficient skills to operate LT A50 safety at the maximum speed with the power reduction system in place ITEM N m kgf m lb ft A Exhoust pipe bolts 10 1 0 7 0 ...

Page 39: ...cylinder head and cylinder Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into the crankcase Remove the piston pin circlip 2 Remove the piston pin and piston Remove the circlip 3 Remove the engine sprocket Remove the recoil starter cup 4 ...

Page 40: ...rotor using the special tool Remove the clutch sleeve nut 09930 40113 Rotor holder Remove the thrust washer 1 wave washer 2 and clutch guide plate 3 Remove the washer 4 and clutch shoe assembly clutch drum Remove the circlip 5 Remove the primary driven gear ...

Page 41: ...nd washer 2 Hold the generator rotor using the special tool Remove the generator rotor nut 09930 40113 Rotor holder Remove the generator rotor using the special tools 09930 30104 Sliding shaft 09930 30161 Attachment C Remove the primary coil Remove the crankcase securing screws ...

Page 42: ...12 ENGINE Separate the crankcase using the special tool 09920 13120 Crankcase separator Remove the countershaft and driveshaft Remove the crankshaft using the special tool 09920 13120 Crankcase separator ...

Page 43: ...ed power and increased fuel consumption CYLINDER Remove carbon from the exhaust port and the upper part of the cylinder Take care not to damage the surface of the cylinder wall Measure the cylinder bore with the cylinder gauge at 20 mm 0 8 in from the top of the cylinder Rebore the cylinder when the cylinder bore exceeds the service limit Oversize pistons are available in two sizes 0 5 mm and 1 0 ...

Page 44: ...piston Unit mm in STD Service Limit Cylinder bore 41 000 41 015 41 065 1 6142 1 6148 1 6167 Piston diam 40 930 40 945 40 880 1 6114 1 620 1 6094 Cylinder to piston 0 065 0 075 0 120 0 0026 0 0030 0 0047 CARBON REMOVAL Remove the carbon from the crown of the piston and piston ring grooves After cleaning the piston ring grooves install the piston rings and rotate them in their respective grooves to ...

Page 45: ... fit the piston ring squarely into the cylinder and measure the piston ring end gap with a thickness gauge If any of the measurements exceed the service limit replace the piston ring with a new one 09900 20101 Vernier calipers 09900 20803 Thickness gauge Piston ring free end gap Service Limit 1st R 3 6 mm 0 14 in 1st T 3 6 mm 0 14 in 2nd R 3 3 mm 0 13 in 2nd T 4 mm 0 16 in Piston ring end gap Serv...

Page 46: ...ION Wear on the big end of the conrod can be estimated by checking the movement of the small end of the rod This method can also check the extent of wear on the parts of the big end of the conrod 09900 21303 V block 75 mm 09900 20701 Magnetic stand 09900 20607 Dial gauge 1 100 mm Conrod deflection Service Limit 3 0 mm 0 12 in If the service limit is exceeded replace the crankshaft assembly or brin...

Page 47: ... web width A Standard 32 0 0 1 mm 1 260 0 004 in A CLUTCH CLUTCH SHOE Inspect the shoes visually for chips cracking uneven wear burn ing and check the depth of the grooves on the shoes If there is no groove at any part of the shoes replace them as a set NOTE Clutch shoes must be changed as a set and never individually CLUTCH WHEEL Inspection visually the condition of the inner clutch wheel surface...

Page 48: ...or oil before inspection Turn the inner ring and check to see that it turns smoothly If it does not turn quietly and smoothly or if there are signs of any abnormalities the bearing is defective and must be replaced with a new one Play REMOVAL Remove the oil seals using the special tool 09913 50121 Oil seal remover Replace the removed oil seals with new ones Remove the bearings using the special to...

Page 49: ...25010 SUZUKI SUPER GREASE A Install the oil seals using the special tool 09913 70210 Bearing installer set Install the bearings using the special tool 09913 70210 Bearing installer set Apply a small quantity of THREAD LOCK SUPER 1303 to the bearing retainer plate screws and tighten them securely 99000 32030 THREAD LOCK SUPER 1303 ...

Page 50: ...e oil to each running and sliding part before reassembling CRANKSHAFT Apply engine oil to the crankshaft bearings inner race When installing the crankshaft into the crankcase it is neces sary to pull its left end into the left crankcase using the special tool 09910 32812 Crankshaft installer Never install the crankshaft into the crankcase by strik ing it with a plastic hammer Always use the specia...

Page 51: ...he tapered portion of the crankshaft and also from the generator rotor Install the generator rotor key 1 onto the crankshaft Apply a small quantity of THREAD LOCK SUPER 1303 to the threads of the generator rotor nut 99000 32030 THREAD LOCK SUPER 1303 Hold the generator rotor using the special tool and tighten the generator rotor nut to the specified torque 09930 40113 Rotor holder Generator rotor ...

Page 52: ...nto groove securely Install the washer 4 and spacer 3 1 Oil seal 2 Thrust washer 3 Wave washer 4 Wave washer 5 Wave washer guide plate 6 Clutch shoe 7 Trust washer 8 Key 9 Clutch drum primary drive gear 0 Spacer A Thrust washer A Clutch shoe nut ITEM N m kgf m lb ft A Clutch shoe nut 85 8 5 61 5 ...

Page 53: ... the guide plate wave washer and thrust washer Hold the generator rotor using special tool Tighten the clutch shoe nut to the specified torque Clutch shoe nut 85 N m 8 5 kgf m 61 5 lb ft 09930 40113 Rotor holder Install the crankcase oil separator 4 Before installing the clutch cover check the oil passage and check valve 6 for clogging and oil seal 5 for damage ...

Page 54: ...efore inserting the pis ton into the cylinder check that the gaps are properly posi tioned Before installing the piston pin apply SUZUKI CCI SUPER oil onto its surface Apply SUZUKI CCI SUPER oil to the big and small ends of the conrod Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into crankcase Install the piston with the arrow mark 1 facing towards the e...

Page 55: ...ied torque Cylinder head nut 9 N m 0 9 kgf m 6 5 lb ft CYLINDER Install the new cylinder base gasket 1 Apply SUZUKI CCI SUPER oil onto the piston and cylinder wall surfaces and then carefully install the cylinder 2 over the piston 1 Recoil starter cup 2 Gasket 3 Circlip 4 Washer 5 Lever 6 Rachet 7 Return spring 8 Reel 9 Lever assembly 0 Spiral spring A Rope assembly ...

Page 56: ...from the cover Pull out the reel When removing and installing the reel spiral spring will expand Protect your hands with gloves REASSEMBLY Hitch the one end 6 of the spring to the reel as shown in the figure and install the spring in the reel Apply SUZUKI SUPER GREASE A to the spiral spring For USA 99000 25030 SUZUKI SUPER GREASE A For the others 99000 25010 SUZUKI SUPER GREASE A Turn the starter ...

Page 57: ...he return spring 2 For USA 99000 25030 SUZUKI SUPER GREASE A For the others 99000 25010 SUZUKI SUPER GREASE A Install the lever on the rachet Install the washer and circlip 3 Confirm that the lever 4 touches the lever guide 5 and pushes the rachet 6 outward when the end of the lever guide is pushed to the case and the starter rope is pulled slowly Remove the cap 7 from the recoil starter grip Unti...

Page 58: ...ie a knot at the end of rope Pull the rope and check that the rachet is pushed out After remounting the recoil starter the following adjustment or necessary Rear brake lever play 2 10 Recoil starter adjustment 2 11 ...

Page 59: ...ION AND CLEANING 4 3 REMOUNTING 4 3 CARBURETOR 4 4 SPECIFICATIONS 4 5 I D NO LOCATION 4 5 REMOVAL 4 6 DISASSEMBLY 4 7 CLEANING 4 7 INSPECTION AND ADJUSTMENT 4 8 REASSEMBLY AND REMOUNTING 4 9 MIXTURE ADJUSTMENT 4 9 CARBURETION 4 10 OIL PUMP 4 11 INSPECTION AND DISASSEMBLY 4 11 REASSEMBLY 4 12 AIR BLEEDING 4 13 CHECKING OIL PUMP 4 13 ...

Page 60: ...EM FUEL TANK AND FUEL VALVE REMOVAL Gasoline is very explosive Extrem care must be taken Turn the fuel valve OFF position Remove the frame cover 5 2 Replace the fuel tank cap 1 Breather hose 2 Fuel tank cap 3 Fuel tank 4 Fuel valve ...

Page 61: ... CREANING 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 Gasket and O rings must be replaced with new ones to prevent fuel leakage REMOUNTING Remount the fuel tank and fuel valve in the reverse order of removal ...

Page 62: ...CATION SYSTEM CARBURETOR 1 Jet needle 2 Throttle valve 3 Starter valve 4 Needle valve 5 Pilot air screw 6 Throttle stop screw 7 Float 8 Needle jet 9 Main jet 0 Pilot jet No 1 A Pilot jet No 2 B Drain plug C Starter lever ...

Page 63: ... No 43F0 Idle r min 1 800 100 r min Float height 24 5 25 0 mm 0 96 0 98 in Main jet M J 55 Jet needle J N 3E3 4th Needle jet N J E 6 Pilot jet P J 15 Air screw A S 1 turns out Throttle cable play 2 4 mm 0 08 0 16 in I D NO LOCATION The carburetor has I D Number A stamped on its body accord ing to its specifications ...

Page 64: ...move the right frame cover 5 2 Remove the clamp Turn the fuel valve to OFF position Disconnect the fuel hose 1 Lossen the carburetor clamp bolt 2 Remove the screws 3 with throttle valve Remove the carburetor assebly Remove the air cleaner case ...

Page 65: ... the screws and float chamber Remove the main jet 4 needle jet 5 pilot jet No 1 6 and pilot jet No 2 7 Remove the needle valve 8 CLEANING Some carburetor cleaning chemicale especially dip type soaking solutions are very corrosive and must be hardled carefully Always follow the chemical manufacturer s in structions on proper use handling and storage ...

Page 66: ...anufacturer s instructions for proper use and cleaning of the carburetor components After cleaning reassemble the carburetor with new seals and gaskets INSPECTION AND ADJUSTMENT Check the following items for any damage or clogging Main jet Throttle valve Pilot jet Float Needle jet Needle valve Gasket NEEDLE VALVE INSPECTION If foreign matter is caught between the valve seat and the needle valve th...

Page 67: ...nt Before adjusting the air fuel mixture make sure that the float height is correct and the vacuum inlet hose and air cleaner are in good condition and free of obstructions Ride the vehicle about one kilometer to determine at which throttle position the engine lacks power or performs poorly Then check the color and appearance of the spark plug and piston crown The air fuel mixture can be made rich...

Page 68: ...anged from the original settings Changes should only be made when adjusting for differences in altitude or other climatic conditions When adjustment is necessary refer to the following chart AIR FUEL MIXTURE RATIO CAN BE CHANGED AS FOLLOWS Throttle opening Method of changing ratio Standard setting Slight Air screw Larger number richer mixture Smaller number leaner mixture Medium Jet needle Richer ...

Page 69: ...emove the stopper screw 1 and from the clutch cover 1 Stopper screw 2 Gasket 3 Oil hose 4 Oil pump cam 5 Plunger 6 Plunger spring 7 Oil pump valve 8 Oil pump driven gear 9 Oil seal 0 Air bleeder screw A O ring B Check valve A Union bolt ITEM N m kgf m lb ft A 5 5 0 55 4 0 ...

Page 70: ...hes or other damage Inspect plunger 1 and spring 2 for proper operation Inspect the oil pump valve 3 Oil pump driven gear 4 for any damage If there are any damages are found replace the part with new one NOTE If the oil pump valve or clutch cover bore wall has any defect replace the clutch cover assembly Inspect the oil passege and check valve 5 for clogging REASSEMBLY Wash the oil pump components...

Page 71: ...n side of the oil pump Run the engine at 2 000 r min Keep the engine speed at 2 000 r min Allow the pump to draw for 5 minutes The measurement on the oil gauge should be within specification 09900 21602 CCI oil gauge Oil discharge amount 0 6 0 8 ml 0 020 0 021 0 027 0 030 US lmp oz for 5 minutes at 2 000 r min During this inspection observe the following points NOTE Adjust the engine idle speed af...

Page 72: ... 5 9 REASSEMBLY AND REMOUNTING 5 9 STEERING AND FRONT SUSPENSION 5 12 REMOVAL AND DISASSEMBLY 5 14 FRONT SUSPENSION 5 14 STEERING 5 14 INSPECTION 5 17 REASSEMBLY AND REMOUNTING 5 19 TOE IN ADJUSTMENT 5 23 REAR BRAKE AND REAR AXLE HOUSING 5 24 REMOVAL AND DISASSEMBLY 5 25 INSPECTION 5 27 REASSEMBLY AND REMOUNTING 5 28 REAR SUSPENSION 5 33 REMOVAL AND DISASSEMBLY 5 34 INSPECTION 5 34 REASSEMBLY AND ...

Page 73: ...STEERING COVER Remove the screws Disconnect the ignition switch lead wires and than remove the steering cover FRAME COVER Remove the frame cover NOTE Replace the fuel tank cap 1 after removing the frame cover Remove the screws 2 and fasteners right and left ...

Page 74: ...t the exterior parts in the reverse order of removal Pay attention following point FRAME COVER Install the frame cover using the fastner Push the botton A of fastener core as shown Fig 1 Install the fastner into the frame cover right and left securelly and then push the head B of fastener core as shown Fig 2 Fig 1 Fig 2 ...

Page 75: ... to the following point Tighten the wheel set nuts to the specified torque Front and rear wheel nut 28 N m 2 8 kgf m 20 5 lb ft Front wheel Rear wheel FRONT REAR 1 Oil seal 2 Bearing 3 Spacer 4 Front wheel hub 5 Bearing 6 Oil seal 7 Front wheel 8 Front wheel center cap 9 Rear wheel hub 0 Rear wheel A Rear wheel center cap B Center cap holder A Wheel nut front and rear B Front hub nut C Rear hub nu...

Page 76: ...im Never apply grease oil or gasoline to the tire bead be cause they will deteriorate the tire The standard tire fitted on this vehicle is AT16 8 7 for the front and rear The use of tires other than the standard may cause in stability It is highly recommended to use the specified tire Mount the tire on the rim by hand as shown NOTE Inspect the sealing portion of the rim before installing the tire ...

Page 77: ...tween the rim line and the wheel rim varies this indicates that the bead is not properly seated If this is so deflate the tire com pletely and unseat the tire bead on both sides Then coat the bead with clean water and re seat the tire Adjust the tire pressure to specification Cold inflation tire pressure Front 20 kPa 0 20 kgf cm2 2 9 psi Rear 20 kPa 0 20 kgf cm2 2 9 psi Vehicle load capacity 38 kg...

Page 78: ...wheel center cap Remove the cotter pin and axle nut 1 Remove the front wheel hub 2 Remove the front brake shoe assembly 3 1 Front brake shoe 2 Spring 3 Front brake cam shaft 4 O ring 5 Dust seal 6 Front brake panel 7 Cam lever A Front brake cam lever nut ITEM N m kgf m lb ft A 3 0 3 2 0 ...

Page 79: ...ont brake cam lever nut and bolt Remove the brake cam lever and front brake camshaft 3 Remove the brake panel Remove the inner dust seal using the special tool 09913 50121 Oil seal remover Remove the wheel hub inner and outer bearing using the spe cial tool 09941 50111 Bearing remover ...

Page 80: ...eeds the service limit The valve of this limit is indicated inside the brake drum 09900 20101 Vernier calipers Brake drum I D Service Limit 80 7 mm 3 18 in BRAKE SHOE Inspect the brake shoes wear or damage If it worn or damaged replace it with new ones Replace the brake shoes as a set otherwise braking per formance will be adversely attected REASSEMBLY AND REMOUNTING Apply SUZUKI SUPER GREASE A to...

Page 81: ... GREASE A When installing the brake cam lever on the camshaft align the panch mark 1 of the cam lever with the slit 2 of the camshaft Apply SUZUKI SUPER GREASE A to the brake cam and pin and install the brake shoes For USA 99000 25030 SUZUKI SUPER GREASE A For the others 99000 25010 SUZUKI SUPER GREASE A Install the front wheel hub and spring Tighten front brake cam lever nut to the specified torq...

Page 82: ... front hub nut 1 to the specified torque Front hub nut 65 N m 6 5 kgf m 47 9 lb ft Install the new cotter pin Install the front wheel 5 4 After installing the front brake adjust the following items Front brake lever play 2 10 ...

Page 83: ...Shock absorber mounting bolt lower and upper 1 Tie rod 2 Inner tie rod end 3 knuckle arm bolt 4 Dust seal 5 Bushing 6 Knuckle arm L 7 Outer tie rod end 8 Spacer 9 Knuckle arm R A Tie rod lock nut B Tie rod end nut C Kunckle arm nut ITEM N m kgf m lb ft A 29 2 9 21 B 29 2 9 21 C 50 5 0 36 ITEM N m kgf m lb ft A 50 5 0 36 B 29 2 9 21 ...

Page 84: ...eering shaft 4 Dust seal 5 Steering shaft holder 6 Steering shaft lower dust seal 7 Bushing 8 O ring A Handleber clamp bolt B Steering shaft holder bolt C Steering shaft lower nut ITEM N m kgf m lb ft A 13 1 3 9 5 B 23 2 3 16 5 C 29 2 9 21 ...

Page 85: ...t brake cable 1 Remove the cotter pin and remove the tie rod end nut 2 Remove the front suspensions arm nuts Remove the front shock absorber upper bolt Remove the front shock absorber and suspension arm Remove the front shock absorber lower bolt 3 Remove the cotter pin and knuckle arm nut 4 Remove the dust seals and spacer ...

Page 86: ... special tools 09923 73210 Bearing remover 09930 30104 Sliding shaft STEERING Remove the front suspension 5 12 Remove the front and rear brake cable Remove the throttle case cover screws Remove the throttle cable Remove the clamp Disconnect the lead wires ...

Page 87: ...ve the cotter pin and steering shaft lower nut 1 and tie rod end nut 2 Remove the tie rods Remove the handlebar clamp bolts Remove the cotter pin Remove the steering shaft holder bolts Remove the steering shaft bushing ...

Page 88: ...SEALS Inspect the dust seals for wear or damage If any damages are found replace the dust seals with new one KNUCKLE ARM BUSHING Insert the spacer into the bushing and inspect for abnormal noise and smooth rotation while rotating the spacer If any damage are found replace the bushing with new one SUSPENSION ARM Inspect the suspension arm and suspension arm bushing for wear or damage If any damages...

Page 89: ...tie rod end for smooth movement If any damage are found replace the tie rod with a new one STEERING SHAFT AND HOLDER Inspect the steering shaft for distortion or bends If any dam ages are found replace the steering shaft with a new one Inspect the two steering shaft holders for wear or damage If any damages are found replace the steering shaft holders with new ones STEERING SHAFT BUSHING Inspect t...

Page 90: ...the steering shaft bushing using the special tool 09924 84510 Bearing installer set Apply SUZUKI SUPER GREASE A to the new dust seal 1 steering shaft holders 2 and new dust seals 3 before remount ing the steering shaft For USA 99000 25030 SUZUKI SUPER GREASE A For the others 99000 25010 SUZUKI SUPER GREASE A To prevent the entry of dirt the dust seal end 4 must face forward when installed on the s...

Page 91: ...sure that the narrow side 1 of the tie rod comes outside NOTE The lock nuts 2 2 2 2 2 have left hand threads Tighten the tie rod end nut to the specified torque and install new cotter pin Tie rod end nut 29 N m 2 9 kgf m 21 lb ft HANDLEBAR Tighten the handlebar clamp bolts temporarily Set the handlebars to mutch its dent mark to the mating sur face between handlebar clamps as shown Tighten the han...

Page 92: ...set Apply SUZUKI SUPER GREASE A to the knuckle arm dust seals Apply SUZUKI SUPER GREASE A to the knuckle arm bush ings and install the spacer and the dust seals For USA 99000 25030 SUZUKI SUPER GREASE A For the others 99000 25010 SUZUKI SUPER GREASE A Tighten the front shock absorber lower nut to the specified torque Tighten the knuckle arm bolt to the specified torque and install a new cotter pin...

Page 93: ...ecified torque Front shock absorber upper bolt 29 N m 2 9 kgf m 21lb ft Tighten the tie rod end nut to the specified torque and install a new cotter pin Tie rod end nut 29 N m 2 9 kgf m 21 lb ft Install the front brake 5 9 Install the front wheel 5 4 After installing the front brake and front suspension adjust the following items Front brake lever play 2 10 TOE IN adjustment 5 23 ...

Page 94: ...oe in is not within specification ad just the tie rod to the right or left until the toe in is within the specified range A B Toe in Toe in Standard 1 5 mm 3 mm 0 06 0 16 in Temporarily tighten the four locknuts Check that the distances C and D are equal as shown If the distances are not equal adjust the tie rod to the right or left until the toe in is within specification Check the toe in again b...

Page 95: ...rake cam 6 O ring 7 Rear brake anchor panel 8 Brake cam lever spring 9 Rear brake cam lever 0 Spacer L A Rear axle shaft B Oil seal C Bearing D Rear axle housing E Spacer L F Chain adjuster G Stopper ring H Mounting flange A Rear brake panel nut B Rear brake cam lever nut ITEM N m kgf m lb ft A 28 2 8 20 5 B 7 7 0 77 5 3 ...

Page 96: ...Remove the cotter pin 1 Remove the rear axle nut by applying the rear brake Remove the rear wheels Remove the spacer 2 3 Remove the rear brake drum cover Remove the rear axle rear brake drum and rear sprocket Remove the rear brake shoes 4 ...

Page 97: ...he rear brake panel Remove the rear brake cam lever bolt and cam lever Remove the rear brake cam 1 brake lining indicator plate 2 spring 3 and O rings 4 Remove the rear axle housing Remove the dust seals using the special tool 09913 50121 Oil seal remover ...

Page 98: ...l before inspection Turn the inner ring and check to see that it turns smoothly If it does not turn quietly and smoothly or if there are signs of any abnormalities the bearing is defective and must be replaced with a new one BRAKE DRUM Inspect the brake drum and measure the brake drum inside diameter to determine the extent of wear If the measurement exceed the service limit replace the brake drum...

Page 99: ... Dial gauge 1 100 mm 09900 20701 Magnetic stand 09910 21304 V block set 100 mm Rear axle runout Service Limit 3 mm 0 12 in REAR SPROCKET Inspect the sprocket teeth for wear If they are worn as illus trated replace the sproket and drive chain REASSEMBLY AND REMOUNTING Reassemble and remount the rear suspension in the reverse or der of removal and disassembly Pay attention to the following points Ap...

Page 100: ...d left side bearing 3 Make sure the sealed side of the bearing face out ward Tighten the rear axle housing bolts to the securely Apply SUZUKI SUPER GREASE A to the rear brake cam shaft and new O rings For USA 99000 25030 SUZUKI SUPER GREASE A For the others 99000 25010 SUZUKI SUPER GREASE A Install the new O rings into the brake camshaft hole NOTE Face the groove on the cam shaft to the inside Lef...

Page 101: ...ghten the rear brake cam lever nut to the specified torque Rear brake cam lever nut 7 5 N m 0 75 kgf m 5 5 lb ft Install the rear brake panele Tighten the rear brake panel nut to the specified torque Rear brake panel nut 28 N m 2 8 kgf m 20 5 lb ft Apply SUZUKI SUPER GREASE A to the brake cam and pin Install the brake shoes For USA 99000 25030 SUZUKI SUPER GREASE A For the others 99000 25010 SUZUK...

Page 102: ...CHASSIS 5 31 Install the brake drum 1 and circrip 2 Install the rear sprocket and rear axle Install the chain cover Install the rear brake drum cover Install the spacer right 3 and left 4 ...

Page 103: ...rear hub nut to the specified torque Rear hub nut 75 N m 7 5 kgf m 55 lb ft Install the new cotter pin After installing the rear brake and drive chain adjust the follow ing items Rear brake lever play 2 10 Drive chain slack 2 8 ...

Page 104: ... ft A 29 2 9 21 B 29 2 9 21 C 102 10 2 74 1 Rear shock absorber 2 Chain case 3 Rear shock absorber lower bolt 4 Swingarm pivot bolt 5 Bushing 6 Spacer 7 Swingarm A Rear shock absorber upper bolt B Rear shock absorber lower nut C Swingarm pivot nut ...

Page 105: ... shock absorber lower bolt 4 INSPECTION REAR SHOCK ABSORBER Inspect the rear shock absorber for oil leakage or other dam age If any oil leakage or damage are found replace the rear shock absorber with a new one Do not attempt to disassemble the rear shock absorber It is unserviceable SWINGARM Inspect the swingarm for distortion or damage If any damages are found replace the swing arm with a new on...

Page 106: ...removal and disassembly Pay attention to the following points Tighten the rear shock absorber upper bolt to the specified torque Rear shock absorber upper bolt 29 N m 2 9 kgf m 21 lb ft Tighten the swingarm pivot nut to the specified torque Swing arm pivot nut 102 N m 10 2 kgf m 74 lb ft Tighten the rear shock absorber lower nut to the specified torque Rear shock absorber lower nut 29 N m 2 9 kgf ...

Page 107: ...5 36 CHASSIS Install the rear axle housing and rear brake 5 27 After installing the rear suspension adjust the following items Rear brake lever play 2 10 Drive chain slack 2 8 ...

Page 108: ...ELECTRICAL SYSTEM 6 1 6 ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING 6 2 IGNITION SYSTEM 6 3 DESCRIPTION 6 3 TROUBLESHOOTING 6 3 INSPECTION 6 4 SWITCH 6 5 ...

Page 109: ... do not allow it to hang down Do not use wire or any other substitute for the band type clamp WIRING PROCEDURE Properly route the wire harness according to WIRE ROUT ING 7 8 USING THE MULTI CIRCUIT TESTER Properly use the multi circuit tester and probes Im proper use can cause damage to the vehicle and tester If the voltage and current values are not known begin measur ing in the highest range Whe...

Page 110: ...AL SYSTEM 6 3 IGNITION SYSTEM DESCRIPTION The ignition system is shown in the diagram below namely the generator CDI Ignition coil unit and spark plug Generator CDI Ignition coil unit Spark plug TROUBLESHOOTING ...

Page 111: ...und NOTE Do not disconnect the ignition coil primary wire 09900 25008 Multi circuit tester set Before using the multi circuit tester and peak volt adapter be sure to refer to the appropriate instruction manual Pull the recoil starter and allow the engine to crank for few times and then measure the ignition coil primary peak voltage Repeat the above procedure a few times and measure the high est ig...

Page 112: ... the generator lead wire Measure the resistance between the Black Yellow lead wire and ground If the resistance is not within the specified value replace the generator with a new one Generator coil resistance 100 160 Ω Ω Ω Ω Ω Black Yellow Black White IGNITION COIL RESISTANCE Measure the ignition coil resistance in the secondary winding If the winding is in sound condition the resistance should be...

Page 113: ...SERVICING INFORMATION 7 1 7 SERVICING INFORMATION CONTENTS TROUBLESHOOTING 7 2 WIRING DIAGRAM 7 6 WIRE AND CABLE ROUTING 7 7 SPECIAL TOOLS 7 11 TIGHTENINGTORQUE 7 13 SERVICE DATA 7 15 ...

Page 114: ...k vent hose Clean or replace 2 Clogged or defective fuel valve Clean or replace 3 Defective carburetor needle valve Replace 4 Clogged fuel hose Clean or replace 5 Clogged fuel filter Clean or replace Engine stalls easily 1 Fouled spark plug Clean or replace 2 Defective CDI Ignition coil unit Replace 3 Clogged fuel hose Clean 4 Clogged carburetor jets Clean 5 Clogged exhaust pipe Clean 6 Damaged cy...

Page 115: ...float height 8 Dirty air cleaner element Clean 9 Clogged fuel hose resulting in inadequate fuel supply Clean and prime to the carburetor 10 Clogged fuel valve Clean Exhaust smoke is dirty or 1 Incorrect engine oil Change thick Engine lacks power 1 Worn cylinder Replace 2 Worn piston rings Replace 3 Stiff piston rings Replace 4 Gas leaks from crankshaft oil seal Replace 5 Insufficient spark plug ga...

Page 116: ... is too heavy or 1 Improper front wheel alignment Adjust stiff 2 Insufficiently lubricated Lubricate 3 Low air pressure in front tires Adjust 4 Tie rod ends tending to seize Replace 5 Linkage connections tending to seize Repair or replace Steering wobbles 1 Unequally inflated tires Regulate 2 Loose front wheel hub nuts Tighten 3 Damaged or worn front wheel hub bearings Replace 4 Worn or loose tie ...

Page 117: ...ng surface Repair surface with emery paper 2 Loose front wheel axle or rear wheel axle Tighten to specified torqoe 3 Worn linings Replace 4 Wrongly fixed spring Set correctly Excessive brake lever 1 Worn brake lever cam Replace brake cam stroke ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1 Defective CDI Ignition coil unit Replace sparking 2 Defective spark plug Repl...

Page 118: ...B Y B W B W B W B Y B Y B Y B Y B Y B W B Y B W B Y B W B Y B W IGNITION SWITCH MAGNETO ENGINE STOP SWITCH CDI UNIT IGNITION COIL EMERGENCY STOP SWITCH B W B Y WIRE COLOR Black with White tracer Black with Yellow tracer B Y B W B Y B W B Y B W B Y B W B Y B Y B R B W B R B W ...

Page 119: ...ING WIRE ROUTING Engine stop switch lead wire Clamp Ignition lead wire Clamp Clamp Clamp Emergency switch lead wire Generator lead wire Clamp To engine stop switch Ignition lead wire Wiring harness Clamp CDI Ignition coil Generator lead wire Clamp ...

Page 120: ...RMATION Rear brake cable Rear brake cable Fit claw of bracket Rear brake cable Throttle cable Engine stop switch lead wire Throttle cable Rear brake cable Front brake cable R Front brake cable L Cable guide CABLE ROUTING ...

Page 121: ...r brake cable Rear brake cable Rear brake cable Cable guide Front brake cable R Front brake cable R Front brake cable L Front brake cable R Engine stop switch lead wire Engine stop switch lead wire Throttle cable Throttle cable Throttle cable Engine stop switch lead wire ...

Page 122: ...7 10 SERVICING INFORMATION Drain hose Drain hose Clamp Breather hose Air vent hose BREATHER AND AIR VENT HOSE ROUTING ...

Page 123: ...0 mm 09900 20701 Magnetic stand 09900 20803 Thickness gauge 09900 20805 Tire depth gauge 09900 21303 V block set 75 mm 09900 21304 V block set 100 mm 09900 25008 Multi circuit tester set 09910 32812 Crankshaft installer 09913 50121 Oil seal remover 09900 00401 L type hexagon wrench set 09920 13120 Crankcase separator 09900 20804 Thickness gauge 09921 20240 Bearing remover set 09900 21602 CCI oil g...

Page 124: ...7 12 SERVICING INFORMATION NOTE When ordering a special tool please confirm whether it is available or not 09941 50111 Bearing remover ...

Page 125: ... 8 20 5 Front hub nut 65 6 5 47 9 Front brake cam lever nut 3 3 0 33 2 43 Front shock absorber lower and upper 29 2 9 21 0 Front suspension arm bolt 50 5 0 36 0 Rear brake cam lever nut 7 7 0 7 5 3 Rear shock absorber lower and upper 29 2 9 21 0 Muffler mounting bolt 23 2 3 16 5 Footrest bolt 15 1 5 11 0 Rear hub nut 75 7 5 55 0 Oil pump union bolt 5 5 0 55 4 0 Steering shaft lower nut 29 2 9 21 0...

Page 126: ...arked bolt 7 marked bolt A mm N m kgf m lb ft N m kgf m lb ft 4 1 5 0 15 1 0 2 3 0 23 1 5 5 3 0 3 2 0 4 5 0 45 3 0 6 5 5 0 55 4 0 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 ...

Page 127: ... 0 14 R Approx 4 1 3 3 2nd 0 16 0 13 T Approx 5 0 4 0 0 20 0 16 Piston ring end gap 0 10 0 25 0 80 0 004 0 010 0 031 Piston ring to groove clearance 1st 0 020 0 060 0 0008 0 0024 2nd 0 020 0 060 0 0008 0 0024 Piston pin bore 12 002 12 010 12 030 0 4725 0 4728 0 4736 Piston pin O D 11 996 12 000 11 980 0 4723 0 4724 0 4717 CONROD CRANKSHAFT Unit mm in ITEM STANDARD LIMIT Conrod small end I D 16 003...

Page 128: ... 416 29 12 DRIVE CHAIN Unit mm in ITEM STANDARD LIMIT Drive chain Type D I D 420 Links 78 20 pitch length 259 0 10 20 Drive chain slack 20 30 0 8 1 2 CARBURETOR ITEM SPECIFICATION Carburetor type MIKUNI VM12SC Bore size 12 mm I D No 43F0 Idle r min 1 800 100 r min Float height 24 5 25 0 mm 0 96 0 98 in Main jet M J 55 Jet needle J N 3E3 4th Needle jet N J E 6 Pilot jet P J 15 Air screw A S 11 8 tu...

Page 129: ...8 Rear brake lever play 4 6 0 16 0 24 Brake drum I D Front 80 7 3 18 Rear 110 7 4 36 Wheel axle runout Rear 3 0 0 12 Wheel rim size Front 7 6 0 AT Rear Toe in with 30 kg load 1 5 3 0 06 0 12 Turning radius 2 0 m 6 6 ft Camber 0 Caster 3 Trail 10 0 39 Steering angle Inside 33 40 Outside 24 Tire size Front AT16 8 00 7 Rear AT16 8 00 7 Tire tread depth Front 4 0 0 16 Rear 4 0 0 16 TIRE PRESSURE COLD ...

Page 130: ... 550 ml 0 58 0 48 US lmp qt Use only unleaded gasoline of at least 87 pump octane or 91 octane or higher rated by the research method Gasoline containing MTBE Methyl Tertiary Butyl Ether less than 10 ethanol or less than 5 methanol with appropriate cosolvents and corro sion inhibitor is permissible Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended R M 2 Use SUZ...

Page 131: ...LT A50K3 K4 03 04 MODELS 8 1 8 LT A50K3 K4 03 04 MODELS CONTENTS SPECIFICATIONS 8 2 SERVICE DATA 8 3 ...

Page 132: ...ent Idle speed 1 800 100 r min TRANSMISSION Transmission 2 416 29 12 Primary reduction 2 650 53 20 Final reduction 3 700 37 10 Drive chain D I D 420 CHASSIS Front suspension Independent swing axle coil spring oil damped Rear suspension Swingarm coil spring oil damped Front wheel travel 52 mm 2 0 in Rear wheel travel 51 mm 2 0 in Caster 3 Trail 10 mm 0 39 in Camber 0 Steering angle 35 Turning radiu...

Page 133: ...8 0 14 R Approx 4 1 3 3 2nd 0 16 0 13 T Approx 5 0 4 0 0 20 0 16 Piston ring end gap 0 10 0 25 0 80 0 004 0 010 0 031 Piston ring to groove clearance 1st 0 020 0 060 0 0008 0 0024 2nd 0 020 0 060 0 0008 0 0024 Piston pin bore 12 002 12 010 12 030 0 4725 0 4728 0 4736 Piston pin O D 11 996 12 000 11 980 0 4723 0 4724 0 4717 CONROD CRANKSHAFT Unit mm in ITEM STANDARD LIMIT Conrod small end I D 16 00...

Page 134: ...2 416 29 12 DRIVE CHAIN Unit mm in ITEM STANDARD LIMIT Drive chain Type D I D 420 Links 78 20 pitch length 259 0 10 20 Drive chain slack 20 30 0 8 1 2 CARBURETOR ITEM SPECIFICATION Carburetor type MIKUNI VM12SC Bore size 12 mm I D No 43F0 Idle r min 1 800 100 r min Float height 24 5 25 0 mm 0 96 0 98 in Main jet M J 55 Jet needle J N 3E3 4th Needle jet N J E 6 Pilot jet P J 15 Air screw A S 11 8 t...

Page 135: ...28 Rear brake lever play 4 6 0 16 0 24 Brake drum I D Front 80 7 3 18 Rear 110 7 4 36 Wheel axle runout Rear 3 0 0 12 Wheel rim size Front 7 6 0 AT Rear Toe in with 30 kg load 1 5 3 0 06 0 12 Turning radius 2 0 m 6 6 ft Camber 0 Caster 3 Trail 10 0 39 Steering angle Inside 33 40 Outside 24 Tire size Front AT16 8 00 7 Rear AT16 8 00 7 Tire tread depth Front 4 0 0 16 Rear 4 0 0 16 TIRE PRESSURE COLD...

Page 136: ...l 550 ml 0 58 0 48 US lmp qt Use only unleaded gasoline of at least 87 pump octane or 91 octane or higher rated by the research method Gasoline containing MTBE Methyl Tertiary Butyl Ether less than 10 ethanol or less than 5 methanol with appropriate cosolvents and corro sion inhibitor is permissible Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended R M 2 Use SU...

Page 137: ...the LT A50K3 K4 03 04 MODELS NOTE Any differences between the LT A50K3 K4 03 04 MODELS and LT A50K5 05 MODEL in specifications and service data are indicated with an asterisk mark Please refer to the chapters 1 through 8 for details which are not given in this chapter SPECIFICATIONS 9 2 SERVICE DATA 9 3 TIGHTENING TORQUE 9 7 REAR BRAKE AND REAR AXLE HOUSING 9 8 ...

Page 138: ... 100 r min DRIVE TRAIN Transmission 2 416 29 12 Primary reduction 2 650 53 20 Final reduction 3 700 37 10 Drive chain D I D 420 or RK420 78 links CHASSIS Front suspension Independent swing axle coil spring oil damped Rear suspension Swingarm coil spring oil damped Front wheel travel 52 mm 2 0 in Rear wheel travel 51 mm 2 0 in Caster 3 Trail 10 mm 0 39 in Toe in 2 mm 0 08 in Camber 0 Steering angle...

Page 139: ...2 Cylinder head distortion 0 05 0 002 Piston ring free end gap 1st R Approx 4 5 0 18 3 6 0 14 T Approx 4 5 0 18 3 6 0 14 2nd R Approx 4 1 0 16 3 3 0 13 T Approx 5 0 0 20 4 0 0 16 Piston ring end gap 0 10 0 25 0 004 0 010 0 80 0 031 Piston ring to groove clearance 1st 0 020 0 060 0 0008 0 0024 2nd 0 020 0 060 0 0008 0 0024 Piston pin bore 12 002 12 010 0 4725 0 4728 12 030 0 4736 Piston pin O D 11 ...

Page 140: ...art Clutch engagement 2 200 2 600 r min Clutch lock up 2 500 2 900 r min ITEM STANDARD LIMIT Primary reduction ratio 2 650 53 20 Final reduction ratio 3 700 37 10 Gear ratios 2 416 29 12 ITEM STANDARD LIMIT Drive chain Type D I D 420 Links 78 20 pitch length 259 0 10 20 Drive chain slack 20 30 0 8 1 2 ITEM SPECIFICATION Carburetor type MIKUNI VM12SC Bore size 12 mm I D No 43F0 Idle r min 1 800 100...

Page 141: ...ry peak voltage More than 100 V B Y Ground ITEM STANDARD LIMIT Front brake lever play 3 7 0 12 0 28 Rear brake lever play 4 6 0 16 0 24 Brake drum I D Front 80 7 3 18 Rear 110 7 4 36 Wheel axle runout Rear 3 0 0 12 Wheel rim size Front Rear 7 6 0 AT Toe in with 30 kg load 1 5 3 0 06 0 12 Turning radius 2 0 m 6 6 ft Camber 0 Caster 3 Trail 10 0 39 Steering angle Inside 33 40 Outside 24 Tire size Fr...

Page 142: ... sion inhibitor is permissible P 03 28 Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended P 19 Fuel tank capacity 2 6 L 0 7 0 6 US lmp gal Engine oil type Use SUZUKI CCI SUPER 2 CYCLE MOTOR LUBRICANT or an equivalent good quality syn thetic based 2 stroke engine oil rated FC under the JASO classification P 03 Use SUZUKI CCI SUPER OIL If they are not avail able u...

Page 143: ...ront brake cam lever nut 3 3 0 33 2 43 Front shock absorber lower and upper 29 2 9 21 0 Front suspension arm bolt 50 5 0 36 0 Rear brake cam lever nut 7 7 0 7 5 3 Rear shock absorber lower and upper 29 2 9 21 0 Muffler mounting bolt 23 2 3 16 5 Footrest bolt 15 1 5 11 0 Rear hub nut 75 7 5 55 0 Oil pump union bolt 5 5 0 55 4 0 Steering shaft lower nut 29 2 9 21 0 Steering shaft holder bolt 23 2 3 ...

Page 144: ...e anchor panel 8Brake cam lever spring 9Rear brake cam lever 0Spacer L ARear axle shaft BOil seal CBearing DRear axle housing ESpacer L FChain adjuster GStopper ring HMounting flange ARear brake panel nut BRear brake cam lever nut CRear sprocket bolt DRear axle housing bolt ITEM N m kgf m lb ft A 28 2 8 20 5 B 7 7 0 77 5 3 C 23 2 3 16 5 D 23 2 3 16 5 ...

Page 145: ...Prepared by 3rd Ed March 2004 1st Ed March 2001 Part No 99500 20212 01E Printed in Japan 148 ...

Page 146: ...Printed in Japan K2 K3 K4 K5 ...

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Suzuki LT-A50, Service Manual

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