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Suzuki LT-F500F 2002, Service Manual

The Suzuki LT-F500F 2002 Service Manual is an essential resource for ATV owners. This comprehensive manual provides step-by-step instructions for maintenance, repairs, and troubleshooting. Easily downloadable for free from manualshive.com, it ensures users have all the information they need to keep their Suzuki in top-notch condition.

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ELECTRICAL SYSTEM     8-17

IGNITION SYSTEM

TROUBLESHOOTING

Spark plug

Ignition
coil

DC-DC
converter

Ignition power
source circuit

Wave form
arrangment
circuit

CPU

Driver

SCR

C

CDI unit

Wave form
arrangment
circuit

Engine
stop switch

Fuse

Ignition
switch

Fuse

Battery

Generator

Bl

G

Y

W

Transfer
switch

Parking
brake
switch

Neutral/
parking
switch

Correct

Continued on next page

• Improper coupler connection

• Faulty ignition switch
• Faulty engine stop switch
• Broken wire harness or poor
  connection of related circuit
  couplers

No spark or poor spark

Check ignition system couplers for poor
connections.

Measure the battery voltage between
input lead wires (O/W and B/W) at the
CDI unit with the ignition switch in the
“ON” position.

Inorrect

Looseness

Make sure the transfer is in the neutral position
and the engine stop switch is in the “RUN” position.
Also, make sure the fuse is not blown and the
battery is fully-charged before diagnosing.

Correct

Summary of Contents for LT-F500F 2002

Page 1: ......

Page 2: ...OPYRIGHT SUZUKI MOTOR CORPORATION 2002 This manual has been prepared on the basis of the latest specifications at the time of publi cation 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 operation and work procedures They may not represent the actual veh...

Page 3: ...need COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit there is an exploded view which provides work instructions and other service information e g tightening torque lubricating points and locking agent points Example Rear suspension ITEM N m kgf m lb ft A 35 3 5 25 5 B 60 6 0 43 5 C 100 10 0 72 5 D 100 10 0 72 5 E 9 5 0 95 7 0 1Rear shock absorber 2Swingarm 3Spacer 4Dust s...

Page 4: ...ypoid gear oil Apply THREAD LOCK SUPER 1360 99000 32130 Apply molybdenum oil solution mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 1 Apply or use brake fluid Apply SUZUKI SUPER GREASE A 99000 25030 USA 99000 25010 Others Measure in voltage range Apply SUZUKI SILICONE GREASE 99000 25100 Measure in resistance range Apply SUZUKI MOLY PASTE 99000 25140 Measure in current range Apply WAT...

Page 5: ...S 1 2 SUZUKI LT F500FK3 2003 MODEL 1 4 SERIAL NUMBER LOCATION 1 4 FUEL OIL AND ENGINE COOLANT RECOMMENDATION 1 4 FUEL 1 4 ENGINE OIL 1 5 FRONT AND REAR DRIVE GEAR OIL 1 5 BRAKE FLUID 1 5 ENGINE COOLANT 1 5 BREAK lN PROCEDURES 1 6 INFORMATION LABELS 1 7 SPECIFICATIONS 1 8 COUNTRY AND AREA CODES 1 10 ...

Page 6: ...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 two or more persons work together pay attention to the safety of each ot...

Page 7: ...en the larger sizes first Always tighten the nuts and bolts from the inside working out diagnoally and to the specified torque Whenever you remove oil seals gaskets packing O rings self locking nuts locking wash ers cotter pins circlips snap rings and other specified parts be sure to replace them with new ones Also before installing these new parts be sure to remove any left over material from the...

Page 8: ... by the Research Method SUZUKI recommends that customers use alcohol free unleaded gasoline whenever possible Use of blended gasoline containing MTBE Methyl Tertiary Butyl Ether is permitted Use of blended gasoline alcohol fuel is permitted provided that the fuel contains not more than 10 etha nol Gasoline alcohol fuel may contain up to 5 methanol if appropriate cosolvents and corrosion inhibi tor...

Page 9: ...s operated where the ambient temperature is below 0 C 32 F BRAKE FLUID Specification and classification DOT 4 ENGINE COOLANT Since antifreeze also has corrosion and rust inhibiting properties always use engine coolant containing antifreeze even if the atmospheric temperature does not go below the freezing point Use an antifreeze designed for aluminum radiators SUZUKI recommends the use of SUZUKI C...

Page 10: ...ng break in engine speed recommendations Keep to these breake in engine speed limits Break in engine speeds Initial 500 km 300 miles Less than throttle Upon reaching an odometer reading of 500 km 300 miles you can subject the vehicle to full throttle oper ation for short periods of time The percentage of antifreeze in the coolant should be between 50 to 60 If the percentage of antifreeze is above ...

Page 11: ...rning no passenger label E 8 Age 16 Iabel E 9 Age 16 Iabel F 0 Manual notice label E A Max AMP caution label E B Max AMP caution label E F C Gearshift label E D Gearshift label F E Front carrier warning label E F Front carrier warning label E F G Rear carrier warning label E H Rear carrier warning label E F I Trailer to warning label E J Trailer to warning label F K ICES Canada label F L Complianc...

Page 12: ...0 1 cu in Compression ratio 10 2 1 Carburetor KEIHIN CVK36 single Air cleaner Polyurethane foam element Starter system Electric and recoil starter Lubrication system Wet sump Idle speed 1 300 100 r min DRIVE TRAIN Clutch Wet multi plate automatic centrifugal type Transmission 5 forward constant mesh 1 reverse with 2 transfer Gearshift pattern All up Foot operated Primary reduction ratio 2 032 63 3...

Page 13: ...0 4 kC 14 Ah 10 HR Generator Three phase A C generator Main fuse 30 A Fuse Head Hi 10 Head Lo 10 Ignition 15 Aux 10 P Source 10 A Headlight 12 V 30 30 W AUX lamp 12 V 40 W Brake light Taillight 12 V 21 5 W Speedometer light LED Coolant temperature gauge light LED Neutral indicator light LED High beam indicator light LED Reverse indicator light LED Parking indicator light LED CAPACITIES Fuel tank i...

Page 14: ...1 10 GENERAL INFORMATION COUNTRY AND AREA CODES The following codes stand for the applicable countries and areas CODE COUNTRY OR AREA E 03 E 28 E 33 USA Canada California USA ...

Page 15: ...ER 2 9 DIFFERENTIAL GEAR AND FINAL BEVEL GEAR OIL 2 11 ENGINE COOLANT 2 12 RADIATOR HOSES 2 13 CLUTCH 2 14 SPARK ARRESTER 2 14 BRAKES 2 15 BRAKE FLUID 2 16 BRAKE HOSES 2 18 TIRES 2 18 STEERING SYSTEM 2 19 SUSPENSIONS 2 20 CHASSIS NUTS AND BOLTS 2 21 GENERAL LUBRICATION 2 23 COMPRESSION PRESSURE CHECK 2 24 COMPRESSION TEST PROCEDURE 2 24 OIL PRESSURE CHECK 2 25 OIL PRESSURE TEST PROCEDURE 2 25 INIT...

Page 16: ... Tighten C Clean L Lubricate Interval Item km Initial 200 Every 1 000 Every 2 000 miles Initial 100 Every 600 Every 1 200 months 1 3 6 Air cleaner C C Exhaust pipe nuts and muffler bolts T T T Valve clearance I I Spark plug I Replace every 6 000 km 4 000 miles Fuel line I I Replace every 4 years Throttle cable play I I I Engine idle speed I I I Engine oil and oil filter R R Front differential gear...

Page 17: ... air cleaner box that is attached to the air cleaner case cover Loosen screw 2 to remove the air cleaner element 3 Separate the polyurethane foam element 4 element frame 5 and element holder 6 Fill a wash pan of a proper size with a non flammable clean ing solvent Immerse the air cleaner element in the cleaning solvent and wash it Press the air cleaner element between the palms of both hands to re...

Page 18: ... m 2 3 kgf m 16 5 lb ft Muffler mounting bolt 23 N m 2 3 kgf m 16 5 lb ft Inspect the air cleaner element for tears A torn ele ment must be replaced If driving under dusty conditions clean the air cleaner element more frequently The surest way to accelerate engine wear is to operate the engine with out the element or with torn element Make sure that the air cleaner element is in good condition at ...

Page 19: ... must be checked and adjusted when the piston is at Top Dead Center TDC of the compres sion stroke Turn the crankshaft until the piston reaches TDC on the com pression stroke by turning the starter cup 5 Turn the starter cap until the line 6 on the generator rotor is aligned with the mark 7 on the crankcase The crankshaft can be turned to align the line 6 and mark 7 by slowly pulling the recoil st...

Page 20: ...30 10121 Spark plug wrench set HEAT RANGE Check spark plug heat range by observing electrode color If the electrode of the spark plug is wet appearing or dark color replace the spark plug with hotter type one If it is white or glazed appearing replace the spark plug with colder type one CARBON DEPOSITS Check to see if there are carbon deposits on the spark plug If carbon is deposited remove it usi...

Page 21: ...he cylinder head and then tighten it to the specified torque Spark plug 11 N m 1 1 kgf m 8 0 lb ft FUEL LINE Inspect the fuel hose for damage and fuel leakage If any dam ages are found replace the fuel hoses with a new one When replacing the fuel hoses remove the fuel tank cover 7 5 0 7 0 8 mm 0 028 0 031 in Check the thread size and reach when replacing the spark plug If the reach is too short ca...

Page 22: ...ustment when the engine is warmed up Connect the electric tachometer or the multi circuit tester to the high tension cord Start the engine and set the engine idle speed between 1 200 and 1 400 r min by turning the throttle stop screw knob 1 Engine idle speed 1 300 100 r min 09900 26006 Tachometer or 09900 25008 Multi circuit tester set Inspect initially at 200 km 100 miles 1 month and every 1 000 ...

Page 23: ...l filler hole When performing an oil change without oil filter replacement the engine will hold about 3 4 L 3 6 US qt 3 0 lmp qt of oil Use an engine oil that meets the API service classifications SF or SG and that has a viscosity rating of SAE 10W 40 Engine oil drain plug 23 N m 2 3 kgf m 16 5 lb ft Install the oil filler cap 2 Start the engine and allow it to run for a few minutes at idling spee...

Page 24: ...ten the oil filter by hand Pour the new engine oil through the oil filler When performing the oil filter change the engine will hold about 3 6 L 3 8 US qt 3 2 Imp qt of oil After three minutes engine idling check the oil level 2 9 Add new engine oil and check the oil level 2 9 Engine oil capacity Oil change 3 4 L 3 6 US qt 3 0 lmp qt Oil and filter change 3 6 L 3 8 US qt 3 2 lmp qt Engine overhaul...

Page 25: ... 3 4 Place an oil pan below the differential gear case and then drain the oil by removing the drain plug 1 and filler cap 2 Tighten the drain plug 1 to the specified torque and pour the specified oil through the filler hole until it over flows Tighten the filler cap 2 to the specified torque Differential gear oil capacity 270 370 ml 9 1 12 5 US oz 9 5 13 0 lmp oz Differential gear oil drain plug 3...

Page 26: ...from the oil level check hole Tighten the filler cap 3 and the oil level check bolt 4 Final bevel gear oil capacity 250 350 ml 8 5 10 1 US oz 8 8 10 6 lmp oz Final bevel gear oil filler cap 33 N m 3 3 kgf m 24 0 lb ft ENGINE COOLANT ENGINE COOLANT LEVEL CHECK Check the engine coolant level by observing the upper 1 and lower 2 lines on the engine coolant reservoir If the level is below the lower li...

Page 27: ...s between the upper and lower lines on the engine coolant reservoir Engine coolant capacity 2 000 ml 2 1 US qt 1 8 lmp qt RADIATOR HOSES Inspect the radiator hoses for damage and engine coolant leak age If any damages are found replace the radiator hoses with new ones Do not open the radiator cap when the engine is hot as you may be injured by escaping hot liquid or vapor Engine coolant may be har...

Page 28: ...knut 3 23 N m 2 3 kgf m 16 5 lb ft Apply grease to the O ring and install the O ring clutch adjuster cap Install the clutch adjuster cap 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others SPARK ARRESTER Extract the spark arrester pipe 1 from the muffler Clean the spark arrester pipe 1 by brush Reinstall the spark arrester pipe 1 Inspect every 2 000 km 1 200 miles 6 mont...

Page 29: ...ing the rear brake pedal and brake lever is as follows NOTE First adjust the brake pedal and then adjust the rear brake lever Brake pedal Turn the adjuster 1 in or out until the pedal height A to the specification after loosening the locknut 2 Tighten the locknut 2 to the specified torque Brake pedal height A A A A 5 15 mm 0 2 0 6 in Rear master cylinder rod locknut 18 N m 1 8 kgf m 13 0 lb ft Ins...

Page 30: ...nd Readjust the rear brake lever if the rear wheels could not roll freely BRAKE FLUID BRAKE FLUID LEVEL Place the handlebar straight Check the brake fluid level by observing the lower limit line on the front brake fluid reservoir Remove the seat Check the brake fluid level by abserving the lower limit line on the rear brake fluid reservoir When the brake fluid level is below the lower limit line r...

Page 31: ... of the hose into a receptacle Squeeze and release the brake lever or the brake pedal sev eral times in rapid succession and squeeze the lever or the pedal fully without releasing it Loosen the air bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle this will remove the tension of the brake lever causing it to touch the handlebar grip or the brake pedal...

Page 32: ...lowing specification 09900 20805 Tire depth gauge Service Limit Tire tread depth Front 4 0 mm 0 16 in Rear 4 0 mm 0 16 in TIRE PRESSURE If the tire pressure is too high or too low steering will be adversely affected and tire wear will increase Therefore main tain the correct tire pressure for good roadability and a longer tire life Cold inflation tire pressure is as follows VEHICLE LOAD CAPACITY L...

Page 33: ...B Toe in 7 4 mm 0 30 0 16 in If the toe in is out of specification bring it into the specified range 7 48 To minimize the possiblility of tire damage from over inflation we strongly recommended that a man ual type air pump be used rather than a high pressure air compressor as found in service stations When fill ing air into the tires never exceed 70 kPa 0 7 kgf cm 10 psi The standard tire fitted o...

Page 34: ...If any damages are found replace the suspen sion arm or bushing with a new one 7 35 Inspect the swinging arm rear axle and bearing for scratches wear or damage If any damages are found replace them with a new one 7 66 Inspect the front and rear shock absorbers for oil leakage or damage If any damages are found replace them with a new one 7 35 and 7 66 Inspect every 2 000 km 1 200 miles 6 months ...

Page 35: ...nut lower 60 6 0 43 5 9 Front shock absorber mounting bolt upper 55 5 5 40 0 0 Tie rod end nut 60 6 0 43 5 A Tie rod locknut 29 2 9 21 0 B Brake air bleeder valve front and rear 7 5 0 75 5 5 C Brake caliper mounting bolt front 26 2 6 19 0 D Brake caliper mounting bolt rear 32 3 2 23 0 E Footrest bolt M8 26 2 6 19 0 F Footrest bolt M10 55 5 5 40 0 G Brake master cylinder mounting bolt front and rea...

Page 36: ...2 22 PERIODIC MAINTENANCE ...

Page 37: ...nt spline Grease 2Brake lever holder and throttle lever 6Throttle cable Motor oil 3Brake pedal 7Starter cable 4Propeller shaft joint spline NOTE Before lubricating each part remove any rust 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 conditions Lubrica...

Page 38: ...d or otherwise defective cylinder head gasket NOTE When the compression pressure goes below specification check the engine for conditions listed above 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 the valves are properly adjusted Warm up the engine before testing Make sure th...

Page 39: ...above items OIL PRESSURE TEST PROCEDURE Connect the tachometer onto the spark plug high tension cord Remove the right mud guard 7 8 Remove the main oil gallery plug 1 Install the oil pressure gauge and adaptor into the main oil gallery Warm up the engine as follows Summer 10 minutes at 2 000 r min Winter 20 minutes at 2 000 r min After warming up the engine increase the engine speed to 3 000 r min...

Page 40: ... the drive train Perform the following Warm up the engine INITIAL ENGAGEMENT INSPECTION Connect the tachometer or the multi circuit tester onto the spark plug high tension cord Start the engine Shift the range lever to the High position Slowly open the throttle and note the engine speed r min when the vehicle begins to move forward 09900 26006 Tachometer or 09900 25008 Multi circuit tester set Eng...

Page 41: ... position Apply the front and rear brakes as firmly as possible Fully open the throttle for two seconds and note the maximum engine speed sustained during the test cycle Lock up speed 3 400 4 000 r min If the lock up speed r min does not coincide with the standard range inspect the following items for any abnormalities Clutch shoes 3 43 Clutch wheel 3 43 Do not apply full power for more than 5 sec...

Page 42: ...ar brake pedal and shift the shift lever 1 into P Parking Inspect the rear wheel for locking by moving the vehi cle back and forth If the rear wheel is unlocked inspect the rear drive 4 28 If it is unable to shift into P adjust the parking interlock cable 7 83 ...

Page 43: ...D SERVICING 3 25 CYLINDER HEAD COVER 3 25 CYLINDER HEAD 3 26 CAMSHAFT 3 36 CAM CHAIN TENSION ADJUSTER 3 38 CYLINDER 3 38 PISTON 3 39 CONROD CRANKSHAFT 3 41 CLUTCH 3 42 TRANSMISSION 3 45 GEARSHIFT FORK 3 48 TRANSFER GEARSHIFT CAM 3 49 OIL PUMP 3 51 CRANKCASE 3 51 GENERATOR COVER 3 56 CLUTCH COVER 3 60 RECOIL STARTER 3 61 DRIVE TRAIN INBOARD SIDE 3 64 SHIM ADJUSTMENT 3 73 REASSEMBLY INFORMATION 3 76...

Page 44: ...06 Starter cup 3 16 3 97 Speedometer gearbox 3 16 3 98 Transfer gears 3 17 3 95 Neutral switch 3 18 3 84 Generator 3 22 3 84 PARTS REMOVAL INSTALLATION Clutch cover 3 18 3 91 Clutch 3 19 3 87 Cam chain 3 20 3 85 Gearshift 3 20 3 85 Gearshift cam stopper 3 21 3 52 Oil pump drive gear 3 21 3 85 Oil pump 3 21 3 84 PARTS REMOVAL INSTALLATION Starter motor 3 4 3 11 Cam chain tension adjuster 3 12 3 105...

Page 45: ...rsing the removal procedure Drain engine oil 2 9 Drain engine coolant 2 12 Remove the seat 7 4 Disconnect the battery lead wires Remove the battery Remove the fuel tank covers 7 5 Remove the mud guard L R 7 8 Remove the rear carrier and rear fender 7 8 and 7 9 Remove the fuel tank 5 3 Remove the right inner fender 7 6 Disconnect the water hoses When disconnecting the lead wires be sure to discon n...

Page 46: ... engine Disconnect the engine ground lead wire 3 and starter motor lead wire 4 Remove the starter motor 5 Disconnect the speed sensor lead wire coupler 6 Disconnect the gearshift lever lead wire coupler 7 Disconnect the generator lead wire coupler 8 and signal gen erator lead wire coupler 9 Disconnect the neutral switch lead wire couplers 0 ...

Page 47: ... switch Disconnect the gearshift arm A and reverse gear cable B Disconnect the spark plug cap C Disconnect the engine coolant temperature switch lead wire D Remove the muffler Remove the exhaust pipe Disconnect the breather hose E ...

Page 48: ...3 6 ENGINE Remove the right footrest Remove the brake pedal Remove the propeller shaft flange coupling bolts front and rear ...

Page 49: ...ENGINE 3 7 Remove the engine mounting bolts and nuts Remove the engine mounting bracket A Remove the engine from the right side ...

Page 50: ...gine mounting nuts are self locking Once the nut has been removed it is no longer of any use Be sure to use new nuts and then tighten them to the specified torque Tighten the bolts E to the specified torque Engine mounting bracket bolt 26 N m 2 6 kgf m 19 0 lb ft ITEM N m kgf m lb ft A 40 4 0 29 0 B 55 5 5 40 0 C 55 5 5 40 0 D 55 5 5 40 0 ...

Page 51: ...que 99000 32030 THREAD LOCK SUPER 1303 Front propeller shaft flange coupling bolt 45 N m 4 5 kgf m 32 5 lb ft Rear propeller shaft flange coupling bolt 30 N m 3 0 kgf m 21 5 lb ft Install the brake pedal by aligning the punched mark on the shaft with the slit of the pedal Apply THREAD LOCK SUPER 1303 to the bolts M10 only and tighten them to the specified torque 99000 32030 THREAD LOCK SUPER 1303 ...

Page 52: ...MATEX 1372 Apply THREAD LOCK 1342 to the muffler mounting bolt A Tighten the muffler mounting bolts and exhaust pipe bolts to the specified torque 99000 32050 THREAD LOCK 1342 Muffler connecting bolt 23 N m 2 3 kgf m 16 5 lb ft Muffler mounting bolt 23 N m 2 3 kgf m 16 5 lb ft Exhaust pipe nut 23 N m 2 3 kgf m 16 5 lb ft Install the gearshift arm NOTE Align the no teeth position on the gearshift a...

Page 53: ...juster screw 3 Locknut 1 8 N m 0 8 kgf m 5 7 lb ft Locknut 2 23 N m 2 3 kgf m 16 5 lb ft Apply SUZUKI SUPER GREASE A to the O ring and install the clutch adjuster cap 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others After installing the engine route the wire harness cables and hoses properly 9 12 Adjust the following items Engine oil 2 9 Engine coolant 2 12 Engine idl...

Page 54: ...Turn the crankshaft and align the TDC line A on the genera tor rotor with the index mark B on the crankcase CAM CHAIN TENSION ADJUSTER After removing the spring holder bolt 1 remove the cam chain tension adjuster GEARSHIFT LEVER Remove the gearshift lever bolt 1 then remove the gearshift lever 2 Remove the shift lever snapring 3 and shift lever assembly 4 ...

Page 55: ...INE 3 13 Remove the gear position switch RECOIL STARTER Remove the recoil starter CYLINDER HEAD COVER Remove the valve inspection caps Remove the cylinder head cover CAMSHAFT Remove the camshaft end cap 1 ...

Page 56: ...the cam chain sprocket bolts and lock washer Remove the camshaft 1 and camshaft sprocket 2 Remove the C ring 4 CYLINDER HEAD Remove the cylinder head nuts Do not drop the cam chain 3 into the crankcase Do not drop the C ring 4 into the crankcase ...

Page 57: ...E If the cylinder head does not come off lightly tap it with a plastic hammer Remove the dowel pins and gasket 1 CYLINDER Remove the cam chain guide 1 Remove the radiator hose 2 Remove the cylinder nuts Remove the cylinder NOTE Be careful not to drop the dowel pins into the crankcase ...

Page 58: ... under the piston so as not to drop the piston pin cir clip into the crankcase ENGINE BOTTOM SIDE SPEEDOMETER GEARBOX Remove the speedometer gearbox STARTER CUP Remove the starter cup nut by using a suitable bar Remove the starter cup Remove the transfer gearshift cam stopper 1 Remove the transfer gearshift shaft snap ring 2 ...

Page 59: ...2 gear 7 the washer 8 and the transfer output gear 9 Remove the starter driven gear shaft 0 the starter idle gear shaft A the gear fork shaft B the gearshift fork C the spacer and washer D the transfer selection dog E and the transfer output gear spacer F Remove the snap ring G washer H and the transfer No 1 gear I Remove the bush J and spacer K Remove the washer L and the gearshift shaft M ...

Page 60: ...eutral switch Remove the O ring 1 spring 2 and pin 3 CLUTCH COVER Remove the clutch adjuster cap Remove the clutch cover Remove the washer 1 clutch release arm 2 and clutch release roller guide 3 Remove the water pump drive joint 4 and pin 5 ...

Page 61: ...UTCH While holding the generator rotor with the special tool remove the clutch shoe nut 09930 44541 Rotor holder Remove the clutch release plate 1 Remove the clutch springs Unlock the clutch sleeve hub nut Clutch shoe nut has left hand threads ...

Page 62: ...he special tool 09920 53730 Clutch sleeve hub holder Remove the clutch shoe assembly and primary driven gear assembly CAM CHAIN Remove the cam chain GEARSHIFT Remove the gearshift cam plate guide 1 Remove the gearshift shaft 2 and gearshift cam plate 3 ...

Page 63: ...VE GEAR Remove the oil pump drive gear bolt by holding the oil pump driven gear with the special tool 09930 40113 Rotor holder Remove the washer 1 and oil pump drive gear 2 Remove the pin 3 and spacer 4 OIL PUMP Remove the snap ring 1 Remove the oil pump driven gear 2 Remove the pin 3 and washer 4 Remove the oil pump ...

Page 64: ...olt with the special tool 09930 44541 Rotor holder Remove the generator rotor with the special tool 09930 30721 Rotor remover Remove the key 1 Remove the starter driven gear 2 Remove the left crankcase bolts Remove the reverse shift cam stopper bolt 3 ...

Page 65: ...ft must remain in the left crankcase half 09920 13120 Crankcase separator DRIVE TRAIN GEARSHIFT CAM Remove the gearshift fork shafts 1 Remove the reverse gearshift fork No 1 and No 2 gearshift forks and then pull out the gearshift cam 2 Remove the reverse shift cam 3 Remove the reverse dog 4 washer 5 the reverse idle gear 6 and shaft 7 Remove the driveshaft and countershaft assembly ...

Page 66: ...3 24 ENGINE Remove the output shaft assembly BALANCER Remove the balancershaft driven gear 1 and balancershaft 2 CRANKSHAFT Remove the crankshaft with the special tool 09920 13120 Crankcase separator ...

Page 67: ... for distortion with a thickness gauge Cylinder head cover distortion Service Limit 0 05 mm 0 002 in 09900 20803 Thickness gauge If the distortion exceeds the limit replace the cylinder head cover ROCKER ARM SHAFT O D Measure diameter of rocker arm shaft Rocker arm O D IN EX Standard 11 973 11 984 mm 0 4714 0 4718 in 09900 20205 Micrometer 0 25 mm Be sure to identify each removed part as to its lo...

Page 68: ...alipers REASSEMBLY NOTE Intake rocker arm shaft A has the oil holes Apply engine oil to the rocker arms and their shafts Install the rocker arms and tighten the rocker arm shaft bolts to the specified torque Rocker arm shaft bolt 28 N m 2 8 kgf m 20 0 lb ft NOTE Align the groove B on the rocker arm shaft with the hole C on the cylinder head cover CYLINDER HEAD DISASSEMBLY Remove the engine coolant...

Page 69: ...ensioner bolt 3 Compress the valve spring and remove the valve cotters from the valve stem with the special tools 09916 14510 Valve spring compressor 09916 14910 Attachment 09916 84511 Tweezers Remove the valve spring retainer and valve spring Remove the valve from the other side ...

Page 70: ...he ser vice limit replace the cylinder head with a new one Cylinder head distortion Service Limit 0 05 mm 0 002 in 09900 20803 Thickness gauge VALVE STEM RUNOUT Support the valve with V blocks as shown and check its runout with a dial gauge The valve must be replaced if the runout exceeds the limit Valve stem runout Service Limit 0 05 mm 0 002 in 09900 20701 Magnetic stand 09900 20607 Dial gauge 1...

Page 71: ...e should be replaced with a new one Valve stem deflection IN EX Service Limit 0 35 mm 0 014 in 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand VALVE STEM WEAR If the valve stem is worn down to the limit as measured with a micrometer where the clearance is found to be in excess of the limit indicated replace the valve if the stem is within the limit then replace the guide After replacing...

Page 72: ...andle NOTE Insert the reamer from the combustion chamber and always turn the reamer handle clockwise VALVE SEAT WIDTH Coat the valve seat with prussian blue uniformly Fit the valve and tap the coated seat with the valve face in a rotating man ner in order to obtain a clear impression of the seating con tact In this operation use the valve lapper to hold the valve head The ring like dye impression ...

Page 73: ...ed to two different angles The seat contact surface is cut at 45 NOTE The valve seat contact area must be inspected after each cut 09916 21111 Valve seat cutter set 09916 24900 Valve seat cutter set 09916 22410 Solid pilot N 140 5 0 09916 24311 Solid pilot N 100 5 0 09916 24935 Valve seat cutter N 608 Insert the solid pilot 1 09916 24311 N 100 5 0 with a slight rotation Seat the pilot snugly INTAK...

Page 74: ...valve seat is pitted or burned use the 45 cutter to con dition the seat some more NOTE Cut only the minimum amount necessary from the seat to pre vent the possibility of the valve stem becoming too close to the camshaft TOP NARROWING CUT If the contact area W is too high on the valve or if it is too wide use the 15 cutter to lower and narrow the contact area The contact area too high and too wide ...

Page 75: ...e after the cylinder head has been reinstalled 2 5 Clean and assemble the head and valve components Fill the intake and exhaust ports with gasoline to check for leaks If any leaks occur inspect the valve seat and face for burrs or other things that could prevent the valve from sealing The contact area too low and too narrow on face of valve Do not use lapping compound after the final cut is made T...

Page 76: ...e valve mechanism Check the valve springs for proper strength by measuring their free length and also by the force required to compress them If the spring length is less than the service limit or if the force required to compress the spring does not fall within the range specified replace both the inner and outer springs as a set 09900 20101 Vernier calipers Valve spring free length IN EX Service ...

Page 77: ...o the stem end and release the compressor to allow the cotter 1 to wedge in between seat and stem Be sure that the rounded lip 2 of the cotter fits snugly into the groove 3 in the stem end 09916 14510 Valve spring compressor 09916 14910 Valve spring compressor attachment 09916 84511 Tweezers Tighten the cam chain tensioner bolt 4 to the specified torque Cam chain tensioner bolt 13 N m 1 3 kgf m 9 ...

Page 78: ... ft CAMSHAFT The camshaft should be checked for wear and also for runout of cams and journals if the engine has been noted to produce abnormal noise or vibration or to lack output power Any of these malconditions could be caused by a worn camshaft CAMSHAFT CAM WEAR Worn down cams are often the cause of mistimed valve opera tion resulting in reduced output power The limit of cam wear is specified f...

Page 79: ...ad cover bolt M6 10 N m 1 0 kgf m 7 0 lb ft NOTE Do not rotate the camshafts with the plastigauge in place Remove the cylinder head cover and read the width of the com pressed plastigauge with envelop scale This measurement should be taken at the widest part If the camshaft journal oil clearance measured exceeds the limit measure the outside diameter of camshaft Replace either the cylinder head se...

Page 80: ...und to be damaged replace it with a new one CYLINDER CYLINDER DISTORTION Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge taking a clearance reading at several places as indicated If the largest reading at any position of the straightedge exceeds the limit replace the cylinder Cylinder distortion Service Limit 0 05 mm 0 002 in 09900 20803 Thickness ...

Page 81: ...the side clearances of the 1st and 2nd rings If any of the clearances exceeds the limit replace both piston and piston rings Piston ring to groove clearance Service Limit 1st 0 18 mm 0 0071 in 2nd 0 15 mm 0 0059 in Piston ring groove width Standard 1st 1 01 1 03 mm 0 0398 0 0406 in 2nd 1 21 1 23 mm 0 0398 0 0484 in Oil 2 51 2 53 mm 0 0988 0 0996 in Piston ring thickness Standard 1st 0 970 0 990 mm...

Page 82: ...0 020 in 2nd 0 50 mm 0 020 in 09900 20101 Vernier calipers 09900 20803 Thickness gauge PISTON PIN AND PIN BORE Using a small bore gauge measure the piston pin bore inside diameter and using a micrometer measure the piston pin out side diameter If the reading exceeds following limit replace both piston and piston pin Piston pin bore I D Service Limit 23 030 mm 0 9067 in 09900 20602 Dial gauge 1 100...

Page 83: ...SIDE CLEARANCE Push the big end of the conrod to one side and measure the side clearance with a thickness gauge Conrod big end side clearance Service Limit 1 0 mm 0 039 in 09900 20803 Thickness gauge If the clearance exceeds the limit replace the crankshaft assem bly with a new one or bring the deflection and the side clearance within the service limit by replacing the worn parts conrod big end be...

Page 84: ...aw width Service Limit 12 9 mm 0 51 in 09900 20101 Vernier calipers CLUTCH DRIVEN PLATES NOTE Wipe off engine oil from the clutch driven plates with a clean rag Measure each driven plate for distortion with a thickness gauge and surface plate Replace driven plates which exceed the limit Driven plate distortion Service Limit 0 10 mm 0 004 in 09900 20803 Thickness gauge 09900 21203 Surface plate CLU...

Page 85: ... clutch onto the clutch wheel and install the clutch shoe assembly Rotate the clutch shoe assembly by hand to inspect that the shoe assembly turns to one direction only and never turns to the opposite direction If the shoe assembly turns to both directions or is locked replace the one way clutch with a new one STARTER CLUTCH Remove the starter clutch securing bolts by holding the rotor with the sp...

Page 86: ...that the starter driven gear turns in the opposite direc tion of the arrow mark c on the rotor while holding the gener ator rotor The gear never turns in the direction of the arrow If there is anything unusual replace the one way clutch Check the starter driven gear bearing If there is anything unusual replace the bearing Remove the bearing with the special tool 09913 70210 Bearing installer remov...

Page 87: ...hown 1 Reverse gear dog 2 Reverse driven gear 3 1st driven gear 4 4th driven gear 5 3rd driven gear 6 5th driven gear 7 2nd driven gear 8 Driveshaft 9 Countershaft 0 4th drive gear A 3rd drive gear B 5th drive gear C 2nd drive gear D Reverse idle gear E Reverse idle shaft ...

Page 88: ...direction of the snap ring Fit it to the side where the thrust is as shown in the figure Never reuse a snap ring After a snap ring has been removed from a shaft it should be discarded and a new snap ring must be installed When installing a new snap ring care must be taken not to expand the end gap larger than required to slip the snap ring over the shaft After installing a snap ring always ensure ...

Page 89: ...ENGINE 3 47 When installing the bushings align the shaft hole with the bushing hole Reverse idle shaft Countershaft Driveshaft ...

Page 90: ...f shifting action If the clearance exceeds the limit replace the fork or its gear or both Shift fork to groove clearance Standard 0 10 0 30 mm 0 004 0 012 in Service Limit 0 50 mm 0 020 in 09900 20803 Thickness gauge 09900 20101 Vernier calipers Shift fork groove width Standard No 1 No 2 5 50 5 60 mm 0 217 0 220 in Reverse 5 00 5 10 mm 0 197 0 201 in Shift fork thickness Standard No 1 No 2 5 30 5 ...

Page 91: ...condition the oil seal removal is not nec essary OIL SEAL INSTALLATION Press the oil seal into the gearshift shaft with special tool to the depth of 0 1 mm 0 0 04 in 09924 84521 Bearing installer set NOTE The stamped mark on the oil seal faces outside Apply a small quantity of the SUZUKI SUPER GREASE A to the oil seal lip 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Othe...

Page 92: ...BLY Disassemble the transfer gearshift cam as shown REASSEMBLY Install the snap ring 1 spring 2 and gearshift cam 3 NOTE The convex side of the gearshift cam 3 face lower side Install the spring 4 washer 5 and snap ring 6 ...

Page 93: ...mp filter using compressed air When installing the O ring apply grease to it 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others The oil pump case securing screw is applied with SUZUKI THREAD LOCK 1342 If an attempt is made to overhaul the pump assembly the screw may be damaged Only the oil pump unit is available as a replacement ...

Page 94: ... to the specified torque 99000 32050 THREAD LOCK 1342 Gearshift cam stopper 10 N m 1 0 kgf m 7 0 lb ft DRIVE BEVEL GEAR DISASSEMBLY Using a chisel unlock the nut Hold the output shaft with the special tool 09930 73150 Output shaft holder Remove the drive bevel gear nut Remove the washer 1 and drive bevel gear 2 Remove the shim 3 ...

Page 95: ...stall the output shaft with a plastic mallet Install the shim 1 Install the drive bevel gear and washer 2 Hold the output shaft with the special tool 09930 73150 Output shaft holder Tighten the drive bevel gear nut to the specified torque Drive bevel gear nut 100 N m 10 0 kgf m 72 5 lb ft ...

Page 96: ...tate the bearing inner race by finger to inspect for abnormal play noise and smooth rotation while the bearings are in the crankcase Replace the bearing in the following procedure if there is any thing unusual BEARING DISASSEMBLY Remove the bearing retainers Play Play ...

Page 97: ...aring remover 1 09923 74510 Bearing remover 2 09941 64511 Bearing remover 3 09930 30104 Sliding shaft NOTE If there is no abnormal noise the bearing removal is not neces sary BEARING REASEMBLY Install the bearing with the special tool 09913 70210 Bearing installer set ...

Page 98: ...e oil pressure regulator 1 When installing the oil pressure regulator 1 tighten it to the specified torque Oil pressure regulator 28 N m 2 8 kgf m 20 0 lb ft Check the operation of the oil pressure regulator by pushing the piston with an appropriately shaped tool If the piston does not operate replace the oil pressure regulator with a new one GENERATOR COVER DISASSEMBLY Remove the generator stator...

Page 99: ...he oil seal 1 with the special tool 09913 50121 Oil seal remover Remove the spacer 2 Remove the bearing with the special tool 09921 20240 Bearing remover set NOTE If there is no abnormal noise the bearing removal is not neces sary Remove the oil seal ...

Page 100: ...EMBLY Install the bearing 1 with the special tool 09913 70210 Bearing installer set NOTE The sealed side of the bearing must face to crankcase Install the bearing with the special tool 09913 70210 Bearing installer set ...

Page 101: ...hen installing the oil seals the stamped mark on the oil seal faces to the special tool 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Apply a small quantity of THREAD LOCK to the screws and install the bearing retainer 99000 32050 THREAD LOCK 1342 Install the generator stator Replace the removed oil seal and O ring with new ones ...

Page 102: ...TION Rotate the rollers 1 by hand to inspect for an abnormal noise and a smooth rotation Replace the clutch release roller assem bly if there is anything unusual REASSEMBLY Fit the adjuster bolts as shown Apply engine oil to the roller shafts Tighten the adjuster nuts temporarily ...

Page 103: ... from the housing 1 Nut 6 Spring 2 Friction plate 7 Spacer 3 Ratchet guide 8 Pin 4 Ratchet 9 Reel 5 Spring cover 1O ring 2Starter cup 3Starter cup nut 4Ratchet set 5Reel 6Spiral spring 7Rope assembly Wear hand and eye protection when removing the reel since the spring may quickly unwind and cause an injury ...

Page 104: ...EASE A Others Turn the starter rope on the reel properly After installing the spiral spring engage the part 2 of the reel with the spiral spring end 3 Hook the rope onto the hook part 4 of the reel turn the reel clockwise three of four times with the rope Install the ratchet related parts NOTE Apply SUZUKI SUPER GREASE A to the shaft and ratchet 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SU...

Page 105: ...ENGINE 3 63 Pull the rope and check that the ratchet is pushed out ...

Page 106: ...m 10 0 kgf m 72 5 lb ft 100 N m 10 0 kgf m 72 5 lb ft 100 N m 10 0 kgf m 72 5 lb ft 1 Front output shaft 2 Rear output shaft 3 Drive bevel gear 4 Shims s 5 Driven bevel gear 6 Shim s 100 N m 10 0 kgf m 72 5 lb ft 30 N m 3 0 kgf m 21 5 lb ft 45 N m 4 5 kgf m 32 5 lb ft ...

Page 107: ...utput shaft 2 After removing the drive bevel gear nut 3 remove the drive bevel gear 4 3 52 Separate the front and rear output shafts DISASSEMBLY Rear output shaft Using a chisel and unlock the nut With the rear output shaft held immovable with a vise remove the nut Replace the removed nut with a new one ...

Page 108: ...evel gear 3 Remove the C rings from the universal joint Remove the bearings by tapping with the special tool and hammer 09913 70210 Bearing installer set Remove the universal joint Using a chisel and unlock the nut Replace the removed C ring with a new one ...

Page 109: ...ove the washer 1 joint yoke 2 oil seal 3 bearig 4 and shim 5 Front output shaft Remove the C rings from the universal joint 3 66 Remove the bearing 3 66 Remove the universal joint Replace the removed nut with a new one The removed bearing and oil seal must be replaced with the new ones ...

Page 110: ...washer 1 joint yoke 2 oil seal 3 and bearing 4 INSPECTION Inspect the universal joint and outer surface of the bearing for scuffing wear and damage If any defects are found replace the bearings and universal joint as a set Replace the removed nut with a new one The removed bearing and oil seal must be replaced with the new ones ...

Page 111: ...is found replace the drive and driven bevel gears as a set REASSEMBLY Reassemble the front and rear output shafts in the reverse order of disassembly Pay attention to the following points NOTE Before reassembly thoroughly clean all parts in cleaning sol vent Rear output shaft Install the shim 1 and bearing 2 NOTE The bearing knock pin A should be positioned inside Apply grease to the lip of the oi...

Page 112: ... dust seal lip Install the universal joint and bearings with the special tool 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others 09913 70210 Bearing installer set NOTE After the backlash and tooth contact have been checked or adjusted reassemble the universal joint Install the C rings by tapping with a copper hammer as shown After reassembling the universal joint check ...

Page 113: ...fied torque Final driven bevel nut 100 N m 10 0 kgf m 72 5 lb ft Stake the nut with a center punch Front output shaft Install the bearing to the shaft NOTE The bearing knock pin A should be positioned inside Apply grease to the lip of the oil seal Install the oil seal to the joint yoke 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others NOTE The lip B of the oil seal sho...

Page 114: ...versal joint and bearings with the special tool 3 70 Install the C rings by tapping with a copper hammer 3 70 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others 09913 70210 Bearing installer set NOTE Reassemble the universal joint in the same manner as the rear one 3 70 After reassembling the universal joint check the joint move ment smoothly If a large resistance is fe...

Page 115: ...r backlash Standard 0 03 0 15 mm 0 001 0 006 in NOTE Adjust the backlash by referring to the chart at the right and using the thickness of the removed shims as a guide Backlash Shim adjustment Under 0 03 mm 0 001 in Increase shim thickness 0 03 0 15 mm 0 001 0 006 in Correct Over 0 15 mm 0 006 in Decrease shim thickness Part No Shim thickness For driven bevel gear 3 76 09181 25051 09181 25052 0918...

Page 116: ...ct rechecked until correct Make sure to check the backlash after the tooth con tact has been adjusted since it may have changed Adjust the tooth contact and backlash until they are both within specification If the correct tooth contact cannot be maintained when adjusting the backlash replace the drive and driven bevel gears Tooth contact Drive bevel gear shim adjustment Driven bevel gear shim adju...

Page 117: ...cate the teeth with engine oil Tighten the rear output shaft nut and drive bevel gear nut to the specified torque Rear output shaft nut 100 N m 10 0 kgf m 72 5 lb ft Drive bevel gear nut 100 N m 10 0 kgf m 72 5 lb ft 09930 73150 Output shaft holder 3 52 Stake the collar of the nut 1 into the notch in the shaft NOTE After the backlash and tooth contact have been checked or adjusted reassemble the u...

Page 118: ...1 00 mm 0 0394 in 1 05 mm 0 0413 in 1 10 mm 0 0433 in 1 15 mm 0 0453 in 24935 19B00 110 24935 19B00 105 24935 19B00 100 24935 19B00 095 24935 19B00 090 Combined shim 0 25 0 25 0 50 mm 0 0197 in 0 25 0 30 0 55 mm 0 0217 in Part No Shim thickness List of shims Aavailable for the driven bevel gear side 09181 25051 09181 25052 09181 25053 09181 25054 09181 25055 09181 25056 09181 25057 09181 25058 091...

Page 119: ...ASSEMBLY Determine the width between the webs referring to the figure when rebuilding the crankshaft Crank web to web width Standard 70 9 71 1 mm 2 791 2 799 in 1 Crankshaft R 2 Washer 3 Crank pin 4 Bearing 5 Conrod 6 Washer 7 Crankshaft L ...

Page 120: ...TTOM SIDE CRANKSHAFT When mounting the crankshaft in the crankcase it is neces sary to pull its left end into the crankcase with the special tool NOTE Use the front fork oil seal installer and suitable bars A as an attachment 09910 32812 Crankshaft installer 09940 52861 Front fork oil seal installer BALANCER Install the balancershaft Install the key 1 Install the balancershaft driven gear by align...

Page 121: ...t fork 4Gearshift fork No 1 5Gearshift fork shaft 6Gearshift cam stopper 7Gearshift cam plate guide 8Gearshift cam plate 9Gearshift cam 0Neutral switch AGearshift fork No 2 BReverse gearshift fork shaft CGearshift cam shaft DGearshift lever 10 N m 1 0 kgf m 7 0 lb ft 19 N m 1 9 kgf m 13 5 lb ft ...

Page 122: ... Install the driveshaft and countershaft Install the reverse idle gear shaft 1 Install the snap ring 2 washer 3 and spacer 4 Install the reverse idle gear 5 and washer 6 Install the reverse dog 7 on the driveshaft ...

Page 123: ...other very closely in external appearance and configuration 8 Gearshift fork No 1 9 Gearshift fork No 2 0 Reverse gearshift fork Install the reverse shift cam A NOTE When installing the reverse shift cam be sure to install the washer B and snap ring C Install the gearshift cam NOTE When installing the gearshift cam let the pin D face the hole E of the gearshifting fork shaft ...

Page 124: ...ation of gearshifting fork is incorrect If this is the case disassemble and trace the mis take SECONDARY DRIVEN OUTPUT SHAFT When installing the secondary driven output shaft assembly be sure to install the C ring 1 for the main bearing and place the pin 2 to the groove for the front side bearing and the pin 3 to the groove for the rear side bearing CRANKCASE Wipe the crankcase mating surfaces bot...

Page 125: ... 22 N m 2 2 kgf m 16 0 lb ft Tighten the crankcase securing bolts for left side Crankcase bolt 6 mm 11 N m 1 1 kgf m 8 0 lb ft Crankcase bolt 8 mm 22 N m 2 2 kgf m 16 0 lb ft NOTE After the crankcase bolts have been tightened check if the each shaft rotates smoothly If a large resistance is felt to rotation try to free the shafts by tapping them with a plastic mallet REVERSE CAM STOPPER BOLT Apply...

Page 126: ...ily or greasy matter to make these surfaces com pletely dry Install the generator rotor assembly Tighten the generator rotor nut to the specified torque with the special tool Generator rotor nut 160 N m 16 0 kgf m 115 5 lb ft 09930 44541 Rotor holder OIL PUMP Apply engine oil to the sliding surfaces of the case outer rotor inner rotor and shaft Install the oil pump Apply THREAD LOCK 1342 to the sc...

Page 127: ...1 and pin 2 Install the oil pump drive gear 3 and washer 4 NOTE Flange side of the gear is positioned inside Tighten the oil pump drive gear nut to the specified torque with the special tool Oil pump drive gear bolt 80 N m 8 0 kgf m 58 0 lb ft 09930 40113 Rotor holder CAM CHAIN Install the cam chain GEARSHIFT Install the gearshift cam plate 1 ...

Page 128: ...3 86 ENGINE Install the spring to the gearshift cam shaft properly Install the gearshift cam shaft assembly while aligning the spring ends with the stopper pin 2 Install the gearshift cam plate guide 3 ...

Page 129: ...utch spring 7 Clutch sleeve hub nut 8 Washer 9Clutch sleeve hub 0 Clutch driven plate A Clutch drive plate B Clutch pressure plate C Collar D Primary driven gear assembly EWasher F Clutch shoe nut G Washer H Clutch shoe assembly I One way clutch J Clutch wheel K Washer 100 N m 10 0 kgf m 72 5 lb ft 130 N m 13 0 kgf m 94 0 lb ft ...

Page 130: ...one onto the clutch sleeve hub 1 Install the clutch pressure plate 2 Install the collar 3 onto the primary driven gear assembly Install the clutch sleeve hub assembly into the primary driven gear assembly Install the washers 4 and 5 on the crankshaft and the countershaft ...

Page 131: ...o the specified torque with the special tool Clutch sleeve hub nut 100 N m 10 0 kgf m 72 5 lb ft 09920 53730 Clutch sleeve hub holder Stake the clutch sleeve hub nut with a center punch Install the one way clutch with facing the OUTSIDE mark outside Install the clutch shoe assembly Install the washer 7 and clutch shoe nut NOTE The convex side of the washer faces outside INSIDE Washer OUTSIDE INSID...

Page 132: ...hoe nut 130 N m 13 0 kgf m 94 0 lb ft 09930 44541 Generator rotor holder Stake to clutch shoe nut with a center punch Install the clutch springs and clutch release plate Tighten the clutch spring bolts diagonally Install the clutch release arm 8 clutch release roller guide 9 and washer 0 The clutch shoe nut has left hand threads ...

Page 133: ...ts 3 and 4 Rotate the adjusting screw 5 counterclockwise until it stops Tighten the locknut 3 Rotate the adjusting screw 5 clockwise 1 4 2 4 turn Tighten the locknut 4 by holding the adjuster screw 5 Locknut 3 8 N m 0 8 kgf m 5 7 lb ft Locknut 4 23 N m 2 3 kgf m 16 5 lb ft Apply SUZUKI SUPER GREASE A to the O ring and install the clutch adjuster cap 99000 25030 SUZUKI SUPER GREASE A USA 99000 2501...

Page 134: ...nap ring has been removed from a shaft the removed snap ring should be discarded and a new snap ring must be installed When installing a new snap ring care must taken not to expand the end gap larger than required to slip the snap ring over the shaft After installing a snap ring always ensure that it is completely seated in its groove and securely fitted 1 Transfer idle gear 2 Transfer NO 1 gear 3...

Page 135: ...ENGINE 3 93 Countershaft Driveshaft ...

Page 136: ...3 94 ENGINE 1Knob 2Rod 3Shift lever assy 4Lever stopper plate 5Gearshift cam 6Gearshift shaft 7Gearshift fork 8Gear fork shaft ...

Page 137: ...stall the spacer 4 Install the bushing by aligning the hole A with the hole B on the shaft Install the transfer No 1 gear 5 Install the washer 6 and snap ring 7 Install the transfer selection dog 8 Install the washer 9 and spacer 0 Install the transfer No 2 gear A Install the washer B ...

Page 138: ...ansfer idle gear D and washer E Install the transfer gearshift shaft F and washer G Install the transfer gearshift fork H and shaft I STARTER DRIVEN GEAR IDLE GEAR Install the starter driven gear and idle gear Install the dowel pins and new gasket 1 ...

Page 139: ...030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Transfer shift cam stopper bolt 23 N m 2 3 kgf m 16 5 lb ft STARTER CUP Apply SUZUKI SUPER GREASE A to the O ring and lip of the oil seal Install the starter cup 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Tighten the starter cup nut by using a suitable bar SPEEDOMETER GEARBOX Remove the speed...

Page 140: ... USA 99000 25010 SUZUKI SUPER GREASE A Others Install the washer speed sensor shaft and rotor Apply SUZUKI SUPER GREASE A to the O ring and washer Install the washer and cap 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Fit a new gasket 7 and install the gearbox Align the protrusion 8 of the gearbox with the groove 9 of the transfer output shaft ...

Page 141: ...er way Install the 2nd ring 3 and the 1st ring 4 NOTE 1st ring and 2nd ring differ in shape 1st ring and 2nd ring have letter R marked on the side Be sure to bring the marked side to the top when fitting them to the piston Position the gaps of the three rings as shown Before inserting the piston into the cylinder check that the gaps are so located When installing the spacer be careful not to allow...

Page 142: ...ew gasket 1 Install the cam chain guide 2 NOTE There is a holder for the bottom end of the cam chain guide cast in the crankcase Be sure that the guide 2 is inserted properly or binding of the cam chain and guide may result Hold each piston ring with properly position insert the piston into the cylinder Tighten the cylinder base nuts temporarily When turning the crankshaft pull the cam chain upwar...

Page 143: ...nal 38 N m 3 8 kgf m 27 5 lb ft Tighten the cylinder head nuts to the specified torque Cylinder head nut 8 mm Initial 10 N m 1 0 kgf m 7 0 lb ft Final 25 N m 2 5 kgf m 18 0 lb ft 6 mm 10 N m 1 0 kgf m 7 0 lb ft Tighten the cylinder base nuts to the specified torque Cylinder base nut 10 N m 1 0 kgf m 7 0 lb ft When installing the cylinder and cylinder head pull the cam chain upward or the chain wil...

Page 144: ...locating pin D on the camshaft with the hole as shown Recheck the position of the line A and marks C Install the lock washer so that it is covering the locating pin Apply THREAD LOCK SUPER 1303 to the bolts and tighten them to the specified torque Camshaft sprocket bolt 15 N m 1 5 kgf m 11 0 lb ft 99000 32030 THREAD LOCK SUPER 1303 Bend up the washer tongue positively to lock the bolts Pull the ca...

Page 145: ... 1216B to the mating surface of the cylinder head cover 3 104 Fit the camshaft end cap 1 99000 31230 SUZUKI BOND 1216B Lightly tighten the cylinder head cover bolts diagonally and then if everything is satisfactory tighten securely with a torque wrench to the specified torque Cylinder head cover bolt 10 N m 1 0 kgf m 7 0 lb ft NOTE When tightening the cylinder head cover bolts the piston must be a...

Page 146: ...3 104 ENGINE LIQUID GASKET APPLYING PLACE LOCATION OF CYLINDER HEAD COVER BOLT 1216B FWD NOTE Fit the gasket to the bolt 1 FWD ...

Page 147: ... kgf m 7 0 lb ft After installing the cam chain tension adjuster turn a screwdriver counterclockwise NOTE As the slotted end turns the tension rod is advanced under spring force and pushes the cam chain tension adjuster against the cam chain Install the new gasket 3 and tighten the spring holder bolt to the specified torque Spring holder bolt 8 N m 0 8 kgf m 5 7 lb ft Adjust the valve clearance 2 ...

Page 148: ...emporarily install the recoil starter GEARSHIFT LEVER Install the shift lever position switch 1 and snap ring 2 Install the shift lever assembly 3 with the pin engaged with the switch 1 Install the snap ring 4 Install the recoil starter Apply a small quantity of THREAD LOCK 1342 to the bolts 99000 32050 THREAD LOCK 1342 Install the gearshift lever 5 ...

Page 149: ...ENGINE 3 107 Install the spark plug 09930 10121 Spark plug wrench set ...

Page 150: ...VE DIFFERENTIAL INSPECTION 4 7 FRONT DRIVE DIFFERENTIAL REASSEMBLY 4 10 FRONT DRIVE DIFFERENTIAL INSTALLATION 4 16 SHIM ADJUSTMENT 4 17 REASSEMBLY INFORMATION 4 20 REAR DRIVING SYSTEM 4 21 REAR DRIVE REMOVAL 4 22 REAR DRIVE DISASSEMBLY 4 23 REAR DRIVE INSPECTION 4 28 REAR DRIVE REASSEMBLY 4 31 REAR DRIVE INSTALLATION 4 36 SHIM ADJUSTMENT 4 38 REASSEMBLY INFORMATION 4 41 ...

Page 151: ... N m 1 7 kgf m 12 5 lb ft 17 N m 1 7 kgf m 12 5 lb ft 45 N m 4 5 kgf m 32 5 lb ft 1Front drive differential gear case 2Shim s RH 3Differential assy 4Shim s LH 5Front drive differential gear case cover 62WD 4WD shifting motor 72WD 4WD shifting pinion 82WD 4WD shifting rack 92WD 4WD shifting fork 02WD 4WD shifting sleeve A4WD switch B2WD switch CBevel pinion gear ...

Page 152: ...he drive shaft from the differential case use the special tool Remove the front propeller shaft flange coupling bolts Disconnect the following lead wire couples 2 2WD lead wire coupler 3 2WD 4WD motor lead wire coupler 4 4WD lead wire coupler Remove the front drive differential gear case mounting bolts Remove the front drive differential assembly out of the frame FRONT DRIVE DIFFERENTIAL DISASSEMB...

Page 153: ...rential gear case cover bolts in a crisscross pattern Remove the differential assembly and shims Remove the bearings from the differential assembly with a commercially available bearing puller NOTE If there is no abnormal condition the bearing removal is not nec essary Do not attempt to disassemble the differential assembly The differential is available only as an assembly The removed bearing must...

Page 154: ...out of its groove and slide it towards the shifting sleeve Remove the universal joint yoke assembly with the special tool 09930 30190 Rotor remover attachment 09930 30104 Sliding shaft Remove the oil seal out of the gear case with the special tool 09913 50121 Oil seal remover NOTE If there is no abnormal condition the oil seal removal is not nec essary The removed oil seal must be replaced with a ...

Page 155: ...ing sleeve BEVEL PINION GEAR Remove the snap ring Remove the pinion gear together with the bearing BEVEL PINION GEAR BEARING Remove the bearing from the pinion gear with the special tool 09913 70210 Bearing installer set NOTE If there is no abnormal condition the bearing removal is not nec essary The removed bearing must be replaced with a new one The removed bearing must be replaced with a new on...

Page 156: ...taller set Remove the universal joint 2WD 4WD SHIFTING Remove the 2WD 4WD shifting fork shaft plug Remove the 2WD 4WD shifting fork 1 springs 2 and shift ing rack 3 by removing shaft FRONT DRIVE DIFFERENTIAL INSPECTION 2WD 4WD SHIFTING Inspect the shifting fork and its rack and pinion for wear and damage If any defects are found replace the shifting fork and its rack and pinion with the new ones I...

Page 157: ...uffing wear and damage If any defects are found replace the bearings and universal joint as a set Insert the universal joint to the bearing and check the play by tuming the universal joint as shown If excessive play is noted replace the bearing with a new one FRONT DRIVE GEAR CASE Inspect the gear case and case cover oil seals for wear or dam age If any wear or damage is found replace the oil seal...

Page 158: ...gear is damaged inspect the ring gear If any defects are found replace the bearing and gear with the new ones BEARING AND GEAR REMOVAL 4 6 Check the gear case bearings for wear or damage If any wear or damage is found replace the bearing with a new one BEARING REMOVAL 4 6 Check the breather rubber case for wear or damage Also check that the joint of the rubber case fits tightly ...

Page 159: ...pinion gear also If any defects are found replace the bearings and ring gear with the new ones BEARING REMOVAL 4 4 FRONT DRIVE DIFFERENTIAL REASSEMBLY Reassemble the front drive in the reverse order of disassembly Pay attention to the following points NOTE Before reassembly thoroughly clean all parts in cleaning sol vent DIFFERENTIAL BEARING Drive the bearings to the differential with the special ...

Page 160: ... 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others BEVEL PINION GEAR BEARING Drive the bearing onto the shaft with the special tool 09913 70210 Bearing installer set BEVEL PINION GEAR PILOT BEARING Drive the bearing into the gear case with the special tool 09913 70210 Bearing installer set BEVEL PINION GEAR Install the pinion gear assembly and fix the bearing race with the s...

Page 161: ...ove 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Apply 4 5 gram of water resistance grease to the outside of seal lip groove 99000 25160 WATER RESISTANCE GREASE Apply grease to the bearing and dust seal lip Install the universal joint and bearings with the special tool 3 70 Install the C rings by tapping with a copper hammer 3 70 99000 25030 SUZUKI SUPER GREASE A ...

Page 162: ...shifting sleeve and splines of universal joint Install the universal joint yoke assembly by tapping with a plastic mallet Fix the universal joint yoke with the snap ring 2WD 4WD SHIFTING Install the 2WD 4WD shifting fork springs and shifting rack as shown Apply sealant to the shifting fork shaft plug 1 and tighten it to the specified torque 99104 31140 SUZUKI BOND 1207B USA 99000 31110 SUZUKI BOND...

Page 163: ...OTE After the backlash and tooth contact have been checked or adjusted apply a sealant to the mating surface of the case When installing the gear case cover align the shifting fork with its groove Apply THREAD LOCK SUPER 1303 to the case cover bolts and tighten them to the specified torque in a crisscross pat tern 99000 32030 THREAD LOCK SUPER 1303 Gear case cover bolt 23 N m 2 3 kgf m 16 5 lb ft ...

Page 164: ... 99104 31140 SUZUKI BOND 1207B USA 99000 31110 SUZUKI BOND 1215 Others 2WD 4WD switch 22 N m 2 2 kgf m 16 0 lb ft 2WD 4WD SHIFTING MOTOR Apply THREAD LOCK SUPER 1303 to the M8 bolt Install the 2WD 4WD shifting motor and tighten its mounting bolts to the specified torque 99000 32030 THREAD LOCK SUPER 1303 2WD 4WD shifting motor mounting bolt M8 23 N m 2 3 kgf m 16 5 lb ft M6 12 N m 1 2 kgf m 8 5 lb...

Page 165: ... m 4 5 kgf m 32 5 lb ft NOTE Align the match mark on the front propeller shaft 3 9 Install a new stopper ring into its groove in the splines Apply grease to the splines of the drive shafts and install the drive shafts to the front drive differential gear case 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others NOTE After installing both drive shafts check the stopper rin...

Page 166: ... checked until correct Refer to the chart at the right for the appropriate shim thickness Backlash Standard 0 05 0 10 mm 0 0020 0 0040 in NOTE Adjust the backlash by referring to the chart at the right and using the thickness of the removed shims as a guide If the backlash is too small replace the right side shim s with a thicker one If the backlash is too large replace the right side shim s with ...

Page 167: ... 4 14 Gear case cover bolt 23 N m 2 3 kgf m 16 5 lb ft Remove the gear case cover 4 4 Measure the thickness of compressed solder with the micrometer 09900 20205 Micrometer Select the proper size of shim s from the right chart accord ing as the compressed solder thickness After selecting the proper size of shim s check or adjust the backlash and tooth contact Part No Shim thickness For left side of...

Page 168: ...ial ring gear several turns in each direc tion This will provide a contact pattern on the coated teeth of ring gear Remove the differential ring gear and compare the coated teeth to the examples shown in 1 2 and 3 If tooth contact is found to be correct example 2 go to the FINAL ASSEMBLY sub section on p 4 14 to complete instal lation If tooth contact is found to be incorrect example 1 and 3 the s...

Page 169: ...4 20 DRIVE TRAIN REASSEMBLY INFORMATION 23 N m 2 3 kgf m 16 5 lb ft Mating surfaces Threaded parts 4 5 gram Left side of ring gear shim s Right side of ring gear shim s ...

Page 170: ... housing Water proof seal Parking pawl lever Parking cam Parking camshaft Parking cam cover Parking cam lever 23 N m 2 3 kgf m 16 5 lb ft 33 N m 3 3 kgf m 24 0 lb ft 20 N m 2 0 kgf m 14 5 lb ft 33 N m 3 3 kgf m 24 0 lb ft 23 N m 2 3 kgf m 16 5 lb ft 100 N m 10 0 kgf m 72 5 lb ft W 23 N m 2 3 kgf m 16 5 lb ft 10 N m 1 0 kgf m 7 3 lb ft 10 N m 1 0 kgf m 7 3 lb ft 23 N m 2 3 kgf m 2 3 kgf m 16 5 lb f...

Page 171: ...r Make sure that the parking cam lever is in P position Remove the parking cam lever Remove the axle housing mounting bolts left and right Remove the rear drive gear case together with the axle hous ing Remove the axle housing bolts left and right Remove the rear axle together with the axle housing left and right P P ...

Page 172: ... PARKING REAR DRIVE SHAFT Remove the parking cam stopper and cover Remove the parking camshaft assembly Remove the parking pawl lever shaft plug 1 Remove the parking pawl lever 2 by removing its shaft Remove the rear drive shaft housing nuts ...

Page 173: ...aterproof seal by tapping with a plastic mallet Remove the parking gear by removing the snap rings Remove the oil seal with the special tool 09913 50121 Oil seal remover NOTE If there is no abnormal condition the oil seal removal is not nec essary The removed oil seal must be replaced with a new one ...

Page 174: ...oval is not nec essary Remove the oil seal with the special tool 09913 50121 Oil seal remover NOTE If there is no abnormal condition the oil seal removal is not nec essary REAR DRIVE GEAR CASE Remove the rear drive shaft coupling joint 1 Unstake the bearing locknut with a small chisel or drill The removed bearing must be replaced with a new one The removed oil seal must be replaced with a new one ...

Page 175: ...ver bolts diagonally and evenly Pry the case cover with 5 mm screws as shown Remove the ring gear shims and washer Remove the oil seal out of the cover with the special tool 09913 50121 Oil seal remover NOTE If there is no abnormal condition the oil seal removal is not nec essary The removed locknut must be replaced with a new one The removed oil seal must be replaced with a new one ...

Page 176: ...ing out of the case with the special tool 09913 70210 Bearing installer set NOTE If there is no abnormal condition the bearing removal is not nec essary Remove the bearing from the shaft with a commercially avail able bearing puller or hydraulic press NOTE If there is no abnormal condition the bearing removal is not nec essary The removed bearing must be replaced with a new one The removed oil sea...

Page 177: ...found replace the pawl and gear as a set PARKING PAWL AND PARKING GEAR REMOVAL 4 23 24 Inspect the splines of rear drive shaft and its coupling joints for wear or damage Also inspect the boot for cuts or damage If any defects are found replace the rear drive shaft and cou pling joint with the new ones Inspect the parking cam thrust bearing and return spring for any flaws or damage If any defects a...

Page 178: ...und replace the oil seal with a new one OIL SEAL REMOVAL 4 25 REAR DRIVE GEAR CASE Check the outer race play and smooth rotation of the bearing by hand while it is on the pinion gear shaft Inspect the pinion gear for wear or damage If the pinion gear is damaged inspect the ring gear also If any defects are found replace the bearing and gear with the new ones BEARING AND GEAR REMOVAL 4 28 Inspect t...

Page 179: ...nd case cover bearings for wear or dam age If any wear or damage is found replace the bearing with a new one BEARING REMOVAL 4 27 28 Check the breather rubber case for wear or damage Also check that the joint of the rubber case fits tightly ...

Page 180: ...leaning sol vent GEAR CASE BEARING Drive the bearings into the gear case and case cover with the special tool 09913 70210 Bearing installer set GEAR CASE OIL SEAL Install the new oil seals into the gear case and case cover with the special tool Apply grease to the new oil seal lips 09913 70210 Bearing installer set 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others ...

Page 181: ...ler set BEVEL PINION GEAR SHIM FINAL ASSEMBLY Install the shims pinion gear assembly and bearing lock nut Tighten the new locknut to the specified torque 09924 41830 Bearing locknut wrench Bearing locknut 100 N m 10 0 kgf m 72 5 lb ft NOTE After the backlash and tooth contact have been checked or adjusted stake the nut with a center punch ...

Page 182: ...5 Others NOTE After the backlash and tooth contact have been checked or adjusted install a new O ring and apply sealant Apply THREAD LOCK SUPER 1303 to the case cover bolts and tighten them to the specified torque in a crisscross pat tern 99000 32030 THREAD LOCK SUPER 1303 Gear case cover bolt 23 N m 2 3 kgf m 16 5 lb ft NOTE After the backlash and tooth contact have been checked or adjusted apply...

Page 183: ...w O ring in the waterproof seal s collar Install the waterproof seal with collar and washer then install the new snap ring 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Apply hypoid gear oil to the coupling joint splines and install the coupling joint to the pinion gear shaft Coat a new O ring with grease and apply sealant to the mat ing surface of the housing then...

Page 184: ...pe cial tool and then apply grease to the seal lip 09913 70210 Bearing installer set 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Install the parking pawl lever and parking camshaft assembly Install the parking pawl lever shaft plug with a new sealing washer and tighten the plug to the specified torque Parking pawl lever shaft plug 15 N m 1 5 kgf m 11 0 lb ft Inst...

Page 185: ...VE INSTALLATION Install the rear drive in the reverse order of removal Pay atten tion to the following points Coat the new O rings with grease and install them into the grooves in the gear case and cover 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Apply grease to the splines of the axle and rear drive shaft splines too 99000 25030 SUZUKI SUPER GREASE A USA 99000 ...

Page 186: ...ling the parking cam lever align the punched marks on the shaft and lever Make sure that the parking cam lever is in P position Tighten the lever bolt to the specified torque Parking cam lever bolt 10 N m 1 0 kgf m 7 3 lb ft Adjust the cable play 7 83 Pour the specified hypoid gear oil SAE 90 in through the filler hole 2 11 Install the rear brake caliper 7 51 Install the rear wheels 7 11 P P ...

Page 187: ...lash should be re checked until cor rect Refer to the chart at the right for the appropriate shim thickness Backlash Standard 0 02 0 06 mm 0 0008 0 0024 in Without gear case cover specification 0 08 0 13 mm 0 0031 0 0051 in Gear case cover assembled specification NOTE Adjust the backlash by referring to the chart at the right and using the thickness of the removed shims as a guide 0 Backlash Shim ...

Page 188: ...new O ring to the gear case cover Do not apply a thread lock to the case cover bolts Gear case cover bolt 23 N m 2 3 kgf m 16 5 lb ft Remove the gear case cover 4 26 Measure the thickness of compressed solder with the micrometer 09900 20205 Micrometer Select the proper size of shim s from the right chart accord ing as the compressed solder thickness After selecting the proper size of shim s instal...

Page 189: ...2 and 3 If tooth contact is found to be correct example 2 go to the FINAL ASSEMBLY sub section on p 4 33 to complete instal lation If tooth contact is found to be incorrect examples 1 and 3 the shim between the pinion gear bearing and gear case must be changed and the tooth contact re checked until correct Tooth contact Shim adjustment Contact at tooth top 1 Decrease shim thickness Contact at toot...

Page 190: ...b ft 110 N m 11 0 kgf m 79 5 lb ft 33 N m 3 3 kgf m 24 0 lb ft 23 N m 2 3 kgf m 16 5 lb ft Mating surfaces Mating surfaces Left side of ring gear shim s Right side of ring gear shim s Pinion gear shim s 5 7 gram 4 5 gram 23 N m 2 3 kgf m 16 5 lb ft Mating surfaces ...

Page 191: ...hed marks 10 N m 1 0 kgf m 7 3 lb ft 15 N m 1 5 kgf m 11 0 lb ft 23 N m 2 3 kgf m 16 5 lb ft 10 N m 1 0 kgf m 7 3 lb ft 23 N m 2 3 kgf m 16 5 lb ft 33 N m 3 3 kgf m 24 0 lb ft With seal washer 20 N m 2 0 kgf m 14 5 lb ft 33 N m 3 3 kgf m 24 0 lb ft ...

Page 192: ...MOUNTING 5 3 FUEL VALVE 5 4 REMOVAL AND INSPECTION 5 4 FUEL STRAINER 5 4 REMOUNTING 5 4 FUEL LEVEL GAUGE 5 5 REMOVAL 5 5 INSPECTION 5 5 REMOUNTING 5 5 CARBURETOR 5 6 CONSTRUCTION 5 6 SPECIFICATIONS 5 7 I D NO LOCATION 5 7 REMOVAL 5 8 DISASSEMBLY 5 9 CLEANING 5 12 INSPECTION 5 12 REASSEMBLY 5 13 REMOUNTING 5 14 ...

Page 193: ...5 2 FUEL SYSTEM FUEL TANK CONSTRUCTION Fuel level gauge Breather hose Fuel tank cap Fuel tank assy Bolt Spacer Cushion rear Cushion front Fuel hose Fuel valve Bolt ...

Page 194: ... 1 Remove the fuel tank mounting bolts Turn the fuel valve to the ON position Disconnect the fuel hose 2 and vacuum hose 3 Remove the fuel tank Drain the fuel completely REMOUNTING Remount the fuel tank in the reverse order of removal Pay attention to the following points Route the fuel hose and breather hoses properly 9 17 Connect the fuel tank breather hose 1 to the fuel tank top cover 2 Gasolin...

Page 195: ...h sediment or rust fuel will not flow smoothly and loss in engine power may result Clean the fuel strainer with compressed air REMOUNTING Remount the fuel valve in the reverse order of removal Gasoline is highly flammable and explosive Keep heat sparks and flames away from gasoline Replace the removed gasket with a new one to prevent fuel leakage ...

Page 196: ...ctly as the float of the fuel gauge assembly moves up and down as shown in the illustra tion REMOUNTING Remount the fuel level gauge in the reverse order of removal NOTE When installing the fuel level gauge indication must be faced forward Gasoline is highly flammable and explosive Keep heat sparks and flames away from gasoline Approx 83 mm F Approx 113 mm 1 2 Approx 142 mm Float Replace the remov...

Page 197: ...tainer Jet Needle Diaphragm assy Spring Hose Cover Starter plunger Spring Guide holder Cap Diaphragm assy Spring Cover Float chamber Slow jet Hose O ring Needle jet holder Main jet Needle valve Float pin Throttele stop screw Pilot screw Float Gasket Starter jet ...

Page 198: ...03 28 E 33 Carburetor type KEIHIN CVK36 Bore size 36 mm I D No 03GF 03GG Idle r min 1 300 100 r min Float height 17 0 1 0 mm 0 67 0 04 in Main jet M J 128 Jet needle J N NBAY Needle jet N J 6 Slow jet S J 35 Pilot screw P S 1 3 8 turns back PRE SET Throttle cable play pulling cable 3 5 mm 0 12 0 20 in Starter enricher plunger cable play 0 5 1 0 mm 0 02 0 04 in ...

Page 199: ...5 8 FUEL SYSTEM REMOVAL Remove the fuel tank 5 3 Loosen the carburetor clamp screws Remove the carburetor side cap 1 Disconnect the throttle cable 2 Remove the carburetor Disconnect the starter cable ...

Page 200: ...asting enrichment valve cover 4 spring 5 coasting enrichment valve 6 and O ring 7 Remove the top cap Remove the spring 8 spring retainer 9 jet needle 0 and diaphragm A Remove the float chamber Do not use compressed air on the carburetor body before removing the diaphragm this may damage the diaphragm ...

Page 201: ...5 10 FUEL SYSTEM Remove the throttle stop screw 1 Remove the O ring 2 Remove the float pin 3 float 4 and needle valve 5 Replace the removed O ring with a new one to prevent fuel leakage ...

Page 202: ...m the end of the bit to prevent drilling into the pilot screw Carefully drill through the plug Thread a self tapping sheet metal screw into the 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 number of turns until the screw is lightly seated Make a note of how many turns were made so the...

Page 203: ... seat Main jet Piston valve Main air jet Starter jet Slow air jet O ring Needle jet air bleeding hole Throttle valve Float Diaphragm Needle valve Pilot outlet and by pass ports Jet needle Some carburetor cleaning chemicals especially dip type soaking solutions are very corrosive and must be handled carefully Always follow the chemical man ufacturer s instructions on proper use handling and storage...

Page 204: ...tor upside down Measure the float height A while the float arm is just contacting the needle valve using vernier calipers Bend the tongue as necessary to bring the float height A to the specified level 09900 20101 Vernier calipers Float height A A A A 17 0 1 0 mm 0 67 0 04 in REASSEMBLY Reassemble the carburetor in the reverse order of disassembly Pay attention to the following points PILOT SCREW ...

Page 205: ...R GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others REMOUNTING Remount the carburetor assembly in the reverse order of removal Pay attention to the following points Align the lug on the carburetor with the intake pipe s cutout After the carburetor assembly has been remounted onto the engine perform the following adjustments Throttle cable play 2 8 Engine idle speed 2 8 ...

Page 206: ...OLING FAN 6 7 REMOVAL 6 7 INSPECTION 6 7 INSTALLATION 6 8 COOLING FAN THERMO SWITCH 6 9 REMOVAL 6 9 INSPECTION 6 9 INSTALLATION 6 9 ENGINE COOLANT TEMPERATURE SWITCH 6 10 REMOVAL 6 10 INSPECTION 6 10 INSTALLATION 6 10 THERMOSTAT 6 11 REMOVAL 6 11 INSPECTION 6 11 INSTALLATION 6 11 WATER PUMP 6 13 REMOVAL 6 13 INSPECTION 6 13 DISASSEMBLY 6 14 REASSEMBLY AND INSTALLATION 6 15 LUBRICATION SYSTEM 6 17 ...

Page 207: ...tor anti leak additive Anti freeze 1 000 ml 2 1 1 8 US lmp pt Water 1 000 ml 2 1 1 8 US lmp pt Anti freeze density Freezing point 50 55 60 30 C 24 F 40 C 44 F 55 C 67 F 20 40 60 80 100 Density 0 10 20 30 40 50 60 70 32 14 4 22 40 58 76 94 Freezing point Fig 1 Engine coolant density freezing point curve C F 0 10 20 30 40 50 60 Density 150 140 130 120 110 100 Biling point C F 302 284 266 248 230 212...

Page 208: ...s If the pressure should fall during this 10 second interval it means that there is a leaking point in the system In such a case inspect the entire system and replace the leaking com ponent or part Do not remove the radiator cap when the engine is hot WATER PUMP RADIATOR COOLING FAN THERMO SWITCH ENGINE COOLANT TEMPERATURE SWITCH THERMOSTAT CYLINDER HEAD CYLINDER RESERVOIR TANK When removing the r...

Page 209: ...d radiator assembly RADIATOR REMOUNTING Install the radiator Connect the radiator hoses 9 18 Connect the siphon hose cooling fan thermo switch lead wire coupler and cooling fan motor lead wire coupler Install the drain plug with a new sealing washer Pour engine coolant 2 12 Install the front fender RADIATOR RESERVOIR TANK REMOVAL AND REMOUNTING Remove the reservoir tank mounting bolts and disconne...

Page 210: ...le of holding that pressure for at least 10 seconds Replace the cap if it is found not to satisfy either of these two requirements Radiator cap valve opening pressure Standard 95 125 kPa 0 95 1 25 kgf cm2 13 5 17 8 psi RADIATOR INSPECTION AND CLEANING Road dirt or trash stuck to the fins must be removed Use of compressed air is recommended for this cleaning Remove the grill upper cover 7 4 Remove ...

Page 211: ...ATION SYSTEM RADIATOR HOSE INSPECTION Remove the front fender 7 6 Any radiator hose found in a cracked condition or flattened must be replaced Any leakage from the connecting section should be corrected by proper tightening ...

Page 212: ... 1 Test the cooling fan motor for load current with an ammeter connected as shown in the illustration The voltmeter is for making sure that the battery applies 12 volts to the motor With the motor with electric motor fan run ning at full speed the ammeter should be indicating not more than 5 amperes If the fan motor does not turn replace the motor assembly with a new one NOTE When making above tes...

Page 213: ...all the cooling fan motor and cooling fan Cooling fan motor mounting screw 8 N m 0 8 kgf m 6 0 lb ft Cooling fan nut 10 N m 1 0 kgf m 7 0 lb ft Install the radiator 6 4 Connect the radiator hoses 6 6 9 18 Pour engine coolant 2 12 Install the front fender ...

Page 214: ... the oil to raise its temperature slowly and read the col umn thermometer 2 when the switch closes or opens 09900 25008 Multi circuit tester set Tester knob indication Continuity test Cooling fan thermo switch operating temperature Standard OFF ON Approx 88 C 190 F ON OFF Approx 82 C 180 F INSTALLATION Install the new O ring 1 Tighten the cooling fan thermo switch to the specified torque Cooling f...

Page 215: ...9900 25008 Multi circuit tester set Tester knob indication Continuity test Engine coolant temp switch operating temperature Standard OFF ON Approx 115 C 239 F ON OFF Approx 108 C 226 F INSTALLATION Apply sealant to the thread portion of the engine coolant tem perature switch 99104 31140 SUZUKI BOND 1207B USA 99000 31110 SUZUKI BOND 1215 Others Tighten the engine coolant temperature switch to the s...

Page 216: ... temperature on a thermometer Read the thermometer just when opening the thermostat This reading which is the temperature level at which the thermo stat valve begins to open should satisfy the standard value Thermostat valve opening temperature Standard 73 5 76 5 C 164 170 F Keep on heating the water to raise its temperature Just when the water temperature reaches specified value the thermostat va...

Page 217: ...e hole A of the thermostat faces upside After installing the thermostat be sure to add engine coolant 2 12 Tighten the thermostat case bolts to the specified torque Install the fuel tank cover 7 5 Thermostat case bolt 10 N m 1 0 kgf m 7 0 lb ft ...

Page 218: ...water pump drive joint 1 Remove the pin 2 INSPECTION MECHANICAL SEAL Visually inspect the mechanical seal for damage with particular attention given to the sealing face Replace the mechanical seal that shows indications of leakage Also replace the oil seal if necessary WATER PUMP SHAFT Rotate the water pump shaft assembly by hand to inspect for abnormal noise and smooth rotation If anything unusua...

Page 219: ...ssary DISASSEMBLY Remove the mechanical seal ring 1 and seal 2 Remove the oil pressure switch 3 NOTE When removing the water pump shaft mechanical seal and seal remove the oil pressure switch to protect it from damage Attach a proper 6 mm bolt to the water pump shaft 4 and remove the water pump shaft Remove the oil seal 5 The removed mechanical seal and seal must be replaced with new ones Be caref...

Page 220: ... suitable size socket wrench Install the oil seal with the special tool Apply grease to the oil seal 09913 70210 Bearing installer set 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Install the water pump shaft by using the suitable size socket wrench Install the new gasket 3 96 Replace the removed seal with a new one Install the mechanical seal taking care about it...

Page 221: ...N m 1 5 kgf m 11 0 lb ft NOTE The seal lip side 1 must face to impeller Replace the O ring with a new one NOTE Apply engine coolant to the O ring NOTE The mechanical seal ring must be assembled with the paint marked A face of the ring toward the impeller Install the water pump cover and tighten its mounting bolts securely Connect the water hoses ...

Page 222: ...EM OIL PRESSURE 2 25 OIL FILTER 2 10 OIL PRESSURE REGULATOR 3 56 OIL SUMP FILTER 3 51 OIL PUMP 3 21 3 51 3 84 1O ring 2Mechanical seal 3Impeller 4Water pump shaft bolt 5Impeller washer 6Seal washer 7Shaft 8Oil seal 9Joint 0Pin 15 N m 1 5 kgf m 11 0 lb ft ...

Page 223: ...H CYLINDER WALL PISTON WALL PISTON RING CONROD BIG END BEARING STARTER CLUTCH PISTON PIN OIL NOZZLE CAM DRIVE CHAIN IN EX CAM FACES IN ROCKER ARM SHAFT CAMSHAFT CYLINDER HEAD COVER SECOND CLUTCH DRIVE DRIVEN PLATES DRIVESHAFT GEARS REVERSE GEARS BEVEL GEARS PRIMARY DRIVEN GEAR SPACER COUNTERSHAFT GEARS COUNTERSHAFT COUNTERSHAFT LEFT END BEARING DRIVESHAFT LEFT END BEARING TRANSFER MISSION INPUT GE...

Page 224: ...COOLING AND LUBRICATION SYSTEM 6 19 ENGINE LUBRICATION SYSTEM Oil jet ...

Page 225: ...MBLY 7 42 INSPECTION 7 44 REASSEMBLY AND REMOUNTING 7 46 TOE IN ADJUSTMENT 7 48 FRONT WHEEL FRONT BRAKE FRONT SUSPENSION AND STEERING REASSEMBLING INFORMATION 7 49 REAR BRAKE 7 50 CONSTRUCTION 7 50 BRAKE PAD REPLACEMENT 7 51 BRAKE FLUID REPLACEMENT 7 52 BRAKE CALIPER REMOVAL AND DISASSEMBLY 7 52 BRAKE CALIPER INSPECTION 7 54 BRAKE CALIPER REASSEMBLY AND REMOUNTING 7 55 BRAKE DISC REMOVAL AND DISAS...

Page 226: ...CHASSIS EXTERIOR PARTS CONSTRUCTION Fuel tank top cover Lid Front fender Front inner fender RH Front inner fender LH Front grill upper Front grip bar Front grill lower Front box Front carrier Muffler cover ...

Page 227: ...CHASSIS 7 3 Rear carrier Rear fender Fuel tank cover Mud guard Battery holder plate Rear box ...

Page 228: ...the front carrier GRILL UPPER LOWER COVERS Remove the grill lower cover 1 Remove the front carrier Abobe Remove the grill upper cover 2 FRONT GRIP BAR Remove the grill upper lower covers Abobe Disconnect the headlight couplers 1 Remove the headlight mounting nuts ...

Page 229: ...he air cleaner duct mounting screw 1 Remove the fuel tank covers NOTE Before removing the fuel tank covers do not attempt to uncou ple the fuel tank covers Remove the fuel tank cap Remove the fuel tank inlet cover 2 Remove the fuel tank top cover 3 Disconnect the fuel breather hose 4 ...

Page 230: ...ve the seat 7 4 Remove the front grip bar 7 4 Remove the fuel tank covers 7 5 Remove the gearshift lever knob 1 Remove the right and left mud guard fasteners screws Remove the right inner fender 2 Remove the power source coupler 3 ...

Page 231: ...X Remove the front box cap 1 Remove the front box mounting screw Turn the front box 2 counterclockwise and remove it Remove the front box holder 3 Remove the cushion 4 from the front box NOTE When installing the cushion to the front box align A to the cut out on the front box ...

Page 232: ...7 8 CHASSIS MUD GUARD Remove the muffler cover 1 Right side hooked part Remove the mud guard 2 REAR CARRIER Remove the rear carrier 1 ...

Page 233: ...tery 1 and its tray Remove the starter motor relay 2 and fuse box neutral relay 3 from the rear fender Remove the air cleaner duct 4 Remove the rear fender bolts Remove the rear fender bolt Remove the right and left mud guard fasteners screws Remove the rear fender Remove the battery holder plate 5 ...

Page 234: ...ASSIS REMOUNTING Remounting the exterior parts in reverse order of removal Pay attention the following points REAR CARRIER Apply THREAD LOCK 1342 to the rear carrier mounting bolts 99000 32050 THREAD LOCK 1342 ...

Page 235: ...front and rear wheels REMOUNTING Remount the wheels in the reverse order of removal Pay atten tion to the following points When installing each wheel make sure the arrow A on the tire points in the direction of rotation Tighten the wheel set nuts to the specified torque Front and rear wheel set nut 50 N m 5 0 kgf m 36 0 lb ft ITEM N m kgf m lb ft A 50 5 0 36 0 AWheel set nut ...

Page 236: ...he rim Mount the tire on the rim by hand as shown NOTE Inspect the sealing portion of the rim before installing the tire on the rim When using the tire lever do not scratch or hit the sealing portion hump of the wheel or it may cause air leakage Never apply grease oil or gasoline to the tire bead because they will deteriorate the tire The standard tire fitted on this vehicle is AT25 8 12 for the f...

Page 237: ...m 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 35 kPa 0 35 kgf cm2 5 1 psi Rear 30 kPa 0 30 kgf cm2 4 4 psi Vehicle load capacity 172 kg 380 lbs Maximum operating pressure 25 kPa 0 25 kgf cm2 3 6 psi 35 kPa 0 35 kgf cm2 5 1 psi 45 kPa 0 45 kgf cm2 6 5 psi Place th...

Page 238: ...er ring snap ring and boot bands for wear or damage If any damages are found replace them with new ones Inspect the axle play by using a push and pull motion given to the axle shaft and wheel spindle as shown Circlip Differential side joint set Differential side boot set Snap ring Circlip Differential side outer boot clamp Differential side inner boot clamp Wheel side inner boot clamp Wheel side o...

Page 239: ...rential side joint double offset joint Slide the boot toward to the center of the front drive shaft and remove the stopper ring from the outer race Separate the outer race from the front drive shaft Wipe off grease and remove the snap ring from the drive shaft Remove the cage ...

Page 240: ...ge 1 by using a pipe 2 Drive shaft joint cage installing pipe diameter A 20 0 mm 0 787 in or more B 27 0 mm 1 063 in or less Do not disassemble the wheel side joint double offset joint If any damages are found replace the wheel side joint with a new one Wash all parts before installation clean the inside and outside of the boot with a cloth Do not wash the boots in any commercially available degre...

Page 241: ...t grease is included in the wheel side boot set or wheel side joint assembly of spare parts Insert the cage into the outer race and fit a stopper ring in the groove of the outer race Position Grease Wheel side Differential side Quantity 40 g 1 4 oz 55 g 1 9 oz Locate the opening of the stopper ring 1 so that the opening is not lined up with a ball ...

Page 242: ...the boot so that the air pressure in the boot becomes the same as the atmospheric pressure at the positions indicated in the illustration A 174 184 mm 6 9 7 2 in Fix the boot on the outer race with a boot band taking care not to distort the boot C Rotation direction D Right side E Left side REMOUNTING Install the front drive shaft 4 16 ...

Page 243: ...stem is filled with an ethylene glycol based DOT 4 brake fluid Do not use or mix different types of fluid such as silicone based or petroleum based brake fluids Do not use any brake fluid taken from old used or unsealed containers Never reuse brake fluid left over from the last servicing or which has been stored for a long periods of time When storing brake fluid seal the container completely and ...

Page 244: ...nting pins 2 and brake caliper mounting bolts 1 to the specified torque Brake pad mounting pin 18 N m 1 8 kgf m 13 0 lb ft Brake caliper mounting bolt 26 N m 2 6 kgf m 19 0 lb ft NOTE After replacing the brake pads pump the brake lever a few times to check for proper brake operation and then check the brake fluid level Do not operate the brake lever during or after brake pad removal Replace the br...

Page 245: ...ve and disconnect the clear hose Fill the reservoir with new brake fluid to the upper end of the inspection window BRAKE CALIPER REMOVAL AND DISASSEMBLY Remove the front wheel 7 11 Disconnect the brake hose from the brake caliper by remov ing the brake hose union bolt 1 and allow the brake fluid to drain into a suitable receptacle Remove the brake caliper by removing the brake caliper mounting bol...

Page 246: ...istons using com pressed air Remove the dust seals and piston seals Remove the cap 2 and loosen the brake caliper holder pin 3 Remove the brake caliper holder 4 Remove the brake caliper holder pin 5 Do not use high pressure air to prevent brake caliper piston damage Do not reuse the dust seal and piston seal to prevent fluid leakage ...

Page 247: ...e the brake cal iper with a new one BRAKE CALIPER PISTON Inspect the brake caliper piston for any scratches or other dam age If any damages are found replace the piston with a new one RUBBER PARTS Replace the removed rubber parts with new ones CALIPER HOLDER Inspect the caliper holder 1 and pin 2 for damage If any dam ages are found replace them with new ones ...

Page 248: ... the pin 1 to the caliper holder 2 to the specified torque Caliper holder pin 18 N m 1 8 kgf m 13 0 lb ft Apply SUZUKI SILICON GREASE to the brake caliper holder pin 99000 25100 SUZUKI SILICONE GREASE Wash the brake caliper components with new brake fluid before reassembly Do not wipe the brake fluid off with a rag after wash ing the components When washing the components use the specified brake f...

Page 249: ... 3 kgf m 16 5 lb ft Install the pads to the caliper Tighten the brake pad mounting pins 7 brake caliper mount ing bolts 8 and brake hose union bolt 9 to the specified torque Brake pad mounting pin 18 N m 1 8 kgf m 13 0 lb ft Brake caliper mounting bolt 26 N m 2 6 kgf m 19 0 lb ft Brake hose union bolt 23 N m 2 3 kgf m 16 5 lb ft NOTE Before remounting the brake caliper push the brake caliper pis t...

Page 250: ...e front wheel 7 11 Remove the cotter pin Loosen the axle nut 1 by applying the front brake Remove the axle nut 1 and spring washer 2 Remove the brake caliper 7 21 Remove the front wheel hub 3 Remove the brake disc Replace the removed cotter pin with a new one ...

Page 251: ...and Brake disc runout Service Limit 0 3 mm 0 012 in If either measurement exceeds the service limit replace the brake disc with a new one BRAKE DISC REASSEMBLY AND REMOUNTING Reassemble and remount the brake disc in the reverse order of removal and disassembly Pay attention to the following points Apply SUZUKI SUPER GREASE A to the wheel hub spline 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010...

Page 252: ...fied torque After installing the front hub nut insert a new cotter pin into the driver shaft MASTER CYLINDER REMOVAL AND DISASSEMBLY Place a rag underneath the brake hose union bolt on the mas ter cylinder to catch any spilt brake fluid Remove the brake hose union bolt and disconnect the brake hose Remove the master cylinder assembly When installing the wheel hub make sure the spacer 1 is properly...

Page 253: ...1 and brake switch 2 Remove the reservoir cap 3 and diaphragm 4 Drain the brake fluid Pull the dust boot 5 out and remove the circlip 6 Remove the piston secondary cup primary cup and spring 7 Secondary cup 8 Piston 9 Primary cup 0 Spring ...

Page 254: ...NDER REASSEMBLY AND REMOUNTING Reassemble and remount the master cylinder in the reverse order of removal and disassembly Pay attention to the following points Specification and classification DOT 4 Wash the master cylinder components with new brake fluid before reassembly Do not wipe the brake fluid off with a rag after wash ing the components When washing the components use the specified brake f...

Page 255: ...ar and tighten the upper clamp bolt first Master cylinder clamp bolt 10 N m 1 0 kgf m 7 0 lb ft A Master cylinder B Master cylinder upper clamp bolt C Handlebar D Clearance Tighten the brake hose union bolt to the specified torque Brake hose union bolt 23 N m 2 3 kgf m 16 5 lb ft Bleed air from the brake system after reassembling the master cylinder 2 17 ...

Page 256: ...r 7Hub bearing 8Outer dust seal 9Lower wishbone arm 0Bushing ADisc cover BFront disc CFront hub AShock absorber mounting upper bolt BShock absorber mounting lower nut CWishbone arm pivot nut DSteering knuckle pinch bolt EFront disc mounting bolt ITEM N m kgf m lb ft A 55 5 5 40 0 B 60 6 0 43 5 C 65 6 5 47 0 D 50 5 0 36 0 E 23 2 3 16 5 ...

Page 257: ...h brake disc 7 26 Remove the brake hose clamp Remove the drive shaft cover Remove the cotter pin and tie rod end nut Remove the front disc cover Loosen the steering knuckle pinch bolts and remove the steering knuckle Replace the removed cotter pin with a new one ...

Page 258: ...rm mounting bolt Loosen the upper wishbone arm pivot bolts nuts and lower shock absorber mounting bolt nut Remove the upper wishbone 1 Loosen the lower wishbone arm pivot bolts nuts Remove the lower wishbone 2 Loosen the engine coolant reservoir mounting bolt Remove the upper shock absorber mounting bolt Remove the shock absorber ...

Page 259: ...ith a new one WISHBONE ARM Inspect the wishbone arms for damage If any damages are found replace the wishbone arm with a new one KNUCKLE END Inspect the knuckle end boot for wear or damage If any dam ages are found replace the knuckle end with a new one Remove the snap ring Remove the knuckle end by using the special tools 09913 70210 Bearing installer set ...

Page 260: ... brake disc cover with a new one BUSHING Inspect the rubber bushing shock absorber wishbone arm for wear or other damage If any damages are found replace the bushing with a new one DUST SEAL Inspect the dust seal lips for wear or damage If any damages are found replace the dust seal with a new one Remove the steering knuckle dust seals by using the special tool 09913 50121 Oil seal remover Replace...

Page 261: ...hile it is in the steering knuckle Rotate the inner race by hand to inspect for abnormal noise and smooth rotation If there is anything unusual replace the bearing with a new one NOTE Make sure to check each bearing in the same manner Remove the hub bearings using the appropriate bar ...

Page 262: ... of the dust seals before installing them 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Install the hub bearings using the special tool 09924 84510 Bearing installer set NOTE Install the outer bearing 1 the spacer 2 and then the inner bearing 3 Make sure the sealed side of the bearing faces out ward Install the steering knuckle dust seal using the special tool 0991...

Page 263: ... the spec ified torque 99000 32030 THREAD LOCK SUPER 1303 USA 99000 32110 THREAD LOCK SUPER 1322 Others Wishbone arm pivot nut 65 N m 6 5 kgf m 47 0 lb ft Tighten the shock absorber mounting lower bolt nut 2 to the specified torque Shock absorber mounting lower nut 60 N m 6 0 kgf m 43 5 lb ft Tighten the shock absorber mounting upper bolt 3 Tighten the engine coolant reservoir mounting bolt Shock ...

Page 264: ...the washer between the tie rod end and steering knuckle Tighten the tie rod end nut to the specified torque Tie rod end nut 55 N m 5 5 kgf m 40 0 lb ft NOTE After installing the tie rod end nut insert a new cotter pin into the tie rod end Install the front wheel hub brake caliper and wheel SPRING PRE LOAD ADJUSTMENT After installing the front shock absorber adjust the spring pre load Position 1 pr...

Page 265: ...st seal 7Cable guide 8Bushing 9Dust seal 0O ring ADust seal BTie rod end inside CTie rod end outside DHandlebar cover bracket EHandlebar cover AHandlebar clamp bolt BSteering shaft holder bolt CSteering shaft nut DTie rod end nut ETie rod locknut ITEM N m kgf m lb ft A 23 2 3 16 5 B 23 2 3 16 5 C 49 4 9 35 5 D 35 3 5 25 5 E 29 2 9 21 0 ...

Page 266: ...Remove the front wheel 7 11 Remove the master cylinder assembly 7 28 Remove the throttle lever case Disconnect the rear brake cable 1 and remove the handlebar switch 2 Remove the auxiliary light cover 3 Remove the speedometer cover 4 Remove the speedometer assembly 5 ...

Page 267: ...he clamp Remove the cotter pins and tie rod end nuts Remove the tie rods Separate the tie rod ends 6 nuts 7 and 8 and tie rods 9 Remove the cotter pin and steering shaft nut Replace the removed cotter pins with new ones The locknuts 7 have left hand threads Replace the removed cotter pins with new ones ...

Page 268: ... clamp wear DUST SEALS AND O RING Inspect the dust seals and O ring for wear or damage If any damages are found replace the dust seals with new ones TIE ROD Inspect the tie rod for distortion or damage If any damages are found replace the tie rod with a new one TIE ROD END Inspect the tie rod end and boots for smooth movement If there are any abnormalities replace the tie rod end with a new one Re...

Page 269: ... If any damages are found replace the steering shaft holders with new ones STEERING SHAFT BUSHING Inspect the steering shaft bushing 1 for wear and damage If any damages are found replace it with a new one Remove the steering shaft bushing with the special tools 09917 23711 Ring nut socket 09924 84510 Bearing installer set Install the steering shaft bushing with the special tool 09924 84510 Bearin...

Page 270: ...aft Install the clip 2 to the dust seal Install the new O ring 3 and dust seal to the steering shaft Tighten the steering shaft nut to the specified torque Steering shaft nut 49 N m 4 9 kgf m 35 5 lb ft NOTE After installing the steering shaft nut install a new cotter pin into the steering shaft Apply SUZUKI SUPER GREASE A to the steering shaft holders and dust seals before remounting the steering...

Page 271: ... installing the tie rod make sure the narrow end 1 of the tie rod comes out HANDLEBARS When installing the lower handlebar holder 1 to the steering shaft the higher mating portion must face to forward Set the handlebars to match its punched mark 2 to the mat ing face of the handlebar clamps First tighten the bolts 3 to the specified torque and then tighten the bolts 4 Handlebar clamp bolt 23 N m 2...

Page 272: ...ntil the toe in is within the specified range A B Toe in Toe in Standard 7 4 mm 0 28 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 by measuring distances A and B If the toe in is not within specification repeat th...

Page 273: ...STEERING REASSEMBLING INFORMATION ITEM N m kgf m lb ft 1 23 2 3 16 5 2 23 2 3 16 5 3 49 4 9 35 5 4 29 2 9 21 0 5 60 6 0 43 5 6 55 5 5 40 0 ITEM N m kgf m lb ft 7 60 6 0 43 5 8 65 6 5 47 0 9 50 5 0 36 0 0 50 5 0 36 0 A 110 11 0 79 5 B 23 2 3 16 5 Washer Washer ...

Page 274: ...e based or petroleum based brake fluids Do not use any brake fluid taken from old used or unsealed containers Never reuse brake fluid left over from the last servicing or which has been stored for a long periods of time When storing brake fluid seal the container completely and keep it away from children When replenishing brake fluid take care not to get dust into the fluid When washing brake comp...

Page 275: ...val Tighten the brake caliper mounting bolts 1 to the specified torque Brake caliper mounting bolts 32 N m 3 2 kgf m 23 0 lb ft NOTE After replacing the brake pads pump the brake lever a few times to check for proper brake operation and then check the brake fluid level Do not operate the brake lever during or after brake pad removal Replace the brake pads as a set otherwise braking performance wil...

Page 276: ...disconnect the clear hose Fill the reservoir with new brake fluid to the upper end of the inspection window BRAKE CALIPER REMOVAL AND DISASSEMBLY Remove the right rear wheel 7 11 Disconnect the brake hose from the brake caliper by remov ing the brake hose union bolt 1 and allow the brake fluid to drain into a suitable receptacle Remove the brake caliper by removing the brake caliper mounting bolts...

Page 277: ... Place a rag over the brake caliper pistons to prevent them from popping out and then force out the pistons using com pressed air Remove the dust seal and piston seal Do not use high pressure air to prevent brake caliper piston damage Do not reuse the dust seal and piston seal to prevent fluid leakage ...

Page 278: ...per with a new one BRAKE CALIPER PISTON INSULATOR Inspect the brake caliper piston and insulator for any scratches or other damage If any damages are found replace the piston insulator with a new one RUBBER PARTS Replace the removed rubber parts with new ones CALIPER HOLDER Inspect the caliper holder for damage If any damages are found replace the caliper holder with new ones ...

Page 279: ...piston seal 1 and dust seal 2 as shown BRAKE CALIPER HOLDER Apply SUZUKI SILICON GREASE to the pin 99000 25100 SUZUKI SILICON GREASE Wash the brake caliper components with new brake fluid before reassembly Do not wipe the brake fluid off with a rag after wash ing the components When washing the components use the specified brake fluid Never use different types of fluid or cleaning solvents such as...

Page 280: ...e routing 9 21 Brake caliper mounting bolt 32 N m 3 2 kgf m 23 0 lb ft Brake hose union bolt 23 N m 2 3 kgf m 16 5 lb ft NOTE Before remounting the brake caliper push the brake caliper pis ton all the way into the caliper The seal washers should be replaced by the new ones to prevent fluid leakage Bleed air from the brake system after reassembling the master cylinder 2 16 Brake fluid if it leaks w...

Page 281: ...ol if necessary 09924 21940 Wheel hub remover 09930 30104 Sliding hammer Remove the brake disc BRAKE DISC INSPECTION Remove the right rear wheel 7 11 Inspect the brake disc for cracks or damage and measure the thickness using the micrometer If any damages are found or if the thickness is less than the service limit replace the brake disc with a new one 09900 20205 Micrometer 0 25 mm Brake disc thi...

Page 282: ...e 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others 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 kgf m 16 5 lb ft NOTE Stamped mark A on the brake disc must face outside Install the spring washer 1 as its convex side B faces to the rear hub nut Tighten the rea...

Page 283: ...linder mounting bolts 2 Disconnect the reservoir hose 3 Loosen the locknut 4 Remove the master cylinder assembly by turning the master cylinder rod 5 Remove the connector 6 and O ring by removing the snap ring 7 Remove the boot 8 and snap ring 9 Remove the push rod 0 Immediately wipe off any brake fluid contacting any part of the vehicle The brake fluid reacts chemically with paint plastics rubber...

Page 284: ...DER INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or damage If any damages are found replace the master cylinder with a new one PISTON AND RUBBER PARTS Inspect the piston surface primary cup secondary cup and boot for any scratches wear or damage If any damages are found replace them with new ones ...

Page 285: ...ing 3 to the master cylinder Install the master cylinder Tighten the locknut 4 Rear master cylinder rod locknut 18 N m 1 8 kgf m 13 0 lb ft Wash the master cylinder components with new brake fluid before reassembly Do not wipe the brake fluid off with a rag after wash ing the components When washing the components use the specified brake fluid Never use different types of fluid or cleaning solvent...

Page 286: ...routing 9 21 Tighten the brake hose union bolt 8 to the specified torque Rear master cylinder mounting bolt 10 N m 1 0 kgf m 7 3 lb ft Brake hose union bolt 23 N m 2 3 kgf m 16 5 lb ft Adjust the brake pedal height and rear brake lever 2 15 The seal washers should be replaced by the new ones to prevent fluid leakage Bleed air from the brake system after reassembling the master cylinder 2 17 ...

Page 287: ...5 5 B 60 6 0 43 5 C 100 10 0 72 5 D 100 10 0 72 5 E 9 5 0 95 7 0 1Rear shock absorber 2Swingarm 3Spacer 4Dust seal 5Bearing ARear shock absorber mounting upper nut BRear shock absorber mounting lower nut CSwingarm pivot locknut DSwingarm pivot bolt LH ESwingarm pivot bolt RH ...

Page 288: ...e hose from the clamp and guide Disconnect the parking cable from the swingarm by removing the clip 1 Remove the rear shock absorbers left and right Loosen the swingarm pivot bolt locknut 2 with the special tool 09940 14970 Swingarm pivot adjust wrench Remove the swingarm pivot bolt 3 RH with the special tool 09900 18710 Hexagon socket 12 mm Remove the swingarm pivot bolt 4 LH Remove the rear swin...

Page 289: ... Remove the dust seals with the special tool Remove the swingarm bearings Inspect the swingarm bearing 1 outer race 2 and bearing plate 3 if any damages are found replace the swingarm bearing with a new one 09913 50121 Oil seal remover Remove the swingarm bearing race and bearing plate by using the special tool 09913 70210 Bearing installer set The removed bearing and dust seal must be replaced wi...

Page 290: ...and disassembly Pay attention to the following points SWINGARM Install the swingarm bearing race and its plate to the swing arm by using the special tool 09913 70210 Bearing installer set NOTE When installing the bearing plate make sure that the bulge of bearing plate faces inside Apply SUZUKI SUPER GREASE A to the swingarm bear ings and lips of dust seals then install them into the swingarm with ...

Page 291: ... NOTE After remounting the swingarm inspect the swingarm whether it moves smoothly Install the rear shock absorbers left and right Tighten the rear shock absorber mounting bolts nuts Rear shock absorber mounting nut upper 35 N m 3 5 kgf m 25 5 lb ft Rear shock absorber mounting bolt nut lower 60 N m 6 0 kgf m 43 5 lb ft NOTE When tightening the rear shock absorber mounting bolt nut place 75 kg 165...

Page 292: ...f m lb ft A 55 5 5 40 0 B 60 6 0 43 5 1Dust seal 2Snap ring 3Bearing 4Rear axle housing RH 5O ring 6Rear axle housing LH 7Rear axle RH 8Rear axle LH 9Rear drive gear case cover 0Trailer towing ARear axle housing bolt BRear axle housing mounting nut ...

Page 293: ...trailer towing 3 Remove the swingarm bracket bolts and nuts 4 Remove the rear axle 5 and rear axle housing 6 Remove the O ring 7 INSPECTION AND DISASSEMBLY REAR AXLE SHAFT Inspect the rear axle shaft for distortion or damages If any dam ages are found replace the rear axle shaft with a new one REAR AXLE HOUSING Inspect the rear axle housing for distortion or damages If any damages are found replac...

Page 294: ...r HUB BEARING Inspect the inner race play of the hub bearing by hand while it is in the rear axle housing Rotate the inner race by hand to inspect for abnormal noise and smooth rotation If there is anything unusual replace the bearing with a new one NOTE Make sure to check each bearing in the same manner Remove the snap ring Remove the hub bearings using the special tool 09921 20240 Bearing remove...

Page 295: ...gs and dust seal with the special tool 09913 70210 Bearing installer set NOTE When installing the hub bearings to the axle housing the sealed cover of inner bearing 1 must face inside and the sealed cover of outer bearing 2 must face outside Apply SUZUKI SUPER GREASE A to the rear axle shaft spline 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others NOTE Overall length o...

Page 296: ...tall the trailer towing 5 and tighten the rear axle housing bolts 4 to the specified torque 99000 32030 THREAD LOCK SUPER 1303 Rear axle housing bolt 55 N m 5 5 kgf m 40 0 lb ft Tighten the axle housing mounting bolts nuts 6 to the speci fied torque Axle housing mounting bolts nuts 60 N m 6 0 kgf m 43 5 lb ft Tighten the final drive gear case cover bolts 7 ...

Page 297: ...AR SWIN GARM AND REAR AXLE SHAFT REASSEMBLING INFORMATION ITEM N m kgf m lb ft 1 100 10 72 5 2 9 5 0 95 7 0 3 100 10 72 5 4 35 3 5 25 5 5 60 6 0 43 5 6 50 5 0 36 0 ITEM N m kgf m lb ft 7 110 11 79 5 8 32 3 2 23 0 9 23 2 3 16 5 0 60 6 0 43 5 A 55 5 5 40 0 ...

Page 298: ...FT LEVER CONSTRUCTION 29 N m 2 9 kgf m 21 0 lb ft 2 0 N m 0 2 kgf m 1 5 lb ft 29 N m 2 9 kgf m 21 0 lb ft Boot Upper cover Lower cover Knob Button Gearshift lever assy Reverse gear cable Bracket Cable stopper Parking cable ...

Page 299: ...ve the E ring and disconnect the reverse gear cable 3 from the reverse arm 4 Disconnect the parking cable 5 from the parking arm 6 Remove the screw Loosen the mounting bolts Remove the upper 7 and lower cover 8 Do not apply lateral force to the cable end Excessive bending of cable may result in damage of flexible joint of cable ...

Page 300: ... interlock cable 0 Remove the gearshift lever assembly INSPECTION GEARSHIFT LEVER ASSEMBLY Inspect the gearshift lever assembly for wear or damage If any damage are found replace the gear shift lever assembly NOTE Do not disassemble the gearshift lever assembly ...

Page 301: ...oot B is fitted securely Install the gearshift covers to the gearshift lever assembly Fit the parking switch read wire s grommet 1 and parking interlock cable s dust cover 2 to the gearshift upper covers 3 Fit the gearshift covers to the dust seal 4 on the gearshift arm pivot Install the lower cover 5 Install the gearshift lever assembly to the frame bracket Apply THREAD LOCK SUPER 1303 to the gea...

Page 302: ...d 1 so that the rod length A would be 23 mm 0 9 in as shown in the illustration NOTE The slant on the shift lever rod must be faced to the right side of the vehicle Install the shift knob to the gearshift lever with the button depressed 99000 32030 THREAD LOCK SUPER 1303 Tighten the screws to the specified torque Gearshift lever screw 2 0 N m 0 2 kgf m 1 5 lb ft Left Right ...

Page 303: ...ard 7 5 to 8 Disconnect the reverse gear cable 1 from the reverse arm 2 by removing the E ring and clip Remove the reverse switch 3 and clip Remove the reverse gear cable 1 with the reverse gear arm Release the cable adjuster lock 7 83 Install the busing 4 to the reverse gear arm 5 Connect the reverse gear arm 5 to the reverse gear cable 6 Install the reverse gear cable 6 and clips 7 to the stoppe...

Page 304: ...Adjust the cable play 7 83 PARKING CABLE Before removing the parking cable keep the gearshift lever in the P position Remove the tank covers left inner fender and left mud guard 7 5 to 8 Disconnect the parking cable 1 from the parking arm 2 Make sure the installation angle of the reverse gear arm is accurate Do not apply lateral force to the cable end Excessive bending of cable may result in damag...

Page 305: ...e adjuster lock 7 83 Connect the parking cam arm 3 to the parking cable 4 Align the punched mark A on the parking cam arm 3 with the punched mark B on the parking cam shaft Install the parking cable 4 and clip 5 to the stopper 6 on the swingarm Make sure that the parking cam arm is in P position Make sure that the installation angle of the parking lever is accurate P P ...

Page 306: ...e 4 through the guides Install the clip 5 Install the parking cable 4 to the parking arm 2 Adjust the cable play 7 83 Do not apply lateral force to the cable end Excessive bending of cable may result in damage of flexible joint of cable ...

Page 307: ...just the rear brake pedal height and rear brake lever play properly 2 15 Shift the shift lever into D Loosen the locknuts 1 Tighten the locknuts 1 with pulling the parking inter lock cable 2 lightly Make sure that the shift lever could be shifted into P when the rear brake pedal is depressed approx 20 mm 0 78 in ...

Page 308: ... piece 2 to an extent where the adjuster 3 slides smoothly NOTE Do not remove the lock piece 2 from the cable adjuster Fit the cable adjuster 4 onto the selection arm 5 securely NOTE Before fitting the cable adjuster make sure that the gear shift lever position is same as the selection lever arm position Push the lock piece 6 into the cable adjuster Slide the lock cover 7 ...

Page 309: ...R MOTOR REMOVAL AND DISASSEMBLY 8 12 STARTER MOTOR INSPECTION 8 13 STARTER MOTOR REASSEMBLY AND REMOUNTING 8 14 STARTER RELAY INSPECTION 8 15 NEUTRAL RELAY INSPECTION 8 16 PARKING BRAKE SWITCH 8 16 IGNITION SYSTEM 8 17 TROUBLESHOOTING 8 17 INSPECTION 8 19 2WD 4WD SELECTING SYSTEM 8 21 DESCRIPTION 8 21 TROUBLESHOOTING 8 22 INSPECTION 8 23 SPEEDOMETER 8 25 PARTS NAMES 8 25 OPERATING PROCEDURE 8 26 I...

Page 310: ...or bends Inspect each terminal for corrosion and contamination CLAMPS Refer to the WIRE HARNESS ROUTING section for proper clamping procedures 9 12 to 9 13 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 substitutes for the band type clamp FUSES When a fuse blows always investigate the cause correct the problem...

Page 311: ...sconnect the battery lead wire first When connecting the battery lead wires be sure to connect the battery lead wire first If the terminal is corroded remove the battery pour warm water over it and clean it with a wire brush After connecting the battery apply a light coat of grease to the battery terminals Install the cover over the battery terminal WIRING PROCEDURE Properly route the wire harness...

Page 312: ...ION OF ELECTRICAL COMPONENTS Battery Main fuse Starter relay Fuse box Neutral relay Parking brake switch Handlebar switch L Front brake switch 2WD 4WD selection button Ignition switch Power source Rear brake switch Ignition coil ...

Page 313: ... fan thermo switch 6 9 Parking position switch Starter motor Regulator rectifier 2WD 4WD selecting relay 2WD 4WD motor 4WD switch 2WD switch Engine coolant temp switch 6 10 Generator Speed sensor CDI unit Neutral switch Reverse switch Gear switch ...

Page 314: ...ued on next page Remove accessories Short circuit of wire harness Faulty electrical equipment Faulty battery Abnormal driving condition Battery runs down quickly Check accessories which use excessive amounts of electricity Check the battery for current leaks 8 8 Measure the charging voltage between the battery terminals 8 8 Correct Current leaks Accessories are installed ...

Page 315: ...8 9 Measure the generator no load voltage 8 9 Continuity Correct Inspect the regulator rectifier 8 10 Correct Inspect the wires Correct Incorrect No continuity Incorrect Incorrect Short circuit of wire harness Poor contact of coupler Faulty battery Battery overcharges Faulty regulator rectifier Faulty battery Poor contact of generator lead wire coupler Others ...

Page 316: ...king each part REGULATED VOLTAGE Remove the seat 7 4 Start the engine turn the ignition switch to AUX and the dimmer switch to HI and run the engine at 5 000 r min Measure the DC voltage between the and battery termi nals using the multi circuit tester If the voltage is not within the specified value inspect the generator and regulator rectifier 8 9 and 8 10 NOTE When making this test be sure that...

Page 317: ...ce Ω Ω Ω Ω Generator coil resistance 0 1 1 5 Ω Ω Ω Ω Black Black Ω Ω Ω Ω Black Ground GENERATOR NO LOAD PERFORMANCE Remove the fuel tank cover 7 5 Disconnect the generator lead wire coupler Start the engine and run it at 5 000 r min Measure the AC voltage between the lead wires of the generator using the multi circuit tester If the voltage is under the specified value replace the AC gener ator wit...

Page 318: ... not within the specified value replace the regu lator rectifier with a new one 09900 25008 Multi circuit tester set Tester knob indication Diode test More than 1 4 V tester s battery voltage NOTE If the tester reads under 1 4 V when the tester probes are not connected replace the battery of multi circuit tester Unit V Tester probe Tester probe A B C D E F A 0 4 0 7 0 3 0 6 0 3 0 6 0 3 0 6 B C D 0...

Page 319: ...r relay when the starter button is pushed Check if the starter motor runs when its terminal is connected to the battery terminal Do not use a thin wire because a large amount of current flows Measure the starter relay voltage at the starter relay connectors between Y B and B W when the starter button is pushed No click Clicks Runs Voltage No voltage Faulty starter relay Loose or disconnected start...

Page 320: ...er starter relay contact Check the starter relay 8 15 Incorrect The starter motor runs when the transfer gear position is in neutral but does not run when the transfer gear position is in any position other than neutral with the parking brake lever grasp firmly Open circuit in wire harness Poor contact of connector Engine does not turn though the starter motor runs Faulty starter clutch Check the ...

Page 321: ...olish it with 400 sand paper and wipe it using a clean dry cloth If there is no undercut scrape out the insulator 1 with a saw blade ARMATURE COIL INSPECTION Check for continuity between each segment and between each segment and the armature shaft using the multi circuit tester If there is no continuity between the segments or there is conti nuity between the segments and shaft replace the armatur...

Page 322: ...I SUPER GREASE A to the lip of the oil seal 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Apply a small quantity of SUZUKI MOLY PASTE to the arma ture shaft 99000 25140 SUZUKI MOLY PASTE Align the match marks on the starter motor case with the match mark on the housing end Apply a small quantity of THREAD LOCK 1342 to the starter motor housing bolts and tighten it ...

Page 323: ...y cover 1 Disconnect the starter motor lead wire battery lead wire and starter relay coupler at the starter relay Remove the starter relay Apply 12 V to the terminals and check for continuity between the positive and negative terminals using the multi circuit tester If the starter relay clicks and continuity is found the relay is ok 09900 25008 Multi circuit tester set Tester knob indication Conti...

Page 324: ...r knob indication Resistance Ω Ω Ω Ω Starter relay resistance Standard 3 5 Ω Ω Ω Ω NEUTRAL RELAY INSPECTION Remove the seat 7 4 Disconnect the neutral relay Apply 12 V to terminals 1 and 2 to 1 and to 2 and check the continuity between 3 and 4 using a multi circuit tester If there is no continuity found replace the neutral relay with a new one 09900 25008 Multi circuit tester set Tester knob indic...

Page 325: ...xt page Improper coupler connection Faulty ignition switch Faulty engine stop switch Broken wire harness or poor connection of related circuit couplers No spark or poor spark Check ignition system couplers for poor connections Measure the battery voltage between input lead wires O W and B W at the CDI unit with the ignition switch in the ON position Inorrect Looseness Make sure the transfer is in ...

Page 326: ...adaptor Inspect the ignition coil 8 20 Measure the pickup coil and power source coil resistance 8 20 Inspect the spark plug 2 7 Faulty spark plug Improper spark plug connection Faulty pickup coil Faulty power source coil Faulty ignition coil Faulty CDI unit Open circuit in wiring harness Improper ignition coupler connection Correct Correct Incorrect Incorrect Incorrect Correct Incorrect Correct ...

Page 327: ...rimary wire 09900 25008 Multi circuit tester set Shift the transfer to the neutral position and turn the ignition switch to the ON position Press the starter button and allow the engine to crank for a few seconds and then measure the ignition coil primary peak voltage Repeat the above procedure a few times and measure the highest ignition coil primary peak voltage Tester knob indication Voltage Ig...

Page 328: ...ircuit tester set Tester knob indication Resistance Ω Ω Ω Ω Ignition coil resistance Primary 0 1 1 5 Ω Ω Ω Ω Terminal Ground Secondary 12 22 kΩ Ω Ω Ω Spark plug cap Terminal PICKUP COIL AND POWER SOURCE COIL RESISTANCE Remove the fuel tank cover 7 5 Disconnect the generator coupler 1 Measure the resistance between the lead wires using the multi circuit tester If the resistance is not within the sp...

Page 329: ...itch turns OFF from ON while the 2WD switch turns ON from OFF Therefore current A is interrupted and the contact point 1 returns to OFF state Now the motor stops operating TO SHIFT FROM 4 WHEEL DRIVE TO 2 WHEEL DRIVE Depress the 2WD 4WD selecting button Current A flows and the contact point 1 closes causing the motor to turn reversely as opposite to the phase of 2WD 4WD The rack as shown moves in ...

Page 330: ...rcuit in wire harness Incorrect Faulty 2WD 4WD selecting relay Incorrect Check the 2WD 4WD selecting button 8 33 Check the 2WD 4WD selecting relay 8 23 to 8 24 Check the 2WD switch or 4WD switch 8 24 Faulty 2WD switch or 4WD switch Incorrect Correct Correct The 2WD 4WD motor runs but does not shift to 2WD 4WD Check the front differential sliding dog 4 7 Turn on the ignition switch Listen for a cli...

Page 331: ... 2 Connect the 12 V battery to the 2WD 4WD motor lead wires as shown If the motor does not run replace the motor assembly with a new one Install the 2WD 4WD motor and tighten the bolts to the speci fied torque 4 15 2WD 4WD SELECTING BUTTON 8 33 2WD 4WD SELECTING RELAY Remove the left inner fender 7 7 Remove the 2WD 4WD selecting relay 12 V 12 V ...

Page 332: ...d C If there is no continuity replace the 2WD 4WD selecting relay with a new one 2WD SWITCH AND 4WD SWITCH Remove the 2WD 4WD motor 8 23 Disconnect the switch couplers 1 2 Remove the 2WD switch 3 and 4WD switch 4 Measure 2WD switch and 4WD switch for continuity using a multi circuit tester If there is no continuity replace the 2WD switch and 4WD switch with a new one 09900 25008 Multi circuit test...

Page 333: ...AMES Parking indicator light Reverse indicator light Neutral indicator light High beam indicator light Engine coolant temperature indicator light Gear position Speedometer Clock hour Odometer tripmeter A B ODO TRIP button Clock Hour button LOW ...

Page 334: ... odometer tripmeter A and tripmeter B as shown Hold down the CLOCK HOUR button over two seconds while pressing the ODO TRIP button the display changes between mph and km h when displaying odometer as shown With each press of the CLOCK HOUR button the dis play changes between clock and hour as shown 1 ODOMETER Displays the total distance travelled TRIPMETER Displays the distance travelled since the...

Page 335: ...r Position Indicator The gear position indicator indicates shift lever positions P R N 1 2 3 4 5 P Shift lever is in parking position The parking indicator also comes on R Shift lever is in reverse position The reverse indicator also comes on N Shift lever is in neutral position The neutral indicator also comes on 1 to 5 Numeral indicates gear position Transfer Position Indicator LOW Shift lever i...

Page 336: ...eter with a new one ITEM Battery Battery ITEM Battery Battery LCD Gear position 4WD Speed Odometer Clock A D M 3 3rd gear position LCD A D M Q Meter illumination J M 4 4th gear position LCD A D M S P Parking LCD and indicator light A D I M P 5 5th gear position LCD A D M R N Neutral LCD and indicator light A D M P High beam indicator light C M R Reverse LCD and indicator light A D L M Engine coola...

Page 337: ...es the tester read ing voltage relatively changes 0 V 12 V or 12 V 0 V If the tester reading voltage does not change replace the speed sen sor with a new one NOTE The highest tester reading voltage 12 V while testing is same as the total voltage of four batteries Apply SUZUKI SUPER GREASE A to the speed sensor O ring before installing it 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUP...

Page 338: ... Remove the socket Remove the bulb Install the new bulb in the reverse order of removal Headlight bulb 12 V 30 30 W Right Left Auxiliary light 12 V 40 W 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 Install the socket cover correctly ...

Page 339: ...XILIARY LIGHT BULB REPLACEMENT Remove the auxiliary light cover 1 Remove the auxiliary light 2 Remove the socket 3 with lead wire Disconnect the lead wire coupler 4 Install the new bulb assembly in the reverse order of removal ...

Page 340: ... Install the new bulb in the reverse order of removal Install the brake light taillight assembly Brake light taillight 12 V 21 5 W 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 Be sure to fix the boss of connector correctly as shown Boss of connector Boss of connector ...

Page 341: ...T TEMPERATURE SWITCH Color Position R O Gr P Color Position Y W Gr Color Position O O W Color Position O W Y G Color Position O W B ON OFF Color Position Terminal Terminal ON OFF OFF ON Color Position Bl O Y 2WD 4WD Color Position O B Bl Color Position W Bl ON OFF Color Position G B W WIRE COLOR B Black Bl Blue G Green Gr Gray O Orange P Pink R Red W White Y Yellow B W Black with White tracer Br R...

Page 342: ...e reverse switch coupler 1 Measure reverse switch for continuity using a multi circuit tester If there is no continuity replace the reverse switch with a new one 09900 25008 Multi circuit tester set GEAR SWITCH Disconnect the gear switch coupler 1 Measure gear switch for continuity using a multi circuit tester If there is no continuity replace the gear switch with a new one 09900 25008 Multi circu...

Page 343: ...te completely use the removed caps 2 as the sealed caps of battery filler holes Do not remove or pierce the sealed areas 3 of the electrolyte container Insert the nozzles of the electrolyte container into the battery s electrolyte filler holes holding the container firmly so that it does not fall Take precaution not to allow any of the fluid to spill Make sure air bubbles are coming up each electr...

Page 344: ...hat the top of the caps do not protrude above the upper surface of the battery s top cover For initial charging use the charger specially designed for MF battery Never use anything except the specified battery Once install the caps to the battery do not remove the caps Do not tap the caps with a hammer when installing them INCORRECT CORRECT For charging the battery make sure to use the charger spe...

Page 345: ...10 hours or 7 A for 1 hour After recharging wait at least 30 minutes and then measure the battery voltage using the multi circuit tester If the battery voltage is less than 12 5 V recharge the battery again If the battery voltage is still less than 12 5 V after recharging replace the bat tery with a new one When a battery is left unused for a long time its voltage needs to be regularly measured Wh...

Page 346: ...GRAM 9 11 WIRING HARNESS CABLE AND HOSE ROUTING 9 12 WIRING HARNESS ROUTING 9 12 CABLE ROUTING 9 15 CARBURETOR HOSE ROUTING 9 16 COOLING SYSTEM HOSE ROUTING 9 18 FRONT DRIVING SYSTEM 9 19 FRONT BRAKE HOSE ROUTING 9 20 REAR BRAKE HOSE ROUTING 9 21 OIL RETURN TANK HOSE ROUTING 9 22 SPECIAL TOOLS 9 23 TIGHTENING TORQUE 9 26 ENGINE 9 26 DIFFERENTIAL 9 27 CHASSIS 9 27 TIGHTENING TORQUE CHART 9 28 SERVI...

Page 347: ... generator 6 Defective CDI unit No fuel reaching the carburetor 1 Clogged fuel tank vent hose 2 Clogged or defective fuel valve 3 Defective carburetor needle valve 4 Clogged fuel hose 5 Clogged fuel filter Replace Replace Repair or replace Tighten See electrical section Adjust Adjust Clean or replace Clean and dry or replace Replace Replace Replace Replace Clean or replace Clean or replace Replace...

Page 348: ...om transmission 1 Gears worn or rubbing 2 Badly worn splines 3 Primary gears worn or rubbing 4 Badly worn bearings 5 Worn bushing Noise seems to come from the transfer 1 Worn or rubbing gear 2 Worn transfer input output shaft 3 Worn bearing 4 Worn bushing Noise seems to come from front rear output shaft bevel gear front drive differential bevel gear and rear drive bevel gear 1 Worn or damage drive...

Page 349: ...shaft 2 Distorted or worn gearshift forks 3 Weakened cam stopper spring on gearshift cam 4 Worn gearshift lever stopper pin Replace Replace Replace Replace Transfer will not shift or shift back 1 Broken or worn sliding dog 2 Broken or worn gearshift fork 3 Worn gearshift cam 4 Weakened cam stopper spring 5 Worn gearshift fork shaft Replace Replace Replace Replace Replace Engine idles poorly 1 Valv...

Page 350: ... plug 8 Incorrect spark plug gap 9 Clogged carburetor jet 10 Incorrect float chamber fuel level 11 Dirty air cleaner element 12 Worn rocker arm or shaft 13 Air leakage from intake pipe 14 Excessive amount of engine oil Adjust Replace Adjust Replace Replace Repair Clean or replace Adjust or replace Clean Adjust float height Clean or replace Replace Tighten or replace Check level and drain Engine ov...

Page 351: ...epair or replace Replace Replace Replace Complaint Symptom and possible causes Remedy Starting difficulty 1 Clogged starter jet 2 Clogged starter jet passage 3 Air leaking from joint between starter body and carbure tor 4 Improperly working starter enricher plunger Clean Clean Tighten adjust or replace gas ket Adjust Idling or low speed trouble 1 Clogged or loose slow jet 2 Clogged pilot jet passa...

Page 352: ...onnections 3 Loose suspension system bolts Regulate Replace Tighten Tires rapidly or unevenly wear 1 Worn or loose front wheel hub bearings 2 Improper front wheel alignment Replace Adjust Steering too noisy 1 Loose nuts and bolts 2 Damaged or worn front wheel hub bearings 3 Insufficiently lubricated Tighten Replace Lubricate Suspension too soft 1 Weakened spring 2 Shock absorber leaks oil 3 Improp...

Page 353: ...ce Replace brake fluid Disassemble and clean master cylinder Clean and lubricate Excessive brake lever stroke 1 Air in hydraulic system 2 Insufficient brake fluid 3 Improper quality of brake fluid Bleed Replenish fluid to specified level and bleed air Replace with correct fluid Brake fluid leakage 1 Insufficient tightening of connection joints 2 Cracked hose 3 Worn piston and or cup Tighten to spe...

Page 354: ...ose lead connections 2 Shorted grounded or open generator coil 3 Shorted or punctured regulator rectifier Repair replace or connect properly Replace Replace Generator charges but charging rate is below specification 1 Lead wires tend to get shorted open circuited or loosely connected at terminal 2 Grounded or open circuited stator coils or generator 3 Defective regulator rectifier Repair or tighte...

Page 355: ...tor rectifier circuit connec tions and make necessary adjustments to obtain specified charging operation Replace the battery and cor rect the charging system Replace Replace Reversed battery polarity 1 Improperly connected battery leads i e to and to Replace the battery and be sure to connect it properly Battery discharged too rapidly 1 Dirty container top and sides 2 Old battery Clean Replace Bat...

Page 356: ...F 12V B W B W P B P B O Y O Y W B W B B W B W P B B B W B W Bl R Bl R G R R B R B P Bl P Bl P Bl Bl W Gr Gr B Bl B Bl W G W G Lbl Lbl Y Y W Y W G R G R Br R Br R Y Bl Y Bl G Bl G Bl Bl W Bl W Bl R Bl R V R O Y O Y O B O B P B P B B R B R W Gr Gr B W B W G W G W B G B G Y W Y W Y G R G R Br R Br R Y Bl Y Bl G Bl G Bl Bl Bl O B O B P B P B B W B W Y Bl Y Bl W Bl W Bl O Bl O Bl O Y O Y O W O W Y G Y ...

Page 357: ...ness clamp to the frame To headlight RH Wiring harness Engine coolant temperature switch Clamp To headlight LH Fix the wiring harness clamp to the frame Speedometer Ignition switch Clamp Handlebar switch LH Rear brake switch Front brake switch 2WD 4WD selecting button Front brake switch 2WD 4WD selecting button Clamp 2WD 4WD selecting relay 2WD 4WD motor 2WD 4WD switch coupler Clamp Handlebar swit...

Page 358: ...ad wire and set them to the groove of the rear fender Neutral switch Reverse switch Regulator rectifier Pass the wiring harness behind the regulator rectifier CDI unit Rear brake switch Clamp Wiring harness Brake light taillight Speed sensor Speed sensor Gear selection switch Gear selection switch Clamp Reverse switch Neutral switch Generator Clamp Wiring harness ...

Page 359: ...N m 0 5 kgf m 3 7 lb ft 6 N m 0 6 kgf m 4 3 lb ft 10 N m 1 0 kgf m 7 0 lb ft Ground wire Starter motor lead wire Clamp Generator lead wire 10 N m 1 0 kgf m 7 0 lb ft Transfer cover Engine coolant temperature switch 10 N m 1 0 kgf m 7 0 lb ft Generator rotor 4 N m 0 4 kgf m 3 0 lb ft Transfer cover Reverse cable braket 160 N m 16 0 kgf m 115 5 lb ft ...

Page 360: ... of the rear brake cable Cable guide Throttle cable Rear brake cable Clamp Front brake switch 2WD 4WD selecting button Throttle cable Starter cable Cable guide Pass the parking cable over the reverse shaft Parking cable Parking cable Parking interlock cable Pass the parking interlock cable over the engine mounting bracket Clamp the parking interlock cable at the protecter A DETAIL A Reverse cable ...

Page 361: ... SERVICING INFORMATION CARBURETOR HOSE ROUTING Insert the air vent hose into the fuel tank cover Air vent hose Carburetor Face the clamp screw head left side Face the clamp screw head up ward Air vent hose ...

Page 362: ...hose Fuel tank Steering shaft Radiator Clamp the breather hose No 2 at 20 mm 0 8 in from hose end 20mm 0 8 in Radiator Steering shaft Connect the breather hose No 2 to the fuel tank top cover Fuel tank Breather hose No 1 Fuel hose Breather hose No 2 Breather hose No 2 Brake hose ...

Page 363: ...Wiring harness 40 mm 1 6 in Wiring harness Downward Backward Downward Brake hose Marking Marking Face the clip end downward Radiator cap Left side Upward Radiator Reservoir tank Forward Upward Downward Fuel tank breather hose No 2 The ends of the clamp should face Cooling fan breather hose 2 0 N m 0 2 kgf m 1 5 lb ft 2 0 N m 0 2 kgf m 1 5 lb ft ...

Page 364: ...diator outlet hose 40 50 mm 1 6 2 0 in Frame 4WD switch harness 2WD 4WD motor harness 2WD switch harness Clamp 2WD 4WD switch harness 2WD 4WD motor harness Pass the motor harness between motor and yoke Clamp Radiator outlet hose Frame 2WD 4WD switch harness 2WD 4WD motor harness ...

Page 365: ...ke caliper L Brake hose Brake caliper R A VIEW A DETAIL B VIEW D VIEW C Face the white mark on the brake hose to the forward Hose guide After touching the brake hose union to the stopper tighten the union bolt to the specified torque Stopper Stopper Front brake caliper R Front brake caliper L Brake hose Clamp Clamp D Brake hose Radiator outlet hose Pass the brake hose above the radiator outlet hos...

Page 366: ... Face the tip of clip to the bottom A Fix the brake hose with the hose guide Clamp Brake hose B Face the white mark to the outside Rear brake master cylinder 35 Pass the brake hose outside of the brake cable Brake cable D C E Brake hose Brake caliper Brake hose Fix the brake hose with the clamp Fix the brake hose with the hose guide After touching the brake union to the stopper tighten the union b...

Page 367: ...TION OIL RETURN TANK HOSE ROUTING Oil return tank Breather hose To valve clearance inspection cap To air cleaner box Breather hose Engine mounting bracket VIEW A Oil return tank Marking Breather hose Marking Breather hose A ...

Page 368: ...rometer 1 100 mm 25 50 mm 09900 20204 Micrometer 1 100 mm 75 100 mm 09900 20205 Micrometer 1 1000 mm 0 25 mm 09900 20511 Cylinder gauge rod 88 mm 09900 20508 Cylinder gauge set 1 100 mm 40 80 mm 09900 20602 Dial gauge 1 1000 mm 09900 20605 Dial calipers 1 100 mm 10 34 mm 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 20803 Tickness gauge 09900 20805 Tire depth gauge 09900 21203 S...

Page 369: ...911 Valve lapper set 09916 14510 Valve lifter 09916 14910 Valve lifter attach ment 09916 21111 09916 24900 Valve seat cutter set 09916 24311 Solid pilot N 100 5 0 09916 22410 Solid pilot N 140 5 0 09916 24935 Valve stem cutter N 608 09916 34542 Reamer handle 09916 34570 Valve guide reamer 5 0 mm 09916 34580 Valve guide reamer 10 8 mm 09916 44310 Valve guide remover installer 09916 53730 Valve guid...

Page 370: ... set 09921 21910 Bearing holder 09923 74510 Bearing remover 09924 21940 Wheel hub remover 09924 41830 Bearing locknut wernch 09924 84510 Bearing installer set 09924 84521 Bearing installer set 09930 10121 Spark plug wrench set 09930 30104 Sliding hammer 09930 30190 Rotor remover attachment 09930 30721 Rotor remover 09930 40113 Rotor holder 09930 44541 Rotor holder 09930 73150 Output shaft holder 0...

Page 371: ...m 11 1 1 8 0 8 mm 22 2 2 16 0 Neutral switch bolt 6 5 0 65 4 5 T D C plug 23 2 3 16 5 Clutch shoe nut 130 13 0 94 0 Generator rotor nut 160 16 0 115 5 Starter clutch bolt 26 2 6 19 0 Oil pump drive gear bolt 80 8 0 58 0 Gearshift cam stopper 10 1 0 7 0 Exhaust pipe nut 23 2 3 16 5 Muffler mounting bolt 23 2 3 16 5 Muffler connecting bolt 23 2 3 16 5 Engine oil drain plug 23 2 3 16 5 Drive driven b...

Page 372: ...36 0 Tie rod end nut 60 6 0 43 5 Tie rod locknut 29 2 9 21 0 Front shock absorber mounting bolt upper 55 5 5 40 0 Front shock absorber mounting nut lower 60 6 0 43 5 Wishbone arm pivot nut 65 6 5 47 0 Hub nut front and rear 110 11 0 79 5 Wheel set nut front and rear 50 5 0 36 0 Brake master cylinder mounting bolt front and rear 10 1 0 7 0 Brake hose union bolt 23 2 3 16 5 Front brake pipe nut 16 1...

Page 373: ...al or 4 marked bolt 7 marked bolt 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 A ...

Page 374: ...2 0 0024 Valve stem deflection IN EX 0 35 0 014 Valve guide I D IN EX 5 000 5 012 0 1969 0 1973 Valve stem O D IN 4 975 4 990 0 1959 0 1965 EX 4 955 4 970 0 1951 0 1957 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve stem end length IN EX 1 7 0 07 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 38 8 1 ...

Page 375: ... EX 12 000 12 018 0 4724 0 4731 Rocker arm shaft O D IN EX 11 973 11 984 0 4714 0 4718 Cylinder head distortion 0 05 0 002 Cylinder head cover distortion 0 05 0 002 ITEM STANDARD LIMIT Compression pressure Automatic decomp actuated Approx 1 000 kPa 10 0 kgf cm2 142 psi 800 kPa 8 0 kgf cm2 114 psi Piston to cylinder clearance 0 030 0 040 0 0012 0 0016 Cylinder bore 87 500 87 515 3 4449 3 4455 Nicks...

Page 376: ...big end side clearance 0 10 0 65 0 004 0 026 1 0 0 039 Conrod big end width 24 95 25 00 0 982 0 984 Crank web to web width 70 9 71 1 2 791 2 799 Crankshaft runout 0 08 0 003 ITEM STANDARD LIMIT Oil pressure at 60 C 140 F Above 120 kPa 1 2 kgf cm2 17 0 psi Below 160 kPa 1 6 kgf cm2 23 0 psi at 3 000 r min ITEM STANDARD LIMIT Clutch release screw 1 4 2 4 turn back Drive plate thickness 2 92 3 08 0 1...

Page 377: ...groove clearance 0 10 0 30 0 004 0 012 0 5 0 020 Reverse fork to groove clearance 0 10 0 30 0 004 0 012 0 5 0 020 Shift fork groove width No 1 No 2 5 5 5 6 0 217 0 220 Transfer 5 5 5 6 0 217 0 220 Reverse 5 0 5 1 0 197 0 201 Shift fork thickness No 1 No 2 5 3 5 4 0 209 0 213 Transfer 5 3 5 4 0 209 0 213 Reverse 4 8 4 9 0 189 0 193 ITEM STANDARD LIMIT Secondary drive bevel gear backlash 0 05 0 15 0...

Page 378: ...t height 17 0 1 0 mm 0 67 0 04 in Main jet M J 128 Jet needle J N NBAY Needle jet N J 6 Slow jet S J 35 Pilot screw P S 1 3 8 turns back PRE SET Throttle cable play 3 5 mm 0 12 0 20 in Choke cable play 0 5 1 0 mm 0 02 0 04 in ITEM SPECIFICATION NOTE Spark plug Type NGK CR6E DENSO U20ESR N Gap 0 7 0 8 0 028 0 031 Spark performance Over 8 0 3 at 1 atm Ignition coil resistance Primary 0 1 1 5 Ω Termi...

Page 379: ...gh beam indicator light LED Engine coolant temp indicator light LED ITEM STANDARD SPECIFICATION LIMIT Rear brake pedal height 5 15 0 2 0 6 Brake caliper cylinder bore Front 32 030 32 080 1 2610 1 2630 Rear 33 960 34 036 1 3346 1 34 Brake caliper piston diam Front 31 948 31 998 1 2578 1 2598 Rear 33 884 33 934 1 3340 1 3360 Brake fluid type DOT 4 Brake disc thickness Front 3 3 3 7 0 130 0 146 3 0 0...

Page 380: ...se 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 Fuel tank including reserve 19 0 L 5 0 4 2 US lmp gal reserve 4 2 L 1 1 0 9 US lmp gal Engine oil type SAE 10W 40 API SF or SG En...

Page 381: ...Prepared by August 2002 Part No 99500 44050 01E Printed in Japan 384 ...

Page 382: ...Printed in Japan K3 ...

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