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Suzuki LT-Z90K7, Service Manual

The Suzuki LT-Z90K7 Service Manual is an essential resource for owners of this popular ATV model. Packed with detailed instructions and diagrams, this comprehensive manual is available for free download at manualshive.com. Ensure optimal performance and maintenance of your Suzuki LT-Z90K7 by accessing this user-friendly and informative manual today.

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7-10     SERVICING INFORMATION

ELECTRICAL

NO SPARKING OR POOR SPARKING

SPARK PLUG SOON BECOMES FOULED WITH CARBON

SPARK PLUG BECOMES FOULED TOO SOON

SPARK PLUG ELECTRODES OVERHEAT OR BURN

GENERATOR DOES NOT CHARGE

GENERATOR DOES CHARGE, BUT CHARGING RATE IS BELOW THE SPECIFICATION

GENERATOR OVERCHARGES

Symptom, possible causes and remedy

• Defective CDI unit.
• Defective ignition coil.
• Defective spark plug.
• Defective generator coil.
• Loose connection of lead wire.
• Open-circuited wiring connections.

Replace.
Replace.
Replace.
Replace.
Connect or tighten.
Check and repair.

Symptom, possible causes and remedy

• Mixture too rich.
• Incorrect gasoline.
• Dirty air cleaner element.
• Incorrect spark plug.

Adjust carburetor.
Change.
Replace.
Replace.

Symptom, possible causes and remedy

• Worn piston rings.
• Worn piston or cylinder.
• Excessive clearance of valve stems in valve 

guides.

• Worn stem oil seal.

Replace.
Replace.
Replace.

Replace.

Symptom, possible causes and remedy

• Too hot spark plug.
• Overheated the engine.
• Loose spark plug.
• Too lean mixture.

Replace with cold type plug.
Tune up.
Retighten.
Adjust carburetor.

Symptom, possible causes and remedy

• Open- or short-circuited lead wires, or loose lead 

connections.

• Short-circuited, grounded or open generator coil.
• Short-circuited or punctured regulator/rectifier.

Repair or replace or retighten.

Replace.
Replace.

Symptom, possible causes and remedy

• Lead wires tend to get short- or open-circuited or 

loosely connected at terminals.

• Grounded or open-circuited generator coil.
• Defective regulator/rectifier.
• Defective cell plates in the battery.

Repair or retighten.

Replace.
Replace.
Replace the battery.

Symptom, possible causes and remedy

• Internal short-circuit in the battery.
• Damaged or defective regulator/rectifier.
• Poorly grounded regulator/rectifier.

Replace the battery.
Replace.
Clean and tighten ground connection.

Summary of Contents for LT-Z90K7

Page 1: ...9 9 5 0 0 4 0 0 2 0 0 1 E ...

Page 2: ... CORPORATION 2006 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 vehicle exactly in detai...

Page 3: ...ENT PARTS AND WORK TO BE DONE Under the name of each system or unit is its exploded view Work instructions and other service information such as the tightening torque lubricating points and locking agent points are provided Example Front and rear wheel 1 Handlebar upper holder 2 Handlebars 3 Handlebar lower holder 4 Steering shaft 5 Steering shaft holder 6 Dust seal 7 Steering shaft lower dust sea...

Page 4: ...sure in voltage range Apply molybdenum oil solution mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 1 Measure in resistance range Apply SUZUKI SUPER GREASE A or equivalent grease 99000 25010 Measure in current range Apply SUZUKI MOLY PASTE 99000 25140 Measure in diode test range Apply SUZUKI RESISTANCE GREASE 99000 25160 Measure in continuity test range Apply SUZUKI BOND 1215 or equiva...

Page 5: ...AUTION NOTE 1 2 GENERAL PRECAUTIONS 1 2 SUZUKI LT Z90K7 07 MODEL 1 4 SERIAL NUMBER LOCATION 1 4 FUEL AND OIL RECOMMENDATION 1 5 FUEL FOR USA AND CANADA 1 5 FUEL FOR OTHER COUNTRIES 1 5 ENGINE OIL AND FINAL REDUCTION GEAR BOX OIL FOR USA 1 5 ENGINE OIL AND FINAL REDUCTION GEAR BOX OIL FOR OTHER COUNTRIES 1 5 BREAK IN PROCEDURES 1 6 INFORMATION LABELS 1 7 SPECIFICATIONS 1 8 DIMENSIONS AND DRY MASS 1...

Page 6: ...se good judgement and basic mechanical safety principles If you are unsure about how to perform a particular service operation ask a more experienced mechanic for advice GENERAL PRECAUTIONS Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the vehicle When 2 or more persons work together pay attention to the safety of each o...

Page 7: ...ad or case bolts and nuts tighten the larger sizes first Always tighten the bolts and nuts diagonally from the inside toward outside and to the speci fied tightening torque Whenever you remove oil seals gaskets packing O rings locking washers self locking nuts cotter pins circlips and certain other parts as specified be sure to replace them with new ones Also before installing these new parts be s...

Page 8: ...ets SERIAL NUMBER LOCATION The frame serial number or V I N Vehicle Identification Number 1 is stamped on the left side of the rear frame pipe The engine serial number 2 is located on the right side of the generator case These numbers are required especially for registering the machine and ordering spare parts RIGHT SIDE LEFT SIDE ...

Page 9: ...ributor to your engine s performance and life Always select good quality engine oil Suzuki recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or equivalent engine oil Use of API SF SG or SH SJ with JASO MA Suzuki recommends the use of SAE 10W 40 engine oil If SAE 10W 40 engine oil is not available select an alternative according to the following chart ENGINE OIL AND FINAL REDUCTION GEAR BOX OIL ...

Page 10: ...ill necessary to allow the moving parts to BREAK IN before subjecting the engine to maximum stresses The future performance and reliability of the engine depends on the care and restraint exercised during its early life Refer to the following throttle position recommendations Keep to these break in throttle position Brake in engine speeds Up to 10 hours Less than 1 2 throttle ...

Page 11: ...ate 2 Compliance label 3 Manual notice Label 4 Tire information label Warning no passenger E 5 Tire information label Warning no passenger F 6 General warning and Age 12 label E 7 General warning label F 8 No passenger mark E 9 No passenger mark E F 0 AGE 12 label F A EC mark label B ICES Canada label C Information label D Approval label ...

Page 12: ... Dry mass 115 kg 253 5 lbs 121 kg 266 8 lbs ENGINE Type Four stroke air cooled OHC Number of cylinders 1 Bore 45 5 mm 1 8 in Stroke 55 2 mm 2 2 in Displacement 90 cm 5 5 cu in Compression ratio 9 5 1 Carburetor MIKUNI VM16 single Air cleaner Polyurethane foam element Starter system Electric and recoil starter Idle speed 1 900 100 r min DRIVE TRAIN Reduction ratio 2 645 1 621 Variable change Reduct...

Page 13: ... AT19 7 8 tubeless AT19 7 8 Rear tire size AT19 7 8 tubeless AT19 7 8 ELECTRICAL Ignition type Electronic ignition CDI Ignition timing 10 B T D C at 1 800 r min Spark plug NGK CR7HSA or DENSO U20FSR U Battery 12 V 21 6 kC 6 Ah 10 HR Main fuse 10 A CAPACITIES Fuel tank 6 0 L 1 6 1 3 US lmp gal Engine oil oil change 950 ml 2 00 1 67 US Imp qt with filter change 1 050 ml 2 21 1 84 US Imp qt overhaul ...

Page 14: ... ENGINE OIL AND OIL FILTER 2 10 FINAL REDUCTION GEAR BOX OIL 2 12 THROTTLE CABLE PLAY 2 13 ENGINE IDLE SPEED 2 13 DRIVE BELT 2 14 DRIVE CHAIN 2 18 BRAKES 2 20 TIRES 2 22 STEERING 2 23 SUSPENSIONS 2 23 CHASSIS NUTS AND BOLTS 2 24 GENERAL LUBRICATIONS 2 27 COMPRESSION PRESSURE CHECK 2 28 COMPRESSION TEST PROCEDURE 2 28 INITIAL ENGAGEMENT AND CLUTCH LOCK UP INSPECTION 2 29 INITIAL ENGAGEMENT INSPECTI...

Page 15: ...ace T Tighten C Clean L Lubricate Interval Initial 1 month Every 3 months Every 6 months Item Air cleaner element C C Exhaust pipe nuts and muffler mounting bolts T T T Valve clearance I I Spark plug I Replace every 18 months Spark arrester C Fuel line I I Replace every 4 years Engine oil and oil filter R R Final reduction gear box oil I Replace every 2 years Throttle cable play I I I Idle speed I...

Page 16: ...uirements AIR CLEANER If the air cleaner is clogged with dust intake resistance will be increased with a resultant decrease in power output and an increase in fuel consumption Check and clean the air cleaner element in the following manner Remove the footrest rid 5 4 Remove the air cleaner box cap 1 Remove the air cleaner element 2 Clean every 3 months ...

Page 17: ...reverse order of removal Remove the drain cap 3 of the air cleaner box to allow any water to drain out 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 ele...

Page 18: ...he exhaust pipe nuts 1 muffler connection bolt 2 and muffler mounting bolts 3 to the specified torque Exhaust pipe nut 23 N m 2 3 kgf m 16 5 lb ft Muffler connection bolt 12 N m 1 2 kgf m 9 5 lb ft Muffler mounting bolt 23 N m 2 3 kgf m 16 5 lb ft Tighten initially at 1 month and every 3 months there after ...

Page 19: ... 2 Remove the valve timing inspection plug 3 and generator cover cap 4 NOTE Valve clearance is to be checked when the engine is cold The intake and exhaust valves must be checked and adjusted when the piston is at Top Dead Center TDC of the compres sion stroke Rotate the crankshaft with a box wrench to set the piston at TDC on the compression stroke Rotate the crankshaft until the line A on the ge...

Page 20: ...off oil from the fitting surfaces of the cylinder head and cover Apply SUZUKI BOND 1215 to the end caps of the cylinder head cover gasket as shown E 99000 31230 SUZUKI BOND 1215 or equivalent bond Apply engine oil to both sides of the washers 6 Install the cylinder head cover 7 Lightly tighten the cylinder head cover bolts and then tighten them to the specified torque Cylinder head cover bolt Init...

Page 21: ...r burnt replace the spark plug with a new one Also replace the spark plug if it has a bro ken insulator damaged thread etc SPARK PLUG INSTALLATION Insert the spark plug and finger tighten it to the cylinder head and then tighten the spark plug to the specified torque Spark plug 11 N m 1 1 kgf m 8 0 lb ft Inspect every 6 months Replace every 18 months Standard Cold type NGK CR7HSA CR8HSA DENSO U20F...

Page 22: ...he muffler Clean the spark arrester pipe 2 by brush Reinstall the spark arrester pipe 2 FUEL LINE Inspect the fuel hose for damage and fuel leakage If any defects are found replace it with a new one When replacing the fuel hose remove the fuel tank cover 5 4 Clean every 6 months Inspect every 3 months Replace every 4 years ...

Page 23: ...the specified torque and then pour the fresh oil through the oil filler hole When performing an oil change without oil filter replacement The engine will hold about 950 ml 2 0 1 67 US lmp qt of oil Use API SF SG or SH SJ with JASO MA Engine oil drain plug 17 5 N m 1 75 kgf m 13 0 lb ft Check the engine oil level above Engine oil capacity Oil change 950 ml 2 00 1 67 US lmp qt With filter change 105...

Page 24: ...l replace ment procedure Remove the oil filter cap 1 and oil filter 2 Replace the oil filter with a new one Install the o ring 3 Install the spring 4 and o ring 5 Install the oil filter cap and tighten the bolt securely NOTE Face the triangle mark A on the cap downward Apply engine oil to the o rings ...

Page 25: ...R BOX OIL REPLACEMENT Place the vehicle on level ground Remove the left footrest mudguard 5 5 Remove the front cooling duct connector 1 and rear cooling duct connector 2 Remove the crankcase cover 3 Remove the oil filler cap 4 Remove the drain plug 5 and drain the oil into an oil pan Reinstall the drain plug 5 Pour new oil through the oil filler hole until the oil flows from oil filler hole Reinst...

Page 26: ...djust the throttle cable play above Warm up the engine NOTE Make this adjustment when the engine is hot Start the engine turn the throttle stop screw 1 and set the engine idle speed as follows Engine idle speed 1 900 100 r min Inspect initially at 1 month and every 3 months there after After the adjustment is completed check that handle bar movement does not raise the engine idle speed and that th...

Page 27: ...r 1 Remove the front cooling duct connector 2 and rear cooling duct connector 3 Remove the crankcase cover 4 Remove the crankcase cover gasket 5 and dowel pin Remove the fixed drive face nut 6 and fixes drive face fan 7 with the special tool 09930 40113 Rotor holder Inspect every 3 months Replace every 6 months ...

Page 28: ...ce 8 Remove the limit clutch housing nut 9 with the special tool 09930 40113 Rotor holder Remove the limit clutch stopper 0 and limit clutch spring A Remove the limit clutch pressure plate B Remove the limit clutch friction plate C and clutch housing D ...

Page 29: ...e belt in the reverse order of removal Pay atten tion to the following points Insert the drive belt as low as possible between the movable driven face to provide the maximum drive belt clearance before installing Install the movable driven face with drive belt Fit the drive belt to the movable driven face so that the arrows on the drive belt outer surface aim toward normal turning direction The dr...

Page 30: ...the specified torque with the special tool 09930 40113 Rotor holder Limit clutch nut 75 N m 7 5 kgf m 54 0 lb ft Tighten the fixed drive face nut to the specified torque with the special tool 09930 40113 Rotor holder Fixed drive face nut 50 N m 5 0 kgf m 36 0 lb ft Rotate the fixed drive face until the drive belt is properly seated and both the drive and driven face rotate together smoothly and wi...

Page 31: ...ce the drive chain and sprockets as a set CHECKING Remove the chain case cover Loosen the rear shock absorber lower bolts 1 and rear axle housing set bolt 2 Tense the drive chain fully by turning both chain adjusters 3 Count out 21 pins 20 pitch on the chain and measure the distance between the two points If the distance exceeds the service limit the chain must be replaced Drive chain 20 pitch len...

Page 32: ...5 mm 0 6 1 0 in After adjusting the drive chain tighten the rear shock absorber lower bolt 2 and rear axle housing set bolt 3 to the specified torque Rear shock absorber lower bolt 94 N m 9 4 kgf m 68 0 lb ft Rear axle housing set bolt 110 N m 11 0 kgf m 79 0 lb ft Tighten the adjusting nut 1 Recheck the drive chain slack NOTE After drive chain adjustment the rear brake Rear brake adjustment 2 20 ...

Page 33: ... equal by adjusting nuts 1 Turn the adjusters 2 so that the brake lever play B is within specification after loosening the locknut Front brake lever play B 4 6 mm 0 16 0 24 in NOTE The difference between W1 and W2 should be 1 mm or less REAR BRAKE LEVER PLAY Loosen the adjuster 1 and 2 Turn the adjuster 2 so that the lever play C is within specifi cation after loosening the locknut Rear brake leve...

Page 34: ... front and rear brake Check brake lining wear as follows Make sure the brake lever play is properly adjusted While fully applying the brake check to see that the extension line of the index mark 1 is within the range 2 If the index mark goes beyond the range the brake shoe assembly must be replaced with a new set of shoes ...

Page 35: ...in the correct tire pressure for good roadability and a longer tire life Cold inflation tire pressure is as follows Cold inflation tire pressure Front 22 5 kPa 0 225 kgf cm 3 3 psi Rear 20 kPa 0 20 kgf cm 29 psi VEHICLE LOAD CAPACITY LIMIT 90 kg 198 lbs Inspect every month 4 0 mm To minimize the possibility of tire damage from over inflation we strongly recommended that a man ual type air pump be ...

Page 36: ...hown and calculate the difference between A and B B A Toe in Toe in 4 5 3 mm 0 17 0 1 in If the toe in is out of specification bring it into the specified range 5 32 SUSPENSIONS Support the vehicle with a jack and wooden blocks Remove the front and rear wheels 5 8 Inspect the suspension arm swingarm and bush for scratches wear or defect If any defects are found replace them with new ones 5 23 and ...

Page 37: ...nuckle nut 60 6 0 43 5 6 Front brake cam lever nut 8 0 8 6 0 7 Steering shaft lower nut 35 3 5 25 5 8 Steering shaft holder bolt 23 2 3 17 0 9 Front brake cable equalizer bolt 7 0 7 5 0 0 Front shock absorber bolt upper and lower 50 5 0 36 0 A Front hub nut 65 6 5 47 0 B Wheel set nut front and rear 55 5 5 40 0 C Swingarm pivot nut 102 10 2 74 0 D Rear shock absorber bolt upper 29 2 9 21 0 E Rear ...

Page 38: ...PERIODIC MAINTENANCE 2 25 ...

Page 39: ...2 26 PERIODIC MAINTENANCE ...

Page 40: ...below 1 Steering shaft holder 2 Brake lever holder 3 Brake cable 4 Throttle cable 5 Drive chain 6 Throttle lever 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 Lubricate every 3 months ...

Page 41: ...ctive 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 bolts are tightened to the specified torque and the valves are properly adjusted Have the engine warmed up before testing Make sure that the battery is ...

Page 42: ... to thoroughly check the operation of the drive train Perform the following Warm up the engine INITIAL ENGAGEMENT INSPECTION Connect the multi circuit tester onto the spark plug high ten sion cord Start the engine Slowly open the throttle and note the engine speed r min when the vehicle begins to move forward 09900 25008 Multi circuit tester set Engagement speed 2 800 3 400 r min If the engagement...

Page 43: ... possible Fully open the throttle for a brief period and note the maxi mum engine speed sustained during the test cycle Lock up speed 5 400 6 000 r min If the lock up speed r min does not coincide with the standard range inspect the following items for any abnormalities Clutch shoe 3 54 Clutch housing 3 54 Movable drive and driven face 3 51 NOTE Release the parking brake lock Do not apply full pow...

Page 44: ...iscosity is too high Clogged oil passage Combination of the above items OIL PRESSURE TEST PROCEDURE Connect the tachometer onto the spark plug high tension cord 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 th...

Page 45: ...ASSEMBLY 3 9 ENGINE COMPONENTS INSPECTION AND SERVICE 3 18 CYLINDER HEAD COVER 3 18 CYLINDER HEAD 3 19 CAMSHAFT 3 28 CAM CHAIN TENSION ADJUSTER AND TENSIONER GUIDE 3 31 CYLINDER 3 31 PISTON AND PISTON RING 3 32 CONROD 3 34 CRANKSHAFT 3 35 STARTER CLUTCH 3 35 GENERATOR 3 37 OIL PUMP 3 38 ENGINE MOUNTING BUSH 3 41 FINAL REDUCTION GEAR BOX 3 42 MOVABLE AND FIXED DRIVE AND DRIVEN FACE 3 50 RECOIL STAR...

Page 46: ...GHT SIDE ENGINE CENTER PARTS REMOVAL INSTALLATION Oil filter strainer 3 14 3 71 Movable drive face driven face 3 15 3 68 Starter motor 3 9 3 77 Recoil starter 3 14 3 71 PARTS REMOVAL INSTALLATION Exhaust pipe muffler 3 4 3 8 Engine sprocket 3 5 3 7 Generator rotor 3 12 3 67 Oil pump 3 13 3 66 PARTS REMOVAL INSTALLATION Cylinder head cover 3 9 3 76 Cylinder head 3 9 3 74 Cylinder 3 11 3 74 Piston 3...

Page 47: ...am cleaner Engine removal is sequentially explained in the following steps Drain engine oil 2 10 Remove the fuel tank cover 5 4 Remove the footrest mudguard left and right 5 5 Remove the left footrestbar 5 5 Remove the front fender 5 5 Remove the spark plug cap 1 Remove the connector 2 and 3 Remove the air cleaner assembly 5 ...

Page 48: ...3 4 ENGINE Remove the carburetor assembly 5 4 7 Disconnect the generator coupler 6 Loosen the muffler clamp bolt Remove the exhaust pipe 7 Remove the gasket 8 Remove the muffler 9 ...

Page 49: ... lead wire 0 and ground lead wire A Remove the chain case cover B Loosen the rear shock absorber lower bolt C Loosen the rear axle housing bolt D Loosen the chain adjusters E Remove the snap ring F and engine sprocket G with drive chain ...

Page 50: ...3 6 ENGINE Remove the engine mounting upper brackets H Remove the engine mounting bolts and nuts Remove the engine from the right side ...

Page 51: ...OTE The engine 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 Install the engine sprocket 1 with drive chain and then install the snap ring 2 ITEM N m kgf m lb ft A 100 10 0 72 5 B 60 6 0 43 5 C 60 6 0 43 5 D 35 3 5 25 5 ...

Page 52: ...lb ft Tighten the muffler clamp bolt to the specified torque Muffler clamp bolt 12 N m 1 2 kgf m 8 5 lb ft Install the carburetor assembly 4 13 After remounting the engine route the wiring harness cables and hoses properly 7 15 Adjust the following items Engine oil 2 10 Throttle cable play 2 13 Engine idle speed 2 13 Drive chain slack 2 18 The removed gasket must be replaced with a new one to prev...

Page 53: ...move the cylinder head cover bolts and then remove the cylinder head cover 1 CYLINDER HEAD Remove the valve timing inspection plug 1 and generator cover cap 2 Turn the crankshaft with a box wrench to set the piston at TDC on the compression stroke Rotate the generator rotor until the line A on the generator rotor is center of the hole in the generator cover ...

Page 54: ...ad Remove the cam chain tension adjuster plug cap 4 Insert the screwdriver into the slotted end of cam chain ten sion adjuster and turn the adjusting screw clockwise with the screwdriver until the push rod locked Remove the cam tension adjuster 5 and gasket 6 Remove the cam sprocket 7 Remove the cylinder head nut 8 ...

Page 55: ... CYLINDER Remove the cylinder head gasket 1 and dowel pins Remove the cam chain guide 2 Remove the cylinder 3 NOTE If the cylinder does not come off easily lightly tap it using a plas tic mallet Remove the cylinder gasket 4 and dowel pins PISTON Place a clean rag over the cylinder base to prevent the piston pin circlip 1 from dropping into the crankcase Remove the piston pin circlip 1 ...

Page 56: ...OR ROTOR COVER Remove the generator rotor cover 1 Remove the gasket 2 and dowel pins Remove the starter idle gear 3 and starter idle shaft 4 GENERATOR ROTOR Hold the generator rotor using the special tool and then remove the generator rotor nut 1 09930 44520 Rotor holder ...

Page 57: ...shaft and then remove the generator rotor using the special tool Remove the generator rotor key 3 Remove the starter driven gear 4 OIL PUMP Remove the oil pump cover 1 Remove the oil pump assembly 2 oil pump sprocket 3 and oil pump chain 4 CAM CHAIN Remove the cam chain 1 Do not hit the generator rotor with a hammer other wise the rotor may be damaged ...

Page 58: ...3 14 ENGINE OIL FILTER Remove the oil filter cap 1 Remove the oil filter 2 and O ring 3 OIL STRAINER Remove the oil strainer cap 1 Remove the oil strainer 2 RECOIL STARTER Remove the recoil starter 1 ...

Page 59: ...the gasket 2 and dowel pins Remove the fixed drive face nut 3 with the special tool 09930 40113 Rotor holder Remove the fixed drive face fan 4 Remove the fixed drive face 5 MOVABLE DRIVEN FACE Remove the limit clutch nut 1 with the special tool 09930 40113 Rotor holder ...

Page 60: ...e limit clutch pressure plate 4 Remove the limit clutch friction plate 5 and clutch housing 6 Remove the limit clutch friction plate 7 and limit clutch 8 Remove the clutch shoe movable driven face assembly 9 with the drive belt 0 NOTE Clutch shoe movable driven face disassembly 3 52 ...

Page 61: ...he left crankcase bolts Separate the crankcase with the special tool 09920 13120 Crankcase separating tool NOTE Fit the crankcase separating tool to the right crankcase so that the tool plate is paralleled with the end face of the crankcase Remove the crankshaft from the crankcase with the special tool 09920 13120 Crankcase separating tool ...

Page 62: ...ER DISASSEMBLY Remove the breather plate 1 Remove the gasket 2 INSPECTION Inspect the cylinder head cover for carbon deposit If the clogged are found clean the cylinder head cover REASSEMBLY Install the breather gasket 1 The removed gasket must be replaced with a new one ...

Page 63: ...2080 THREAD LOCK SUPER 1322 CYLINDER HEAD DISASSEMBLY Remove the intake pipe 1 and insulator 2 Remove the cam chain guide 3 Remove the camshaft retainer 4 Remove the rocker arm shafts 5 Identify the position of each removed part Organize the parts in their respective groups i e exhaust or intake so that they can be installed in their original locations ...

Page 64: ...nd remove the two cotter halves 9 from the valve stem 09916 14510 Valve lifter 09916 14521 Valve lifter attachment 09916 84511 Tweezers Remove the valve spring retainer 0 valve spring A and spring seat B Pull out the valve C from the combustion chamber side Be careful not to damage the tappet sliding surface with the special tool ...

Page 65: ...LVE FACE WEAR The thickness of the valve face decreases as the face wears Visually inspect each valve face for wear and replace any valve with an abnormally worn face Measure the valve face thickness T if it is out of specification replace the valve with a new one Valve head thickness T Service Limit 0 5 mm 0 02 in 09900 20101 Vernier calipers VALVE STEM RUNOUT Support the valve using V blocks and...

Page 66: ...lve stem and valve face for wear and pitting If it is worn or damaged replace the valve with a new one VALVE STEM DEFLECTION Lift the valve about 10 mm 0 39 in from the valve seat Measure the valve stem deflection in two directions perpendicu lar to each other by positioning the dial gauge as shown If the deflection measured exceeds the limit then determine whether the valve or the guide should be...

Page 67: ...ement after inspecting related parts carry out the steps shown in valve guide servicing VALVE GUIDE SERVICING Using the valve guide remover drive the valve guide out toward the intake or exhaust camshaft side 09916 44310 Valve guide remover installer NOTE Discard the removed valve guide subassemblies Only oversized valve guides are available as replacement parts Part No 11115 30D70 Re finish the v...

Page 68: ...OTE Be sure to cool down the cylinder head to ambient air tempera ture Insert the reamer from the combustion chamber and always turn the reamer handle clockwise VALVE SEAT WIDTH INSPECTION Visually check for valve seat width on each valve face If the valve face has worn abnormally replace the valve Coat the valve seat with a red lead Persian Blue and set the valve in place Rotate the valve with li...

Page 69: ...ll 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 INTAKE EXHAUST seat angle 45 45 seat width 0 9 1 1 mm 0 09 0 11 in 0 9 1 1 mm 0 09 0 11 in valve diameter 22 5 mm 0 89 in 19 mm 0 75 in valve guide I D 5 500 5 512 mm 0 2165 0 2170 in 5 500 5 512 mm 0 2165 0 2170 in ...

Page 70: ... IN 32 8 mm 1 29 in EX 32 8 mm 1 29 in 09900 20102 Vernier calipers Valve spring tension Standard IN EX 110 126 N 11 0 12 6 kgf 26 8 mm 79 5 91 1 lbs 1 05 in REASSEMBLY Install the valve spring seat Apply MOLYBDENUM OIL SOLUTION to the oil seal 1 and press fit it into position P MOLYBDENUM OIL SOLUTION Insert the valve with its stem coated with MOLYBDENUM OIL SOLUTION all around and along the full...

Page 71: ...m 09916 14510 Valve lifter 09916 14521 Valve lifter attachment 09916 84511 Tweezers Be sure that the rounded lip E of the cotter fits snugly into the groove F in the stem end Install the other valves and springs in the same manner as described previously 2 Valve spring retainer 3 Valve cotter Be sure to restore each spring and valve to their original positions Be careful not to damage the valve an...

Page 72: ...l replace the camshaft assem bly CAM WEAR Inspect the camshaft for wear or damage Measure the cam height H with a micrometer Cam height H Service Limit IN 27 62 mm 1 087 in EX 27 50 mm 1 082 in 09900 20202 Micrometer 25 50 mm ROCKER ARM INSPECTION Inspect the rocker arm for damage If any defects are found replace it with a new one When checking the valve rocker arm the inside diameter of the valve...

Page 73: ... Measure the diameter of rocker arm shaft with a micrometer Rocker arm shaft O D Standard 9 990 9 981 mm 0 3933 0 3929 in 09900 20205 Micrometer 0 25 mm REASSEMBLY Install the cam shaft 1 Install the rocker arms 2 and wave washer 3 Install the rocker arm shafts 5 Apply molybdenum oil solution onto the rocker arm shaft P MOLYBDENUM OIL SOLUTION ...

Page 74: ... camshaft retainer screw to the specified torque Camshaft retainer screw 5 5 N m 0 55 kgf m 4 0 lb ft Install the cam chain guide mounting bolt to the specified torque Cam chain guide mounting bolt 10 N m 1 0 kgf m 7 0 lb ft ...

Page 75: ...g surface of the cam chain tensioner and guide If any defects are found replace it with a new one CYLINDER CYLINDER DISTORTION Check the gasket surface of the cylinder for distortion with a straightedge and thickness gauge taking a clearance reading at several places indicated If the largest reading at any position of the straightedge exceeds the limit replace the cylinder head Cylinder distortion...

Page 76: ...ON DIAMETER Measure the piston outside diameter at 10 mm 0 4 in A from the piston skirt end using a micrometer If the measurement is less than the limit replace the piston Piston diameter Service Limit 45 380 mm 1 7860 in at 10 mm 0 4 in from the skirt end 09900 20204 Micrometer 25 50 mm PISTON TO CYLINDER CLEARANCE Subtract the piston diameter from the cylinder bore diameter above If the piston t...

Page 77: ...replace the piston pin Piston pin O D Service Limit 13 980 mm 0 5503 in 09900 20205 Micrometer 0 25 mm PISTON RING TO GROOVE CLEARANCE Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge If any of the clearances exceeds the limit replace both the piston and piston rings 09900 20803 Thickness gauge 09900 20202 Micrometer 25 50 mm Piston ring to groove clearance Ser...

Page 78: ...ing a small bore gauge measure the inside diameter of the conrod small end If the inside diameter of the conrod small end exceeds the limit replace the conrod Conrod small end I D Service Limit 14 040 mm 0 5527 in 09900 20602 Dial gauge 1 1 000 mm 1 mm 09900 22403 Small bore gauge 18 35 mm CONROD DEFLECTION AND BIG END SIDE CLEARANCE Wear on the big end of the conrod can be estimated by checking t...

Page 79: ...kshaft with a new one NOTE Place the crankshaft onto the V blocks so that it becomes hori zontally Measure the runout from the tips of the crankshaft Crankshaft runout Service Limit 0 08 mm 0 003 in 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09910 21304 V block set 100 mm STARTER CLUTCH INSPECTION Install the starter driven gear onto the starter clutch and turn the starter driven g...

Page 80: ...t H 99000 32080 THREAD LOCK SUPER 1322 or equivalent thread lock Tighten the bolts while holding the rotor with the special tool Starter clutch bolt 10 N m 1 0 kgf m 7 0 lb ft 09930 44520 Rotor holder STARTER DRIVEN GEAR BEARING INSPECTION Inspect the starter driven gear bearing for any wear or damage If any defects are found replace the stater driven gear bearing with a new one STARTER DRIVEN GEA...

Page 81: ...sor route the wire properly Apply a small quantity of THREAD LOCK SUPER 1322 to the CKP sensor mounting bolts 1 and tighten them securely H 99000 32080 THREAD LOCK SUPER 1322 or equivalent thread lock CKP sensor mounting bolts 6 N m 0 6 kgf m 4 5 lb ft Apply a small quantity of THREAD LOCK SUPER 1322 to the generator coil mounting bolts 2 and tighten them securely H 99000 32080 THREAD LOCK SUPER 1...

Page 82: ...nd inner rotor 2 for any scratches or other damage If any defects are found replace them with new ones Rotate the oil pump by hand and check that it moves smoothly If it does not move smoothly replace the oil pump assembly RESASSEMBLY Install the pump cover 1 Do not attempt to disassemble the oil pump assem bly The oil pump is available only as an assembly ...

Page 83: ...9913 70210 Bearing installer set Apply SUZUKI SUPER GREASE A to the lip of the oil seals X 99000 25010 SUZUKI SUPER GREASE A or equivalent grease BEARING INSPECTION Rotate 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 The removed oil seals m...

Page 84: ...cial tool 09921 20240 Bearing remover set Bearing 25 REASSEMBLY Press the bearings with the special tool 09913 70210 Bearing installer set Bearing 32 NOTE The stamped mark side of the bearing faces inside The removed bearings must be replaced with new ones ...

Page 85: ...g an appropriate size steel tubes 1 and vise remove the engine mounting bush 2 LH RH and rear INSTALLATION Using an appropriate side steel tube and vise press in the bush into the crankcase LH RH and rear Bush end A must be flush the crankcase surface ...

Page 86: ...g 1 and gasket Drain final reduction gear box oil Remove the final reduction gear box cover bolts and gasket Remove the final reduction gear box cover 2 Remove the gasket 3 and dowel pins Remove the snap ring 4 and final driven gear 5 Remove the idle gear 6 and washer 7 ...

Page 87: ...emove the chain guide 9 P Remove the dust seal 0 and bearing retainer A Remove the counter shaft B with a plastic mallet COUNTER SHAFT INSPECTION Inspect the counter shaft wear or damage If any defects are found replace it with a new one ...

Page 88: ...ew ones FINAL REDUCTION GEAR BOX INSPECTION AND DISAS SEMBLY Rotate the bearing inner race by finger to inspect for abnormal play noise and smooth rotation while the bearings are in the those cases Replace the bearing in the following procedure if there is any thing unusual Remove the bearings with the special tool 09921 20240 Bearing remover set 1 12 2 17 Remove the oil seal 3 with the special to...

Page 89: ...ring 4 Remove the rear axle shaft washer 5 Remove the bearing 6 with the special tool 9913 20240 Bearing remover set 20 Remove the rear axle shaft housing 7 Remove the oil seal 8 with the special tool 09913 50121 Oil seal remover ...

Page 90: ...axle housing E 99000 31110 SUZUKI BOND 1215 or equivalent bond Tighten the rear axle housing bolts to the specified torque Rear axle housing bolt 60 N m 6 0 kgf m 43 5 lb ft Install the bearing with the special tool 09913 70210 Bearing installer set 1 25 09913 70210 Bearing installer set 2 17 3 20 The removed bearings must be replaced with new ones ...

Page 91: ...Install the snap ring 8 Install the oil seals with the special tool 09913 70210 Bearing installer set 47 09913 70210 Bearing installer set 30 The removed bearings must be replaced with new ones The removed oil seal must be replaced with a new one The removed oil seal must be replaced with a new one ...

Page 92: ...counter shaft 0 Install the idle gear A Apply final reduction gear box oil to the gears Install the final driven gear B to the counter shaft Install the snap ring C Install the gasket D and dowel pins The removed gasket must be replaced with a new one ...

Page 93: ... plug E to the specified torque Final reduction gear box cover bolts 10 N m 1 0 kgf m 7 0 lb ft Final reduction gear box drain plug bolt 10 N m 1 0 kgf m 7 0 lb ft The removed drain plug bolt gasket and final reduc tion gear box bolt gaskets must be replace with a new one ...

Page 94: ...ovable drive face L Movable driven face 7 Roller M Roller 8 Movable drive spacer N Pin 9 Movable drive face plate O Fixed driven face 0 Damper P Bearing A Limit clutch stopper Q Snap ring B Limit clutch spring R Needle bearing C Limit clutch pressure plate A Fixed drive face nut ITEM N m kgf m lb ft D Limit clutch friction plate B Limit clutch nut A 50 5 0 36 0 E Clutch housing C Clutch shoe nut B...

Page 95: ...rn or damaged replace them with new ones MOVABLE AND FIXED DRIVE FACE INSPECTION Inspect the movable drive face for any abnormal condition such as stepped wear or discoloration caused by burning If any defects are found replace them with new ones ROLLER INSPECTION Inspect each roller and their sliding surface for wear or damage If any defects are found replace the rollers as a set NOTE The rollers...

Page 96: ...TCH SHOE MOVABLE DRIVEN FACE DISASSEMBLY Hold the clutch shoe assembly 1 with the special tool 09930 40113 Rotor holder Loosen the clutch shoe nut 2 Attach the special tool to the clutch shoe movable driven face assembly and compress the clutch shoe assembly by turning in the special tool handle 3 09922 31420 Clutch spring compressor Remove the clutch shoe nut 4 Do not remove the clutch shoe nut b...

Page 97: ...he clutch shoe assembly 5 and spring 6 Remove the movable driven face spring seat 7 Remove the O rings 8 Remove the oil seals 9 Install the oil seal with the special tool 09913 70210 Bearing installer set 35 Do not attempt to disassemble the clutch shoe assem bly ...

Page 98: ...shoe thickness Service Limit 2 5 mm 0 098 in 09900 20102 Vernier calipers CLUTCH HOUSING INSPECTION Inspect the clutch housing for any abnormal surface damage Measure the inside diameter of the clutch housing If the measurement exceeds the service limit replace the clutch housing with a new one Clutch housing I D Service Limit 110 5 mm 4 350 in MOVABLE DRIVEN FACE SPRING INSPECTION Measure the mov...

Page 99: ...0 74 in MOVABLE AND FIXED DRIVEN FACE INSPECTION Inspect the driven face for any abnormal condition such as stepped wear or discoloration caused by burning If any damages are found replace the then with new ones CLUTCH SHOE MOVABLE DRIVEN FACE DIASSEMBLY INSTALLATION Install the new O rings 1 Apply SUZUKI SUPER GREASE A to the oil seal lips and movable driven face inside grease groove X 99000 2503...

Page 100: ...ollers and pins 2 Install the spring seat by aligning the hole Install the spring and spring plate by aligning the spring ends with the holes Compress the spring 3 with the special tool 09922 31420 Clutch spring compressor To prevent damaging the oil seal lip from during installation slide the lip using a 0 1 mm steel sheet as a guide ...

Page 101: ... the special tool from the clutch shoe assembly Tighten the clutch shoe nut to the specified torque with the special tool 09930 40113 Rotor holder Clutch shoe nut 60 N m 6 0 kgf m 43 5 lb ft Align the flats A of the fixed driven face end and clutch shoe plate ...

Page 102: ...3 58 ENGINE RECOIL STARTER 1 Friction plate 6 Reel 2 Spring 7 Spiral spring 3 Friction plate 8 Knob 4 Friction spring 9 Rope 5 Starter cap 0 Starter case ...

Page 103: ...ing 3 and washer 4 Remove the cap 5 from the knob 6 Untie a knot at the rope Remove the starter cup 7 Hook the rope to the groove A of the reel 8 Remove the reel 8 Wear hand and eye protection when removing the reel since the spiral spring may quickly unwind and cause an injury ...

Page 104: ...000 25010 SUZUKI SUPER GREASE A or equivalent Turn the rope on the reel properly After installing the spiral spring engage the part A of the reel with the spiral spring end 2 Hook the rope onto the hook part B of the reel Turn the reel counterclockwise three or four times with the rope Lace the end of the rope through the recoil starter case hole C Tie a knot at the end of the rope Install the cap...

Page 105: ...OCK 1303 to the bolt 7 Tighten the bolt 7 to the specified torque J 99000 32050 THREAD LOCK 1303 or equivalent Recoil starter friction plate bolt 5 0 N m 0 5 kgf m 3 5 lb ft Pull the rope and check that the ratchet is pushed out ...

Page 106: ...HAFT Determine the width between the webs referring to the figure when rebuilding the crankshaft Crank web to web width Standard 49 0 1 mm 1 929 0 003 in When mounting the crankshaft in the crankcase it is neces sary to pull its left end into the crankcase with the special tools 09910 32812 Crankshaft installer 09911 11310 Attachment 09913 70210 Bearing installer set 35 1 Bearing 4 Conrod 7 Cranks...

Page 107: ...ce of the right and left crankcases Install the dowel pins to the left crankcase Apply engine oil to the conrod big end Never fit the crankshaft into the crankcase by striking it with a plastic hammer Always use the special tool otherwise the accuracy of the crankshaft alignment will be affected ...

Page 108: ...ti gauge with the enve lope scale Crankshaft thrust clearance Standard 0 02 0 07 mm If the thrust clearance is not within specification select the proper size of shim After selecting the proper size of shim place it on the right crankshaft LIST OF SHIMS Part number Shim thickness Part number Shim thickness 09181 35101 0 50 0 002 mm 09181 35109 0 95 0 002 mm 09181 35025 0 55 0 002 mm 09181 35110 1 ...

Page 109: ...of SUZUKI BOND 1215 is as follows Make surfaces free from moisture oil dust and other foreign materials Spread on surfaces thinly to form an even layer and assemble the crankcases within few minutes Take extreme care not to apply any BOND 1215 to the oil hole oil groove and bearing Apply to distorted surfaces as it forms a comparatively thick film ...

Page 110: ... 10 N m 1 0 kgf m 7 0 lb ft After the crankcase bolts have been tightened check if the crankshaft rotate smoothly CAM CHAIN Install the cam chain 1 onto the sprocket OIL PUMP Apply engine oil to the oil pump assembly Install the oil pump assembly 1 sprocket 2 and oil pump chain 3 ...

Page 111: ...1 Degrease the tapered portion of generator rotor and also the crankshaft Use nonflammable cleaning solvent to wipe off oily or greasy matter and make these surfaces completely dry Install the key 2 Install the generator rotor 3 Tighten the generator rotor nut to the specified torque with the special tool Generator rotor nut 80 N m 8 0 kgf m 58 lb ft 09930 44520 Rotor holder ...

Page 112: ...over bolt 10 N m 1 0 kgf m 7 0 lb ft MOVABLE DRIVEN Install the movable drive spacer 1 and movable drive face assembly 2 Install the drive belt 3 to the movable driven face 4 NOTE With the clutch shoe spring compressed by hands install the drive belt 3 between the movable driven face 4 and fixed driven face The removed gasket must be replaced with a new one to prevent oil leakage Degrease the driv...

Page 113: ...ssembly 5 with the drive belt 6 Install the limit clutch friction plate 7 and limit clutch 8 Install the limit clutch friction plate 9 and clutch housing 0 Install the limit clutch pressure plate A Install the limit clutch stopper B and limit clutch spring C ...

Page 114: ...DRIVE Install the fixed drive face 1 Install the fixed drive face fan 2 Install the fixed drive face nut 3 with the special tool 09930 40113 Rotor holder Fixed drive face nut 50 N m 5 0 kgf m 36 0 lb ft Install the gasket 4 and dowel pins Install the crankcase cover bolts to the specified torque Crankcase cover bolt 10 N m 1 0 kgf m 7 0 lb ft ...

Page 115: ...stall the oil filter cap and tighten the bolts securely NOTE Face the triangle mark A on the cap downward B Bolt with clamp OIL STRAINER Install the oil strainer 1 Install the oil strainer cap 2 and gasket 3 The removed O ring must be replaced with a new one to prevent oil leakage The removed O ring must be replaced with a new one to prevent oil leakage The removed gasket 3 must be replaced with a...

Page 116: ...o the piston NOTE 1st ring and 2nd ring differ in shape Be sure to bring the concave side of 1st ring to the top when fitting it to the piston 2nd ring has letter RN marked on the side Be sure to bring the marked side ring to the top when fitting it to the piston Position the gaps of the three ring as shown Before inserting each piston into the cylinder check that the gaps are so located A Exhaust...

Page 117: ...wipe off oil from the fitting surface of the crank case Apply SUZUKI BOND 1215 to the crankcase B as shown E 99000 31080 SUZUKI BOND 1215 or equivalent bond Install the dowel pins and gasket 1 onto the crankcase Hold each piston ring with the piston ring sections positioned correctly and put it into the cylinder Make sure that the piston rings are caught by the cylinder skirt NOTE When mounting th...

Page 118: ...t 1 25 N m 2 5 kgf m 18 0 lb ft NOTE Be sure to install the washer with rounded side facing up After tightening the cylinder head nut 1 to specified torque tighten the cylinder nuts 2 to the specified torque Cylinder head nut 2 10 N m 1 0 kgf m 7 0 lb ft CAMSHAFT ASSEMBLY Turn the generator rotor until the line on the generator rotor is aligned with the center of the hole in the generator cover Th...

Page 119: ...cket bolt to the specified torque Cam sprocket bolt 11 N m 1 1 kgf m 8 lb ft Install the gasket 1 and cam chain tension adjuster 2 to the cylinder Tighten the cam chain tension adjuster mounting bolts to the specified torque Cam chain tension adjuster mounting bolt 10 N m 1 0 kgf m 7 0 lb ft Turn the adjusting screw counter clockwise with a screw driver until the push rod unlocked Install the cam ...

Page 120: ... N m 1 5 kgf m 11 lb ft Valve timing inspection plug 17 5 N m 1 75 kgf m 12 5 lb ft CYLINDER HEAD COVER Thoroughly wipe off oil from the fitting surfaces of the cylinder head and cover Apply SUZUKI BOND 1215 to the end caps of the cylinder head cover gasket as shown E 99000 31230 SUZUKI BOND 1215 or equivalent bond After installing the cam chain tension adjuster check to be sure that the adjuster ...

Page 121: ...I SUPER GREASE A to the O ring Install the starter motor 1 X 99000 25010 SUZUKI SUPER GREASE A or equivalent grease INTAKE PIPE Install the O ring 1 to insulator 2 Install the O ring 3 to intake pipe 4 Tighten the intake pipe bolts to the specified torque Intake pipe bolt 6 N m 0 6 kgf m 4 lb ft The removed washers must be replaced with new ones to prevent oil leakage The removed O ring must be re...

Page 122: ...NSPECTION AND CLEANING 4 3 INSTALLATION 4 4 CARBURETOR 4 5 SPECIFICATIONS 4 6 I D NO LOCATION 4 6 REMOVAL 4 7 DISASSEMBLY 4 8 CLEANING 4 11 INSPECTION AND ADJUSTMENT 4 11 REASSEMBLY AND INSTALLATION 4 12 Gasoline must be handled carefully in an area well ventilated and away from fire or sparks ...

Page 123: ...4 2 FUEL SYSTEM FUEL TANK AND FUEL VALVE 1 Fuel tank breather hose 5 Fuel valve 2 Fuel tank cap 6 Fuel hose 3 Fuel tank A Fuel valve bolt ITEM N m kgf m lb ft 4 O ring A 4 6 0 46 3 5 ...

Page 124: ... hose 3 Remove the fuel tank 4 Remove the fuel valve assembly 5 FUEL FILTER INSPECTION AND CLEANING If the fuel filter is dirty with sediment or rust fuel will not flow smoothly and loss in engine power may result Clean the fuel filter with compressed air also check the fuel filter for cracks Gasoline is highly flammable and explosive Keep heat spark and flame away ...

Page 125: ...ention to the following points Tighten the fuel valve bolts to the specified torque Fuel valve bolt 4 5 N m 0 45 kgf m 3 0 lb ft Install the fuel tank and tighten the bolts securely Rout the fuel tank breather hose 1 7 18 The removed gaskets and O ring must be replaced with new ones to prevent fuel leakage ...

Page 126: ...r G Needle jet 2 Carburetor top cap 0 Washer H Main jet 3 Gasket A O ring I Float pin 4 Spring B Spring J Float 5 Spring seat C Throttle stop screw K Gasket 6 O ring D O ring L Float chamber 7 Jet needle E Needle valve M Drain hose 8 Piston valve F Pilot jet ...

Page 127: ... body according to its specifications ITEM SPECIFICATION Carburetor type MIKUNI VM16SH Bore size 16 I D N 08H0 Idle r min 1 900 100 r min Float height 16 mm Main jet M J 80 Jet needle J N 4LA43 1 Needle jet N J E 1M Pilot jet P J 17 5 Air screw A S PRE SET 1 Throttle cable play 3 5 mm 0 12 0 20 ...

Page 128: ...the fuel hose 1 Remove the air vent hose 2 Remove the vacuum hose 3 Loosen the drain plug 4 Drain the fuel from the carburetor Remove the drain hose from the clamp 5 Loosen the clamp bolt 6 Remove the carburetor mounting bolts nuts 7 Remove the carburetor top cap 8 Remove the carburetor assembly 9 ...

Page 129: ... DISASSEMBLY Remove the spring 1 and piston valve 2 from the throttle cable Remove the spring seat 3 Remove the jet needle 4 washer 5 and spring 6 from the piston valve 2 Remove the float chamber 7 Remove the gasket 9 ...

Page 130: ...e float pin 0 Remove the float A Remove the needle valve B Remove the main jet C and needle jet D Remove the pilot jet E Remove the throttle stop screw F Remove the spring G washer H and O ring I from the throttle stop screw F ...

Page 131: ...4 10 FUEL SYSTEM Remove the choke lever J Remove the starter plunger K ...

Page 132: ... caught between the valve seat and the nee dle valve the gasoline will continue flowing and overflow If the needle valve is worn beyond the permissible limit similar trouble will occur Conversely if the needle valve sticks the gasoline will not flow into the float chamber Clean the float chamber and float parts with gasoline Some carburetor cleaning chemicals especially dip type soaking solutions ...

Page 133: ...cting the needle valve with vernier calipers Float height A 16 1 mm 0 6 0 03 in 09900 20102 Vernier calipers If the float height A is out of specification bend the float arm 1 to bring the float height A to the standard range After adjusting check the float height A REASSEMBLY AND INSTALLATION Reassemble and install the carburetor in the reverse order of removal and disassembly Pay attention to th...

Page 134: ... 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the gasket 2 Install the piston valve 3 to the carburetor The removed gasket must be replaced with a new one to prevent fuel leakage The removed O ring must be replaced with a new one The removed gasket must be replaced with a new one Align the slit A of the piston valve 3 with the projec tion B on the carburetor body ...

Page 135: ...o the specified torque Carburetor mounting bolt 6 N m 0 6 kgf m 4 5 lb ft Install the fuel hose 7 Install the air vent hose 8 Install the vacuum hose 9 NOTE Do not squall each hose After installing the carburetor perform the following Inspect fuel leakage Engine idle r min adjustment 2 13 Throttle cable play adjustment 2 13 ...

Page 136: ...ISASSEMBLY 5 14 REASSEMBLY AND INSTALLATION 5 16 STEERING AND FRONT SUSPENSION 5 20 CONSTRUCTION 5 20 REMOVAL AND DISASSEMBLY 5 22 INSPECTION 5 23 REASSEMBLY AND INSTALLATION 5 24 REASSEMBLY AND INSTALLATION 5 28 INSTALLATION 5 30 TOE IN ADJUSTMENT 5 32 REAR BRAKE AND REAR AXLE HOUSING 5 33 CONSTRUCTION 5 33 REMOVAL 5 34 INSPECTION AND DISASSEMBLY 5 37 REASSEMBLY AND INSTALLATION 5 40 REAR SUSPENS...

Page 137: ... Footrest lid 2 Front fender 8 Right footrest mudguard 3 Rear fender 9 Left footrest mudguard 4 Rear lower fender 0 Front grip 5 Right fuel tank cover A Right footrest bar ITEM N m kgf m lb ft 6 Left fuel tank cover B Left footrest bar A 55 5 5 40 0 ...

Page 138: ...tener a Installation Let the center piece stick out toward the head so that the pawls 2 close Insert the fastener into the installation hole NOTE To prevent the pawl 2 from damage insert the fastener all the way into the installation hole Push in the head of center piece until it becomes flush with the fastener outside face ...

Page 139: ...5 4 CHASSIS REMOVAL SEAT Remove the seat FOOTREST LID Remove the footrest lid FUEL TANK COVER Remove the seat above Remove the footrest lid above Remove the screw 1 and fastener ...

Page 140: ...the footrest lid 5 4 Remove the screws 1 and fasteners Remove the bolts 2 Remove the right footrest mudguard 3 FOOTREST BAR Remove the fuel tank cover 5 4 Remove the footrest lid 5 4 Remove the footrest mudguard left and right above Remove the footrest bar left and right FRONT FENDER Remove the seat 5 4 Remove the footrest lid 5 4 Remove the footrest mudguard left and right above Remove the igniti...

Page 141: ...ve the footrest lid 5 4 Remove the fuel tank cover 5 4 Remove the footrest mudguard left and right 5 5 Disconnect the battery cable first and then battery cable Remove the battery band 1 Remove the battery 2 and CDI unit 3 Remove the starter relay 4 Remove the breather hose 5 ...

Page 142: ...STALLATION Install the exterior parts in the reverse order of removal Pay attention to the following points FOOTREST BAR Apply THREAD LOCK 1342 to the footrest mounting bolts and tighten footrest mounting bolts the specified torque J 99000 32050 THREAD LOCK 1342 Footrest mounting bolt 55 N m 5 5 kgf m 40 0 lb ft ...

Page 143: ... the vehicle on level ground Support the vehicle with a jack or block and remove the front and rear wheel set nuts Remove the front and rear wheels 1 Front tire 4 Rear wheel 2 Front wheel A Wheel set nut front rear ITEM N m kgf m lb ft 3 Rear tire A 55 5 5 40 0 ...

Page 144: ...se order of removal Pay attention to the following points 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 55 N m 5 5 kgf m 40 0 lb ft ...

Page 145: ...ound replace the rim with a new one Clear up the sealing portion of the rim Apply tire lubricant to the tire bead and the flange of the rim Mount the tire on the rim by hand as shown When using the tire levers 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 standar...

Page 146: ...d If this is so deflate the tire com pletely and unseat the tire bead on both sides Then coat the bead with clean water and re seat the tire Adjust the tire pressure to the specified pressure Cold inflation tire pressure Front 22 5 kPa 0 225 kgf cm 3 3 psi Rear 20 kPa 0 20 kgf cm 2 9 psi Vehicle load capacity 90 kg 198 0 lbs Maximum operating pressure 25 kPa 0 25 kgf cm 3 6 psi Place the tire unde...

Page 147: ...al C Brake plate 4 Wheel hub outer bearing D Limit indicator 5 Front wheel hub E Brake cam lever 6 Spacer F Front brake cam lever bolt 7 Wheel hub inner bearing G Spring 8 Inner dust seal A Front hub nut ITEM N m kgf m lb ft 9 Front brake shoe B Front brake cam lever nut A 65 6 5 47 0 0 Front brake camshaft B 8 0 8 6 0 ...

Page 148: ... front hub nut 1 Remove the front washer 2 and wheel hub 3 Remove the front brake shoe assembly 4 Remove the spring 5 Remove the front brake adjusting nut 6 Remove the front brake cam lever nut bolt 7 Remove the brake cam lever 8 and front brake camshaft 9 Remove the brake plate 0 Remove the O rings A ...

Page 149: ...1 Vernier calipers Brake drum I D Service Limit 110 7 mm 4 35 in BRAKE SHOE Inspect the brake shoes for wear or damage If any defects are found replace it with new ones FRONT BRAKE DUST SEAL Inspect the front brake drum dust seal 1 for wear or damage If any defects are found replace it with a new one DUST SEAL Remove the axle spacer 2 Replace the brake shoes as a set otherwise braking performance ...

Page 150: ...r race play of the wheel hub bearing by hand while it is in the wheel hub 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 Remove the wheel hub outer bearing with the special tool 09941 50111 Bearing remover Remove the spacer 1 ...

Page 151: ...b inner bearing with the special tool 09913 70210 Bearing installer set Install the wheel hub outer bearing with the special tool and suitable size socket wrench 09924 84510 Bearing installer set A Clearance First install the wheel hub inner bearing then install the spacer and outer bearing The sealed cover of the bearing must face outside The removed bearing must be replaced with a new one The re...

Page 152: ...he front brake drum dust seal 1 to the groove of the front brake drum 2 Align the front brake drum A with the groove of front brake drum dust seal B Apply WATER RESISTANCE GREASE to the each dust seal lip 99000 25160 RESISTANCE GREASE or equivalent The removed dust seals must be replaced with new ones ...

Page 153: ... GREASE A to the front brake cam shaft and pin and then install the brake shoes X 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the front wheel hub and spring Tighten front brake cam lever nut to the specified torque Front brake cam lever nut 8 N m 0 8 kgf m 6 0 Ib ft The removed O rings must be replaced with new ones Be careful not to apply too much grease to the cam shaft and pin If gr...

Page 154: ...o the specified torque Front hub nut 65 N m 6 5 kgf m 47 0 Ib ft Install the cotter pin Install the front wheel 5 8 After installing the front brake adjust the front brake lever play 2 20 The removed cotter pin must be replaced with a new one ...

Page 155: ...sorber upper nut ITEM N m kgf m lb ft 3 Bush B Front shock absorber lower nut A 50 5 0 36 0 4 Steering knuckle arm C Front suspension arm bolt B 50 5 0 36 0 5 Knuckle arm bush D Steering knuckle arm nut C 65 6 5 47 0 6 Spacer E Tie rod end nut D 60 6 0 43 5 7 Dust seal F Tie rod locknut E 50 5 0 36 0 8 Tie lod end F 29 2 9 21 0 ...

Page 156: ...seal 2 Handlebars 8 Steering shaft bush 3 Handlebar lower holder 9 O ring ITEM N m kgf m lb ft 4 Steering shaft A Handlebar clamp bolt A 25 2 5 18 0 5 Steering shaft holder B Steering shaft holder bolt B 23 2 3 17 0 6 Dust seal C Steering shaft lower nut C 35 3 5 25 5 ...

Page 157: ...heel 5 8 Remove the front grip 5 7 Remove the front brake 5 13 Remove the front brake cable 1 Remove the cotter pin and tie rod end nut 2 Remove the cotter pin and knuckle arm nut 3 Remove the knuckle arm 4 Remove the front shock absorber 5 Remove the front suspension arm 6 ...

Page 158: ...es with the special tools 09923 73210 Bearing remover 09930 30104 Sliding shaft SUSPENSION ARM Inspect the suspension arm and suspension arm bush for wear or damage If any defects are found replace it with a new one FRONT SHOCK ABSORBER Inspect the shock absorber body and bush for damage and oil leakage If any defects are found replace it with a new one Do not attempt to disassemble the front shoc...

Page 159: ...t FRONT SUSPENSION Tighten the front suspension arm bolts to the specified torque Front suspension arm pivot nut 65 N m 6 5 kgf m 47 0 lb ft Tighten the front shock absorber bolts to the specified torque Front shock absorber upper bolt 50 N m 5 0 kgf m 36 0 Ib ft Front shock absorber lower bolt 50 N m 5 0 kgf m 36 0 Ib ft Tighten the knuckle arm nut to the specified torque and install the cotter p...

Page 160: ...front wheel 5 9 After installing the front brake and front suspension adjust the following items Front brake lever play 2 20 STEERING Remove the front fender 5 5 Remove the front suspension 5 22 Remove the steering head cover 1 Remove the right grip 2 front brake lever 3 Remove the left grip 4 left handle switch 5 and rear brake lever 6 Disconnect the left handle switch coupler 7 and parking brake...

Page 161: ...e the cotter pins and tie rod end nuts 2 Remove the tie rods Remove the handlebar clamp 3 Remove the steering shaft holder 4 and steering shaft 5 Remove the steering shaft bush with the special tools and suitable size wrench 09924 84521 Bearing installer set 09930 30721 Rotor remover ...

Page 162: ...for wear and tie rod end for smooth movement If any defects are found replace it with a new one STEERING SHAFT AND HOLDER Inspect the steering shaft for distortion or bend If any defects are found replace it with a new one Inspect the steering shaft holders 1 holder shafts 2 and dust seals 3 for wear or damage If any defects are found replace them with new ones The locknuts 6 have left hand thread...

Page 163: ...lower dust seal 1 O ring 2 and steering shaft 3 99000 25160 SUZUKI RESISTANCE GREASE or equivalent Install the steering shaft lower dust seal 1 and O ring 2 to the steering shaft 3 Tighten the steering shaft lower nut to the specified torque and install the cotter pin Steering shaft lower nut 35 N m 3 5 kgf m 25 5 Ib ft The removed steering shaft bush must be replaced with a new one To prevent the...

Page 164: ... 0 Ib ft TIE ROD Tighten the tie rod end nuts to the specified torque and install the cotter pins Tie rod end nut 50 N m 5 0 kgf m 36 0 lb ft NOTE The lock nuts 1 have left hand threads HANDLEBARS Set the yellow mark on the handlebar lower holder to the for ward The removed cotter pins must be replaced with new ones Forward ...

Page 165: ...der First tighten the bolts 1 to the specified torque and then tighten the bolts 2 to the specified torque Handlebar clamp bolt 25 N m 2 5 kgf m 18 0 lb ft NOTE The higher portion of handlebar holder must face forward so that the clearance C of holder is in back of the handlebars Align the punched mark D on the handlebars with the mating surface E of left brake lever holder 3 Align the punched mar...

Page 166: ...CHASSIS 5 31 Install the left handle switch 4 and left grip 5 Align the punched mark F on the handlebars with the mating surface G of throttle lever 6 Install the right grip 7 ...

Page 167: ... toe in is within the specified range B A Toe in Toe in Standard 4 5 3 mm 0 17 0 1 in Temporarily tighten the four locknuts 3 Check that the distance 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 distance A and B If the toe in is not within specification repeat the adjus...

Page 168: ...r 5 Rear brake drum H Spring 6 Rear brake shoe I Limit indicator 7 Rear axle J Rear brake cam lever 8 Dust seal A Rear axle lock nut ITEM N m kgf m lb ft 9 Rear axle housing bearing B Rear axle nut A 180 18 0 130 0 0 Spacer C Rear sprocket nut B 180 18 0 130 0 A Rear brake anchor pin D Rear brake cam lever nut C 28 2 8 2 0 B Rear housing E Rear axle housing bolt D 8 0 8 6 0 C Rear sprocket flange ...

Page 169: ...er pin and rear axle nut 1 Remove the rear wheel 2 Remove the rear axle washer 3 and rear wheel hub 4 Remove the rear axle lock nut 5 and axle nut 6 with the spe cial tool 09940 92430 Rear axle nut wrench set Remove the rear brake drum outer seal 7 ...

Page 170: ...emove the rear brake drum cover 8 Loosen the rear brake cable 9 Remove the rear brake drum 0 Remove the rear brake shoes A Remove the rear brake cable B rear brake cam lever C limit indicator D spring E and spacer F ...

Page 171: ...ther hose G Remove the O rings H Disengage the drive chain I from the rear sprocket Remove the rear axle shaft J and sprocket K Draw out the rear axle shaft J to the right side Remove the chain guide L chain case M and rear axle N ...

Page 172: ...ect the brake shoes for wear or damage If any wear or defects are found replace the brake shoes as a set REAR BRAKE DRUM OUTER SEAL Inspect the rear drum outer seal and inner seal for wear or dam age If any defects are found replace them with new ones Remove the rear brake inner seal with the special tool 09913 50121 Oil seal remover REAR BRAKE DRUM COVER Inspect the rear brake drum cover for wear...

Page 173: ... 23 in 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block set 100 mm REAR SPROCKET Inspect the rear sprocket teeth for wear If they are worn as illus trated replace the sprocket and drive chain as a set A Normal wear B Excessive wear Remove the rear sprocket 1 Remove the dust seal 2 REAR AXLE HOUSING Inspect the rear axle housing for damage If any defects are found repl...

Page 174: ... with the special tool 09913 50121 Oil seal remover REAR AXLE HOUSING BEARING Inspect the inner race play of the rear axle housing 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 ...

Page 175: ...20 09923 73210 Bearing remover 17 Remove the spacer 1 REASSEMBLY AND INSTALLATION Reassemble and install the rear brake and rear axle housing in the reverse order of removal and disassembly Pay attention to the following points REAR SPROCKET AND REAR AXLE Install the dust seal with the special tool 09913 70210 Bearing installer ...

Page 176: ... stamped mark A on the rear sprocket should face out side Tighten the rear sprocket nut to the specified torque Rear sprocket nut 28 N m 2 8 kgf m 20 0 Ib ft Install the rear sprocket flange 1 to the rear axle shaft 2 ...

Page 177: ...ing them X 99000 25010 SUZUKI SUPER GRESE A or equivalent Install the rear axle housing bearing with the special tool Install the dust seals with the special tool 09924 84510 Bearing installer set First install the left bearing 1 then install the spacer 2 and right bearing 3 The sealed cover of the bearing must face outside Left Right Left Right ...

Page 178: ...the axle housing Apply a small quantity of THREAD LOCK SUPER 1322 to the anchor pin nut H 99000 32110 THREAD LOCK SUPER 1322 REAR BRAKE Apply SUZUKI SUPER GREASE A to the rear brake cam shaft and O rings X 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the O rings into the brake camshaft hole NOTE Face the groove on the camshaft to the inside The removed O rings must be replaced with new ...

Page 179: ...aft REAR BRAKE DRUM COVER Install the rear brake inner seal with the special tool 09913 70210 Bearing installer Apply SUZUKI RESISTANCE GREASE to the rear brake inner seal X 99000 25160 SUZUKI RESISTANCE GREASE or equivalent grease Apply SUZUKI BOND 1215 to the rear brake cover E 99000 31110 SUZUKI BOND 1215 or equivalent bond Install the rear brake drum cover so that the water drain tube 1 downwa...

Page 180: ...UZUKI SUPER GREASE A or equivalent grease Apply a small quantity of THREAD LOCK SUPER 1322 to the rear brake drum cover mounting screws H 99000 32110 THREAD LOCK SUPER 1322 or equivalent thread lock SUZUKI RESISTANCE GREASE to the around the rear brake drum outer seal 99000 25160 SUZUKI RESISTANCE GREASE Be careful not to apply too much grease to the cam and pin If grease gets on the lining brake ...

Page 181: ...0 Ib ft H 99000 32110 THRAD LOCK SUPER 1322 or equivalent thread lock 09940 92460 Rear axle nut wrench set Tighten the rear hub nut to the specified torque Rear hub nut 75 N m 7 5 kgf m 54 0 Ib ft Install the cotter pin After installing the rear brake and rear axle housing adjust the following items Rear brake lever play 2 20 Drive chain slack 2 18 The removed cotter pin must be replaced with a ne...

Page 182: ...e cover 0 Swingarm pivot bush 3 Chain case A Swingarm 4 Chain guide B Spacer 5 Swingarm pivot shaft A Rear shock absorber upper bolt ITEM N m kgf m lb ft 6 Dust seal B Rear shock absorber lower bolt A 29 2 9 21 0 7 Chain buffer C Swingarm pivot nut B 94 9 4 18 0 8 Oil seal C 102 10 2 74 0 ...

Page 183: ...el 5 8 Remove the rear brake and rear axle housing 5 34 Remove the chain guide 1 chain case 2 and rear axle housing 3 Remove the rear shock absorber 4 Remove the breather hose 5 Remove the swingarm pivot nut 6 and shaft Remove the swingarm 7 ...

Page 184: ... a new one REAR SHOCK ABSORBER DUST SEAL Remove the collars Inspect the dust seal lips and collars for wear or damage If any defects are found replace the dust seals and collars with new ones Remove the dust seals REAR SHOCK ABSORBER BEARING Inspect the bearings for abnormal noise and smooth movement Do not attempt to disassemble the rear shock absorber It is unserviceable ...

Page 185: ...e and replace it if the runout exceeds the limit 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block set 100 mm Swingarm pivot shaft rumout Service Limit 0 6 mm 0 02 in SWINGARM Inspect the swingarm for distortion or damage If any defects are found replace the swingarm with a new one Remove the dust cover 1 Remove the oil seal 2 ...

Page 186: ...ng remover 09930 30104 Sliding shaft Remove the swingarm spacer 4 SWINGARM BUSH Inspect the swingarm bush for wear or damage If any defects are found replace awingarm bushes with new ones SWINGARM SPACER Inspect the swingarm spacer for wear or damage If any defects are found replace swingarm spacer with a new one ...

Page 187: ...he following points Press the bearing into the rear shock absorber to the depth of 4 mm 0 157 in with the special tool and suitable socket wrench 09924 84521 Bearing installer set Apply SUZUKI SUPER GREASE A to lip of the dust seals and collars X 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Install the dust seals 1 and collars 2 into the rear shock absorber The removed bearing must be re...

Page 188: ...suitable socket wrench 09941 94513 Steering race installer Install the swingarm spacer 1 Install the swingarm pivot bushes with the special tool 09941 34513 Steering race installer Install the outer spacer 2 Apply SUZUKI RESISTANCE GREASE to the outer spacers 99000 25160 SUZUKI RESISTANCE GREASE Install the oil seals ...

Page 189: ...seals 99000 25160 SUZUKI RESISTANCE GREASE Install the dust seals 3 and chain buffer 4 Tighten the swingarm pivot nut to the specified torque Swingarm pivot nut 102 N m 10 2 kgf m 74 0 Ib ft Tighten the rear shock absorber upper bolt to the specified torque Rear shock absorber upper bolt 29 N m 2 9 kgf m 21 0 Ib ft ...

Page 190: ...pecified torque Rear shock absorber lower bolt 94 N m 9 4 kgf m 68 0 Ib ft Install the rear axle housing and rear brake 5 40 Install the rear wheel 5 9 After installing the rear suspension adjust the following items Rear brake lever play 2 20 Drive chain slack 2 18 ...

Page 191: ...CTRICAL COMPONENTS 6 5 CHARGING SYSTEM 6 7 TROUBLESHOOTING 6 7 INSPECTION 6 8 STARTER SYSTEM 6 11 TROUBLESHOOTING 6 11 STARTER MOTOR REMOVAL 6 12 STARTER MOTOR DISASSEMBLY 6 13 STARTER MOTOR INSPECTION 6 14 STARTER MOTOR REASSEMBLY 6 15 STARTER MOTOR INSTALLATION 6 16 STARTER RELAY INSPECTION 6 16 IGNITION SYSTEM 6 18 TROUBLESHOOTING 6 18 INSPECTION 6 20 SWITCHES 6 23 BATTERY 6 24 SPECIFICATIONS 6...

Page 192: ... the coupler itself and do not pull the lead wires Inspect each terminal on the coupler for being loose or bent Inspect each terminal for corrosion and contamination CLAMP Clamp the wiring harness at such positions as indicated in WIRING HARNESS ROUTING 7 14 Bend the clamp properly so that the wiring harness is clamped securely In clamping the wiring harness use care not to allow it to hang down D...

Page 193: ... charging the battery Be sure to recharge the battery in a well ventilated and open area Note that the charging system for the MF battery is different from that of a conventional battery Do not replace the MF battery with a conventional battery CONNECTING THE BATTERY When disconnecting terminals from the battery for disassem bly or servicing be sure to disconnect the battery lead wire first When c...

Page 194: ...ed If voltage is applied the tester will be damaged After using the tester be sure to turn the switch to the OFF position 09900 25008 Multi circuit tester set NOTE When connecting the multi circuit tester use the needle pointed probe to the back side of the lead wire coupler and connect the probes of tester to them Use the needle pointed probe to prevent the rubber of the water proof coupler from ...

Page 195: ...ELECTRICAL SYSTEM 6 5 LOCATION OF ELECTRICAL COMPONENTS 1 Battery 2 Starter relay 3 Fuse 10 A 4 CDI unit 5 Generator 6 CKP sensor 7 Ignition coil ...

Page 196: ...6 6 ELECTRICAL SYSTEM 1 Ignition switch 2 Parking brake switch 3 Engine stop switch 4 Starter button 5 Starter motor 6 Regulator rectifier ...

Page 197: ...tage between the battery terminals 6 9 Is the regulated voltage OK Step 4 1 Measure the resistance of the generator coil 6 9 Is the resistance of generator coil OK YES Remove accessories NO Go to Step 2 YES Go to Step 3 NO Short circuit of wiring harness Faulty electrical equipment YES Faulty battery Abnormal driving condition NO Go to Step 4 YES Go to Step 5 NO Faulty generator coil Disconnected ...

Page 198: ...e current between battery terminal and the battery lead wire using the multi circuit tester If the reading exceeds the specified value leakage is evident 09900 25008 Multi circuit tester set R Tester knob indication Current 20 mA Battery current leak Under 1 mA NOTE When checking to find the excessive current leakage remove the couplers and connectors one by one checking each part YES Go to Step 6...

Page 199: ...08 Multi circuit tester set W Tester knob indication Voltage Regulated voltage Charging output 13 5 15 2 V at 2 800 r min GENERATOR COIL RESISTANCE Remove the left footrest mudguard 5 5 Disconnect the generator coupler 1 Measure the resistance between the W R wire and ground with the multi circuit tester If the resistance is out of specified valve replace the genera tor coil with a new one 09900 2...

Page 200: ...nce 20 V and more at 2 800 r min When engine is cold REGULATOR RECTIFIER Disconnect the regulator rectifier coupler 1 Remove the regulator rectifier 2 Measure the voltage between the lead wire with the multi circuit tester as indicated in the table below If the voltage is not within the specified value replace the regulator rectifier with a new one 09900 25008 Multi circuit tester set Tester knob ...

Page 201: ...click sound heard Step 2 1 Check if the starter motor runs when its terminal is connected to the battery terminal Do not use thin wire because a large amount of current flows Does the starter motor run YES Go to Step 2 NO Go to Step 3 YES Faulty starter relay Loose or disconnected starter motor lead wire Loose or disconnected between starter relay and battery terminal NO Faulty starter motor Start...

Page 202: ...ER MOTOR REMOVAL Disconnect the battery lead wire Remove the left footrest mudguard 5 5 Remove the starter motor mounting bolts 1 and engine grand lead wire 2 Disconnect the starter motor lead wire 3 YES Go to Step 4 NO Faulty engine stop switch Faulty starter button Faulty parking brake switch Faulty ignition switch Poor contact of connector Open circuit in wiring harness YES Poor contact of the ...

Page 203: ...EM 6 13 STARTER MOTOR DISASSEMBLY Disassemble the starter motor as shown in the illustration 1 O ring 4 Starter motor case 2 Housing end inside 5 Housing end outside 3 Armature 6 Starter motor lead wire mounting bolt ...

Page 204: ...commutator for discoloration abnormal wear or undercut A If abnormal wear is found replace the armature with a new one If the commutator surface is discolored polish it with 400 sand paper and wipe it using a clean dry cloth If there is no undercut scrape out the insulator with a saw blade 1 Insulator 2 Segment ARMATURE COIL INSPECTION Check for continuity between each segment and between each seg...

Page 205: ... the starter motor in the reverse order of disassem bly Pay attention to the following points Apply SUZUKI SUPER GREASE A to the lip of the oil seal X 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Apply SUZUKI MOLY PASTE to the armature shaft Z 99000 25140 SUZUKI MOLY PASTE Apply SUZUKI SUPER GREASE A to the O ring X 99000 25010 SUZUKI SUPER GREASE A or equivalent grease ...

Page 206: ...tery Remove the starter relay cover 1 Disconnect the starter relay coupler 2 Disconnect the battery lead wire 3 starter motor lead wire 4 Remove the starter relay 5 Apply 12 V to A and B 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 se...

Page 207: ...ce is not within the standard range replace the starter relay with a new one 09900 25008 Multi circuit tester set V Tester knob indication Resistance W Starter relay resistance 3 6 W Tighten the starter relay lead wire mounting bolt to the speci fied torque Starter relay lead wire mounting bolts 4 5 N m 0 45 kgf m 3 0 lb ft ...

Page 208: ...and the battery is fully charged before diagnosing Step 1 1 Check the ignition system couplers for poor connections Is there connection in the ignition system couplers YES Go to Step 2 NO Poor connection of couplers O W B Ignition coil Engine stop switch Spark plug Fuse 10A Battery Generator CKP sensor CDI unit W R B W B W W R Br Br O W O W O W W B B O O O W Parking brake switch R R O R O Ignition...

Page 209: ...the ignition coil 6 21 Is the ignition coil OK Step 7 1 Measure the CKP sensor peak voltage and resistance 6 21 NOTE The CKP sensor peak voltage inspection is applicable only with the multi circuit tester and peak volt adaptor Is the peak voltage and resistance OK YES Go to Step 3 NO Faulty ignition switch Faulty engine stop switch Broken wiring harness or poor connection of related circuit couple...

Page 210: ...ition coil primary wires 09900 25008 Multi circuit tester set Turn the ignition switch to the ON position Push the starter button and allow the engine to crank for a few seconds and then measure the ignition coil primary peak volt age Repeat the above procedure a few times and measure the highest ignition coil primary peak voltage If the voltage is lower than the standard values inspect the igniti...

Page 211: ...SENSOR PEAK VOLTAGE Remove the seat 5 4 NOTE Make sure all of the couplers are connected properly Disconnect the CDI unit coupler 1 Measure the CKP sensor peak voltage in the following proce dure Connect the multi circuit tester with the peak volt adaptor as follows CKP sensor Probe Brown lead wire Probe Black White lead wire or ground 09900 25008 Multi circuit tester set Turn the ignition switch ...

Page 212: ...same manner as on the CDI unit coupler W Tester knob indication Voltage CKP sensor peak voltage 1 5 V and more If the peak voltage on the generator coupler is within the specifi cation but on the CDI unit coupler is not within specification replace the wiring harness with a new one If both peak voltages are not within specification replace the generator coil with a new one CKP SENSOR RESISTANCE Re...

Page 213: ...ester knob indication Continuity test IGNITION SWITCH ENGINE STOP SWITCH STARTER BUTTON PARKING BRAKE SWITCH Color ON OFF RUN Position B Y B W R O Color Position O G O W Color Position B W Y G OFF ON Color Position O W B WIRE COLOR O Orange R Red B W Black with White tracer B Y Black with Yellow tracer O G Orange with Green tracer O W Orange with White tracer W B White with Black tracer Y G Yellow...

Page 214: ...round Remove the caps 2 NOTE After filling the electrolyte completely use the removed cap 2 as sealing 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 4 into the bat tery s electrolyte filler holes holding the container firmly so that it does not fall Take precaution not to allow any of the fluid t...

Page 215: ...e 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 the caps have been installed to the battery do not remove the caps Do not tap the caps with a tool such as hammer when installing them CORRECT INCORRECT For charging the battery make sure to use the cha...

Page 216: ...riod B Stop charging Recharging time 0 5 A for 5 to 10 hours or 5 A for 30 min utes After recharging wait for 30 minutes and more and check the battery voltage with a multi circuit tester If the battery voltage is the 12 5 V and less recharge the bat tery again If battery voltage is still 12 5 V and less after recharging replace the battery with a new one When the vehicle is not used for a long pe...

Page 217: ...13 OIL STRAINER 7 13 OIL PUMP 7 13 ENGINE LUBRICATION SYSTEM CHART 7 13 WIRING DIAGRAM 7 14 WIRING HARNESS CABLE AND HOSE ROUTING 7 15 WIRING HARNESS ROUTING 7 15 CABLE ROUTING 7 17 FUEL HOSE PIPING 7 18 REAR BRAKE BREATHER HOSE ROUTING 7 19 COOLING DUCT ROUTING 7 20 EXHAUST PIPE COVER 7 21 SPECIAL TOOLS 7 22 TIGHTENING TORQUE 7 25 ENGINE 7 25 FUEL 7 25 CHASSIS 7 26 TIGHTENING TORQUE CHART 7 27 SE...

Page 218: ...e CDI unit Defective ignition coil Open circuited wiring connections Defective generator coil 3 No fuel reaching the carburetor Clogged fuel hose Clogged or defective fuel valve Defective carburetor needle valve Clogged fuel filter Adjust Repair or replace Adjust Replace Replace See electrical section Retighten Repair or replace Tighten Replace Clean or replace Clean and dry Replace Replace Replac...

Page 219: ...o come from the movable drive and driven face Worn or slipping drive belt Worn rollers in movable drive face Adjust Replace Replace Replace Clean Replace Replace Replace Replace Replace Replace bearing retainer Replace Replace Symptom possible causes and remedy Worn or damaged clutch shoe Worn clutch housing Replace Replace Symptom possible causes and remedy Valve clearance out of adjustment Poor ...

Page 220: ...ue to poorly working timing advance circuit Defective CDI unit Defective ignition coil Defective generator coil Low float chamber fuel level Clogged fuel hose resulting in inadequate fuel supply to the carburetor Clogged fuel valve Clogged air cleaner element Sucking air from carburetor joint Replace Replace Adjust Adjust Replace Replace Replace Replace Adjust float height Clean and prime Clean Cl...

Page 221: ...ce Clean Regap or replace Tighten or replace Adjust float height Replace Retighten or replace Drain out excess oil Symptom possible causes and remedy Heavy carbon deposit on piston head Not enough oil in the engine Use of incorrect engine oil Low float chamber fuel level Air leakage from intake pipe Incorrect spark plug Clogged exhaust pipe muffler Ignition timing too advanced due to defective tim...

Page 222: ...ses and remedy Clogged or loose pilot jet Air leaking from carburetor joint Clogged pilot outlet port Clogged bypass port Starter plunger not fully closed Clean or tighten Tighten or replace defective part Clean Clean Adjust Symptom possible causes and remedy Clogged main jet Clogged needle jet Improperly working piston valve Clogged fuel filter Clean Clean Adjust Clean or replace Symptom possible...

Page 223: ...ct front tires Damaged or worn suspension arms and related bushings Distorted front wheels Loose chassis nuts and bolts Regulate Tighten Replace Replace or tighten Replace Replace Replace Tighten Symptom possible causes and remedy Unequally inflated tires Improper front wheel alignment Worn front wheel hub bearings Distorted frame Defective shock absorber Regulate Adjust Replace Repair or replace ...

Page 224: ... causes and remedy Distorted wheel rims Damaged or worn rear axle housing bearings Defective or incorrect tires Defective rear axle Loose nuts or bolts on rear suspension Loose rear wheel hub nuts Loosen rear axle housing mounting bolts Improper rear brake adjustment Rear shock absorber leaks oil Damaged or worn rear swingarm and related bush ings Replace Replace Replace Replace Retighten Tighten ...

Page 225: ...nd shoes Replace Adjust Symptom possible causes and remedy Carbon adhesion on lining surface Loose front wheel hub nut or rear wheel hub nut Damaged wheel hub bearings Worn linings Wrongly fixed spring Repair surface with sandpaper Tighten to specified torque Replace Replace Set correctly Symptom possible causes and remedy Worn brake lever cam Replace brake cam Symptom possible causes and remedy R...

Page 226: ... clearance of valve stems in valve guides Worn stem oil seal Replace Replace Replace Replace Symptom possible causes and remedy Too hot spark plug Overheated the engine Loose spark plug Too lean mixture Replace with cold type plug Tune up Retighten Adjust carburetor Symptom possible causes and remedy Open or short circuited lead wires or loose lead connections Short circuited grounded or open gene...

Page 227: ...intermittent short circuiting Internally short circuited generator Defective regulator rectifier Repair or replace Replace Replace Symptom possible causes and remedy Run down battery Defective switch contacts Brushes not seating properly on starter motor commutator Defective starter relay Defective main fuse Repair or replace Replace Repair or replace Replace Replace ...

Page 228: ...rial as a result of overcharging Internal short circuit in the battery Too low battery voltage Too old battery Check the generator regulator rectifier and circuit connections and make necessary adjustments to obtain specified charging operation Replace the battery and correct the charging sys tem Replace the battery Recharge the battery fully Replace the battery Symptom possible causes and remedy ...

Page 229: ...RAINER 2 12 OIL PUMP 3 38 ENGINE LUBRICATION SYSTEM CHART OIL STRAINER OIL PUMP OIL FILTER CRANKSHAFT BEARING L OIL NOZZLE CRANK PIN CYLINDER WALL CONROD SMALL END CYLINDER ROCKER ARM ROCK ARM SHAFT CAM CHAIN PISTON PIN CYLINDER HEAD CAM SHAFT CONROD BIG END BEARING MAIN GALLERY OIL PAN ...

Page 230: ... B W W B O W B W B W Y G B W B W B W W R W R R R Br W R Br W B W B Y G O W O W B O O R W B W B Y G O W O O O R B BATTERY WIRE COLOR B Br O R B W B Y O B O G O W R B R W W B W R Y G Black Brown Orange Red Black with White tracer Black with Yellow tracer Orange with Black tracer Orange with Green tracer Orange with White tracer Red with Black tracer Red with White tracer White with Black tracer Whit...

Page 231: ...Clamp Clamp Clamp Battery plus lead wire Generator Starter motor Wiring harness Clamp Generator Batery minus lead wire Battery minus lead wire Wiring harness Hardle switch L Rear brake switch Clamp Hardle switch L Rear brake switch Ignition switch Wiring harness Brather hose Air vent hose Battery plus lead wire Regulater rectifier lead wire Clamp Breather hose Battery plus lead wire Battery minus ...

Page 232: ...7 16 SERVICING INFORMATION Passthe wiring harness down side of the CKP sensor 10 N m 1 0 kgf m 7 0 lb ft 6 0 N m 0 6 kgf m 4 0 lb ft ...

Page 233: ...Rear brake cable Rear engine mounting plate Rear brake cable Rear brake cable Front brake cable Throttle cable Throttle cable Throttle cable 1 2 7 4 5 4 1 mm 0 15 0 03 in 5 2 mm 0 19 0 07 in 3 1 mm 0 11 0 03 in 12 5 mm 0 47 0 19 in 1 Pass the rear brake cable through downside of the frame 6 Fix the boot of the front brake cable 2 Pass the brake cables through downside of the frame 7 Pass the rear ...

Page 234: ...7 18 SERVICING INFORMATION FUEL HOSE PIPING Fuel tank breather hose Handlbers Vacum hose Clip Clip Fuel hose Fuel valve ...

Page 235: ...AR BRAKE BREATHER HOSE ROUTING Clamp Clamp Rear swingarm 2 1 Rear brake breather hose 1 Pass the rear brake breather hose through downside of the rear shock absorber 2 Insert the rear brake breather hose into the joint to the root ...

Page 236: ...7 20 SERVICING INFORMATION COOLING DUCT ROUTING Setting position Setting position Attach the E G SID mark of an engine side 45 Setting position ...

Page 237: ...SERVICING INFORMATION 7 21 EXHAUST PIPE COVER 8 5 8 5 8 5 5 6 4 5 ...

Page 238: ...0 20605 Dial calipers 1 100 mm 10 34 mm 09900 20607 Dial gauge 1 100 mm 10 mm 09900 20701 Magnetic stand 09900 20803 09900 20806 Thickness gauge 09900 20805 Tire depth gauge 09900 21304 V block set 100 mm 09900 22401 10 18 mm Small bore gauge 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set 09910 32812 Crankshaft installer 09911 11310 Attach ment 09913 50121 Oil seal remov...

Page 239: ...6 14521 Attachment 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 53360 Valve guide installer attachment 09916 84511 Tweezers 09917 14910 Valve clearance adjusting driver 09920 13120 Crankshaft separator 09921 20240 Bearing remover set 09922 31420 Clutch spring compressor 09923 73210 09923 74511...

Page 240: ...09924 84521 Bearing installer set 09930 10121 Spark plug wrench set 09930 30104 Sliding shaft 09930 40113 Rotor holder 09930 30721 Rotor remover 09930 31920 09930 34980 Rotor remover 09930 44520 Rotor holder 09940 92460 Rear axle nut wrench set 09941 34513 Steering race installer 09941 50111 Bearing remover ...

Page 241: ...t 10 1 0 7 0 Generator rotor cover bolt 10 1 0 7 0 Generator cover cap 15 1 5 11 0 Valve timing inspection plug 17 5 1 75 12 5 Crank case cover bolt 10 1 0 7 0 Engine oil drain plug 17 5 1 75 12 5 Final reduction gear box cover bolt 10 1 0 7 0 Final reduction gear box drain 10 1 0 7 0 Engine mounting nut Front 100 10 72 5 under and rear 60 6 0 43 5 Engine mounting upper bracket 35 3 5 25 5 Muffler...

Page 242: ...5 18 0 Front shock absorber bolt upper and lower 50 5 0 36 0 Front hub nut 65 6 5 47 0 Wheel set nut front and rear 55 5 5 40 0 Front brake cable equalizer bolt 8 0 8 6 0 Front brake cam lever nut 8 0 8 5 8 Swingarm pivot nut 102 10 2 74 0 Rear shock absorber bolt upper 29 2 9 21 0 lower 94 9 4 68 0 Rear hub nut 75 7 5 54 0 Rear brake cam lever nut 8 0 8 6 0 Rear axle housing set bolt 110 11 0 79 ...

Page 243: ... 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 ...

Page 244: ...7 0 0018 0 0022 Valve guide I D IN EX 5 500 5 512 0 2165 0 2170 Valve stem O D IN 4 975 4 990 0 1958 0 1964 EX 4 955 4 970 0 1950 0 1956 Valve stem deflection IN EX 0 35 0 014 Valve stem runout IN EX 0 05 0 002 Valve stem end length IN EX 3 0 0 12 Valve head thickness IN EX 0 5 0 02 Valve seat width IN EX Valve head radial runout IN EX 0 03 0 001 Valve spring free length IN EX 32 8 1 29 Valve spri...

Page 245: ...MIT Compression pressure 1 500 kPa 15 kgf cm 213 psi 1 300 kPa 13 kgf cm 185 psi Piston to cylinder clearance 0 020 0 030 0 0008 0 0012 0 120 0 0047 Cylinder bore 45 500 45 515 1 7913 1 7919 Nicks or Scratches Piston diam 45 490 45 475 1 7909 1 7903 Measure at 10 mm 0 4 in from the skirt end 45 380 1 7860 Cylinder distortion 0 05 0 002 Piston ring free end gap 1st Approx 5 5 0 22 2nd Approx 5 3 0 ...

Page 246: ...30 0 5523 Piston pin O D 13 986 14 000 0 5506 0 5511 13 980 0 5503 ITEM STANDARD LIMIT Conrod small end I D 14 006 14 024 0 5514 0 5521 14 040 0 5527 Conrod deflection 3 0 0 12 Conrod big end side clearance 0 10 0 45 0 006 0 019 1 0 0 04 Conrod big end width 16 95 17 00 0 67 0 669 Crank web to web width 49 0 1 1 9291 0 004 Crankshaft runout 0 08 0 003 ITEM STANDARD LIMIT Clutch housing I D 110 00 ...

Page 247: ...h 19 9 0 78 18 9 0 74 Movable driven face spring free length 105 0 4 13 99 8 3 92 Drive chain Type RK 530 Links 60 20 pitch length 319 4 12 57 Drive chain slack 15 25 0 6 1 0 ITEM SPECIFICATION Carburetor type MIKUNI VM16H Bore size 16 mm I D No 08H0 Idle r min 1 900 100 r min Float height 16 1 0 mm 0 6 0 04 in Main jet M J 80 Jet needle J N 4LA43 1 Needle jet N J E 1M Pilot jet P J 17 5 Air screw...

Page 248: ...ion coil primary peak voltage 150 V and more Ground B CKP sensor peak voltage 1 5 V and more Br Ground Generator coil resistance Charging 0 5 2 0 W W R Ground CKP sensor 150 230 W Br Ground Generator no load voltage when engine is cold 20 V AC and more at 2 800 r min Generator output 70 W at 5 000 r min Regulated voltage 13 5 15 2 V Starter relay resistance 3 6 W Battery Type designation YTX7A BS ...

Page 249: ...e runout Rear 6 0 0 23 Wheel rim size Front Rear AT19 7 8 Toe in with 63 kg 4 5 3 0 17 0 1 Turning radius 2 5 m 8 2 ft Camber 0 6 Caster 3 Trail 11 0 4 Steering angle 37 5 Right Left ITEM STANDARD LIMIT Cold inflation tire pressure Solo riding Front 22 5 kPa 0 225 kgf cm 3 3 psi Rear 20 kPa 0 20 kgf cm 2 9 psi Tire size Front AT 19 7 8 tubeless Rear AT 19 7 8 tubeless Tire tread depth Front 4 0 0 ...

Page 250: ...than 5 methanol with appropriate cosolvents and corrosion inhibitor is permissible P 28 33 Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended Others Fuel tank capacity 6 0 L 0 7 0 6 US lmp gal Engine oil type SAE 10W 40 API SF SG or SH SJ with JASO MA Engine oil capacity Change 950 ml 1 6 1 3 US lmp qt Filter charge 1 050 ml 2 21 1 84 US lmp qt Overhaul 1 100 ml...

Page 251: ...Prepared by September 2006 Part No 99500 40020 01E Printed in Japan 254 ...

Page 252: ...Printed in Japan K7 ...

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