Suzuki RM250 Owner'S Service Manual Download Page 108

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Summary of Contents for RM250

Page 1: ... ...

Page 3: ... result in death or injury 4 CAUTION Indicates a potential hazard that could result in motorcycle damage NOTE Indicates special information to make maintenance easier or instructions clearer COMPETITION MOTORCYCLES The Suzuki RM250 is a high performance competition only motorcycle It is not designed or approved for general off highway riding as it does not meet U S Environmental Protection Agency ...

Page 4: ...it properly Gasoline vapors can catch fire easily Do not smoke when servicing the machine Do not service the machine in an area where there are open flames or sparks A WARNING o o Brake fluids and engine coolant can be hazardous to humans and pets Brake fluid and engine coolant are harmful or fatal if swal lowed and harmful if it comes in contact with your skin or eyes Keep brake fluid and engine ...

Page 5: ...work together pay attention to the safety of each other After reassembly inspect parts for tightness and operation A WARNING Servicing the machine without proper clothes and protective gear can be hazardous You can be injured if you do not wear Rroper clothes and protective gear Be sure to wear proper clothes and shoes for servicing and wear protective glasses mask or gloves as necessary P III REP...

Page 6: ... MARK MATERIALS SUZUKI SUPER GREASE A 99000 25030 _ SUZUKI SILICONE GREASE 99000 25100 THREAD LOCK SUPER 1303 99000 32030 SUZUKI BOND 1207B 99104 31140 Use or apply OOT4 brake fluid FROtIT FIIIKDlL SUZUKI FORK OIL 55 05 99000 99001 555 ...

Page 7: ...RIALS U1 I I ___ l SUZUKI REAR SUSPENSION OIL 55 25 99000 99001 525 Use engine coolant Apply engine oil or transmission oil Tighten a nut or bolt to the specified torque Replace a part with a new one when ressembling J ...

Page 8: ... MEMO ...

Page 9: ...OUNTING AND MOUNTING CYLINDER PISTON AND EXHAUST VALVE CLUTCH KICK STARTER TRANSMISSION AND CRANKSHAFT FUEL SYSTEM COOLING SYSTEM ELECTRICAL SYSTEM FRONT AND REAR WHEELS FRONT AND REAR BRAKES FRONT FORK AND STEERING REAR SUSPENSION SERVICE DA TA SPECIAL TOOLS WIRE CABLE AND HOSE ROUTING SPECIFICA TIONS ...

Page 10: ...1 1 GENERAL INSTRUCTIONS LOCATION OF PARTS CD Clutch lever Engine kill switch Throttle grip Front brake lever Fuel tank cap Choke idle adjust knob Q Gearshift lever Kick starter lever Rear brake pedal ...

Page 11: ...ne power Mix fuel and the engine oil at the ratio of 32 1 NOTE Mix gasoline and the engine oil thoroughlv when the tem perature is below aoe 32 OF Vegetable based oils can separate easier than mineraloils Use premixture oil as soon as possible after mixing or lubrication performance of the engine oil can decrease Do not mix vegetable based 011 and mineral oil Insert the end of the breather hose in...

Page 12: ...he transmission into neutral 3 Open the throttle 1 8 1 4 turn and depress the kick starter lever forcefully To restart after the motorcycle has fallen 1 Shift the transmission into neutral 2 Open the throttle completely and depress the kick start er lever forcefully 3 Close the throttle gradually as engine speed increases 4 Wait until engine revs smoothly Stopping the Engine 1 Shift the transmissi...

Page 13: ... gear When neutral is desired press or Jjft the lever to a position halfway between low and 2nd gear BREAK IN When the Motorcycle Is New 1 Warm up the engine before starting off 2 Ride for 10 minutes using less than 1 2 throttle opening with various throttle opening 3 Ride for 20 minutes using less than 3 4 throttle opening with various threatle opening NOTE The break in period is the period of gr...

Page 14: ... and Cylinder Front fork CHECK FOR Heat range fouled electrode tightness Loose high tension cord Lubrication Oil level Coolant fevel Radiator hose damage Coolant leak Smooth operation Play Smooth operation Fluid level Brake lever pedal play Operation Slack lubrication chain oint clip condition Wear dama e Smooth operation Front fork air pressure Spoke tension Rim lock ti hteness Tire pressure Smoo...

Page 15: ...ing R Cylinder head cylinder exhaust valve and muffler C R Drive chain Clean and lubricate after every race Adjust slack every 30 minutes Engine sprocket R Rear sprocket R Check and retighten sprocket bolts at initial and subsequent 10 minutes of riding and each race thereafter Drive chain buffer R Drive chain guide R Kick starter lever Apply orease after every race Brake I I I Replace brake hose ...

Page 16: ...fouled Rich air fuel mixture Rich oil gasoline mixture Clean the spark plug with a brush or wire and check the spark plug gap with a thickness gauge Spark plug gap 0 55 0 65 mm 0 022 0 026 in Standard Spark plug NGK R411 BS B A CAUTION Changing the spark plug heat range improperly can damage the engine Select the spark plug heat range only after adjusting the ignition timing carburetor setting and...

Page 17: ...r Installation Apply grease to the element holder where it contacts the element Install the inner and outer elements onto the element holder as triangle mark faces the screw II CAUTION Improper element installation allows dust and dirt to enter the combustion chamber It can result in piston and cylinder wear Be sure to check the element seals properly after install ing the elements Install the air...

Page 18: ...of the oil level hole Tighten the filler cap and oil level screw firmly Transmission Oil Change Warm up the engine Place the motorcycle on the level ground and hold the motorcycle vertically Remove filler cap G and drain plug Drain oil thoroughly Tighten the drain plug firmly Pour specified amount of oil Oil change 750 ml 0 8 US qt Overhaul 850 ml 0 9 US qt Tighten the filler cap Run the engine fo...

Page 19: ...olant Use SUZUKI GOLDEN CRU ISER 1200NA or equivalent anti freeze and Summer coolant w hich is compatible with alu minum radiator mixed with distilled water at the ratio of 50 50 NOTE The radiator cylinder and cylinder head are made ofaluminum al oy Using non recommended engine coolant may corrode aluminum alloy and may clog the coolant pas sageways A WARNING Engine coolant is harmful if swallowed...

Page 20: ...oosen lock nut Turn adjuster so the clutch lever has 10 15 mm 0 4 0 6 in play at the clutch lever end before pressure is felt Tighten lock nut THROTTLE CABLE Adjust the throttle cable playas follows Loosen lock nut D Turn adjuster so the throttle grip has 2 4 mm 0 08 0 16 in play Tighten lock nut CD Remove the throttle housing cover Apply oil to the throttle cable Apply grease to the throttle cabl...

Page 21: ... for scratches cracks and wear around the piston bosses Remove minor scuffs w ith 1000 1200 sand paper Check piston ring wear Remove carbon deposits from the piston ring groove EXHAUST VALVE Remove the exhaust valve CT 6 3 Remove carbon deposits from the exhaust valve and ex haust valve guide Check for wear and damage EXHAUST SILENCER Silencer Inspection and Replacement Remove the seat and the rig...

Page 22: ...g adjuster 0 Check that both right and left alignment mark are at the same position Tighten the axle nut Replace the cotter pin with a new one Tightening torque 100 N m 10 0 kg m 72 5 Ib ft Tighten the lock nut securely NOTE Pull the upper drive chain tight and lock it by plac ing a bar between the drive chain and rear sprocket while tightening the axle nut This will help prevent the chain ad just...

Page 23: ...ace the sprockets as necessary NOTE When replacing a worn sprocket it is likely that the drive chain will need ta be rep aced as well DRIVE CHAIN GUIDE BUFFER TENSIONER ROLLER Drive Chain Guide Inspect the drive chain guide CD for bends and damage NOTE The drive chain can hit a bent guide causing noise and drive chain wear Inspect the chain guide defense for wear Drive Chain Guide Buffer Inspect t...

Page 24: ... pets Brake fluid is harmful or fatal if swallowed and harmful if it comes in contact with your skin or eyes Keep brake fluid away from children Call your doctor im mediately if brake fluid is swallowed and induce vomit ing Flush eyes or skin with water if brake fluid gets in eyes or comes in contact with skin A WARNING The use of any fluid except DOT4 brake fluid from a sealed containter can dama...

Page 25: ...djuster to obtain the specified play Brake lever play 5 20 mm 10 20 0 79 in Tighten the lock nut cD CAUTION Brake lever play less than 5 mm 0 20 in can cause brake dragging Do not adjust the brake lever play less than 5 mm 0 20 in Brake Pedal Height Adjustment Adjust the rear brake pedal height as follows Loosen lock nut CD Adjust the brake pedal height by turning the adjuster to locate the pedal ...

Page 26: ...he wheel bearing for rattles Replace the bear ings jf necessary a 13 3 Inspect the w heel rim runout C7 13 3 Spoke Nipple and Rim Lock Inspect the spokes for tension Retighten the spoke nip ples with a spoke nipple wrench so as all spokes have same tension Inspect the rim lock for tightness Tire Pressure Inspect front and rear tire pressure Cold inflation tire pressure 70 110kPa O 7 1 1 kg cm2 10 ...

Page 27: ...n linkage often according to con Keep seals fresh pivot points ditons 6 Steering stem C Every 5 races More Clean and pack the bearings bearings often according to con Keep seals fresh ditions 7 Choke idle A Pre race Lightly oil the choke idle adjust adjust knob knob shaft 8 Drive chain B Pre race and between Keep chain thoroughly lubed at every moto all times Always check wear and alignment The fo...

Page 28: ... 0 7 5 Master cylinder set bolt rear 10 1 0 7 5 Master cylinder rod lock nut A 18 1 8 13 0 Brake hose union bolt front master cylinder 18 1 8 13 0 Brake hose union bolts front and rear 23 2 3 16 5 Brake pad mounting bolts front and rear 20 2 0 14 5 Brake caliper mounting bolts front 23 2 3 16 5 Brake bleeder plugs front and rear 8 0 8 5 5 Disk plate screw front and rear 9 0 9 6 0 Front axle holder...

Page 29: ... marked bolt Diameter mm N m kg m Ib It N m kg m Ib ft 4 2 0 0 2 1 5 2 0 0 2 1 5 5 3 0 0 3 2 0 5 0 0 5 3 5 6 6 0 0 6 4 5 10 0 1 0 7 0 8 13 0 1 3 9 5 15 0 1 5 11 0 10 29 0 2 9 21 0 50 0 5 0 36 0 12 45 0 4 5 32 5 85 0 8 5 61 5 14 65 0 6 5 47 0 135 0 13 5 97 5 16 105 0 10 5 76 0 210 0 21 0 152 0 18 160 0 16 0 115 5 240 0 24 0 173 5 I ...

Page 30: ...ssion Piston ring worn or stuck Cylinder worn Air leak from cylinder gasket Air leak from crankshaft oil seat Incorrect ignition timing Carburetor fuel level maladjustment Insufficient Fuel deterioration power Brake dragging Exhaust pipe cracked or clogged with carbon Exhaust valve maladjustment Exhaust valve carbon deposits Air cleaner element clogged Carburetor jets clogged Incorrect fuel level ...

Page 31: ...d Replace E haust valve malfunction Clean adjust or replace Piston ring stuck Replace Engine speed does Too high engine idle speed Adjust not return smoothly Exhaust valve does Carbon deposits on exhaust valve Clean not work Exhaust valve damage Replace Governer damage Replace Exhaust valve shaft damage Replace Valve spring damage Replace Spark plug does Ignition coil malfunction Replace not ignit...

Page 32: ...ce Radiator cap seal damage Replace Incorrect radiator cap valve pressure Replace Cylinder or cylinder head cracked Replace Cylinder or cylinder head O rings damage Replace Clutch does not Clutch lever play maladjustment Adjust disengage Clutch spring damage Replace Clutch plates distortion Replace Clutch slipping Clutch cable play maladjustment Adjust Weakened clutch spring Replace Clutch pressur...

Page 33: ...sity Replace Damping force maladjustment Adjust Damping valve malfunction Replace Standard spring too soft Use optional spring Hard front High fork oil level Adjust suspension High fork oil viscosity Replace Damping force maladjustment Adjust Inner tube distortion Replace Soft rear Weakened spring Replace suspension Damping force maladjustment Adjust Low gas pressure Adjust Standard spring too sof...

Page 34: ... can alter the carburetor settings based on the following in formation and specifications Carburetor Specifications Bore 38 mm Main jet 180 Jet needle R1470NS 3rd Cut aw ay 5 Slow jet 52 Air screw 1 1f2turns out Float height 16 0 mm 0 55 in Setting parts 175 178 185 and main jet 1 90 PRINCIPLES OF CARBURETOR TUNING Carburetor Components and Functions The carburetor consists of a number of parts as...

Page 35: ...fuel mixture is supplied by checking the color of exhaust smoke spark plug throttle response power etc Second replace or adjust the part s related to the throttle opening range by refer ring to the following instructions The sizes referred to in the illustrations are those of stan dard setting Slow Jet The slow jet meters the fuel supplied to the slow system Each jet size is indicated by a number ...

Page 36: ... w ill move the nee dle position by half to the richer side MS type jet needles can be available as optional parts Air fuel mixture Needle type and clip position l ean R1470MS lst Rl470NS 2nd R1470MS 2nd R1470NS 3rd R1470MS 3rd R1470NS 4th R1470MS 4th R1470NS 5th Rich R1 470MS 5th Jet Needle 0 0 of Needle Clip Taper angle Needle number R 1470 NS r L Some alplabets are stamped on the jet needle ins...

Page 37: ...ation changes about 10 in the 0 to 40 C temperature difference the one in the center shows about 20 change in the 0 to 2 OOOm altitude difference and the one at the right shows about 5 change in the 0 to 100 humidity difference As for humidity its normal range is from 20 to 95 Therefore the possible effect of humidity 01 the oxygen concentration is so little that it can be disregarded Consequently...

Page 38: ...mproves when the choke is applied 3 Acceleration is poor 4 The spark plug is burned white 5 The speed of the engine fluctuates and lack of power is noticed 6 Detonation and pinging are experienced Tuning Procedure The following indicates the correct tuning proce dure for this motorcycle Understand the proce dure by first riding the motorcycle where it will be used and adjust the engine to the best...

Page 39: ...l Set the air screw as specified buretar according to the actual race conditions 2 See if the selected slow jet is correct or not by judging the air fuel mixture If air fuel mix 1 Adjust the air fuel mixture by turning the air ture is rich replace it with smaller one If screw within 1 2 2 turns out air fuel mixture is lean replace it w ith larger 1 2 turn out one 1 1f turns out 2 turns out 2 If th...

Page 40: ...4 MACHINE TUNING MEMO ...

Page 41: ...adjuster screw counterclockwise and the 15th position is the standard position Standard setting 15th click Compression Damping Force Adjustment Turn the adjuster screw clockwise until it stops that is full hard NOTE To set the adjuster you must gently turn the ad juster screw clockwise until it stops then back it out the recommended number of turns Do not force the adjuster screw post the stopped ...

Page 42: ... pull the outer tube any more than 250 mm 9 84 in from the axle holder of the inner tube Front Fork Oil Air Bleeding Lift up the special tool and outer tube press down on the special tool slowly Repeat this process 2 3 times Repeat the same process untill no more bubbles come from oil Wait 10 minutes and then measure the oil Jevel NOT Compress the front fork fullV Set the fork in a ver tical posit...

Page 43: ...mp 0 130 mm 5 12 in 488 ml 116 5 17 2 USllmp 0 121 mm 4 76 in 495 ml 116 7 17 4 USllmp 0 NOTE An oil eve lower Dr higher than the above range will affect the front fork performance Be sure to adjust the front fork oil level within the above range NOTE Front fork body should contain the same type oil as fork cylinder contains NOTE See page 15 5 for fork cylinder oil replacement procedure Front Fork...

Page 44: ...p 1 Decrease fork oil capacity end of travel Feels too soft near end 0 Jump 1 Adjust the compression damping to a of travel and bottoms 0 Large bump stiffer settting harshly 2 Increase fork oil capacity Feels too hard in the 0 Jump 1 Adjust the compression damping to a beginning of stroke 0 Large bump softer setting 0 Series of medium bumps 0 Series of small bumps Feels too soft and 0 Series of me...

Page 45: ...e standard position Standard setting 10th click Rebound Damping Force Adjustment Turn the adjuster screw clockwise until it stops that is full hard NOTE To set the adjuster you must gently turn the ad juster screw clockwise until it stops then back it out the recommened number of turns Do not force the adjuster screw past the stoppedposition or you may damage the ad juster Turn the adjuster screw ...

Page 46: ...ear wheel lifted off the ground Measure the distance L2 from the seat bolt to the chain adjuster lock nut with the motorcycle off the stand and riding the motorcycle normally in full riding gear Find the sag by subtracting L2 from L1 Standard sag range is 95 105 mm 3 7 4 1 in When the sag Adjustment procedure measured is Less than 95 mm Increase spring pre set length by 3 7 in turning the spring a...

Page 47: ...atively until the optimum settings are Provides poor traction obtained 2 Replace the spring with an optional soher one NOTE When adjusting the damping setting attempt turning the adjuster 1 to 2 click stops at a time for each adjustment SUSPENSION BALANCE Balancing the front to rear suspension properly is the most critical adjustment for suspension perfor mance If the front forks are adjusted hard...

Page 48: ...uel tank Drain transmission oil t 7 2 5 Drain coolant 0 11 21 Remove the exhaust pipe fitting springs with the special tool 09920 20310 Spring hook Remove the muffler fitting bolts Remove the exhaust pipe and muffler Disconnect the radiator hoses Disconnect the lead wires Remove the spark plug Remove the carburetor Remove the engine sprocket cover Remove the drive chain Remove the chain buffer fit...

Page 49: ...en the engine mounting nuts Tightening torque N m kg m Ib ft CD 43 4 3 31 0 35 3 5 25 5 65 6 5 47 0 NOTE Replace the self locking nuts with new ones Reassemble the parts in the reverse order of removaL NOTE Route the cables and lead wires correctly l a 19 1 After mounting the engine inspect the following items Transmission oil level c r 2 5 Coolant level c r 2 5 Throttle cable play c r 2 7 Clutch ...

Page 50: ... MEMO ...

Page 51: ...CYliNDER PISTON AND EXHAUST VALVE 6 1 CYLINDER PISTON AND EXHAUST VALVE 2 5 kg m _ 2 8 kg m Q fJ 4 1 kg m J ...

Page 52: ...onally to prevent cylinder head distortion Remove the cylinder head O rings CYLINDER REMOVAL Remove the exhaust pipe c r 5 1 Remove the exhaust valve rod cover Unhook the stopper and remove the exhaust valve rod Remove the four cylinder nuts NOTE Loosen the cylinder nuts diagonally Remove the radiator hose connecting right and left radiators Remove the radiator mounting bolts and move the radi ato...

Page 53: ... stopper screw Remove the exhaust valve shaft Remove the exhaust valve guide stopper screws Remove the exhaust valves CYLINDER HEAD INSPECTION Remove carbon deposits from the cylinder head Inspect the cylinder head for cracks around the spark plug hole Inspect for cylinder head distortion Service limit 0 05 mm 0 002 in CYLINDER INSPECTION Remove carbon deposits from the exhaust port Inspect the cy...

Page 54: ...breather hose and filter Remove carbon deposits from the filter and clean it PISTON AND PISTON RING INSPECTION Remove the piston ring from the piston ring groove Remove carbon deposits from the piston Inspect the piston for wear scratches and damage Measure the piston outer diameter 24 mm 10 94 in from the skirt end Service limit 66 950 mm 2 6381 in 09900 20203 Micrometer 150 75 mml Measure the pi...

Page 55: ...er and measure the piston ring end gap with a thickness gauge Service limit 0 85 mm 0 033 in 09900 20803 Thickness gauge Measure the piston ring free end gap Service limit 5 1 mm 0 20 in EXHAUST VALVE INSPECTION Remove carbon deposits from the exhaust valve and valve guide Inspect the exhaust valve and valve guide for wear and scratches Inspect the return spring for spring tension Inspect the spac...

Page 56: ...n the piston top to the exhaust port side and fit the piston Fit the piston pin and piston pin circlip Piston pin circlip end should face upside NOTE Replace the piston pin circlip with a new one Place cloth on the crankcase tD prevent piston pin cir clip from dropping into the crankcase chamber EXHAUST VALVE REASSEMBLING Apply engine oil to the exhaust valve and valve guide Fit the sha1t to the e...

Page 57: ...the locating pin and insert the piston into the cylinder Tighten the cylinder nuts to the specified torque accord ing to the specified tightening order as shown Tightening torque 38 N m 3 8 kg m 27 5 Ib fU Fit the exhaust valve rod Install the spacer spring exhaust valve cap and retainer Tighten the screws temporarily Turn the exhaust valve cap clockwise one turn Tighten the screws Inspect the exh...

Page 58: ...orque ac cording to the specified tightening order as shown Tightening torque 25 N m 2 5 kg m 18 0 Ib ftl Reassemble the engine mounting bracket r r 5 2 Reassemble the spark plug and spark plug cap Connect the radiator hose and tighten the clamps Pour coolant r 7 2 5 Inspect coolant leak ...

Page 59: ...CLUTCH 1 CLUTCH 9 0 kg m ...

Page 60: ...ure plate Remove the drive and driven plates CLUTCH PLATE INSPECTION Drive Plate Measure the drive plate thickness and claw w idth Service limit Thickness 2 4 mm 0 09 in Claw width 15 3 mm 0 60 in Inspect the drive plates for wear distortion and discolo ration Driven Plate Measure the driven plate distortion Service limit 0 10 mm 0 004 in Inspect the driven plates for wear and discoloration Clutch...

Page 61: ...lease rack teeth with the pinion gear Replace the o ring with a new one Fit the cover Tighten the bolts diagonally Reassemble the rear brake pedal f CT 14 11 Fit the clutch release arm Inspect the clutch cable play c r 2 7 Fill the transmission with specified transmission oil to the correct level r T 2 5 PRIMARY DRIVEN GEAR ASS Y REMOVAL Drain transmission oil 0 2 5 Drain coolant Disconnect the ra...

Page 62: ...ve the bearing PRIMARY DRIVEN GEAR ASS Y INSPECTION Inspect the clutch sleeve hub and primary driven gear ass y for w ear and cracks Inspect the needle bearing for damage PRIMARY DRIVEN GEAR ASS Y REASSEMBLY Fit the washer and needle bearing Fit the primary driven gear ass y Fit the washer clutch sleeve hub and tock washer Tighten the clutch sleeve hub nut with the special tool to the specified to...

Page 63: ...el pins Replace the O ring with a new one Fit the clutch cover and bolts Tighten the clutch cover bolts diagonally Reassemble the kick starter lever Reassemble the clutch release arm Reassemble the rear brake pedal r r 14 111 Reassemble the radiator hose and refill coolant c r 11 21 Refill transmission oil r r 2 5 J ...

Page 64: ... MEMO ...

Page 65: ...KICK STARTER 8 1 KICK STARTER ...

Page 66: ...g pliers Remove the kick idle gear Unhook the kick return spring Remove the kick starter shaft Remove the following parts from the kick starter shaft Spring guide Kick return spring Washer Spring Kick starter Remove the circlip with snap ring pliers Remove the kick drive gear KICK STARTER INSPECTION Inspect the oil seal for oil leakage and oil seal lip damage Inspect the return spring for damage I...

Page 67: ...ch marks on the kick starter and kick starter shaft when fitting the kick starter Fit the kick starter ass y to the crankcase Hook the return spring Reassemble the kick idle gear Reassemble the clutch a 7 5 Reassemble the clutch cover a 7 5 Reassemble the kick starter lever Reassemble the clutch release arm Reassemble the rear brake pedal c r 14 11 Connect the radiator hose Refill coolant c r 11 2...

Page 68: ... MEMO ...

Page 69: ...TRANSMISSION AND CRANKSHAfT 9 TRANSMISSION AND CRANKSHAFT I IU ...

Page 70: ...12 4 Remove the exhaust valve actuator GEARSHIFT LINKAGE REMOVAL Remove the gearshifting shaft Remove the two screws Remove the pawl lifter Remove the driven gear Be careful that the pins and springs do not fly off Remove the gearshift cam bolt PRIMARY DRIVE GEAR Remove the primary drive gear with the special tool 09910 20116 Conrad holder CRANKCASE SEPARATION Remove the crankcase fitting screws ...

Page 71: ...th a plastic hammer TRANSMISSION REMOVAL Remove the gearshift fork shafts and forks Remove the gearshift cam Remove the drive shaft ass y and countershaft ass y CRANKSHAFT REMOVAL Remove the crankshaft with the special tool 09920 13120 Crankcase separating tool GEARSHIFT LINKAGE INSPECTION Inspect the gearshift shaft for bends and damage Inspect the return spring for damage Inspect the pawls sprin...

Page 72: ...lines for abnormal wear and discoloration Inspect the gearshift cam groove for abnormal wear and damage Inspect the gearshift forks and shafts for wear and damage Measure the gearshift fork thickness with a vernier caliper Standard 4 60 4 70 mm 0 181 0 185 in Measure the gearshift fork groove w idth w ith a vernier caliper Standard 4 80 4 90 mm O 189 0 193 in ...

Page 73: ...s and dial gauge Service limit 0 05 mm 0 002 in 09900 20605 Dial gauge Measure the crankshaft web to web width with a verni er caliper Standard 57 9 58 1 mm 12 28 2 29 inl OIL SEAL INSPECTION REMOVAL AND INSTAL LATION Inspect the oil seal lips for wear and damage Remove the oil seal with the special tool 09913 50121 Oil seal remover TRANSMISSION ANO CRANKSHAFT 9 5 J ...

Page 74: ...ION REMOVAL AND INSTAL LATION Inspect the bearings for play discoloration wear and seizure Move the inner race by finger and inspect for smooth movement Remove the bearing retainers Remove the bearing with the special tools 09923 73210 09923 74510 09930 30102 Bearing puller Bearing puller Rotor remover slide shaft Fit the bearing with the special tool 09914 79610 Bearing Oil seal installer OUT SID...

Page 75: ...k 1303 to the bearing retainer screw CRANKSHAFT INSTALLATION Fit the crankshaft into the left crankcase half with the special tool 09910 3281 2 Crankshaft installer TRANSMISSION REASSEMBLY TRANSMISSION ANO CRANKSHAfT 9 ...

Page 76: ...driveshaft and countershaft turn without resistance Fit the new gasket and dowel pins CRANKCASE REASSEMBLY Fit the left crankcase half on the right crankcase half Tighten the crankcase bolts NOTE Tighten the bolts graduallv and diagonally to guide the crankshaft into the bearing If it is hard to tighten the bolts separate the crankcase and confirm that the trans mission parts are assembled correct...

Page 77: ...wl lifter Apply thread lock 1303 to the screws and tighten them Fit the gearshift return spring to the gearshift shaft properly Align the center lines of drive and driven gears Reassemble the exhaust valve actuator Reassemble the stator and magneto rotor 0 12 4 Reassemble the kick starter r r 8 3 Reassemble the clutch r r 7 3 Reassemble the piston and cylinder a 6 5 Remount the engine c 7 5 2 TRAN...

Page 78: ... MEMO ...

Page 79: ...FUEl SYSTEM 10 1 FUEL SYSTEM I I U I 1 ...

Page 80: ...able from the throttle valve Push the cable holder and turn it 90 Remove the cable holder jet needle set spring and set collar Remove the screws Remove the carburetor float chamber Remove the buffer plate Remove the float pin and floats Remove the needle valve ass y Remove the pin and disassemble the needle valve ass y Remove the main jet and slow jet Remove the choke idle adjuster knob Remove the...

Page 81: ...ip just contacts the float valve Standard float height 6 0 mm 10 63 in Carburetor Reassembly Reverse the sequence of removal REED VALVE Reed valve Removal Remove the carburetor a 10 2 Remove the six bolts Remove the intake pipe and reed valve Reed Valve Inspection Inspect the reeds for damage Inspect the reed valve stoppers for damage Inspect the valve seat rubber for damage NOTE Be careful not to...

Page 82: ... MEMO ...

Page 83: ...COOLING SYSTEM COOLING SYSTEM ID ...

Page 84: ...ty 1100 ml 12 3 US pt Tighten the radiator cap firmly Run the engine a few minutes and inspect the coolant level f r r 2 5 RADIATOR CAP INSPECTION Inspect the radiator cap for function with a radiator cap pressure gauge Radiator cap valve release pressure 95 125 kPa 10 95 1 25 kg em 13 5 17 B psil NOTE Apply water to radiator cap seal before fitting the radiator cap to the pressure gauge RADIATOR ...

Page 85: ...move the oil seal with the special tool 09913 50121 Oil seal remover Remove the bearing Reassembly Fit the bearing and circlip Apply transmission oil to the bearing Apply thread lock 1303 to the outer surface of the oil seal Fit the oil seal Apply grease to the oil seal lip Insert the water pump shaft Fit the water pump driven gear and circlip Reassemble the clutch cover rJ 7 5 Reassemble the wate...

Page 86: ... MEMO ...

Page 87: ...ELECTRICAL SYSTEM 12 1 ELECTRICAL SYSTEM r 3 5 kg m ...

Page 88: ...e blue lead of ignition coil and the black tip to the green lead ground Connect the high tension lead with the red lead attached to the spark plug cord and the black e lead to the green lead groundl Set the test selector knob to IG COIL position Switch on the power Note the spark in the spark plug window It should be strong and continuous not intermittent across pre set 8 mm 1 0 3 in gap Allow the...

Page 89: ...can damage circuit elements in the COl unit Use a circuit tester of the type used by radio repairmen A High grade circuit tester or an ohmmeter is preferred Positive probe pin c B A A W B A 100 200 A W B 18 0 ii A 5 9 5 10 CD G 1 2 BIY 0 100 200 0 W BI 5 13 5 15 z B W 1 2 Wire color G Green R Red B R Black with Red tracer B W Black with White tracer B Y Black with Yellow tracer R W Red with White ...

Page 90: ...0 n MAGNETO ROTOR AND STATOR REMOVAL AND RESSEMBLY Remove the bolts and magneto cover Remove the screws and stator Disconnect the lead wires Loosen the nut with a special tool 09930 40113 Rotor holder Remove the magneto rotor with the special tool Remove the key 09930 30113 Flywheel rotor remover Loosen the screws and remove the stator ...

Page 91: ... correctly Fit the key into the crankshaft Fit the magneto rotor Apply Thread l ock Super 303 to the nut and tight en the nut to the specified torque with the special tool 99000 32030 THREAD LOCK SUPER 303 09930 40113 Rotor holder lightning torque 35 N m 3 5 kg m 25 5 Ib ttl Reassemble the magneto cover ELECTRICAL SYSTEM 12 5 j ...

Page 92: ... MEMO ...

Page 93: ...FRONT AND REAR WHEELS J 6 5 kg m J 0 9 kg m fRONT ANO REAR WHEELS 13 1 d k1 ...

Page 94: ...ten the axle holder tighten the upper nuts first and then tighten the lower nuts so that the lower side of the holder has clearance REAR WHEEL REMOVAL AND REASSEMBLY Rear Wheel Removal Place the motorcycle on a block to lift the rear wheel off the ground Remove the cotter pin and axle nut Loosen the chain adjuster lock nuts and chain adjusters Remove the rear wheel Rear Wheel Reassembly Reassemble...

Page 95: ...nd wheel hub Inspect for bearing damage WHEEL BEARING REMOVAL AND REASSEMBLY Front Wheel Bearing Removal Fit the bearing remover into the wheel bearing 09941 50110 Bearing remover Insert the wedge bar into the slit of the bearing remover from the opposite side Hit the wedge bar with a hammer and remove the bear ing and spacer Rear Wheel Bearing Removal Remove the dust seal Remove the circlip with ...

Page 96: ...l Bearing Reasembly Apply grease to the bearings Reassemble the spacer and bearings with the special tool 09941 34513 Bearing installer set NOTE After reassembling the bearings inspect the bear ings for smooth movement Fit the circlips NOTE Place the manufacturer s code indicated side of the dust seal outside when installing the dust seal DISC PLATE REPLACEMENT Apply thread lock super 1303 to the ...

Page 97: ...FRONT AND REAR BRAKES 14 1 FRONT AND REAR BRAKES i 10 kg m 2 3 kg m 1 0 kg m t 1 8 kg m t 1 8 kg m J 2 0 kg m l g i 2 3 kg m t 0 8 kg m ...

Page 98: ...ifferent types of brake fluid A CAUTION Spilled brake fluid can damage painted surface and plas tic parts Be careful not to spill any brake fluid when servicing brake fluid Wipe spilled fluid up immediately Remove the reservoir cap Connect a transparent tube to the bleeder valve and set the other end into a receptacle Pour brake fluid up to the UPPER line Pump the brake lever pedal until air buble...

Page 99: ... 7 14 2 Reassemble the reservoir cap BRAKE PADS REPLACEMENT Front Brake Pads Remove the pad mounting bolts Remove the caliper mounting bolts and caliper Remove the brake pads NOTE Replace the two brake pads as a set Fit the new brake pads into the caliper and tighten the pad mounting bolts temporarily Tighten the caliper mounting bolts Tightening torque 23 N m 2 3 kg m 16 5 Ib ft Tighten the brake...

Page 100: ...at the brake pads after reassembling BRAKE DISC INSPECTION Measure the front and rear brake disc thickness Service limit Front 2 5 mm 10 10 inl Rear 4 0 mm 0 5 in Measure the front and rear brake disc runout Service limit 0 3 mm 0 01 in CALIPER WARNING The use of any brake fluid except DOT4 brake fluid from 8 sealed container can damage the brake system and lead to an accident Use only DOT4 brake ...

Page 101: ... fluid up immediately Front Caliper Removal and Disassembly Place a drain pan under the caliper and remove the union bolt Remove the pad mounting bolts Remove the caliper mounting bolts Remove the brake pads and spring from the caliper Remove the caliper braket from the caliper Remove the boots from the caliper bracket Wrap the caliper with a rag to prevent brake fluid scat ter and piston pop out ...

Page 102: ...ING Fingers can get caught between piston and caliper body when removing the piston Do not place your fingers on the piston when removing the piston Remove the piston seal and dust seal Caliper Inspection Measure the caliper cylinder bore with a small bore gauge Fron 27 000 27 050 mm 11 0630 1 0650 in Rear 30 000 30 050 mm 11 1811 1 1831 in Inspect the caliper cylinder for scuffing Measure the cal...

Page 103: ...Ib ft Tighten the brake hose union bolt to the specified torque Tightening torque 23 N m 12 3 kg m 16 5 Ib ft Refill brake fluid and bleed air from the brake system a 14 21 Rear Caliper Reassembly Apply brake fluid to the piston seal and fit the piston seal CD and dust seal Fit the piston into the caliper Fit the spring and pads Tighten the brake pad mounting bolts temporarily Apply silicone greas...

Page 104: ...e brake system Bnd lead to an accident Use only DOT4 brake fluid from 8 sealed container Never use or mix different types of brake fluid A CAUTION Spilled brake fluid can damage painted surface and plas tic parts Be careful not to spill any fluid when filling the brake fluid reservoir Wipe spilled fluid up immediately Front Master Cylinder Removal and Disassembly Drain brake fluid r r 14 3 Loosen ...

Page 105: ...ylinder clamp bolts Remove the dust seal boot CD Remove the circlip with snap ring pliers Remove the push rod Remove the piston cup set 1 Master Cylinder Inspection Measure the cylinder bore with a small bore gauge Front 11 000 11 043 mm 10 4331 0 4348 in Rear 14 000 14 043 mm 10 5512 0 5529 in Measure the cylinder piston diameter w ith a micrometer Front 10 957 10 984 mm 0 4314 0 4324 in Rear 13 ...

Page 106: ...old the brake hose with a wrench to prevent the brake hose from twisting when tightening the adaptor Refill brake fluid and bleed air from the brake system 0 14 21 Reassemble the reservoir cap Rear Master Cylinder Reassembly Fit the piston cup set and push rod Fit the circlip with snap ring pliers Fit the boot Tighten the master cylinder clamp bolts to the specified torque Tightening torque 10 N m...

Page 107: ...rake pedal pivot bolt Remove the return spring Remove the cotter pins and pin Reassembly Reassemble the pin washer and cotter pins Fit the return spring Apply grease to the brake pedal pivot bolt Tighten the bolt Fit the washer and cotter pins Adjust the brake pedal height a 2 12 FRONT AND REAR BRAKES 14 11 ...

Page 108: ... MEMO ...

Page 109: ...fRONT fORK ANO STEERING 15 1 FRONT FORK AND STEERING I I t J 3 0 kg m t J 3 5 kg m I 1 0 kg m 2 0 kg m ...

Page 110: ...ront Fork Disassembly NOTE If the fork has not been disassembled before you may find that some threaded components are very tight Set rebound and compression damper settings to the minimum settings before disassembling Thoroughly clean the fork before disassembly A CAUTION Scratches or other damage on the inner tube or on the oil seal lip will cause oil leak Avoid scratching or damaging the inner ...

Page 111: ...the inner tube and inspect it for smooth movement CAUTION Clamping the axle holder too tight can damage it which will affect riding stability Do not clamp the axle holder too tight Loosen the center bolt completely from the bottom of fork with a 21 mm socket wrench Press the fork cap inward until the center bolt and lock nut are exposed on the opposite end Place the stopper plate around the inner ...

Page 112: ...he inner rod thread into the fork cylinder will damage the inner rod oil seal Do not remove the inner rod lock nut Remove the stopper plate while pressing the fork cap bolt inward Remove the fork cylinder and fork spring NOTE The push rod can come out of the inner rod w hen the center bolt is removed Remove the dust seal and the stopper ring CAUTION Scratches on the inner tube could cause oil leak...

Page 113: ... cap bolt and 30 mm open end wrench on the flat portion of fork cylinder body Place a drain pan under the fork cylinder Pull off the fork cap bolt while pressing in the inner rod Push and pull the inner rod to drain the oil NOTE The compression damping adjuster will pop loose suddenly when removed from fork cyinder Be careful not to spray fork oil when removing the adjuster NOTE The fork cylinder ...

Page 114: ...clean clean them with a nylon brush and fork oil Measure the free length of front fork spring Service limit 478 5 mm 118 8 in Fork Cylinder Reassembly Clean the fork cylinder thread Apply front fork oil to the O rings and slide bush Extend the inner rod fully and pour the specified amount of fresh front fork oil into the fork clinder Fork cylinder oil type SUZUKI FORK OIL 55 05 Fork cylinder oil c...

Page 115: ...y release the inner rod and wait until the in ner rod comes out and stops The inner rod must come out to fully exterded position by itself Pull the inner rod to examine whether it has come out fully Front Fork Reassembly NOTE The fork outer body and fork cylinder must contain the same type of oil Replace both fork outer body oil and fork cylinder together Remove the old oit from the fork parts CAU...

Page 116: ...essive play after installing it replace it with a new one CAUTION Teflon coating damage on the slide bushing can decrease front fork performance When installing the slide bushing be careful not to damage the teflon coating Apply fork oil on the outer sureface of the oil seal to make it easy to fit Insert the inner tube in the outer tube Install the oil seal with the special tool until the stopper ...

Page 117: ...t front fork or caliper brack et for Jeft front fork in a vise Be sure to protect the axle holder or caliper bracket with a rag when clamping with the vise CAUTION Clamping the axle holder too tight can damage it and it will affect riding stability Do not clamp the axle holder too tight Insert the fork spring Make sure more than 14 mm 0 55 in of inner rod thread is exposed on the end Insert the fo...

Page 118: ...ken if the inner rod is not correctly tightend Insert the inner rod fully into the center bolt before tight ening the lock nut Apply thread lock 1303 to the center bolt thread Remove the stopper plate while pressing in the fork cap bolt Tighten the center bolt to the inner tube Tightening torque 6 5 kg m Release the front fork from the vise and hold it vertically Fit the fork cylinder holder on th...

Page 119: ...air and pour correctly measuhed fork oil Use an injector to measure the oil Standard oil amount 440 ml 14 9 15 5 US Imp ozl NOTE Damage to the O ring on the fork cap can cuase oil leaks Replace with a new one in case of damage Apply fork oil to the O ring of the fork cap and attach the fork cap to the outer tube Raise the outer tube and tighten it to the fork cap bolt Front Fork Mounting Tighten t...

Page 120: ... nut Remove the upper bracket Remove the steering nut with the special tool 09940 14960 Steering nut socket wrench Remove the lower bracket Steering Inspection Inspect the bearing races for wear Inspect the needle bearings for wear Inspect the steering stem for distortion Steering Bearing Replacement NOTE Replace the outer race and bearing as set Remove the upper and lower outer races with the spe...

Page 121: ...the steering stem upper bearing dust seal and steer ing stem nut Tighten the steering stem nut with the special tool 09940 14960 Steering nut socket wrench Tightening torque 45 N m 4 5 kg m 32 5 Ib ftl Move the steering stem right and left several times to seat the bearings Turn back the steering stem nut by IA to Ih turn Fit the steering stem head nut and tighten it temporarily Remount the front ...

Page 122: ...e the front wheel r T 13 2 Reassemble the handlebar Rock the front fork forward and backward to ensure that the steering has no play Inspect the steering for smooth movement so that the handlebar can move right and left under its own weight ...

Page 123: ...REAR SUSPENSION 16 REAR SUSPENSION 6 0 kg m ...

Page 124: ...ve the rear shock absorber mounting bolts and nuts Remove the rear shock absorber Loosen the lock nut and turn the adjuster with the spe cial tool 09910 60611 Universal clamp wrench Rear Shock Absorber Inspecion Inspect the rear suspension for oil leak Inspect the damper rod for bends and smooth movement Inspect the stopper rubber for deterioration and damage Inspect the bearing for play and smoot...

Page 125: ...and body Bearing Replacement Remove the dust seals Remove the circlip Set a pipe washer bolt M 10 and nut 1M 10 as shown Tighten the nut and remove the bearing Apply grease to the bearing Set pipes washers bolt M 0 and nut M 0 as show n Tighten the nut and fit the bearing Fit the circlip Apply grease to the dust seal and fit it as grooved side faces outside Rear Shock Absorber Reassembly Fit the s...

Page 126: ...up the air cleaner box and move it backward Step 1 Place the outlet tube between the flame body tubes Step 21 Set the air cleaner mounting boss at the outside of the frame boss Step 3 Fit the both right and left upper flanges to the seat rails Step 41 Reassemble the cleaner cover Step 5 Reassemble the frame cover and seat Tune the rear suspension c r 4 131 ...

Page 127: ...ry the rear cushion unit Remove the spring from the rear cushion unit NOTE Inspect the rear cushion unit for oil leak Remove the valve cap Push the gas valve core with a screwdriver to bleed out nitrogen gas REAR SUSPENSION 16 5 CD Screwdriver or small punch Vise Drain Pan Oilean Beaker Specified Shock Oil 5525 o Rags Nitrogen tank Filler Hose and Nozzle J Regulator Assembly Owner s Service Manual...

Page 128: ...face and body Remove the compression adjuster ass y Place a drain pan under the rear cushion unit Move the rod and drain the oil Push the valve core again to make the bladder in the reser voir at the normal condition Move the rod and pour the oil as shown NOTE Be sure to extend the rod after filling the oil Tilt the rear cushion unit as shown and pour the fresh rear suspension oil into the reservo...

Page 129: ...le com pressed air free from water can be substituted WARNING Applying too much pressure to the rear cushion unit may rupture the rear cushion unit Be sure to pressure the rear cushion unit to the specified A CAUTION Riding the motorcycle with the abnormal gas pressure can damage the rear cushion unit low gas pressure can result in oil leakage Abnormal gas pressure cannot obtain nor mal rear cushi...

Page 130: ...haft runout with a dial gauge and V blocks Service limit 0 3 mm O 01 in Inspect the swing arm for cracks and damage Inspect the bearings bushings and oil seals for damage Insert the bushings into the bearings and inspect them for play and smooth movement Bearing Replacement Remove the bearings and oil seals with the special tools 09923 74510 09930 30102 Bearing pul er Rotor remover slide shaft C I...

Page 131: ...ghten the rear cushion rod nut to the specified torque Tightening torq Je 100 N m 10 0 kg m 72 5 Ib ft Reassemble the chain guide Reassemble the rear caliper r r 14 7 Fit the rear brake hose guides Reassemble the brake pedal 0 14 11 Reassemble the rear wheel r 7 13 2 REAR SUSPENSION LINKAGE Rear Suspension linkage Removal Remove the swing arm a 16 6 Remove the swing arm linkage bolts Rear Suspensi...

Page 132: ...earings w ith the special tools 09923 74510 09930 30102 Bearing puller Rater remove siids shaft Apply grease to the bearings Fit the bearings with the special tool 09941 34513 Bearing installer set Fit the circlips NOTE See page 16 3 for cushion unit lawer bearing replacement SPECIAL TOOL ...

Page 133: ...nuts to the specified torque Tightening torque A 60 N m 16 0 kg m 43 5 Ib It B 60 N m 16 0 kg m 43 5 Ib ftJ c 100 N m 110 0 kg m 72 5 Ib It 0 80 N m IB O kg m 58 0 Ib It E 100 N m 110 0 kg m 72 5 Ib It F 70 N m 17 0 kg m 51 0 Ib It Reassemble the swing arm c r 16 8 REAR SUSPENSION 16 11 11 ...

Page 134: ... MEMO ...

Page 135: ...1st 0 20 0 40 0 85 end oap 2nd 0 008 0 016 0 033 Piston ring to 1st 0 020 0 060 groove clearance 2nd 0 0008 0 0024 Piston pin bore 18 000 18 006 18 030 0 7087 0 7089 0 7098 Piston pin 0 0 17 995 18 000 17 980 0 7085 0 7087 0 6724 CONROD CRANKSHAFT Unit mm in ITEM STANDARD LIMIT Conrad small end 1 0 23 003 23 0 11 23 040 0 9056 0 9059 0 907 1 Crank web to web width 58 0 0 1 2 283 0 004 Crankshaft r...

Page 136: ...Cut away C A Slow jet S J By pass 8 P Pilot outlet P O Air screw A S Throttle cable play STANDARD LIMIT 11 0 kPa 1 1 kg cm2 16 psi Unit mm in Except ratio STANDARD 2 652161 231 3 769 149 131 2 153 128 131 1 705 29 171 1 411124 171 1 157 122 191 1 000 23 23 0 10 0 30 10 004 0 012 4 80 4 90 10 189 0 193 4 60 4 70 0 181 0 185 STANDARD Type DAIDO 0 1 0 520DS5 Links 112 20 pitch length 45 55 11 8 2 2 S...

Page 137: ...Brake disc thickness Front 3 0 0 2 2 5 0 11 8 0 008 0 10 Rear 4 5 0 2 4 0 0 177 0 008 0 15 Brake disc runDut Front Rear 0 30 0 01 Master cylinder bore Front 11 000 11 043 0 4331 0 4348 Rear 14 000 14 043 0 5512 0 5529 Master cylinder piston diam Front 10 957 10 984 0 43 14 0 4324 Rear 13 957 13 984 0 5495 0 5506 Brake caliper cylinder bore Front 27 000 27 050 1 0630 1 0650 Rear 30 000 30 050 11 18...

Page 138: ...ir pressure Atmospheric pressure Rear shock absorber gas 1000 kPa pressure 110 kg em 142 psi Rear shock absorber spring 255 0 pre set length 110 0 Rear wheel travel 324 112 8 Swingarm pivot shaft runout TIRE PRESSURE Front Rear 70 110kPa 0 7 1 1 kg cm1 10 16 psi Unit mm in LIMIT NOTE 478 5 118 8 See page 4 9 and 4 10 1000 1200 kPa 10 12 kg cm2 142 170 psi 0 3 10 01 ...

Page 139: ...850 ml 10 8 US qt Front fork oil type SUZUKI fork oil 55 05 or an equivalent fork oil Front fork oil capacity Outside 440 ml each leg Fork 114 9 15 5 US Imp oz See page 4 10 Cylinder Inside 145 ml See page 15 6 Fork 14 9 5 1 US Imp Filled in the fork Cylinder cylinder Coolant type SUZUKI GOLDEN CRUISER 1200NA Use an anti freeze summer coolant compat ible with aluminum radiator mixed w ith dis till...

Page 140: ...holder 0994 345 3 Bearing installer set 09900 06 08 Snap ring pliers 09900 20508 Cylinder gauge set 09930 70210 COl unit test lead 09923 732 0 Bearing puller 09941 50110 Wheel bearing remover 09900 09003 Impact dirver set 09900 20602 Dial gauge 099 3 50 2 Oil seal remover 09923 745 0 Bearing puller 09940 14911 09940 14960 Steering nut socket wrench 09941 54911 Bearing outer race remover 09900 20 0...

Page 141: ...rk oil level Conrod holder gauge 09925 18010 09940 54851 Steering bearing 09910 32812 Crankshaft installer Front fork spaser installer 09921 20200 Bearing remover 09920 20310 Spring hook SPECIAL TOOLS 18 2 09910 60611 Universal clamp wrench 09940 42810 Fork cylinder holder ...

Page 142: ...19 1 WIRE CABLE AND HDSE RDUTING WIRE CABLE AND HOSE ROUTING Throttle cabel ThroUle cable Front brake hose Clutch cable Clutch cable clamp 1 j ...

Page 143: ...WIRE CABLE AND HOSE ROUTING 19 1 Carburetor air vent hose R CLAMP ...

Page 144: ...19 3 WIRE CABLE AND HDSE RDUTING Rear shock absorber spring mm 0 12 in Guide Bolt ...

Page 145: ...WIRE CABLE AND HDSE RDUTING 19 4 Radiator lead wire ...

Page 146: ...19 5 WIRE CABLE AND HOSE ROUTING 1 ...

Page 147: ...m 2 787 in Piston displacement 249 em 15 2 cu in SPECifiCATIONS 20 1 Corrected compression ratio 8 7 1 EX VALVE OPEN and 10 4 1 Carburetor KEIHIN PJ38 single Air cleaner Polyurethane foam element Starter system Primary kick Lubrication system Fuel oil premixture of 32 1 TRANSMISSION Clutch Wet multi plate type Transmission 5 speed constant mesh Gearshift pattern l down 4 up Primary reduction 2 652...

Page 148: ...a way adjustable Linkage suspension system spring pre load fully ad justable compression damping force 21 way ad justable rebound damping force 21 way adjustable 45 0 right left 62 0 45 108 mm 4 3 in 2 3 m 17 5 II Disc brake hydraulically operated Disc brake hydraulically operated 80 100 21 51M 110 90 1962M 310 mm 12 2 in 324 mm 12 8 in Electronic Ignition COl 7 B T O C at 9 000 rpm NGK R4118S 8 T...

Page 149: ...TION CYLINDER REASSEMBLING CYLINDER REMOVAL DISC PLATE REPLACEMENT DRIVE CHAIN AND SPROCKETS DRIVE CHAIN GUIDE BUFFER TENS10NER ROLLER ELECTRICAL CIRCUIT ENGINE COOLANT ENGINE COOLANT REPLACEMENT ENGINE DISMOUNTING AND MOUNTING ENGINE MOUNTING EXHAUST VALVE EXHAUST VALVE INSPECTION EXHAUST VALVE REASSEMBLING EXHAUST VALVE REMO VAL FRONT AND REAR WHEEL INSPECTION FRONT FORK FRONT FORK DISASSEMBLY F...

Page 150: ...RIMARY DRIVEN GEAR ASSY REMOVAL RACK AND PINION INSPECTION RADIATOR RADIATOR CAP INSPECTION REAR SHOCK ABSORBER OIL REPLACEMENT REAR SHOCK ABSORBER DISPOSAL REAR SHOCK ABSORBER INSPECTION REAR SHOCK ABSORBER REASSEMBLY REAR SHOCK ABSORBER AND AIR CLEANER REMOVAL REAR SUSPENSION REAR SUSPENSION LINKAGE REAR SUSPENSION LINKAGE REASSEMBLING REAR WHEEL REMOVAL AND REASSEMBLY REED VALVE SERVICE DATA SP...

Page 151: ...ION REASSEMBLY TRANSMISSION REMOVAL TROUBLESHOOTING ENGINE TROUBLESHOOTING CHASSIS WATER PUMP WHEEL BEARING REMOVAL AND REASSEMBLY WHEELS AND TIRES WIRE CABLE AND HOSE ROUTING PAGE 9 7 9 3 3 1 3 4 11 3 13 3 2 13 19 1 ...

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