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Suzuki RM85, Owner'S Service Manual

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Suzuki RM85 Owner'S Service Manual Download Page 147

15-6     FRONT AND REAR BRAKES

BRAKE CALIPER

FRONT CALIPER REMOVAL AND 
DISASSEMBLY

• Drain brake fluid. (

15-4)

• Place a drain pan under the caliper and remove the union bolt

1

.

• Remove the caliper mounting bolts 

2

.

• Remove the brake pads and spring 

3

 from the caliper.

• Remove the caliper bracket 

4

 from the caliper.

• Wrap the caliper with a rag to prevent brake fluid scatter and

piston pop-out.

 WARNING

The use of any brake fluid except DOT 4 brake fluid
from a sealed container can damage the brake system
and lead to an accident.

Use only DOT 4 brake fluid from a sealed container.
Never use or mix different types of brake fluid.

 WARNING

Brake fluid can be hazardous to humans and pets.
Brake fluid is harmful or fatal if swallowed, and harm-
ful if it comes in contact with your skin or eyes.

Keep brake fluid away from children. Call your doctor
immediately if brake fluid is swallowed, and induce
vomiting. Flush eyes or skin with water if brake fluid
gets in eyes or comes in contact with skin.

CAUTION

Spilled brake fluid can damage painted surfaces and
plastic parts.

Be careful not to spill any fluid when servicing the cal-
iper. Wipe spilled fluid up immediately.

Summary of Contents for RM85

Page 1: ...Part No 99011 02B82 01A April 2006 EN TK RM85 L OWNER S SERVICE MANUAL ...

Page 2: ...t of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator The manual contains important safety information and instructions which should be read carefully before operating the motorcycle ...

Page 3: ...ce and without incurring any obligation to make the same or similar changes to vehicles previous built or sold Suzuki Motor Corporation believes in conservation and protection of Earth s natural resources To that end we encourage every vehicle owner to recycle trade in or properly dispose of as appropriate used motor oil engine coolant and other fluid and tires WARNING CAUTION NOTE Please read thi...

Page 4: ...our friends rides motocross ask your Suzuki dealer how to go about joining a club If your friends do ride you can all join a club or start one of your own Practice on level ground Before you begin riding you should find a good place to practice the skills you need to ride safely Find a flat open area with enough space to maneuver Check with your Suzuki dealer or call police department if you do no...

Page 5: ...ATION The frame number 1 is stamped on the steering head The engine serial number 2 is stamped on the right side of the crankcase assembly Write down the serial numbers here for your future reference Frame No Engine No ...

Page 6: ...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 WARNING Brake fluids and engine coolant can be hazardous to humans and pets Brake fluid and engine coolant are harmful or fatal if swallowed and harmful if it comes in con tact with your skin or eyes Keep brake fluid and engine coolan...

Page 7: ...enuine SUZUKI parts are high quality parts which are designed and built specially for SUZUKI vehicles NOTE Use of replacement parts which are not equivalent in quality to genuine SUZUKI parts can lead to per formance problems and damage WARNING Servicing the machine with engine running can be hazardous You can be caught in the moving parts such as the drive chain sprockets etc Be sure to stop the ...

Page 8: ... MATERIALS Apply SUZUKI SUPER GREASE A 99000 25010 Apply SUZUKI SILICONE GREASE 99000 25100 Apply THREAD LOCK SUPER 1303 99000 32030 Apply THREAD LOCK SUPER 1322 99000 32110 Apply SUZUKI BOND 1207B 99000 31140 Use or apply DOT 4 Brake fluid ...

Page 9: ...99000 99001 SS5 Use SUZUKI REAR SUSPENSION OIL SS 25 99000 99001 S25 Use engine coolant SUZUKI COOLANT 99000 99032 11X Apply engine oil or transmission oil Tighten a nut or bolt to the specified torque Replace a part with a new one when reassembling ...

Page 10: ... MEMO ...

Page 11: ...OVAL AND INSTALLATION 5 CYLINDER PISTON AND EXHAUST VALVE 6 CLUTCH 7 KICK STARTER 8 GEARSHIFTING 9 TRANSMISSION AND CRANKSHAFT 10 FUEL SYSTEM 11 COOLING SYSTEM 12 ELECTRICAL SYSTEM 13 FRONT AND REAR WHEELS 14 FRONT AND REAR BRAKES 15 FRONT FORK AND STEERING 16 REAR SUSPENSION 17 SERVICING INFORMATION 18 ...

Page 12: ... GENERAL INSTRUCTIONS LOCATION OF PARTS 1 2 FUEL AND OIL RECOMMENDATION 1 3 INTRUCTING YOUNG RIDER 1 4 THIS IS IMPORTANT ADVICE TO A PARENT 1 4 STARTING ENGINE 1 5 STARTING OFF 1 7 BRAKING 1 7 STOPPING ENGINE 1 8 BREAK IN RUNNING IN 1 8 ...

Page 13: ...brake lever 6 Fuel tank cap 7 Fuel valve 8 Carburetor starter knob 9 Gearshift lever 0 Rear brake fluid reservoir A Rear suspension compression damping adjuster B Kick starter lever C Front suspension compression damping adjuster D Front suspension rebound damping adjuster E Rear brake pedal F Rear suspension rebound damping adjuster ...

Page 14: ...ughly when the tempera ture is below 0 C 32 F Vegetable based oils can separate easier than mineral oils Use premixture oil as soon as possible after mixing or lubrica tion performance of the engine oil can decrease Do not mix vegetable based oil and mineral oil Insert the end of the breather hose into the steering stem head after refueling CAUTION A mixture containing too little oil will cause pi...

Page 15: ...ize the name of each control The name suggests its function Know the route of drive from engine to wheels Learn the order in checking written items for INSPECTION BEFORE RIDING It is highly recommended that the parent shows examples by demonstrating NOTE Check to be sure that young rider has perfectly learned Let your child demonstrate for you Rule 2 Rehearse before riding out for the first time L...

Page 16: ...of riding fatigue comes from loss of body heat due to wind Abrasive injuries can be avoided by protection clothing Rule 6 Avoid stiff clothes Make sure that knee and elbow actions are free and that torso bending is not interferred with Free body movements are essential for safe riding NOTE The helmet gloves boots goggles and jacket are essential items of clothing STARTING ENGINE STARTING COLD ENGI...

Page 17: ... starter lever again As this motorcycle has a primary kick start system the engine can be started with the transmission in any gear position only if the clutch is disengaged by squeezing the clutch lever Upon starting the engine run it for 30 to 60 seconds to sta blize its speed Push the starter knob back to original position STARTING WARM ENGINE Shift the transmission into neutral Open the thrott...

Page 18: ...ever kick up gearshift lever while twisting back the throttle grip Now pick up speed on second Repeat this sequence to shift upward step by through third fourth and fifth to top BRAKING To slow down 1 twist throttle grip forward and 2 brake front and rear wheels Just before you come to a stop pull in clutch lever and shift down into NEUTRAL WARNING Twisting the throttle grip fully in standing star...

Page 19: ... Warm up the engine bofore starting off 2 Ride for 1 hour using less than 1 2 throttle opening with vari ous throttle opening 3 Ride for 1 hour using less than 3 4 throttle opening with vari ous throttle opening The break in running in period is the period of greatest wear The bolts and nuts of the new machine can loosen quickly Be sure to retighten the bolts and nuts during the break in run ning ...

Page 20: ...8 CLUTCH CABLE 2 9 THROTTLE CABLE 2 10 FUEL HOSE 2 10 FUEL VALVE 2 11 CYLINDER HEAD CYLINDER AND PISTON 2 12 EXHAUST VALVE 2 12 EXHAUST SILENCER 2 13 DRIVE CHAIN AND SPROCKETS 2 13 DRIVE CHAIN GUIDE BUFFER TENSIONER ROLLER 2 15 BRAKES 2 16 FRONT FORK 2 17 REAR SUSPENSION 2 18 WHEELS AND TIRES 2 18 STEERING 2 19 LUBRICATION 2 20 TIGHTENING TORQUE 2 21 ...

Page 21: ...tion Drive chain Slack lubrication chain joint clip condition Drive chain guide buffer Wear damage Suspension Smooth operation Front fork air pressure Wheels Spoke tension Rim lock tightness Tires Tire pressure Steering Smoothness play Exhaust pipe Firm fixation Bolts and nuts Tightening torque WHAT TO CHECK CHECK FOR All items of inspection before practice above plus Air cleaner Cleanliness Clutc...

Page 22: ...erhaul or storage Clutch I Replace clutch plates as necessary Throttle cable and clutch cable I L Carburetor I Fuel hose I Replace every 4 years Piston R Piston ring R Cylinder head cylinder C Exhaust valve C Muffler I Drive chain I L R Adjust slack every 30 minutes Engine sprocket I Rear sprocket I Check and retighten sprocket bolts at initial and subsequent 10 minutes of riding and each race the...

Page 23: ...ark plug Tighten the spark plug with specified tightening torque after tightening the spark plug temporarily with fingers Spark plug 28 N m 2 8 kgf m 20 5 lb ft Porcelain tip color Cause White overheated Hot type spark plug Advanced ignition timing Lean air fuel mixture Deteriorated fuel Black fouled Cold type spark plug Retarded ignition timing Rich air fuel mixture Rich oil gasoline mixture NGK ...

Page 24: ...lvent and wash it A MOTUL AIR FILTER CLEAN or equivalent cleaning solvent Squeeze the element by grasping it to remove excess sol vent Do not twist or wring the element or it will develop cracks Dry the element in a plastic bag pour in some foam filter oil B and work the oil into the element B MOTUL AIR FILTER OIL or equivalent filter oil Squeeze the element to remove excess oil INSTALLATION Apply...

Page 25: ...and dirt to enter the combustion chamber It can result in piston and cylinder wear Be sure to check the element seals properly after installing the elements WARNING Transmission oil and exhaust pipes can be hot enough to burn you Wait until the oil drain plug and exhaust pipes are cool enough to touch with bare hands before draining oil WARNING New and used oil and solvent can be hazardous Chil dr...

Page 26: ...t again as above procedure Tighten the filler cap and oil level screw firmly Oil level screw 5 5 N m 0 55 kgf m 4 0 lb ft TRANSMISSION OIL CHANGE Warm up the engine Place the motorcycle on the level ground and hold the motor cycle vertically Remove filler cap 1 and drain plug 2 Drain oil thoroughly Tighten the drain plug firmly Oil drain plug 23 N m 2 3 kgf m 16 5 lb ft Pour specified amount of mo...

Page 27: ...50 Adding only water will dilute engine coolant and it may decrease cool ing performance If the motorcycle is to be exposed to temperatures below 31 C 24 F the percentage of antifreeze should be increased to 55 or 60 according to figure 1 WARNING You can be injured by scalding fluid or steam if you open the radiator cap when the engine is hot Do not open the radiator cap when the engine is hot Wai...

Page 28: ...ant leakage Radiator hose cracks and deterioration Radiator mounting condition Radiator breather hose condition Radiator fin condition CLUTCH CABLE Adjust the clutch cable play as follows MAJOR ADJUSTMENT Loosen lock nut 1 Turn adjuster 2 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 1 Clutch lever play 10 15 mm 0 4 0 6 in WARNING...

Page 29: ...tle cable play 2 4 mm 0 08 0 16 in Remove the throttle housing cover Apply oil to the throttle cable Apply grease to the throttle cable spool FUEL HOSE Inspect the fuel hose for damage and fuel leakage If any defects are found the fuel hose must be replaced with a new one Replace the fuel hose every four years 10 15 mm 0 4 0 6 in WARNING Inadequate throttle cable play can cause engine speed to ris...

Page 30: ...valve 2 Clean the fuel filter with compressed air NOTE If the fuel filter is dirty with sediment fuel will not flow smoothly WARNING Gasoline is highly flammable and explosive Keep heat sparks and flames away from gasoline CAUTION The O ring 3 must be replaced with a new one to pre vent fuel leakage ...

Page 31: ...piston 6 4 Remove carbon deposits from the top surface of the piston Check for scratches cracks and wear around the piston bosses Remove minor scuffs with 1 000 1 200 sand paper Check piston ring wear Remove carbon deposits from the piston ring groove EXHAUST VALVE Remove the exhaust valve 6 4 Remove carbon deposits from the exhaust valve and exhaust valve guide Check for wear and damage Inspect t...

Page 32: ...Replace the glass wool 1 with a new one if necessary SILENCER REASSEMBLY Install the glass wool 1 and the black frontal pipe to the alu minum case Tighten three bolts NOTE To seal between the black frontal pipe flange and the aluminum case apply SUZUKI BOND 1207B to the contact area of the flange 99000 31140 SUZUKI BOND 1207B DRIVE CHAIN AND SPROCKETS DRIVE CHAIN SLACK Place the motorcycle on the ...

Page 33: ... have play 20TH PITCH LENGTH Pull the drive chain tight and measure the 20th pitch length Service Limit 259 mm 10 2 in DRIVE CHAIN LUBRICATION Remove the chain clip and master link from the drive chain and remove the drive chain NOTE Be careful not to bend the chain clip Inspect for wear and damage of the drive chain and replace it if necessary Clean the drive chain with non flammable cleaning sol...

Page 34: ...NOTE The drive chain can hit a bent guide causing noise and drive chain wear Inspect the chain guide defense 2 for wear DRIVE CHAIN GUIDE BUFFER Inspect the drive chain guide buffer 3 for wear and cracks NOTE The drive chain can touch the swingarm directly if the chain guide buffer is worn out This will cause drive chain and swing arm damage DRIVE CHAIN TENSIONER ROLLER Inspect the drive chain ten...

Page 35: ...is harmful or fatal if swallowed and harm ful if it comes in contact with your skin or eyes Keep brake fluid away from children Call your doctor immediately if brake fluid is swallowed and induce vomiting Flush eyes or skin with water if brake fluid gets in eyes or comes in contact with skin WARNING The use of any fluid except DOT 4 brake fluid from a sealed container can damage the brake system a...

Page 36: ... by turning the adjuster 2 to locate the pedal 0 10 mm 0 0 4 in below the top face of the footrest Tighten lock nut 1 Rear master cylinder rod lock nut 18 N m 1 8 kgf m 13 0 lb ft FRONT FORK Move the front fork up and down several times and inspect for smooth movement Inspect for damage and oil leaks Place a stand under the chassis tube to lift the front wheel off the ground Remove the air bleed s...

Page 37: ...5 SPOKE NIPPLE AND RIM LOCK Inspect the spokes for tension by squeezing the spoke nip ples Retighten the spoke nipples with a spoke nipple wrench so as all spokes have same tension Spoke nipple 4 N m 0 4 kgf m 2 9 lb ft Inspect the rim lock 1 for tightness TIRE PRESSURE Inspect front and rear tire pressure Tire pressure cold 70 110 kPa 0 7 1 1 kgf cm2 10 16 psi CAUTION Improperly tightening the sp...

Page 38: ...MAINTENANCE 2 19 STEERING Inspect the steering by moving the front forward and back ward and right and left If the steering has play or binds inspect steering stem head nut tightness and steering bear ings 16 13 ...

Page 39: ...s the lower end Lube the cable ends where they pivot 2 Throttle grip throttle housing cable A Pre race Lightly oil the inside of throttle spool Keep free from dirt 3 Rear brake pedal C Pre race Grease the brake pedal pivot 4 Swingarm C Every 3 races More often according to conditions Clean and pack the bearings Keep seals fresh Grease the seals 5 Rear suspension linkage pivot points C Every 3 race...

Page 40: ...r mounting bolt front 10 1 0 7 3 Master cylinder mounting bolt rear 10 1 0 7 3 Rear master cylinder rod lock nut 18 1 8 13 0 Brake hose adaptor front 18 1 8 13 0 Brake hose union bolt front and rear 23 2 3 16 5 Brake caliper mounting bolt front 23 2 3 16 5 Brake caliper mounting bolt rear 23 2 3 16 5 Brake bleeder valve front and rear 7 5 0 75 5 5 Disc mounting screw front and rear 8 5 0 85 6 0 Di...

Page 41: ...lt 7 marked or crown headed bolt N m kgf m lb ft N m kgf m lb 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 23 0 2 3 16 5 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 ...

Page 42: ...3 TROUBLESHOOTING 3 1 CONTENTS TROUBLESHOOTING TROUBLESHOOTING 3 2 ENGINE 3 2 CHASSIS 3 5 ...

Page 43: ...ation Fouled spark plug Fuel hose clogged Air cleaner clogged Carburetor jets clogged Low compression Piston ring worn or stuck Cylinder worn Air leak from cylinder gasket Air leak from crankshaft oil seal Incorrect ignition timing Carburetor fuel level maladjustment Replace Clean or replace Clean or replace Clean or replace Clean Replace Replace or rebore Replace Replace Adjust Adjust Insufficien...

Page 44: ...ring stuck Adjust or replace Adjust Adjust Replace Replace Clean or replace Replace Replace Clean adjust or replace Replace Exhaust valve does not work Carbon deposits on exhaust valve Exhaust valve damage Governer damage Exhaust valve shaft damage Valve spring damage Clean Replace Replace Replace Replace Spark plug does not ignite Ignition coil malfunction Spark plug malfunction Generator malfunc...

Page 45: ...l wear or damage Radiator cap seal damage Incorrect radiator cap valve pressure Cylinder or cylinder head cracked Cylinder or cylinder head O rings damage Replace Repair Repair or replace Replace Replace Replace Replace Replace Replace Replace Replace Clutch does not disengage Clutch lever play maladjustment Clutch spring damage Clutch plates distortion Adjust Replace Replace Clutch slipping Clutc...

Page 46: ...Low oil level Low fork oil viscosity Damping force maladjustment Damping valve malfunction Stardard spring too soft Replace Replenish Replace Adjust Replace Use optional spring Hard front suspension High fork oil level High fork oil viscosity Damping force maladjustment Inner tube distortion Adjust Replace Adjust Replace Soft rear suspension Weakened spring Damping force maladjustment Low gas pres...

Page 47: ... MEMO ...

Page 48: ...CIPLES OF CARBURETOR TUNING 4 2 CARBURETOR TUNING IN PRACTICE 4 5 FRONT FORK TUNING 4 8 FRONT FORK 4 8 FRONT FORK SPRING REPLACEMENT AND OIL LEVEL ADJUSTMENT 4 9 REAR SUSPENSION TUNING 4 13 REAR SUSPENSION 4 13 SUSPENSION BALANCE 4 16 BALANCE TEST 4 16 BALANCING TIPS 4 16 ...

Page 49: ... based on the fol lowing information and specifications Carburetor Specifications PRINCIPLES OF CARBURETOR TUNING CARBURETOR COMPONENTS AND FUNCTIONS The carburetor consists of a number of parts as shown below The asterisk marked parts are pre cisely machined which meter the intake air oxy gen and fuel so that the air fuel mixture ratio is controlled accurately They can be divided by three operati...

Page 50: ...rations are those of standard setting SLOW JET The pilot jet meters the fuel supplied to the pilot sys tem Each jet size is indicated by a number Larger number means a larger bore diameter and fitting a larger numbered pilot jet enriches the air fuel mix ture AIR SCREW AIR SCREW The pilot air screw is located in the inlet air passage and meters the air for the pilot system As it has a right hand t...

Page 51: ...the needle clip position by half change jet needle from 24NAAH type to 24NCDH type This change will move the needle position by half to the leaner side JET NEEDLE NEEDLE NUMBER Changing the needle itself controls air fuel mixture ratio particulary on lower mid throttle opening The smaller the O D the richer the air fuel mixture becomes MAIN JET The main jet like the pilot jet meters fuel flow Air ...

Page 52: ... to 100 humidity difference As for humidity its normal range is from 20 to 95 Therefore the possible effect of humidity on the oxygen concentration is so little that it can be disregarded Consequently we can say that the oxygen concentration varies by as much as 20 depending on the temperature and altitude under normal riding conditions On the other hand different from the air the fuel gasoline ha...

Page 53: ...ngine fluctuates and lack of power is noticed 6 Detonation and pinging are experienced TUNING PROCEDURE The following indicates the correct tuning procedure for this motorcycle Understand the procedure by first riding the motorcycle where it will be used and adjust the engine to the best condition after judging the air fuel mixture Carburetor standard setting Main jet 128 Jet needle 24NAAH 3rd Slo...

Page 54: ...ediate system by selecting the proper needle size Changing standard needle within one size larger or smaller will cover almost any race condi tion 4 Fine adjustment of slow system After a proper standard setting has been obtained by the procedure 1 through 3 fine tune the carbu retor according to the actual race conditions 1 Adjust the air fuel mixture by tuning the air screw within 1 2 2 turns ou...

Page 55: ...r you may damage the adjuster Turn the adjuster screw out to the standard position Standard setting 7 clicks out from the stiffest position REBOUND DAMPING FORCE ADJUSTMENT Turn the adjuster screw 2 clockwise until it stops It is the stiffest position NOTE To set the adjuster you must gently turn the adjuster screw clockwise until it stops then back it out the recommended num ber of turns Do not f...

Page 56: ...level of the outer tube Move the inner rod slowly with the special tool more than ten times until no more bubbles come out from the oil 09940 52841 Inner rod holder NOTE Refill front fork oil up to the top of the outer tube to find bubbles while bleeding air 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 tube or...

Page 57: ...74111 Front fork oil level gauge 99000 99001 SS5 SUZUKI FORK OIL SS 05 or an equivalent fork oil NOTE Be sure to adjust the fork oil level within the above mentioned range the front fork performance will deteri orate The oil level should be increased or decreased by 3 mm 0 12 in at a time Make sure that the oil level is the same as both fork legs Pull up the inner rod with the special tool 09940 5...

Page 58: ...kgf m 14 5 lb ft Apply fork oil to the fork cap s O ring Tighten the fork cap bolt to the specified torque Fork cap bolt 35 N m 3 5 kgf m 25 5 lb ft Remount the front forks to the steering stem 16 10 OPTIONAL SPRING The number of end coils shows the fork spring rate CAUTION Be sure to adjust the rebound damping force adjuster to the softest position before installing the fork cap bolt 1 5 mm 1 5 m...

Page 59: ...und damping to a softer setting 2 Decrease fork oil capacity 3 Replace the spring with an optional softer one Feels too soft overall and bottoms Jump Large bump When braking 1 Adjust the compression damping to a stiffer set ting 2 Increase fork oil capacity 3 Replace the spring with an optional stiffer one Feels too hard near end of travel Jump 1 Decrease fork oil capacity Feels too soft near end ...

Page 60: ...lockwise It is at stiffest position and turn it out to standard setting NOTE Do not force the adjuster screw past the stopped position or the adjuster may be damaged Standard setting 2 turns out from stiffest position SPRING PRE LOAD ADJUSTMENT Remove the seat frame covers and frame side tube Remove the cleaner box Loosen the lock nut 1 Turn the adjuster 2 clockwise or counterclockwise to change t...

Page 61: ... in REAR SUSPENSION After the sag measurement has been set between 85 mm 3 3 in to 95 mm 3 7 in test ride the motorcycle and adjust the sus pension for the rider and track conditions referring to the guide below Spring Spring rate Part No Marking paint Soft Option 44 N mm 4 4 kgf mm RM85 46 N mm 4 6 kgf mm RM85L 62211 03B80 GREEN 2 line 62211 03B90 GREEN Standard 46 N mm 4 6 kgf mm RM85 48 N mm 4 ...

Page 62: ...e the spring with an optional softer one Hits bumps too harshly Jump Large bump Series of medium bumps 1 Adjust the compression damping to a softer S setting See note below 2 Adjust the sag to a larger measurement closer to 95 mm 3 Replace the spring with an optional softer one Feels harsh and tends to sink Series of medium bumps Series of small bumps 1 Adjust the rebound damping to a softer S set...

Page 63: ...o bottom where as it felt fine before the front fork adjustment was made BALANCE TEST Stand next to the motorcycle on level ground Place one foot on the foot rest closest to you Sharply push down The front and rear suspensions should both collapse equally BALANCING TIPS Check for air pressure build up in front forks Heat and altitude will increase air pressure in the front forks Always stay within...

Page 64: ...5 ENGINE REMOVAL AND INSTALLATION 5 1 CONTENTS ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL AND INSTALLATION 5 2 REMOVAL 5 2 INSTALLATION 5 5 ...

Page 65: ...e fuel valve lever to the OFF position and disconnect the fuel hose Remove the radiator cover 4 Remove the fuel tank mounting bolts 5 left and right Remove the fuel tank by unhooking the band 6 from the hooked part Drain transmission oil 2 7 Drain engine coolant 12 3 Remove the exhaust pipe fitting springs with the special tool 09920 20310 Spring hook ...

Page 66: ...ing bolts Remove the exhaust pipe and muffler Remove the exhaust pipe and gasket Disconnect the radiator hose 1 Disconnect the radiator hose 2 Remove the spark plug cap 3 and spark plug 4 Disconnect the magneto lead wire coupler 5 Remove the lead wire hose clamp ...

Page 67: ...ND INSTALLATION Loosen the carburetor clamp screws and remove the carbure tor Remove the magneto cover Remove the drive chain Remove the clutch release arm 1 and disconnect the clutch cable Remove the engine mounting bolts ...

Page 68: ...t the swingarm in its position and hold it with the swingarm pivot shaft Mount the engine on the frame Tighten the engine mounting nuts Tightening torque NOTE Replace the self locking nuts with new ones Reassemble the removed parts in the reverse order of removal NOTE Route the cables and lead wires correctly 18 15 and 16 Reassemble the drive chain clip so the slit end faces opposit the direction ...

Page 69: ...intake pipe Apply a small quantity of engine oil to the exhaust pipe O ring Install the exhaust gasket and exhaust pipe After mounting the engine inspect the following items Transmission oil level 2 7 Engine coolant level 2 8 Throttle cable play 2 10 Clutch lever play 2 9 Drive chain slack 2 13 ...

Page 70: ...OVAL 6 4 EXHAUST VALVE REMOVAL 6 4 CYLINDER HEAD INSPECTION 6 5 CYLINDER INSPECTION 6 5 PISTON AND PISTON RING INSPECTION 6 6 EXHAUST VALVE INSPECTION 6 7 CONROD INSPECTION 6 8 PISTON RING AND PISTON REASSEMBLY 6 8 EXHAUST VALVE REASSEMBLY 6 8 CYLINDER REASSEMBLY 6 10 EXHAUST VALVE GOVERNOR REMOVAL AND DISASSEMBLY 6 12 EXHAUST VALVE GOVERNOR INSPECTION 6 13 EXHAUST VALVE GOVERNOR REASSEMBLY AND IN...

Page 71: ...6 2 CYLINDER PISTON AND EXHAUST VALVE CONSTRUCTION CYLINDER PISTON AND EXHAUST VALVE 28 N m 2 8 kgf m 20 5 lb ft 28 N m 2 8 kgf m 21 0 lb ft 25 N m 2 5 kgf m 18 0 lb ft ...

Page 72: ...ug 3 Remove the cylinder head 4 NOTE Loosen the cylinder head nuts diagonally to prevent cylinder head distortion CYLINDER REMOVAL Remove the cylinder head above Remove the exhaust pipe 5 2 Remove the cylinder head O rings 1 and 2 Remove the exhaust valve rod cover 3 and gasket Remove the bolt 4 and disconnect the exhaust valve rod CAUTION Set the pin A provided with machine to the lever before lo...

Page 73: ...ylinder head and cylinder 6 3 Remove the piston pin circlip 1 NOTE Place cloth on the crankcase to prevent the piston pin circlip from dropping into the crankcase chamber Remove the piston pin 2 Remove the piston 3 Remove the conrod small end bearing 4 Remove the piston ring EXHAUST VALVE REMOVAL Remove the cylinder head and cylinder 6 3 Remove the breather hoses Remove the exhaust valve cover 1 ...

Page 74: ...osits from the cylinder head Inspect the cylinder head for cracks around the spark plug hole Inspect for cylinder head distortion Cylinder head distortion Service Limit 0 05 mm 0 002 in CYLINDER INSPECTION Remove carbon deposits from the exhaust port Inspect the cylinder for cracks and replace the cylinder if nec essary Inspect the cylinder bore for wear nicks and scratches NOTE Chrome plated cyli...

Page 75: ...posits from the piston Inspect the piston for wear scratches and damage Measure the piston outer diameter 16 mm 0 63 in from the skirt end Piston outer diameter Service Limit 47 880 mm 1 8850 in 09900 20202 Micrometer 25 50 mm Measure the piston pin bore and piston pin diameter 09900 20605 Dial gauge 09900 20205 Micrometer 0 25 mm Remove carbon deposits from piston ring and piston ring groove Fit ...

Page 76: ...ring free end gap Service Limit 3 2 mm 0 13 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 exhaust valve shaft and arm for damage Inspect the exhaust valve breather hoses for clogging with tar If clogging is found clean up it NOTE Using several brands of engine oil may cause tar ...

Page 77: ... oil to the piston pin and bearing Install the bearing to the conrod small end Face the depression on the piston top to the exhaust port side and install the piston 1 Install the piston pin 2 and piston pin circlips 3 End gap of the circlip should not be aligned with the cutaway in the piston pin bore NOTE Replace the piston pin circlip with a new one Place cloth on the crankcase to prevent piston...

Page 78: ...CYLINDER PISTON AND EXHAUST VALVE 6 9 Install the spacers 1 springs 2 valve shaft arm 4 and shaft Tighten the bolt 3 Tighten the stopper bolt 5 Install the gasket and cover ...

Page 79: ...er nut 25 N m 2 5 kgf m 18 0 lb ft Tighten the nut 2 Install the exhaust rod cover and gasket CAUTION If the piston pin end is not at the proper position you can not insert the piston into the cylinder properly and the piston ring will be damaged Locate the piston ring end to the locating pin and insert the piston into the cylinder Incorrect Correct 3 1 2 4 CAUTION Set the pin A provided with mach...

Page 80: ...linder head nuts to the specified torque accord ing to the specified tightening order as shown Cylinder head nut 28 N m 2 8 kgf m 20 5 lb ft Reassemble the exhaust pipe 5 6 Reassemble the spark plug and spark plug cap Connect the radiator hose and tighten the hose clamp Pour engine coolant 12 3 Inspect engine coolant leak ...

Page 81: ...n transmission oil 2 7 Drain engine coolant 12 3 Remove the exhaust pipe 5 2 Remove the rear brake pedal 15 14 Remove the clutch cover 7 3 Remove the exhaust valve bolt 6 4 Remove the exhaust valve governor 1 Remove the exhaust valve actuator 2 Remove the pin 3 by pushing the retainer 4 down ...

Page 82: ... 6 13 Remove the spring 5 retainer 6 and bearing 7 Remove the washers 8 spacer 9 bearing 0 and stator A Remove the balls B EXHAUST VALVE GOVERNOR INSPECTION Inspect the bearing for wear Replace the bearing if there is anything unusual ...

Page 83: ...LATION Installation is in the reverse order of removal and disassembly Pay attention to the following points Apply transmission oil to the exhaust valve gevernor Install the exhaust valve actuator 1 Install the exhaust valve governor with the groove A engaged with the actuator arm B Install the actuator lever and exhaust valve rod cover 6 10 Install the brake pedal 15 14 Pour transmission oil 2 7 ...

Page 84: ...2 CLUTCH 7 3 CLUTCH PLATE REMOVAL 7 3 CLUTCH PLATE INSPECTION 7 3 CLUTCH SPRING INSPECTION 7 4 CLUTCH RACK AND PINION INSPECTION 7 4 CLUTCH PLATE REASSEMBLY 7 4 CLUTCH SLEEVE HUB REMOVAL 7 5 CLUTCH SLEEVE HUB INSPECTION 7 6 CLUTCH SLEEVE HUB REASSEMBLY 7 6 ...

Page 85: ...7 2 CLUTCH CONSTRUCTION CLUTCH 70 N m 7 0 kgf m 50 5 lb ft ...

Page 86: ...emove the clutch springs Remove the pressure plate Remove the rack 3 and bearing 4 from the pressure plate Remove the drive plates and driven plates CLUTCH PLATE INSPECTION Measure the drive plate thickness Drive plate thickness Service Limit 2 4 mm 0 094 in Inspect the drive plates for wear distortion and discoloration Measure the driven plate distortion Driven plate distortion Service Limit 0 10...

Page 87: ...t the clutch release rack and pinion for wear and dam age Inspect the clutch release arm for smooth movement and oil leakage around the oil seal CLUTCH PLATE REASSEMBLY Apply transmission oil to the drive plates 1 and driven plates 2 and install them to the clutch sleeve hub Install the rack 3 and bearing 4 NOTE The roller side of the bearing must face to the rack side Install the pressure plate 1...

Page 88: ...ally Reassemble the rear brake pedal 15 14 Install the clutch release arm 1 Install the kick starter lever 2 Pour transmission oil 2 7 Pour engine coolant 2 8 Inspect the clutch cable play 2 9 CLUTCH SLEEVE HUB REMOVAL Remove the pressure plate and clutch plates 7 3 Flatten the lock washer 1 Hold the clutch sleeve hub with the special tool and loosen the nut 09920 53740 Clutch sleeve hub holder Re...

Page 89: ...r 6 CLUTCH SLEEVE HUB INSPECTION Inspect the clutch sleeve hub and primary driven gear ass y for wear and cracks Inspect the kick idle gear and needle bearing for damage and wear CLUTCH SLEEVE HUB REASSEMBLY Install the washer 2 and needle bearing 1 Apply transmission oil to the needle bearing 1 Install the kick idle gear 3 and snap ring 4 ...

Page 90: ...he clutch sleeve hub lock washer 1 and clutch sleeve hub nut 2 Tighten the clutch sleeve hub nut with the special tool to the specified torque 09920 53740 Clutch sleeve hub holder Clutch sleeve hub nut 70 N m 7 0 kgf m 51 0 lb ft Bend the lock washer to secure the nut 1 ...

Page 91: ...ns Replace the gasket with a new one Install the clutch cover and bolts Tighten the clutch cover bolts diagonally 7 5 Connect the radiator hose Install the clutch release arm and kick starter lever Reassemble the rear brake pedal 15 14 Pour transmission oil 2 7 Pour engine coolant 2 8 ...

Page 92: ...8 KICK STARTER 8 1 CONTENTS KICK STARTER CONSTRUCTION 8 2 KICK STARTER 8 2 KICK STARTER 8 3 REMOVAL 8 3 INSPECTION 8 4 REASSEMBLY 8 4 ...

Page 93: ...8 2 KICK STARTER CONSTRUCTION KICK STARTER ...

Page 94: ... the kick starter drive gear 3 Install the kick starter lever temporally to remove the kick starter shaft Turn the kick starter lever counterclockwise until the kick starter 4 come off the kick starter guide 5 Remove the following parts from the kick starter shaft Spacer 6 Kick return spring 7 Washer 8 Kick starter 9 Spring 0 Kick starter shaft A Remove the kick starter guide B and kick starter st...

Page 95: ... wear Inspect the kick drive gear teeth for damage Inspect the kick drive gear ratchet part for wear and damage Inspect the kick starter stopper 4 REASSEMBLY Install the kick starter stopper and kick starter guide Apply THREAD LOCK SUPER 1322 to the bolt Tighten the bolt 99000 32110 THREAD LOCK SUPER 1322 Install the return spring 1 into the kick shaft s hole Install them to the crankcase ...

Page 96: ...arter shaft when installing the kick starter Reassemble the kick idle gear Reassemble the primary driven gear ass y and clutch 7 6 Reassemble the kick starter lever as shown A CORRECT B INCORRECT Reassemble the clutch release arm Reassemble the rear brake pedal 15 14 Pour transmission oil 2 7 Pour engine coolant 2 8 Inspect the clutch lever play Inspect for transmission oil leaks Inspect the kick ...

Page 97: ... MEMO ...

Page 98: ...9 GEARSHIFTING 9 1 CONTENTS GEARSHIFTING CONSTRUCTION 9 2 GEARSHIFT LINKAGE 9 2 GEARSHIFT LINKAGE 9 3 REMOVAL 9 3 INSPECTION 9 4 REASSEMBLY 9 4 ...

Page 99: ...9 2 GEARSHIFTING CONSTRUCTION GEARSHIFT LINKAGE 19 N m 1 9 kgf m 13 5 lb ft 23 N m 2 3 kgf m 16 5 lb ft ...

Page 100: ...d clutch assembly 7 5 Remove the gearshift lever Remove the gearshift shaft 2 Remove the two screws Remove the pawl lifter 3 Remove the gearshift cam shifter 4 NOTE Be careful that the pins and springs do not fly off Remove the gearshift pawls 5 pins 6 and springs 7 Loosen the gearshift cam bolt 8 and remove the stopper plate 9 ...

Page 101: ...g 2 INSPECTION Inspect the gearshift shaft 1 for bends and damage Inspect the return spring 2 for damage Inspect the pawls 3 springs 4 and pins 5 for damage Inspect the gearshift cam stopper REASSEMBLY Reassemble the washer 1 and gearshift cam stopper 2 and the spring 3 ...

Page 102: ...ing the stopper plate 1 Tighten the gear shift cam bolt 2 Gearshift cam bolt 23 N m 2 3 kgf m 16 5 lb ft Install the springs pins and pawls to the shifter Wider side A of pawl should be positioned outside With the pawls held in pushed position install the pawl lifter 3 ...

Page 103: ... SUPER 1322 Reassemble the gearshift return spring 1 to the gearshift shaft properly Align the center teeth on the gearshift shaft with the center teeth on the gearshift cam shifter Install the gearshift lever Reassemble the clutch and clutch cover 7 6 Install the kick starter lever and clutch release arm Pour transmission oil 2 7 Pour engine coolant 2 8 ...

Page 104: ...R REMOVAL 10 3 CRANKCASE SEPARATION 10 3 TRANSMISSION REMOVAL 10 4 CRANKSHAFT REMOVAL 10 4 TRANSMISSION INSPECTION 10 4 CRANKSHAFT INSPECTION 10 6 OIL SEAL INSPECTION REMOVAL AND INSTALLATION 10 6 BEARING INSPECTION REMOVAL AND INSTALLATION 10 7 CRANKSHAFT INSTALLATION 10 8 TRANSMISSION REASSEMBLY 10 9 CRANKCASE REASSEMBLY 10 10 PRIMARY DRIVEN GEAR REASSEMBLY 10 11 ...

Page 105: ...10 2 TRANSMISSION AND CRANKSHAFT CONSTRUCTION TRANSMISSION AND CRANKSHAFT 70 N m 7 0 kgf m 50 5 lb ft ...

Page 106: ...ve the kick starter idle gear and kick starter shaft 8 3 Remove the gearshift linkage 9 3 Remove the exhaust valve governor 6 11 PRIMARY DRIVE GEAR REMOVAL Hold the conrod with the special tool and loosen the primary drive gear nut Remove the primary drive gear nut 09910 20116 Conrod holder NOTE The primary drive gear nut has left hand thread CRANKCASE SEPARATION Remove the crankcase bolts Separat...

Page 107: ...nd countershaft ass y 5 CRANKSHAFT REMOVAL Remove the crankshaft with the special tool 09920 13120 Crankcase separating tool TRANSMISSION INSPECTION Inspect the gear teeth dogs and gearshift grooves for abnor mal wear and damage Inspect the bushings and splines for abnormal wear and dis coloration Inspect the gearshift cam groove for abnormal wear and dam age ...

Page 108: ...sure the gearshift fork groove width with a vernier cali pers Gearshift fork groove width Measure the gearshift fork to groove clearance with a thick ness gauge Gearshift fork Groove clearance Service Limit 0 45 mm 0 018 in Standard No 1 3 80 3 90 mm 0 150 0 154 in No 2 No 3 4 30 4 40 mm 0 169 0 173 in Standard No 1 3 95 4 05 mm 0 156 0 159 in No 2 No 3 4 45 4 55 mm 0 175 0 179 in ...

Page 109: ...00 21304 V block NOTE Place the crankshaft onto the V blocks so that it becomes hori zontally Measure the runout from the tips of the crankshaft Measure the crankshaft web to web width with a vernier cali pers Width between webs Standard 44 9 45 1 mm 1 767 1 775 in OIL SEAL INSPECTION REMOVAL AND INSTALLATION Inspect each oil seal lip for wear and damage Remove the oil seal with the special tool 0...

Page 110: ...913 70210 Bearing installer set NOTE Be sure to check the direction of the crankshaft bearing oil seals before fitting them BEARING INSPECTION REMOVAL AND INSTALLATION Inspect the bearings for play discoloration wear and seizure Move the inner race by finger and inspect for smooth move ment OUT SIDE Left Right OUT SIDE ...

Page 111: ...the bearings with the special tool 09913 70210 Bearing installer set Remove the bearing 3 with the special tool 09921 20220 Bearing remover set CRANKSHAFT INSTALLATION Install the crankshaft into the left crankcase half with the spe cial tool 09910 32812 Crankshaft installer ...

Page 112: ...the illustration Replace the removed snap ring with a new one Apply transmission oil to the following parts driveshaft coun tershaft transmission gears bearings gearshift forks gear shift shafts gearshift cam Reassemble the driveshaft 1 and countershaft 2 with gears installed Left Right Thrust Sharp edge W Washer asher Washer ...

Page 113: ... gasket 1 and dowel pins 2 Install the right crankcase half on the left crankcase half Tighten the crankcase bolts Crankcase bolt 10 N m 1 0 kgf m 7 3 lb ft NOTE Tighten the bolts gradually and diagonally to guide the crank shaft into the bearing If it is hard to tighten the bolts separate the crankcase and confirm that the transmission parts are assembled correctly Inspect the crankshaft for smoo...

Page 114: ...rod holder Primary driven gear nut 70 N m 7 0 kgf m 50 5 lb ft NOTE The primary driven gear nut has left hand thread Reassemble the gearshift linkage 9 4 Reassemble the kick idle gear and kick starter shaft 8 4 Reassemble the exhaust valve governor 6 13 Reassemble the stator and magnet rotor 13 6 Reassemble the clutch and clutch cover 7 6 Reassemble the kick starter lever Reassemble the piston and...

Page 115: ... MEMO ...

Page 116: ...L SYSTEM 11 1 CONTENTS FUEL SYSTEM CONSTRUCTION 11 2 FUEL SYSTEM 11 2 CARBURETOR 11 3 REMOVAL AND DISASSEMBLY 11 3 INSPECTION 11 5 REASSEMBLY 11 5 REED VALVE 11 5 REMOVAL 11 5 INSPECTION 11 5 REASSEMBLY 11 6 ...

Page 117: ...11 2 FUEL SYSTEM CONSTRUCTION FUEL SYSTEM ...

Page 118: ...en the carburetor clamp screws and remove the carbure tor Remove the carburetor top cap and throttle valve Compress the spring 2 with collar 3 and disconnect the throttle cable 1 from the throttle valve Remove the spring 4 and jet needle 5 from the throttle valve Throttle valve spring A Throttle valve collar B Spring C Jet needle D Throttle valve E ...

Page 119: ...se 3 Loosen the screws and remove the carburetor float chamber 5 Remove the float pin 6 and floats 7 Remove the jet holder 8 Remove the needle valve ass y 9 Remove the main jet 0 and slow jet A Remove the starter knob B Remove the pilot screw C and throttle stop screw D ...

Page 120: ...the float tip just con tacts the float valve Standard float height A 19 0 5 mm 0 75 0 02 in REASSEMBLY Reverse the sequence of removal NOTE Fit the projection of the carburetor to the depression on intake pipe REED VALVE REMOVAL Remove the carburetor 11 3 Remove the four bolts Remove the intake pipe and reed valve INSPECTION Inspect the reeds for damage Inspect the reed valve stoppers for damage I...

Page 121: ...11 6 FUEL SYSTEM REASSEMBLY Reverse the sequence of removal ...

Page 122: ...NG SYSTEM 12 2 ENGINE COOLANT 12 3 ENGINE COOLANT REPLACEMENT 12 3 RADIATOR 12 3 RADIATOR CAP INSPECTION 12 3 RADIATOR REMOVAL 12 4 COOLING SYSTEM INSPECTION 12 4 RADIATOR INSTALLATION 12 4 WATER PUMP 12 5 WATER PUMP REMOVAL AND INSPECTION 12 5 WATER PUMP REASSEMBLY 12 6 ...

Page 123: ...12 2 COOLING SYSTEM CONSTRUCTION COOLING SYSTEM 2 5 N m 0 25 kgf m 1 8 lb ft 2 5 N m 0 25 kgf m 1 8 lb ft ...

Page 124: ...the radiator cap firmly Run the engine a few minutes and inspect the coolant level RADIATOR RADIATOR CAP INSPECTION Inspect the radiator cap for function with a radiator cap pres sure gauge Radiator cap valve release pressure 95 125 kPa 0 95 1 25 kgf cm2 13 5 17 8 psi NOTE Apply water to radiator cap seal before fitting the radiator cap to the pressure gauge WARNING You can be injured by scalding ...

Page 125: ...the radiator by removing its mounting bolts COOLING SYSTEM INSPECTION Inspect the following items Radiator coolant leakage Radiator hose cracks and deterioration Radiator mounting condition Radiator breather hose condition Radiator fin condition RADIATOR INSTALLATION Reverse the sequence of removal COOLING SYSTEM HOSE ROUTING 18 10 and 11 ...

Page 126: ...e clutch cover 7 3 Remove the snap rings 2 with snap ring pliers Remove the impeller Inspect the impeller for damage Inspect the bearing for smooth inner race movement Remove the snap ring and bearing with the special tool 09916 44910 Valve guide driver Inspect the oil seal 1 for damage Remove the oil seal 1 with the special tool 09913 50121 Oil seal remover ...

Page 127: ...2110 THREAD LOCK SUPER 1322 Apply grease to the machanical seal lip Insert the water pump shaft Install the bearing with the special tool 09916 44910 Valve guide driver 09916 53340 Valve guide installer Install the snap ring 1 Reassemble the clutch cover and water pump cover 7 5 Connect the radiator hose Pour engine coolant and transmission oil 2 7 and 8 ...

Page 128: ...LECTRICAL SYSTEM CONSTRUCTION 13 2 ELECTRICAL SYSTEM 13 2 ELECTRICAL CIRCUIT 13 2 IGNITION SYSTEM 13 3 IGNITION COIL INSPECTION 13 4 CDI UNIT INSPECTION 13 4 STATOR COIL INSPECTION 13 5 MAGNETO ROTOR AND STATOR REMOVAL AND REASSEMBLY 13 5 ...

Page 129: ...IT Color code B W Black with White tracer B Y Black with Yellow tracer B R Black with Red tracer W Bl White with Blue tracer R W Red with White tracer 35 N m 3 5 kgf m 25 5 lb ft Magneto B R R W B W CDI Unit B Y Engine stop switch Ignition coil W Bl Spark plug B W B W B W ...

Page 130: ...e Blue terminal Ground probe probe NOTE Do not disconnect the ignition coil primary wire 09900 25008 Multi circuit tester set Shift the transmission into neutral and pull the clutch lever Depress the kick starter lever force fully Repeat the above procedure a few times and measure the highest ignition coil primary peak voltage Tester knob indication Voltage If the voltage is lower than the specifi...

Page 131: ...lead wires with the multi circuit tester as shown in the illustration 09900 25008 Multi circuit tester Tester knob indication Diode Unit V NOTE is open circuit voltage 1 511 V Primary White Blue Ground 0 2 1 0 Ω Secondary Plug cap Ground 12 20 kΩ Positive probe pin Diode terminal Negative probe pin COM terminal 1 2 3 4 5 6 1 0 165 0 765 0 000 0 300 2 3 0 165 0 765 0 589 1 189 0 589 1 189 0 165 0 7...

Page 132: ...EASSEMBLY Remove the screws and magneto cover Remove the bolts and stator Disconnect the lead wires Remove the cylinder and piston 6 3 and 4 Hold the conrod with the special tool and loosen the nut 09910 20116 Conrod holder Remove the magneto rotor with the special tools Remove the key 09930 30211 Flywheel rotor remover Attachment G 09930 30141 Flywheel rotor remover Attachment A Black Red Black W...

Page 133: ...he special tool Apply THREAD LOCK SUPER 1322 to the nut and tighten the nut to the specified torque 09910 20116 Conrod holder 99000 32110 THREAD LOCK SUPER 1322 Magneto rotor nut 35 N m 3 5 kgf m 25 5 lb ft Align the line on the stator with triangle mark on the crank case Install the magneto cover Reassemble the piston and cylinder 6 8 and 10 ...

Page 134: ...EMOVAL 14 3 INSPECTION 14 3 FRONT WHEEL BEARING REMOVAL 14 4 FRONT WHEEL BEARING REASSEMBLY 14 4 FRONT WHEEL INSTALLATION 14 4 REAR WHEEL 14 5 REMOVAL 14 5 INSPECTION 14 5 REAR WHEEL BEARING REMOVAL 14 6 REAR WHEEL BEARING REASSEMBLY 14 6 REAR WHEEL INSTALLATION 14 6 DISC PLATE REPLACEMENT 14 7 REAR SPROCKET REPLACEMENT 14 7 ...

Page 135: ...NT AND REAR WHEELS 8 5 N m 0 85 kgf m 6 0 lb ft 8 5 N m 0 85 kgf m 6 0 lb ft 44 N m 4 4 kgf m 32 0 lb ft 8 5 N m 0 85 kgf m 6 0 lb ft 65 N m 6 5 kgf m 47 0 lb ft 40 N m 4 0 kgf m 29 0 lb ft FWD 4 N m 0 4 kgf m 3 0 lb ft 4 N m 0 4 kgf m 3 0 lb ft ...

Page 136: ... collars INSPECTION AXLE SHAFT Support the axle shaft with V blocks and measure the axle shaft runout Service Limit 0 25 mm 0 010 in WHEEL RIM Measure the wheel rim runout with a dial gauge Service Limit 2 0 mm 0 08 in axial and radial WHEEL BEARING Turn the inner race by finger and inspect it for smooth move ment Inspect the clearance between the outer race and wheel hub Inspect for bearing damag...

Page 137: ... 09941 34513 Bearing installer set NOTE The sealed cover of the bearing must face outside Reassemble the left side disc side bearing first and then reassemble the right side bearing After reassembling the bearings inspect the bearings for smooth movement FRONT WHEEL INSTALLATION Install the front wheel axle collars and front axle Tighten the axle nut to the specified torque Axle nut 44 N m 4 4 kgf...

Page 138: ...25 mm 0 010 in WHEEL RIM Measure the wheel rim runout with a dial gauge Service Limit 2 0 mm 0 08 in axial and radial WHEEL BEARING Turn the inner race by finger and inspect it for smooth move ment Inspect the clearance between the outer race and wheel hub Inspect for bearing damage WHEEL SPACER Inspect the rear wheel collars and the dust seals for wear and cracks Replace the collars together with...

Page 139: ...ler set NOTE After reassembling the bearings inspect the bearings for smooth movement Install the snap ring 1 at the left side sprocket side Install the dust seals and apply grease to its lips NOTE The sealed cover of the bearing must face outside Reassemble the left side sprocket side bearing first and then reassemble the right side bearing REAR WHEEL INSTALLATION Reassemble the rear wheel and ax...

Page 140: ...only to the specified torque Brake disc screw 8 5 N m 0 85 kgf m 6 0 lb ft Front brake disc nut 8 5 N m 0 85 kgf m 6 0 lb ft NOTE When installing the front disc first tighten the screws to the specified torque and then tighten the nuts 1 to the specified torque REAR SPROCKET REPLACEMENT Remove the rear wheel 14 5 Replace the rear sprocket Tighten the nuts to the specified torque Rear sprocket nut ...

Page 141: ... MEMO ...

Page 142: ...ALIPER REMOVAL AND DISASSEMBLY 15 6 REAR CALIPER REMOVAL AND DISASSEMBLY 15 7 CALIPER INSPECTION 15 8 CALIPER CLEANING 15 8 FRONT CALIPER REASSEMBLY 15 9 REAR CALIPER REASSEMBLY 15 9 MASTER CYLINDER 15 10 FRONT MASTER CYLINDER REMOVAL AND DISASSEMBLY 15 10 REAR MASTER CYLINDER REMOVAL AND DISASSEMBLY 15 11 MASTER CYLINDER INSPECTION 15 12 MASTER CYLINDER CLEANING 15 12 FRONT MASTER CYLINDER REASSE...

Page 143: ... 1 0 kgf m 7 3 lb ft 23 N m 2 3 kgf m 16 5 lb ft 23 N m 2 3 kgf m 16 5 lb ft 10 N m 1 0 kgf m 7 3 lb ft 10 N m 1 0 kgf m 7 3 lb ft 23 N m 2 3 kgf m 16 5 lb ft 18 N m 1 8 kgf m 13 0 lb ft 7 5 N m 0 75 kgf m 5 5 lb ft 23 N m 2 3 kgf m 16 5 lb ft 10 N m 1 0 kgf m 7 3 lb ft ...

Page 144: ...R line when the brake fluid level drops below LOWER line WARNING Brake fluid can be hazardous to humans and pets Brake fluid is harmful or fatal if swallowed and harm ful if it comes in contact with your skin or eyes Keep brake fluid away from children Call your doctor immediately if brake fluid is swallowed and induce vomiting Flush eyes or skin with water if brake fluid gets in eyes or comes in ...

Page 145: ...r valve Pour brake fluid into the reservoir Bleed air from the brake system 15 3 Reassemble the reservoir cap BRAKE PAD REPLACEMENT FRONT BRAKE PAD Remove the caliper mounting bolts Remove the brake pads by removing the clip 1 and pad mounting pin 2 NOTE Replace the two brake pads as a set Install the new brake pads to the caliper NOTE When installing the inner pad seat it on the hating part 3 of ...

Page 146: ...tted to the inner pad 3 Tighten the caliper mounting bolts Caliper mounting bolt 23 N m 2 3 kgf m 16 5 lb ft NOTE Pump the brake pedal several times to seat the brake pads after reassembling BRAKE DISC BRAKE DISC INSPECTION Measure the front and rear brake disc thickness Service Limit 2 5 mm 0 10 in Measure the front and rear brake disc runout Service Limit 0 30 mm 0 01 in BRAKE DISC REPLACEMENT 1...

Page 147: ...e the brake system and lead to an accident Use only DOT 4 brake fluid from a sealed container Never use or mix different types of brake fluid WARNING Brake fluid can be hazardous to humans and pets Brake fluid is harmful or fatal if swallowed and harm ful if it comes in contact with your skin or eyes Keep brake fluid away from children Call your doctor immediately if brake fluid is swallowed and i...

Page 148: ...R CALIPER REMOVAL AND DISASSEMBLY Drain brake fluid 15 4 Place a rag under the brake hose union bolt to catch spilled brake fluid Remove the caliper mounting bolts 1 and disconnect the brake hose 2 WARNING Fingers can get caught between piston and caliper body when removing the piston Do not place your fingers on the piston when remov ing the piston ...

Page 149: ...ve the piston Remove the piston seal 5 and dust seal 6 CALIPER INSPECTION Inspect the caliper cylinder wall and piston surface for scratch corrosion or other damages If any abnormal condi tion is noted replace the caliper Inspect the rubber parts If any damages are found replace it with a new one WARNING Fingers can get caught between piston and caliper body when removing the piston Do not place y...

Page 150: ...ng bolts to the specified torque Caliper mounting bolt 23 N m 2 3 kgf m 16 5 lb ft Tighten the brake hose union bolt to the specified torque Brake hose union bolt 23 N m 2 3 kgf m 16 5 lb ft Refill brake fluid and bleed air from the brake system 15 4 REAR CALIPER REASSEMBLY Apply brake fluid to the piston seal 1 and dust seal 2 then install them to the caliper Install the piston into the caliper A...

Page 151: ...n contact with your skin or eyes Keep brake fluid away from children Call your doctor immediately if brake fluid is swallowed and induce vomiting Flush eyes or skin with water if brake fluid gets in eyes or comes in contact with skin WARNING The use of any fluid except DOT 4 brake fluid from a sealed container can damage the brake system and lead to an accident Use only DOT 4 brake fluid from a se...

Page 152: ...AL AND DISASSEMBLY Drain brake fluid 15 4 Remove the rear brake pedal 15 14 Place a rag under the hose to catch spilled brake fluid Remove the union bolt 1 Remove the master cylinder mounting bolts 2 Remove the clamp and disconnect the hose reservoir Remove the dust seal boot 3 Remove the snap rings 4 with snap ring pliers Remove the push rod 5 Remove the piston cup set 6 and spring 7 Remove the c...

Page 153: ...lvents to wash the mas ter cylinder parts Brake fluid DOT 4 FRONT MASTER CYLINDER REASSEMBLY Apply brake fluid to the piston cup set Install the spring piston cup set and washer Install the snap ring with snap ring pliers Install the dust boot Reassemble the brake lever Tighten the master cylinder mounting bolts to the specified torque When remounting the master cylinder on the handlebars set the ...

Page 154: ... Connect the reservoir hose to the connector and clamp it Apply THREAD LOCK SUPER 1322 to the master cylinder mounting bolts 99000 32110 THREAD LOCK SUPER 1322 Tighten the master cylinder mounting bolts to the specified torque Master cylinder mounting bolt 10 N m 1 0 kgf m 7 3 lb ft Reassemble the rear brake pedal 15 14 Tighten the brake hose union bolt to the specified torque Brake hose union bol...

Page 155: ...emove the cotter pin and pin from the push rod end Remove the return spring REASSEMBLY Reassemble the pin washer and cotter pin to the push rod end Install the return spring Apply grease to the brake pedal pivot shaft Install the washer and cotter pin NOTE Replace the cotter pin with new one Adjust the brake pedal height 2 17 ...

Page 156: ...RK AND STEERING CONSTRUCTION 16 2 FRONT FORK AND STEERING 16 2 FRONT FORK 16 3 REMOVAL 16 3 DISASSEMBLY 16 3 INSPECTION 16 5 REASSEMBLY 16 7 REINSTALLATION 16 11 STEERING 16 12 REMOVAL 16 12 INSPECTION 16 13 BEARING REPLACEMENT 16 13 REASSEMBLY 16 14 ...

Page 157: ...ONSTRUCTION FRONT FORK AND STEERING 26 N m 2 6 kgf m 19 0 lb ft 23 N m 2 3 kgf m 16 5 lb ft 23 N m 2 3 kgf m 16 5 lb ft 35 N m 3 5 kgf m 25 5 lb ft 20 N m 2 0 kgf m 14 5 lb ft 55 N m 5 5 kgf m 40 0 lb ft 65 N m 6 5 kgf m 47 0 lb ft ...

Page 158: ...assembly Hold the fork body and loosen the fork lower clamp bolts 3 Remove the front forks DISASSEMBLY NOTE Set rebound damping adjuster to the softest settings before dis assembling Record the setting before turning the adjuster Thoroughly clean the fork before disassembly CAUTION Scratches or other damage on the inner tube or on the oil seal lip will cause oil leak Avoid scratching or damaging t...

Page 159: ... 5 Invert the front fork and stroke the inner rod several times to let out fork oil Under the inverted condition of front fork drain oil to hold it for a few time Remove the damper rod bolt with the special tool 09940 30250 Front fork assembling tool Remove the damper CAUTION Do not disassemble the damper rod assembly Disas sembling the damper rod assembly can lead to trou ble ...

Page 160: ... the outer tube Remove the slide bushing 3 from the inner tube Remove the following parts from the inner tube Slide bushing 3 Seal retainer 4 Oil seal 5 Stopper ring 6 Dust seal 7 INSPECTION Inspect the cylinder bolt for damage If it is damaged replace it with a new one Replace the O ring with a new one ...

Page 161: ...ssembly for scratches or bending If it has scratches or is bent replace it with a new one Measure the free length of front fork spring Service Limit Standard spring 444 mm 17 48 in Inspect the teflon coating metals slide bushing and guide bushing for wear or damage If they are worn or damaged replace them with new ones Inspect the metal particles on the teflon coating metals If they are not clean ...

Page 162: ...eal retainer 4 guide bushing 5 and slide bushing 6 Clean the parts and keep them free from dust NOTE Inspect the bushings for burrs If there is a burr remove it with a knife taking care not to peel off the teflon coating If the bush ings have a large crack or excessive play after installing them replace them with the new ones Apply front fork oil to the guide slide bushing Insert the inner tube in...

Page 163: ...the front fork center bolt 99000 32110 THREAD LOCK SUPER 1322 Apply fork oil to the O rings Tighten the front fork center bolt to the special torque with the special tool Front fork center bolt 55 N m 5 5 kgf m 40 0 lb ft 09940 30250 Front fork assembling tool Install the spring guide 1 lock nut 2 onto the inner rod CAUTION Use of grease as a substitute fork oil when installing the oil seal can re...

Page 164: ...n Move the outer tube up and down several strokes until no more bubbles come out from the oil Keep the front fork vertically and wait 5 6 minutes NOTE Always keep oil level over the cartridge top end or air may enter the cartridge during this procedure Take extream attention to pump out air completely Hold the front fork vertically and adjust fork oil level with the special tool NOTE When adjustin...

Page 165: ...mbling the front fork cap Slowly turn the fork cap bolt 2 to seat at the lock nut 3 by hand tightening Hold the fork cap bolt and tighten the lock nut to the specified torque Inner rod lock nut 20 N m 2 0 kgf m 14 5 lb ft Apply fork oil to the fork cap s O ring Temporarily tighten the fork cap bolt to the outer tube 1 5 mm 1 5 mm 0 06 in 1 5 mm 0 06 in CAUTION Be sure to adjust the rebound damping...

Page 166: ... fork lower clamp bolts 1 to the specified torque Fork lower clamp bolt 23 N m 2 3 kgf m 16 5 lb ft Tighten the fork cap bolt 2 to the specified torque Fork cap bolt 35 N m 3 5 kgf m 25 5 lb ft Tighten the fork upper clamp bolts 3 to the specified torque Fork upper clamp bolt 23 N m 2 3 kgf m 16 5 lb ft Install the front wheel 14 4 Install the brake caliper 15 8 Install the fork covers brake hose ...

Page 167: ...plate Remove the handlebar holder bolts 1 and handlebars Remove the brake hose guide Remove the front fender Loosen the steering stem head nut and upper clamp bolts Remove the steering stem head 1 Remove the front fork Remove the steering nut with the special tools 09940 14930 Steering nut socket wrench Remove the steering stem 1 ...

Page 168: ...lower outer races with the special tools 09941 54911 Steering race remover 09941 74911 Steering bearing installer Remove the lower bearing Install the lower bearing to the steering stem using a suitable size spacer Install the upper and lower outer races with the special tools 09941 34513 Steering outer race and swingarm bearing installer CAUTION Press fit the bearing by pressing the inner race A ...

Page 169: ...0 lb ft Reassemble the front wheel and the brake caliper 14 3 and 15 8 Reassemble the handlebars Align the punched mark on the handlebars with the mating surface of front side of the left handlebar holder Set the punched mark FWD mark on the handlebar holders as shown in the illustration Tighten the handlebar holder bolts to the specified torque NOTE First tighten the handlebar holder bolts A Hand...

Page 170: ...EPLACEMENT PROCEDURE 17 6 REAR SHOCK ABSORBER DISASSEMBLY AND INSPECTION 17 9 REAR SHOCK ABSORBER REASSEMBLY 17 10 REAR SHOCK ABSORBER DISPOSAL 17 10 SWINGARM 17 11 SWINGARM REMOVAL 17 11 SWINGARM INSPECTION 17 12 BEARING REPLACEMENT 17 12 SWINGARM REASSEMBLY 17 13 REAR SUSPENSION LINKAGE 17 13 REAR SUSPENSION LINKAGE REMOVAL 17 13 REAR SUSPENSION LINKAGE INSPECTION 17 14 CUSHION LEVER AND CUSHION...

Page 171: ...RUCTION REAR SUSPENSION 58 N m 5 8 kgf m 42 0 lb ft 60 N m 6 0 kgf m 43 5 lb ft 60 N m 6 0 kgf m 43 5 lb ft 80 N m 8 0 kgf m 58 0 lb ft 80 N m 8 0 kgf m 58 0 lb ft 18 N m 1 8 kgf m 13 0 lb ft 60 N m 6 0 kgf m 43 5 lb ft FWD FWD ...

Page 172: ...ove the frame covers and seat 5 2 Loosen the air cleaner clamp screw A Remove the frame side tube 1 Loosen the bolts and screw 2 Remove the air cleaner box Loosen the rear shock absorber upper mounting bolt and nut 3 Loosen the rear shock absorber lower mounting bolt and nut 4 Remove the rear shock absorber ...

Page 173: ...9910 60611 Universal clamp wrench Remove the spring seat 3 spring retainers 4 and the spring 5 from the rear shock absorber REAR SHOCK ABSORBER INSPECTION Inspect the rear shock absorber for oil leakage Inspect the damper rod for scratch damage and smooth movement Inspect the bump rubber for deterioration and damage Inspect the damper rod hidden by the bump rubber by moving the bump rubber Inspect...

Page 174: ...rom spring free length RM85 4 8 mm 0 18 in compressed from spring free length RM85L Spring set length adjustable range 2 12 mm 0 08 0 47 in compressed from spring free length Rear shock absorber lock nut 45 N m 4 5 kgf m 29 0 lb ft REAR SHOCK ABSORBER INSTALLATION Remount the rear shock absorber to the frame and the cush ion lever Tighten the upper and lower mounting bolts and nuts to the specifie...

Page 175: ...ap Press the valve with a screwdriver to bleed out nitrogen gas WARNING Releasing high pressure gas from the rear shock absorber unit can be hazardous Never perform any servicing until the nitrogen gas pressure has been released from the rear shock absorber unit When releasing the gas pressure place a rag over the gas valve and use the tip of a screw driver etc to press the valve Do not use your f...

Page 176: ...ied rear suspension oil as shown while moving the rod NOTE Be sure to extend the rod after filling the oil Tilt the shock absorber unit as shown and pour the fresh rear suspension oil fully into the reservoir tank 99000 99001 S25 SUZUKI REAR SUSPENSION OIL SS 25 Oil capacity Approx 195 ml 6 6 6 9 US Imp oz Cover the compression adjuster hole by the root of your thumb Tilt and shake the rear shock ...

Page 177: ...rear shock absorber unit can be hazardous Flammable gas such as gas welding oxygen can create a fire hazard Use nitrogen gas If is nitrogen gas is not available compressed air free from water can be substituted WARNING Applying too much pressure to the rear shock absorber unit may rupture the rear shock absorber unit Be sure to fill the rear shock absorber unit to the spec ified pressure CAUTION R...

Page 178: ...the stopper 1 with the screwdriver or equiva lent and remove it from the rear shock absorber body Depress the seal case 2 with the screwdriver until the circlip 3 is fully exposed Remove the circlip 3 NOTE Avoid scratching the inner surface of the shock absorber body to avoid oil leaks Extract the damper rod assembly from the shock absorber body Inspect the oil seal and O rings Inspect the damper ...

Page 179: ...17 8 Pressure the rear shock absorber unit with nitrogen gas to 1 000 kPa 10 kgf cm2 142 psi 17 8 Reassemble the spring and adjust the spring set length 17 5 Tighten the valve cap Remount the rear shock absorber to the frame 17 5 REAR SHOCK ABSORBER DISPOSAL High pressure nitrogen gas is sealed in the rear shock absorber unit Be sure to release gas before disposing the rear shock absorber unit Rem...

Page 180: ...uide 1 Remove the rear brake hose guide 2 Remove the rear brake caliper 3 Remove the drive chain Remove the rear cushion rod bolt and nut 4 Remove the swingarm pivot nut 5 Remove the swingarm by removing the pivot shaft Remove the following parts from the swingarm Spacer 6 Dust seal 7 Washer 8 ...

Page 181: ...cers and oil seals for damage Insert the spacers into the bearings and inspect them for play and smooth movement BEARING REPLACEMENT Remove the bearing and coller with the special tool 09930 30102 Sliding hummer 09923 73210 Bearing puller Press fit the bearing 1 and coller 2 into the swingarm 3 with the special tool and a suitable tool 09924 84521 Bearing installer set Apply grease to the bearings...

Page 182: ...0 lb ft Tighten the rear cushion rod 5 nut to the specified torque Rear cushion rod nut 80 N m 8 0 kgf m 58 0 lb ft Reassemble the chain guide Reassemble the rear brake caliper 15 8 Reassemble the rear wheel 14 6 Adjust the drive chain slack 2 13 REAR SUSPENSION LINKAGE REAR SUSPENSION LINKAGE REMOVAL Loosen the cushion lever bolt nut Loosen the cushion rod upper bolt nut Loosen the shock absorber...

Page 183: ... rod for damage Inspect the dust seals and spacers for damage Inspect the bearings for damage Insert the spacers into the bearings and inspect them for smooth movement CUSHION LEVER AND CUSHION ROD BEARING REPLACEMENT Remove the spacers and dust seals Remove the circlips Remove the bearings with the special tool 09921 20220 Bearing remover set ...

Page 184: ...m 0 9 in in diameter and 4 mm 0 2 in in length 09941 34513 Bearing installer set NOTE Position the bearings by refering to the illustration of page 17 16 Install the circlips Install the dust seals Apply grease to the spacers and dust seals NOTE Position the dust seal so that the outside letter faces outside ...

Page 185: ...kgf m 58 0 lb ft D 60 N m 6 0 kgf m 43 5 lb ft E 80 N m 8 0 kgf m 58 0 lb ft CAUTION Improperly reassembled rear suspension linkage bolts can interfere with suspension move ment and damage the rear suspension linkage Make sure that the rear shock absorber rebound damping adjuster on the bottom bracket of the rear shock absorber is located to the right side Insert the rear suspension linkage bolts ...

Page 186: ...18 SERVICING INFORMATION 18 1 CONTENTS SERVICING INFORMATION SERVICE DATA 18 2 SPECIAL TOOLS 18 7 WIRE CABLE AND HOSE ROUTING 18 9 SPECIFICATIONS 18 17 SETTING DATA 18 19 ...

Page 187: ...N Approx 4 0 0 16 3 2 0 13 Piston ring to groove clearance 0 020 0 060 0 0008 0 0024 Piston ring end gap 0 20 0 40 0 008 0 0016 0 80 0 031 Piston pin bore 14 002 14 008 0 5513 0 5515 14 030 0 5524 Piston pin O D 13 995 14 000 0 5510 0 5512 13 980 0 5504 Reed valve clearance 0 2 0 008 ITEM STANDARD LIMIT Conrod small end I D 18 003 18 011 0 7088 0 7091 18 040 0 7102 Crank web to web width 44 9 45 1...

Page 188: ...0 002 0 010 0 45 0 018 Shift fork groove width No 1 3 95 4 05 0 156 0 159 No 2 No 3 4 45 4 55 0 175 0 179 Shift fork thickness No 1 3 80 3 90 0 150 0 154 No 2 No 3 4 30 4 40 0 169 0 173 ITEM STANDARD LIMIT Drive chain Type D I D 428DS Links 118 RM85 122 RM85L 20 pitch length 259 10 2 Drive chain slack 40 50 1 6 2 0 ITEM SPECIFICATION Carburetor type KEIHIN PE28 Bore size 28 mm I D No 03B3 Float he...

Page 189: ... thickness Front 2 8 3 2 0 110 0 126 2 5 0 10 Rear 2 85 3 15 0 112 0 124 2 5 0 10 Brake disc runout 0 30 0 012 Master cylinder bore Front 11 000 11 043 0 4331 0 4348 Rear 12 700 12 743 0 5000 0 5017 Master cylinder piston diam Front 10 957 10 984 0 4314 0 4324 Rear 12 657 12 684 0 4983 0 4994 Brake caliper cylinder bore Front 30 230 30 306 1 1902 1 1931 Rear 27 000 27 076 1 0630 1 0660 Brake calip...

Page 190: ... air pressure 0 kPa 0 kgf cm2 0 psi Rear shock absorber gas pressure 1 000 kPa 10 kgf cm2 142 psi Rear shock absorber spring pre set length RM85 3 1 mm 0 12 in compressed from spring free length RM85L 4 8 mm 0 19 in compressed from spring free length Rear shock absorber damping force adjuster Rebound 2 turns out Compres sion 3 4 turns out Rear shock absorber spring rate RM85 46 N mm 4 6 kgf mm RM8...

Page 191: ...num radiator mixed with distilled water only at the ratio of 50 50 Engine coolant tank capacity 570 ml 1 20 1 00 US Imp qt Transmission oil type SAE 10W 40 API SF SG or SH SJ with JASO MA Transmission oil capacity Change 550 ml 1 16 0 97 US Imp qt Overhaul 650 ml 1 37 1 14 US Imp qt Brake fluid type DOT 4 Front fork oil type SUZUKI FORK OIL SS 05 or equivalent fork oil Front fork oil capacity each...

Page 192: ... Dial gauge 09900 20605 Dial gauge 09900 20803 Thickness gauge 09900 25008 Multi circuit tester 09910 20116 Conrod holder 09910 32812 Crankshaft installer 09910 60611 Universal clamp wrench 09913 50121 Oil seal remover 09913 70210 Bearing installer set 09916 44910 Valve guide driver 09916 53340 Valve guide installer 09917 50410 Bearing remover 09920 13120 Crankcase separating tool 09920 20310 Spri...

Page 193: ...ver Attach ment A 09930 30211 Flywheel rotor remover Attach ment G 09940 14930 Steering nut socket wrench 09940 30250 Front fork assem bling 09940 52841 Inner rod holder 09940 52861 Front fork oil seal installer set 09941 34513 Bearing installer set 09941 53630 Rear shock absorber wrench 09943 74111 Front fork oil level gauge ...

Page 194: ...top switch lead wire should be passed under the steering stem head Engine stop switch lead wire Magnet lead wire CDI unit lead wire Engine stop switch lead wire Magnet lead wire Clamp Ignition coil 20 Apply adhesive agent between the cushion and frame Face the clamp end to Down side Apply adhesive agent between the cushion and frame Cushion ...

Page 195: ...18 10 SERVICING INFORMATION Radiator hose must be passed on right side of frame tube Muffler Cylinder breather hose Face the clamp screw to up side Exhaust breather hose Frame Radiator ...

Page 196: ... to back side Face the white mark on the radiator hose to back side Face the clamp screw to back side A Chain roller Frame Carburetor overflow hose Carburetor air vent hose Clamp Clamp Make sure that the clamp doesn t contact with roller VIEW OF A Exhaust valve breather hose Radiator overflow hose Magneto lead wire Clamp Cylinder breather hose 45 ...

Page 197: ...The front brake hose must be passed in front of the number plate Front brake hose Front brake hose guide Front brake hose Front fork cover Front brake hose Front brake hose Front fork cover Clamp the upper different portion in brake hose diameter After touching the brake hose union to the stopper tighten the union bolt to the specified torque Front brake caliper Washer Hose clamp ...

Page 198: ...SERVICING INFORMATION 18 13 Rear caliper Brake hose Guide Top Stopper Clamp Clamp No bent Bolt Rear master cylinder Bracket No contact ...

Page 199: ...FORMATION VIEW OF B 90 B Install the clutch lever at an angle of 30 with horizon Before install the throttle grip apply grease to the handlebars lightly Front brake master cylinder Brake lever A p p r o x 3 0 A VIEW OF A ...

Page 200: ...SERVICING INFORMATION 18 15 Radiator hose Throttle cable Clamp Clutch cable ...

Page 201: ...18 16 SERVICING INFORMATION Throttle cable Brake hose Clutch cable Cross the throttle cable and clutch cable above the number plate mounting boss ...

Page 202: ...eed valve Number of cylinders 1 Bore 48 mm 1 890 in Stroke 46 8 mm 1 843 in Displacement 84 7 cm3 5 2 cu in Corrected compression ratio 9 5 1 EX VALVE OPEN 10 9 1 EX VALVE CLOSE Carburetor KEIHIN PE28 Single Air cleaner Polyurethane foam element Starter system Primary kick Lubrication system Fuel oil premixture of 30 1 TRANSMISSION Clutch Wet multi plate type Transmission 6 speed constant mesh Gea...

Page 203: ... ft RM85 2 0 m 6 6 ft RM85L Front brake Disc brake hydraulically operated Rear brake Disc brake hydraulically operated Front tire size 70 100 17 40M RM85 70 100 19 42M RM85L Rear tire size 90 100 14 49M RM85 90 100 16 52M RM85L ELECTRICAL Ignition type Electronic Ignition CDI Ignition timing 15 B T D C at 11 000 r min Spark plug NGK BR10ES CAPACITIES Fuel tank 5 0 L 1 3 1 1 US Imp gal Transmission...

Page 204: ...LUG OIL LEVEL mm mm mm COMP ADJ POSITION RE BOUND ADJ POSITION SPRING SPRING SPRING SET LENGTH mm mm mm SUG mm mm mm COMP ADJ POSITION LOW COMP ADJ POSITION HIGH RE BOUND ADJ POSITION FINAL REDUCTION RATIO MAKER SIZE PRESSURE kPa kPa kPa MAKER SIZE PRESSURE kPa kPa kPa COMMENT EVENT DATE LOCATION ENGINE CARBURETOR CHASSIS FRONT FORK REAR SUSPENTION FRONT TIRE REAR TIRE ...

Page 205: ... MEMO ...

Page 206: ...ollow these safety precautions may increase your risk of injury Wear a helmet eye protection and bright protective clothing Don t ride after consuming alcohol or other drugs This owner s service manual contains important safety information Please read it carefully ...

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