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5. NECESSARY MATERIALS

RV50 requires the following material in addition to the general service equipment, tools, lubricants,

cleaning solvent, every doth and so forth. For further details, refer to the pertiment items in this manual.

Thread Lock Cement

This cement is applied to the front fork upper

bracket bolts and outer tube nuts.

Optional part No. 99000 32040

10

Grease

Special grease "A" type should be used for lubrica

tion of the crankshaft and other oil seals.

Suzuki special grease "A" part No. 99000 25010

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Summary of Contents for RV50

Page 1: ... ...

Page 2: ...and regular inspection and maintenance of these points are of vital importance This manual is written to assist the mechanics in the efficient servicing of the R V50 and includes important information about the construction inspection and service procedures of the components All the measure ments contained in this manual are based on the metric system but the values are also given in inches in par...

Page 3: ...LEFT RIGHT SI DE VIEWS 2 ...

Page 4: ...Stability and Steering 14 7 TUNE UP 15 Oil Pump 15 Spark Plug 15 Transmission Oil 16 Clutch 16 Carburetor Throttle Cable Play 17 Ignition Timing 17 Battery _ II l it 18 Air Cleaner 19 Muffter Ii 19 8 ENGINE 20 Removal from Frame 20 Disassembly and Assembly 23 Necessary Points on Assembly 30 Engine Lubrication System 34 Carburetor 36 Kick Starter System 38 Transmission System 39 Clutch System 40 Ai...

Page 5: ...um Horse Power Maximum Torque Starter 2 stroke air cooled gasoline engine Single inclined forward 41 0 x 3 7 8 mm 1 61 x 1 49 in 49 cc 3 0 cu in 6 3 4 hp 6 000 rpm 0 5 kg m 3 62 ft lb 5 000 rpm Kick primary FUEL SYSTEM Carburetor VM 14SC Air Cleaner Wet polyurethane filter Fuel Tank Capacity 3 5 ltr 0 9 2 0 77 US Imp gal LUBRICATION SYSTEM Engine Suzuki CCI Lubrication system Gear Box 500 cc 1 06 ...

Page 6: ...Angle Trail Turning Radius BRAKES Front Brake Rear Brake ELECTRICAL EQUIPMENT Generator Battery Fuse Head Lamp Tail Brake Lamp Neutral Indicator Lamp Speedometer Lamp Turn Signal Lamp High Beam Indicator Lamp Turn Signal Indicator Lamp The specifications subject to change without notice 3 842 73 19 2 333 35 15 Telescopic forks with coil spring Swinging arm with hydraulic damper and coil springs 43...

Page 7: ... 2 PERFORMANCE CURVES HP 4 Max 4HP at 6 000rpm 3 m at 5 00brpm 2 0 ____ _____ _____ ____ ____ ____ 1 __ 1 2 3 4 5 6 7 ENGINE REVOLUTION R P M B X 10 3 m 0 5 0 4 0 3 0 2 Gr H 500 400 300 w CJ 0 1 z 0 H fi U z 0 u J w J lL ...

Page 8: ...ch as crankshaft crankshaft bearings con rod piston and cylinder wall are positively lubricated by fresh oil which is separately pressure deliv ered from the variable displacement oil pump This unique force oiling system is called the SUZUKI CCI Put gasoline only in the fuel tank and lubrication oil in the oil tank Recommended fuel and oil are as follows FUEL GASOLINE OF 85 95 OCTANE OIL SUZUKI CC...

Page 9: ...rings oil seals 6 09920 70111 Snap ring opener Removal or Installation of snap rings 7 09930 10111 Spark plug wrench Removal or Installation of spark plug 8 09930 20111 Point wrench with 0 35 mm Adjustment of contact point gauge 9 09930 30113 Rotor remover Removal of flywheel 10 09930 40113 Engine sprocket flywheel Locking engine sprocket or flywheel holder 11 09931 00111 rl Pf kinn 10 TI 0 0 12 0...

Page 10: ...ine sprocket flywheel holder Impact driver set Loosening 09900 09101 Tightening 09900 09102 Bit 09900 09202 Hydrometer Pocket tester Electro tester Dial gauge 09931 20120 J V 09931 30120 L 6lmm 09931 30130 L 74mm 0 Timing tester Bearing and oil seal installing tool Point wrench with 0 35mm gauge Steering stem lock nut wrench 6mm stud installing tool 9 ...

Page 11: ...and so forth For further details refer to the pertiment items in this manual Thread Lock Cement This cement is applied to the front fork upper bracket bolts and outer tube nuts Optional part No 99000 32040 10 Grease Special grease A type should be used for lubrica tion of the crankshaft and other oil seals Suzuki special grease A part No 99000 25010 ...

Page 12: ...range of plug Replace starter 3 Carburetion Adjust 4 Engine compression loss Repair as necessary If the spark is weak 1 Damage in spark plug Replace 2 Incorrect spark plug gap Adjust 3 Damage in spark plug cap Replace 4 Dirty contact points Clean and adjust 5 Bad insulation in condenser Replace 6 Damage in ignition coil or I Replace primary coil If there is no spark 1 Damage in spark plug Replace ...

Page 13: ...amaged 7 Ignition timing too advanced 8 Defective primary pinion and gear 9 Crankshaft bearings worn 10 Defective transmission gear 11 Defective transmission bearings If Engine Overheats I Repair or replace Repair or replace Replace Replace Replace Tighten securely Replace Retighten securely Repair or replace Replace Replace Remedy Repair or replace Replace piston Clean Replace Replace Replace Adj...

Page 14: ...n muffler exhaust pipe exhaust port and combustion chamber Piston rings stiff by carbon deposit r Clutch slippage f Check Points 1 Improperly adjusted clutch 2 Clutch springs worn 3 Clutch plates worn 1 Improper weight oil 2 Uneven clutch spring tension Check Points do not engage shifting cam groove damaged 2 Gear shifting forks not moved smoothly on cam 3 Gear shifting fork damaged 4 Gears seized...

Page 15: ... lock nut tight Adjust 2 Steering stem bent Repair or replace 3 Steel balls damaged Replac e 2 Handlebar is not stable 1 Incorrect wheel alignment Replace 2 Play in front wheel fitting Repair 3 Steel balls damaged l Replace 4 Fork stem bent Repair or replace 5 Bearing races worn or damaged Replace 6 Front fork bent Repair or replace 7 Swinging arm bent Repair 8 Fork spring worn Replace 3 wheel is ...

Page 16: ...djuster lock nut j Cable adjuster Spark Plug Spark plug gap Measure the gap using a thickness gauge The standard spark plug gap is as follows Standard 0 6 0 7 mm Spark plug gap Heat range The NGK BP6HS or Nippon Denso W20FP spark plug is standard for this motorcycle However the spark plug may be affected by changes in temperature altitude carburetion or ignition timing If for some reason the stand...

Page 17: ...l filler cap Drain plug 3 Measure 500 cc 1 06 0 88 US Imp pt of the recommended oil See page 7 in a measuring beaker and pour it into the transmission cham ber slowly 16 Measuring beaker 4 Refit the oil filler cap Clutch Clutch adjustment is made in two stages i e ad justment of play in the clutch cable and the clutch release mechanism CD Clutch cable adjuster 2 Loosen the release screw locking nu...

Page 18: ...the adjuster in or out until 0 5 mm adjustment is obtained 3 Secure the adjuster again with the lock nut and reinstall the carburetor top cover Carburetor top cover Throttle cable play rJ Lock nut Throttle cable adjuster Ignition Timing Incorrect ignition timing decreases engine perform ance and shortens the life of the engine Before checking or adjusting the ignition timing be sure that the conta...

Page 19: ... ignition timing in piston travel from T D C 18 Standard ignition timing 1 50 mm B T D C 20 Degree The magneto is originally set so that the correct ignition timing point can usually be obtained by only adjusting the contact point gap within the range of 0 3 0 4 mm However if the magneto base is removed or the point is renewed the rela tive positions between the base point and crank case may chang...

Page 20: ... 4 Wash the filter with dean gasoline 5 After wringing gasoline out of the filter soak it according to the removal procedures in the reverse order Muffler The existence of carbon or tar in the muffler de creases exhaust efficiency causing poor engine performance To clean 1 Unscrew the locking screw at the end of the muffler and pull out the baffle pipe CJ Baffle pipe 2 Remove carbon deposits by ge...

Page 21: ...ngine from the frame Cylinder head cylinder piston carburetor clutch assembly gear shifting shaft flywheel magneto contact breaker assembly and oil pump Prior to removal throughly clean the engine with a steam cleaner or cleaning solvent to remove road dirt The removal procedure is as follows Removal from Frame 1 Removing seat Required tool 12mm Sra bolt 2 Disconnecting battery ground cord l 20 3 ...

Page 22: ...tion cap 8 Slackening carburetor clip bolt Required tbol rrr J big size 9 Disconnecting fuel and air vent hoses Turn the fuel cock lever to the O position to prevent fuel flow and pull out the fuel and air vent hoses from the carburetor 10 Removing carburetor Required tool se and 12mm Pull out the carburetor and then remove the throttle and the starter valve CDThrottle valve 2 Starter valve 11 Rem...

Page 23: ...p CDOil tank Engine oil pipe 14 Removing muffler cover Required tool big size D Muffler cover 22 15 Removing muffler Required tool 12 mm and 14 mm Muffler bolt 16 Removing drive chain Required tool Remember the direction of the chain joint clip and take care not to lose it CD Drive chain Chain joint clip 17 Removing engine sprocket cover Required tool big size sprocket cover ...

Page 24: ...is section explains the work necessary for sepa rating the crankcase When disassembling the engine take the following steps For reassembling the engine after inspection or repair follow the reverse order of disassembly 1 Draining transmission oil Required tool or 1 21 mm Place the engine on the working bench and drain out transmission oil by removing the drain plug 2 Removing left crankcase cover ...

Page 25: ...om the crankshaft screw the rotor remover counter clockwise and turn the handle clockwise CDRotor remover 5 Removing magneto stator Required tool Small size Take off the magneto stator removing three screws and disconnect the neutral switch wire from the switch body 24 Magneto stator Neutral switch wire 6 Flattening engine sprocket washer Required tool and 7 Removing engine sprocket and o O 27 mm ...

Page 26: ...0 Removing cylinder head and cylinder Required tool 10mm Tightening torque 60 100kg cm 4 4 7 3 ft lb Slacken the cylinder head nuts in reverse of tight ening sequence The figures on the cylinder head indicate the tightening order 11 Removing piston pin circlip Required tool u r J small size or 12 Removing piston pin Push the end of the piston pin with a rod CDPiston pin 25 ...

Page 27: ...between the connecting rod and the crankcase in order to lock the counter shaft and slacken the clutch sleeve hub nut CD Piston holder 15 Disassembling clutch Required tool m i big size 26 16 Removing kick starter spring Required tool mallet or soft hammer Pull out the kick starter spring guide and remove the spring as shown in the figure Q Kick starter springguide 2JKick starter spring 17 Removin...

Page 28: ...lock the crank shaft and loosen the primary pinion lock nut j Piston holder 20 Removing primary pinion key Required tool C0Primary pinion key 21 Removing shifting cam stop Required tool 12mm CD Shifting earn stop 2 Shifting cam stop bolt 22 Removing gear shifting shaft 1 Gear shifting shaft 23 Removing shifting cam guide Required tool Shifting cam guide Lock washer Shifting cam 27 ...

Page 29: ...d o c J big size 26 Separating crankcase Required tool Set the crankcase separating tool on the left crank case as shown in the figure Separate the crank case into right and left halves by screwing the handle of the special tool in At the same time push in the engine oil pipe at the right side of the case so as not to damage it 27 Removing oil pump Required tool small size Push out the engine oil ...

Page 30: ...with a mallet or a soft hammer Crankshaft 30 Removing kick startershaft Pull out the kick starter shaft and remove the kick starter pinion from the kick startershaft Kick starter pinion Kick starter shaft 31 Removing third drive and second driven gears Required tool Special tool 09920 70111 Remove the snap rings with the snap ring opener and pull out the gears G CD Snap ring opener 32 Removing oil...

Page 31: ... work to be done when assembling the engine 1 Transmission and crankshaft For the installation of gears circlips washers and bearings refer to the illustration Spacer Washer Install this side Left case 1 Apply engine or transmission oil to the bearings and gears 2 Apply a little grease to the lips of oil seals 30 Right case Washer Washer ...

Page 32: ...and right crankcases clean their mating surfaces and replace the gasket with a new one 2 The crankcase screws should be tightened ac cording to the tightening order and used in the position as shown in the figure The figures indicate the tightening order 5 Piston rings A Keystone type ring and a flat ring are used for the first and the second ring of RVSO respectively therefore the first and secon...

Page 33: ...der In case of installing a rebored cylinder be sure to check if the edges of the ports and skirt are cham fered If the edges are sharp chamfer them with a 32 scraper or emery paper This will prolong life of the piston and the piston rings The designed chamfer is as illustrated in the figure 8 Cylinder head When installing the cylinder head tighten 4 cylin der head fixing nuts evenly in the sequen...

Page 34: ...to expel air in the oil pipe from the oil tank 2 When the air bubbles have disappeared screw in the bolt or screw securely 3 Loosen the screws located on the engine oil outlet union bolts 4 Supply the specified engine oil to the outlets with a oil filler as shown in the figure CD Oil filler 11 Kick starter shaft return spring 1 Turn the kick starter shaft clockwise all the way 2 Insert one end of ...

Page 35: ...idle gear and kick starter pinion as illustrated below Crankshaft Primary pinion Primary gear Kick starter gear Idle gear Kick starter pinion Oil pump The plunger and the differential plunger are always pressed to the right side by the spring and their move ments to the right are restricted by the cam or the stationary base fitted on the right side of the pump body The plunger is worm geared in it...

Page 36: ...m surface PlunEer This graph shows the relation between control lever opening and oil discharge when the driving worm speed is running at 400 rpm For the machine having the engine number up to RVS0 44515 Inlet side 15 5 1 6 r 8 55 1 61 1 i 0 0 crankshaft side 1 94 0 35 r 1 1 1 1 15 24S 49 full opening Control lever angle degree For the machine having the engine number or and from RVS0 44516 0 0 i ...

Page 37: ...alve extending into the main air passageway The fuel discharge outlet is located in this venturi area so that the vacuum pressure can draw out the fuel This carburetor incorporates not only both a main and slow system but also a easy start system For further details of the carburetor please refer to the SUZUKI S Service Manual Carburetor and Carburetion of 1971 Specifications Type Main jet Jet nee...

Page 38: ...thod Throttle opening Slight Medium High Method to change the ratio Pilot air adjusting screw S Jt To leaner To richer To leaner To richer Jet Needle Main Jet Larger number Smaller number Richer mixture Leaner mixture Standard setting 1 4th position from top groove Number 65 2 The fuel level inside the float chamber should be set in its correct position To adjust the fuel level measure the height ...

Page 39: ...air screw gradually from its fully closed position and set it when the engine reaches its highest speed 5 Drop the engine speed by turning the throttle valve stop screw 6 Repeat the steps 4 and 5 two or three times and the proper idle speed will be obtained As the kick starter system is the primary kick starting type the engine can be started regardless of the gear position when the clutch is dise...

Page 40: ...t CD CD Kick starter pawl spring Kick starter pawl roller C DKick starter pawl Q Kick starter shaft Kick starter shaft stopper Transmission System CV I Kick starter pinion The transmission is a constant mesh 4 speed Construction and operating methods are explained in this section Engine power is transmitted to the drive shaft through the clutch countershaft gears on countershaft and gears on the d...

Page 41: ...ions The driven plates are meshed in the sleeve hub on the countershaft and are unable to transmit power in this state But when pressed together between the drive plates by the force of the ciutch spring acting through the pressure plate the frictional forc e produced allows power to be transmitted When the clutch is disengaged the spring force acting on the pressure plate does not act on the clut...

Page 42: ... Clutch housing Driven plate Pressure plate Clutch hub Clutch spring Air Cleaner The element is made of washable spongy plastics and contains oil in it so as to further prevent dust from penetration The construction is shown in the figure 41 ...

Page 43: ... Charging System Primary coil Ignition coil Condenser Contact breaker Flywheelrnagneto OFF ON Ignition switch The charging system using a flywheel magneto is shown in the figure The charging coil and the lamp coil are fitted on the magneto stator and generate alternating current when the flywheel rotor turns The charging system has two circuits one is engaged by setting the ignition switch to the ...

Page 44: ... storage Initial charging rate Specific gravity of electrolyte Recharge 0 4A 10 12 Hours 1 280 at 20 C 68 F To check the battery condition in capacity measure the specific gravity of the electrolyte by a hydrometer and refer to the following list SPECIFIC GRAVITY at 20 C 68 F CONDITION NECESSARY MEASURE 1 250 1 280 OK 1 220 1 250 Under charged Recharge Below 1 220 Run down Replace or recharge Caut...

Page 45: ...oving the front fender Required tool 10 mm 3 Disconnecting horn 4 Removing the headlamp Required tool m small 44 10 BODY The construction is shown in illustration 5 upper bracket bolts Front 12mm Required tool 22mm remove the upper brack the handlebar and speedometer the upper bracket apply thread lock cement to the thread portion of bolts bracket bolt ...

Page 46: ... steel balls 22 on the upper 18 on Exercise head so Install the top cone race the steering stem lock nut so Screw in ance between the in the vertical direction so turns 7 inner tube Required tool Inner tube nut Special tool 09920 70111 stem lock nut wrench When inner tube to the outer tube Inner tube Spring guide Inner tube to the springs I 1 45 ...

Page 47: ... and assembfy Front wheel 1 Loosening front axfe nut Required tool 14mm Remove the front axle nut and pull out the axle 2 Removing front wheel 3 Removing rim from wheel hub Required tool 12mm Tightening torque 150 200kg cm 11 14ft lb Deflate the tire and loosen the wheel hub nuts 46 4 Splitting rim Required tool 12mm Tightening torque 150 200kg cm 11 14ft lb Wheel nut ...

Page 48: ...der to get enough friction force without high air pressure the wheel is specially designed and carel made However the rim might slip if the maintenance is not done properly therefore be sure to do the following necessary points when assembling or disassembling the wheel Caution 1 Do not use any tool such as a tire lever to insert between rim and tire when taking off the tire from the rim 2 The tir...

Page 49: ...ght side respectively Rear Shock Absorber The hydraulic damper is of sealed construction and works at a damping resistance of 30 and 6 kg 0 5 m sec in its tension and compression strokes respectively The construction is shown in the figure and the graph show the relationship ofspring load and travel 48 lb kg 329 147 9 38 17 39 4 1 55 Deflection 70 mm 2 76 in ...

Page 50: ...meter at 23 mm I clearance 0 9 in above the piston skirt in the direction perpendi cular to the piston pin hole Piston Open end 0 10 0 30 mm 1 0 mm Replace Measure the gap ring 0 004 0 012 in 0 004 in with a thickness I gauge when the I ring is inserted into the lower part of cylinder Crank Con rod 3 mm Check the shake shaft small end 0 12 in at TDC with dial shake guage Radial below 0 06 mm Recti...

Page 51: ...witch in night time position Charging Replace With fully charged capacity in battery day time Charging Replace With fully charged capacity in battery day time I Charging Replace With fully charged capacity in I battery night time Ignition over 7 mm Replace The testing gap is to performance 0 276 in be connected in series with spark plug Contact 0 3 0 4 mm I point gap 0 012 0 016 in Ignition Resist...

Page 52: ...t Rear Replace Measur e the diam shoe 106mm eter when the shoes 4 17 in are installed in place Brake Wear Front Rear Front Rear Replace drum 110mm 110 7 mm 4 33 in 4 36in Drive Slack 15 20 mm Adjust chain 0 6 0 8 in Tire Wear in Front Rear Replace Depth 1 6mm 0 06in 51 ...

Page 53: ...0 430 20 _ 31 8 Chain adjuster spacer nut 450 600 33 43 9 Rear brake cam lever bolt 50 80 3 6 5 8 10 Rear brake torque link nuts 100 150 7 2 11 11 Rear shock absorber nuts 200 300 14 _ 22 12 Rim nuts 150 _ 200 11 14 13 Wheel fitting nuts 150 _ 200 11 rv 14 Tightening torque for general bolts Tightening torque Bolt diameter mm Usual bolt S marked bolt kg cm lb ft kg cm lb ft 5 10 40 1 5 2 9 30 60 2...

Page 54: ...53 ...

Page 55: ...54 ...

Page 56: ...EXPLODED VIEW OF ENGINE ...

Page 57: ... play screw and pilot air screw screw and pilot air screw Check contact point gap and ignition timing Check contact point gap and ignition timing Lubricate contact breaker cam oi et e ig 1 en cy in er an cylinder head nuts Lubricate emove car on Every 8 000 mi an c ean Replace contact point I Battery Check and service electrolyte Check and service electrolyte rt f ol C J J I Drive chain Adjust Adj...

Page 58: ...V 1 7W Turn signal r Fuse 15A E IG Ignition BA Bauery HO Horn TL Tail lamp Chargingcoil Silicon rectifier Charging lighting coil Flywheel magneto CJ Charging lighting coil HL Head amp I1o Spark plug Right rear turn signallarnp 6V8W Tail Brake lamp 16V3 lOW Lehraartum signal lamp 6V SW ...

Page 59: ...SUZUKI fla111amats11 Nisl1i1 P 0 Box J H JJ11 mi lfs J t m 11 1978 9 73 Printed iri Jap m ...

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