Suzuki TS200R Service Manual Download Page 1

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Summary of Contents for TS200R

Page 1: ......

Page 2: ...es distributed ih your country might differ in minor respects from the standard specification and if they do it is because some minor modifications which are of no consequence in most cases as far as...

Page 3: ...VIEW OF TS200R For Conventional front fork model For Inverted front fork model...

Page 4: ...RMATION CONTENTS VIN AND SERIAL NUMBER LOCATIONS 1 1 FUEL OIL AND COOLING SOLUTION RECOMMENDATIONS 1 1 BREAKING IN PROCEDURES 1 2 SPECIAL MATERIALS 1 3 PRECAUTIONS AND GENERAL INSTRUCTIONS 1 5 SPECIFI...

Page 5: ...search Method For other models Gasoline used should be graded 85 95 octane or higher An unleaded gasoline is recommended ENGINE OIL Use SUZUKI CCI oil or SUZUKI CCI Super oil They are formulated to gi...

Page 6: ...city total 900 ml 0 95 0 79 US Imp qt CAUTION Mixing of anti freeze summer coolant should be limited to 60 Mixing beyond it would reduce its efficitmcy If the anti freeze summer coolant mixing ratio i...

Page 7: ...LOCK SUPER 1303 99000 32030 THREAD LOCK SUPER 1324 99000 32120 Part Throttle grip Clutch lever Speedometer cable and tachometer cable Speedometer gear box Brake pedal shaft Side stand Kick starter lev...

Page 8: ...1200NA Non Amine type 99000 99032 1 ox OIL SUZUKI FORK OIL 10 99000 99044 1 OG Part Disc bolt Page 7 1 7 2 7 31 Gearshift retainer screw and bolt 3 32 Pawellifter nut and cam guide screw 3 33 Cam driv...

Page 9: ...commended oils o When more than 2 persons perform work together pay attention to the safety of each other o After the reassembly check parts for tightness and operation o Treat gasoline which is extre...

Page 10: ...te dust extractor facility If high speed tools are used they should always be so equipped If possible dampen before cutting or drilling Dampen dust and place it in a properly closed receptacle and dis...

Page 11: ...3rd 1 400 21 15 4th 1 095 23 21 5th 0 916 22 24 Top 0 800 20 25 Drive chain TAKASAGO RK520SO 106 links CHASSIS Front suspension Telescopic coil spring oil dampened Rear suspension Link type suspensio...

Page 12: ...RES 2 3 BATTERY 2 3 CYLINDER NUTS CYLINDER HEAD NUTS AND EXHAUST PIPE NUTS 2 3 CYLINDER HEAD CYLINDER AND MUFFLER 2 4 SPARK PLUG 2 4 AIR CLEANER 2 5 TRANSMISSION OIL 2 6 COOLING SYSTEM 2 6 CARBURETOR...

Page 13: ...ths 2 12 24 36 48 Battery I I I I Cylinder nuts cylinder head nuts and exhaust T T T T T pipe nuts Cylinder head cylinder and muffler c c c c Spark plug I R R R R Air cleaner Clean every 3 000 km Tran...

Page 14: ...tion points are indicated below NOTE Before lubricating each part clean offany rusty spots and wipe offany grease oil dirt or grime Lubricate exposedparts which are subject to rust with motor oil or g...

Page 15: ...ecting the battery lead wire 8 lead wire first CAUTION Read the II ELECTRICAL SECTION I for the servicing battery CYLINDER NUTS CYLINDER HEAD NUTS AND EXHAUST PIPE NUTS Tighten Initial 1 000 km 2 mont...

Page 16: ...n deposits periodically SPARK PLUG Inspect 1 000 km 2 months and Replace Every 6 000 km 12 months Remove the carbon deposits with a wire or pin and adjust the spark plug gap to 0 6 0 8 mm 0 02 0 03 in...

Page 17: ...hands do not twist or wring the element or it will develop tears Immerse the element in MOTOR OIL SAE 30 or 1OW 40 and squeeze the oil out of the element leaving it slightly wet with oil Fit the clean...

Page 18: ...old about 950 ml of oil Install the filler cap correctly Start up the engine and allow it to run for several seconds at idling speed Turn off the engine and wait for about one minute and check the oil...

Page 19: ...sen lock nut CD Adjust the cable play to 0 5 1 0 mm by turning adjuster Throttle cable play 0 5 1 0 mm 0 02 0 04 in After adjusting the cable play tighten the lock nut CD IDLE R MIN ADJUSTMENT Adjust...

Page 20: ...he red mark CD on the oil pump control lever is aligned with the index mark when the throttle valve is positioned as above If the marks are not aligned loosen the lock nut and turn the adjuster in or...

Page 21: ...eplaced CHECKING Loosen the exle nut CD Tense the drive chain fully by adjusting the chain adjusters Count out 21 pins on the chain and measure the distance between the two If the distance exceeds fol...

Page 22: ...oil sold commercially as drive chain oil Such oil too can spoil the 0 rings or seals CAUTION The standard drive chain is TAKASAGO RK520SO SUZUKI recommends that the abovementioned standard drive chain...

Page 23: ...tion of brake pads can be checked by observ ing the limit line CD front caliper and groove rear caliper marked on the pad When the wear exceeds the limit mark replace the pads with new ones Refer to p...

Page 24: ...cle Front brake Bleed the air from the bleeder valve Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it Loosen the bleeder valve by...

Page 25: ...0 mm 0 12 in 09900 20805 Tire depth gauge TIRE PRESSURE If the tire pressure is too high or too low steering will be adversely affected and tire wear increased Therefore main tain the correct tire pre...

Page 26: ...front fork assembly by supporting the machine so that the front wheel is off the ground with wheel straight ahead grasp lower fork tubes near the axle and pull forward If play is found perform steer...

Page 27: ...Front axle clamp bolt 15 25 1 5 2 5 11 0 18 0 Handlebar clamp bolt 18 28 1 8 2 8 13 0 20 0 Front fork upper clamp bolt 22 35 2 2 3 5 16 0 25 5 j Front axle shaft 50 80 5 0 8 0 36 0 58 0 Front brake ma...

Page 28: ...PERIODIC MAINTENANCE AND TUNE UP PROCEDURES 2 16...

Page 29: ...ED VALVE 3 20 BEARINGS 3 21 OIL SEALS 3 21 CRANKSHAFT 3 21 CLUTCH 3 22 TRANSMISSION 3 23 CRANK BALANCER SHAFT AND DRIVEN GEAR 3 26 ENGINE REASSEMBLY 3 27 BEARINGS 3 27 OIL SEALS 3 27 CRANKSHAFT 3 28 C...

Page 30: ...9 Magneto rotor 3 8 Piston 3 7 Primary driven gear 3 10 Magneto stator and pick up Oil pump 3 8 Crank balancer gear and coil 3 9 Intake pipe 3 8 shaft 3 10 Neutral indicator switch 3 9 Reed valve 3 8...

Page 31: ...il Refer to page 2 6 Drain coolant Refer to page 2 6 Remove the frame covers CD Remove the seat Remove the radiator covers Turn the fuel cock lever to OFF position and disconnect the fuel hose Remove...

Page 32: ...pler Remove the oil pump cover by removing the screws Disconnect the oil pump inner cable J and throttle cable Disconnect the tachometer cable Remove the clutch release arm with the clutch cable Remov...

Page 33: ...brake firmly Disconnect the magneto lead wires Remove the magneto lead wire clamps Remove the ignition coil mounting screws Remove the engine mounting bolts j and brackets Remove the swingarm pivot sh...

Page 34: ...N m kg m lb ft G 28 34 2 8 3 4 20 0 24 5 55 88 5 5 8 8 40 0 63 5 20 30 2 0 3 0 14 5 21 5 Apply THREAD LOCK SUPER 1322 to the engine sprocket bolts and tighten them to the specified torque 99000 32110...

Page 35: ...muffler mounting bolt and clamp screw to the specified torque Tightening torque 10 16 N m 1 0 1 6 kg m 7 0 11 51b ft 18 28 N m 1 8 2 8 kg m 13 0 20 0 lb ft 1 5 2 5 N m 0 15 0 25 kg m 1 0 1 8 lb ft TRA...

Page 36: ...linder head Disconnect the oil hose CD by loosening the clamps Remove the cylinder by removing the four nuts NOTE For disassembling the exhaust valve related parts refer to page 3 15 Place a clean rag...

Page 37: ...ial tool 09910 34510 Piston pin puller Remove the oil pump and 0 ring CAUTION Do not use the removed 0 ring Remove the intake pipe and reed valve Remove the magneto cover Remove the magneto rotor nut...

Page 38: ...il Remove the neutral indicator switch Remove the rotor key CD Remove the 0 ring contact and spring CAUTION Do not use the removed 0 ring Remove the clutch cover NOTE For disassembling the water pump...

Page 39: ...e the washer CD and primary driven gear assembly Remove the kick starter shaft assemblies Remove the circlip with a snap ring pliers and remove the kick starter idle gear washers and concaved washer R...

Page 40: ...ft with a plastic hammer Remove the gearshift shaft Remove the pawl lifter and cam guide Remove the cam driven gear by removing the bolt NOTE When removing the cam driven gear do not loose the gear sh...

Page 41: ...special tool 09910 20115 Conrod holder CAUTION This nut has left hand threads Remove the balancer drive gear and key Remove the crankcase securing bolts and screw Remove the two retainers and then rem...

Page 42: ...ting tool Remove the gearshift fork shafts G gearshift cam and forks Remove the countershaft and driveshaft together Remove the crankshaft with the special tool 09920 13120 Crankshaft remover Crankcas...

Page 43: ...he kick starter guide and kick starter stopper Remove the oil pump drive gear CD from the clutch cover Remove the tachometer driven gear sleeve and driven gear Remove the clutch release arm pinion ENG...

Page 44: ...at several places Service Limit 0 05 mm 0 002 in 09900 20803 Thickness gauge If the largest reading at any portion of the straightedge exceeds the limit rework the surface by rubbing it against emery...

Page 45: ...icks scratches wear or other damage Remove the oil seal with the special tools 09921 20200 Bearing remover 09930 30102 Sliding shaft CAUTION The removed oil seal should be replaced with a new one CYLI...

Page 46: ...er To chamfer use a scraper taking care not to nick the wall surface NOTE Minor surface flaws on the cylinder wall due to seizure or similar abnormalities can be corrected by grinding the flaws off wi...

Page 47: ...STON DECARBON De carbon the crown of the piston and piston ring grooves After cleaning the grooves fit the rings and rotate them in their respective grooves to be sure that they move smoothly Carbon i...

Page 48: ...uge measure the piston pin bore inside diameter If reading exceeds the following service limit replace it with a new one Service Limit 18 030 mm 0 7098 in 09900 20605 Dial calipers PISTON PIN O D Usin...

Page 49: ...ching the sliding surface of piston and ring STD clearance 1st 0 050 0 070 mm 0 0020 0 0028 in 2nd 0 025 0 060 mm 0 0008 0 0024 in 09900 20803 Tichness gauge NOTE 1st ring and 2nd ring differ in the s...

Page 50: ...T RUNOUT Support the crankshaft by V blocks with a dial gauge rigged to read the runout as shown Service Limit 0 05 mm 0 002 in Excessive crankshaft runout is often responsible for abnormal engine vib...

Page 51: ...eck distortion Service Limit Thickness 2 4 mm 0 094 in Claw width 11 0 mm 0 43 in Distortion 0 10 mm 0 004 in 09900 20101 Vernier calipers 09900 20803 Thickness gauge CLUTCH SPRING FREE LENGTH Measure...

Page 52: ...D Driveshaft Driveshaft right bearing Low driven gear 5th driven gear 4th driven gear 3rd driven gear 0 Top driven gear 2nd driven gear Driveshaft left bearing Countershaft 5th drive gear 3rd 4th driv...

Page 53: ...179 in No 2 5 45 5 55 mm 0 215 0 219 in Shift fork thickness Standard No 1 No 3 4 3 4 4 mm 0 169 0 173 in No 2 5 3 5 4 mm 0 209 0 212 in 09900 20101 Vernier calipers 09900 20803 Thickness gauge REASS...

Page 54: ...ENGINE When mounting the circlip pay attention to the direction of the circlip Fit it to the side where the thrust is as shown in the figure with the rounded side against the gear surface crum Sharp...

Page 55: ...r mounting the 2nd drive gear check that TOP drive gear spins smoothly by moving it with your fingers This procedure may be performed only twice before shaft replacement is required CRANK BALANCER SHA...

Page 56: ...ive parts and com ponents NOTE Apply engine oil to each running and sliding part before reassembling BEARINGS Install the new bearings with the special tools 09913 75520 Bearing installer 09913 75810...

Page 57: ...he crankcase with the special tools 0991 0 32812 Crankshaft installer 0991 0 32820 Crankshaft installer spacer 09911 1131 0 Crankshaft installer attachment CAUTION Never fit the crankshaft into the cr...

Page 58: ...uge with envelop scale STD Thrust clearance 0 01 0 07 mm 0 0004 0 0028 in If the clearance is not within specification select the proper size of shim After selecting the proper size of shim place it o...

Page 59: ...xamine the photograph for correct installing posi tions and directions CD For 5th driven gear No 1 For Top driven gear No 3 For 3rd 4th drive gear No 2 CD Pawl lifter Cam driven gear Pawl No 1 Pawl No...

Page 60: ...n 99000 31110 SUZUKI BOND No 1215 Apply SUZUKI Bond No 1215 Left crankcase Assemble the cases after few minutes and tighten the bolts and screw to the specified torque Tightening torque 9 13 N m 0 9 1...

Page 61: ...ith the special tool 0991 0 20115 Conrod holder Tightening torque 60 80 N m 6 0 8 0 kg m 43 5 58 0 lb ft NOTE This nut has left hand threads CAM DRIVEN GEAR AND GEARSHIFT SHAFT Apply THREAD LOCK SUPER...

Page 62: ...ts and tighten them Apply THREAD LOCK 1342 to the cam driven gear bolt and tighten it 99000 32050 THREAD LOCK 1342 Fit a spring to the gearshift shaft correctly as shown in the photo Install the gears...

Page 63: ...ied torque with the special tool 0991 0 20115 Conrod holder Tightening torque 45 55 N m 4 5 5 5 kg m 32 5 40 0 lb ft KICK STARTER SHAFT When installing the kick starter align the punched marks Install...

Page 64: ...I tool h the specla Wit 40 60 N m 0 43 5 lb ft torque k m 29 Tightemng 4 0 6 0 g hub holder 0 Clutch sleeve 09920 5371 CD Clutch spring Pressure plate Drive plate No 1 Th 1 4 mm Driven plat Thrust bea...

Page 65: ...with the special tool 09910 20115 Conrod holder Fit the new 0 ring and dowel pins Install the oil pump drive gear with shaft CAUTION Use a new gasket to prevent oil leakage Engage the teeth of clutch...

Page 66: ...oove with the key and install the magneto rotor to the crankshaft Apply THREAD LOCK SUPER 1324 to the rotor nut and tighten it to the specified torque with the special tool 99000 32120 THREAD LOCK SUP...

Page 67: ...Each ring in place should be so positioned as to hug the locating pin Install the bearing and two thrust washers to the conrod Before installing the piston to the conrod be sure to apply SUZUKI CCI Oi...

Page 68: ...ER AND CYLINDER HEAD Tighten the cylinder nut in the criss cross manner to the specified torque Tightening torque 23 27 N m 2 3 2 7 kg m 16 5 19 5 lb ft Connect the oil hose to the cylinder and fix th...

Page 69: ...ng numerical order on the cylinder head Tightening torque 23 27 N m 2 3 2 7 kg m 16 5 19 5 lb ft NOTE Cap nuts CD position is as shown in the phtograph Apply THREAD LOCK SUPER 1322 to the kick lever b...

Page 70: ...COOLING SYSTEM CONTENTS COOLING SYSTEM 4 1 COOLING SOLUTION 4 2 RADIATOR AND RESERVOIR TANK 4 2 THERMOSTAT 4 5 WATER PUMP 4 6 WATER THERMO GAUGE 4 9 II...

Page 71: ...ure dependent control over the flow of coolant through the radiators The valve is actuated by the temperature sensive was contained in the pellet Referring to the following illustration the thermostat...

Page 72: ...or 60 according to the Fig 2 NOTE The characteristics of different anti freezes vary Read the label to know the protection you will have CAUTION Do not put in more than 60 anti freeze or less than 50...

Page 73: ...r louvers Disconnect the radiator hoses and reservoir hose Remove the radiators RESERVOIR TANK REMOVAL Remove the fuel tank Refer to page 3 2 Remove the reservoir tank INSPECTION Before removing the r...

Page 74: ...er of these two requirements Radiator cap valve release pressure 90 15 kPa 0 90 0 15 kg cm2 12 8 2 1 psi 3 Road dirt or trashes stuck to the fins must be removed Use of compressed air is recommended f...

Page 75: ...ater contained in the pan as shown in the illustration Note that the immersed thermostat is in suspension Heat the water by placing the pan on a stove and observe the rising temperature on the thermom...

Page 76: ...ND DISASSEMBLV Drain transmission oil Refer to page 2 6 Drain coolant Refer to page 2 6 Remove the first muffler Refer to page 3 2 Disconnect the tachometer cable Refer to page 3 3 Remove the kick sta...

Page 77: ...with a water pump plier Remove the circlip and remove the water pump driven gear CD and pin Remove the water pump shaft with a plastic hummer Remove the oil seal and mechanical seal CAUTION The remov...

Page 78: ...UZUKI BOND No 12078 Install the new oil seal with a suitable size sleeve NOTE Oil seal lip CD must be installed toward the water pump driven gear When installing the ring it must be installed with its...

Page 79: ...lue does not change in the proportion indicated in the table must be replaced 09900 25002 Pocket tester If the resistance noted to show infinity or too much difference in resistance value water thermo...

Page 80: ...UEL COCK 5 1 CARBURETOR 5 2 CARBURETOR SETTING TABLE 5 3 REMOVAL AND DISASSEMBLY 5 4 INSPECTION 5 5 NEEDLE VALVE INSPECTION 5 6 FLOAT HEIGHT ADJUSTMENT 5 6 REASSEMBLY AND REMOUNTING 5 6 OIL PUMP 5 7 A...

Page 81: ...ver to RES position and drain fuel Remove the fuel cock assembly WARNING Gasoline is very explosive Extreme care must be taken CLEANING Oust from the fuel tank tends to build up in the filter which wh...

Page 82: ...N FUEL AND LUBRICATION SYSTEM 5 2 i u fl oo 1 CD 0 ring Throttle valve spring E ring Jet needle Throttle valve Air vent hose J Throttle valve stop screw Air screw Needle jet Pilot jet Main jet Needle...

Page 83: ...2 0803 Idler min 1 400 100 r min FIoat height 12 9 1 0 mm 0 51 0 04 in Main jet M J 170 Main air jet M A J 0 6mm Jet needle J N 60HY36 3rd Needle jet N J N 8 Cut away C A 4 0 Pilot jet P J 35 By pass...

Page 84: ...page 3 2 Loosen the clamp screws and remove the carburetor Refer to page 3 3 Remove the carburetor top end cap and remove the throt tle valve assembly Disconnect the throttle cable Remove the float ch...

Page 85: ...emove the main jet needle jet and pilot jet Remove the starter lever and starter plunger INSPECTION Check the following items for any damage or clogging Main jet Throttle valve Pilot jet Pilot outlet...

Page 86: ...DJUSTMENT To check the float height invert the carburetor body hold ing the float arm pin so that the pin will not slip off With the float arm kept free measure the height while float arm is just in c...

Page 87: ...en the screw good and hard CHECKING OIL PUMP Use the special tool to check the pump for capacity by meas uring the amount of oil the pump draws during the specified interval Have the tool filled with...

Page 88: ...TION 6 1 INSPECTION 6 1 CHARGING SYSTEM 6 4 DISCRIPTION 6 4 INSPECTION 6 5 EXHAUST VALVE ACTUATOR 6 7 WATER TEMPERATURE METER 6 8 INSPECTION 6 8 OIL LEVEL GAUGE 6 8 LAMPS 6 9 COMBINATION METER 6 10 RE...

Page 89: ...n the other hand when the protrusion on the rotor passes the pick up coil the currents are generated they flow to the ignition timing control circuit and they are converted into one ignition signal Th...

Page 90: ...onnection is as indicated Make sure that the three needle sparking distance is at least 8 mm Spark performance STD 8 mm 0 3 in 09900 281 06 Electro tester Checking with pocket tester Ignition coil res...

Page 91: ...robe of tester to 0 B W p Gr 0 0 7 30 35 140 30 130 co B W 1 6 1 6 0 00 a p 00 10 60 60 250 CD Gr 00 10 60 60 250 Unit kn EB Probe of tester to w y B 0 w 5 25 1 5 7 co 0 y 5 25 6 30 0 CD B 1 5 3 15 CA...

Page 92: ...ectifier and is turned into DC current then it charges the battery Function of Regulator 13 0 c 0 u L G I I Cll m Lighting switch c 0 J While the engine r min is low and the generated voltage of AC ge...

Page 93: ...a result the generated voltage will start to charge the battery once again Due to the repetition of the above operation of the regulator the battery voltage will be maintained constant preventing over...

Page 94: ...C generator is faulty STD No load performance More than 33 V AC at 5 000 r min 09900 25002 Pocket tester AC GENERATOR STATOR COIL Using the pocket tester check the continuity between the lead wires of...

Page 95: ...10 B W Black with White tracer CAUTION B W 20 100 20 100 20 100 10 60 As SCR and diodes are used inside this regulator rectifier unit the resistance values will differ when an ohmmeter other than SUZU...

Page 96: ...meter should indicate H The second test wiII check the accuracy of the meter in the H and C positions Connect a 226 ohm resistor between the B G lead wire of the water thermo gauge and the ground lead...

Page 97: ...6 9 ELECTRICAL SYSTEM LAMPS HEADLIGHT TAIL BRAKE LIGHT TURN SIGNAL LIGHT For France For the others LICENSE LIGHT...

Page 98: ...ing this test it is not necessary to remove the combination meter For Canada T N 8 e m II I iiiO I I II SP Speedometer light TA Tachometer light SP I 8 High beam indicator light T Turn signal indicato...

Page 99: ...B Black Lg Light green Bl Blue 0 Orange Br Brown R Red G Green w White Gr Gray y Yellow FRONT BRAKE LIGHT SWITCH n 0 W B OFF ON 0 o REAR BRAKE LIGHT SWITCH p 0 W B OFF ON 0 Q SIDE STAND SWITCH or n G...

Page 100: ...Do not remove or pierce the sealed areas of the elec trolyte container Insert the nozzles of the electrolyte container into the Upper cover breather Cathpde plates battery s electrolyte filler holes h...

Page 101: ...he caps Using SUZUKI pocket tester measure the battery voltage The tester should indicate more than 12 5V DC as shown in the Fig If the battery voltage is lower than the specifi cation charge the batt...

Page 102: ...for more than 30 minutes and check the battery voltage with a pocket tester If the battery voltage is less than the 12 5V recharge the battery again If battery voltage is still less than 12 5V after...

Page 103: ...FRONT FORK FOR INVERTED TYPE 7 18 REMOVAL AND DISASSEMBLY 7 18 INSPECTION 7 21 REASSEMBLY AND REMOUNTING 7 21 STEERING STEM 7 25 REMOVAL AND DISASSEMBLY 7 25 INSPECTION 7 29 REASSEMBLY AND REMOUNTING...

Page 104: ...28 1 8 2 8 13 0 20 0 2 5 4 0 0 25 0 4 1 8 3 0 REMOVAL Remove the front brake disc cover Loosen the front axle holder nuts and axle shaft Draw out the axle shaft and remove the front wheel NOTE Do not...

Page 105: ...0 2 5 4 0 0 25 0 4 1 8 3 0 REMOVAL Remove the right front fork cover Loosen the front axle holder bolt and axle shaft Draw out the axle shaft and remove the front wheel NOTE Do not operate the brake l...

Page 106: ...the slit of the adapter Drive out the bearing by knocking the wedge bar CAUTION The removed dust seal and bearing should be replaced with new ones AXLE SHAFT Check the axle shaft runout with a dial g...

Page 107: ...teps Install the wheel bearing with the special tools 09924 8451 0 Bearing installer set 09924 84521 Bearing installer set CAUTION First install the wheel bearing for left side Left side Right side Wh...

Page 108: ...k model SG Apply SUZUKI SILICONE GREASE 99000 25100 I L I For conventional front fork model L Tightening torque ITEM N m kg m lb ft CD 5 8 0 5 0 8 3 5 6 0 0 18 28 1 8 2 8 13 0 20 0 20 25 2 0 2 5 14 5...

Page 109: ...ng the caliper mounting bolts Fig 1 For conventional front fork model Fig 2 For inverted front fork model NOTE Do not operate the brake lever while dismounting the caliper Remove the brake pads by rem...

Page 110: ...e and catch the brake fluid in a suitable receptacle CAUTION Never re use the brake fluid left over from the last servicing and stored for long periods Remove the caliper Remove the pads by removing t...

Page 111: ...use high pressure air to prevent piston damage Remove the dust seals and piston seals CALIPER AND DISC INSPECTION Inspect the caliper cylinder bore wall for nicks scratches or other damage Inspect eac...

Page 112: ...s the service limit Service Limit 0 3 mm 0 012 in 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand CALIPER REASSEMBLV Reassemble and remount the caliper in the reverse order of removal and a...

Page 113: ...Disconnect the front brake switch lead wires Place a cloth underneath the union bolt on the master cylinder to catch spilled drops of brake fluid Unscrew the union bolt and disconnect the brake hose...

Page 114: ...with the special tool 09900 061 08 Snap ring pliers Remove the piston primary cup with return spring MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other damage Insp...

Page 115: ...eassembly Never use cleaning solvent or gasoline to wash them Apply brake fluid to the cylinder bore and all the internals to be inserted into the bore Reassemble and remount the master cylinder Refer...

Page 116: ...m kg m lb ft CD 15 30 1 5 3 0 11 0 21 5 Th1342 Apply THREAD LOCK 1342 99000 32050 15 25 1 5 2 5 11 0 18 0 REMOVAL AND DISASSEMBLY Remove the front wheel Refer to page 7 1 Remove the front brake calip...

Page 117: ...09940 30230 Hexagon socket 17 mm Remove the front fork assembly Remove the front fork cap bolt G spacer spring seat and spring Invert the fork and stroke it several times to remove oil Hold the fork...

Page 118: ...le holding the outer tube or caliper mounting portion of the outer tube by vise separate the inner tube from the outer tube as shown Remove the inner tube metal G outer tube metal washer and oil seal...

Page 119: ...Reassemble and remount the front fork in the reverse order of removal and disassembly and also carry out the following steps Install the front fork Refer to page 7 13 INNER TUBE METAL Install the meta...

Page 120: ...s cosity rating meets specifications below Fork oil type Fork oil 10 99000 99044 1 OG SUZUKI FORK OIL 10 Capacity each leg 555 ml 18 8 19 5 US Imp oz Hold the front fork vertical and adjust the fork o...

Page 121: ...e ITEM N m kg m lb ft CD 30 40 3 0 4 0 21 5 29 0 18 22 1 8 2 2 13 0 16 0 30 40 3 0 4 0 21 5 29 0 REMOVAL AND DISASSEMBLY Remove the front wheel Refer to page 7 1 Remove the left front fork cover Refer...

Page 122: ...fter loosening the upper clamp bolt Remove the front fork assembly by loosening the lower clamp bolt Remove the cap Remove the nut Q and spacer guide Remove the spacer and spring Adjust the compressio...

Page 123: ...placed along with oil seal and dust seal when assembling the front fork Remove the damper rod bolt NOTE If it is difficult to loosen the damper rod bolt use the airimpact wrench Remove the inner rod w...

Page 124: ...operating smoothly REASSEMBLV AND REMOUNTING Reassemble and remount the front fork in the reverse order of removal and disassembly Also observe the following instruc tions OIL SEAL CASE Install the n...

Page 125: ...oove of outer tube and metal outer surface and install the outer tube metal Install the oil seal retainer and oil seal with the special tools 09940 52820 Front fork oil seal installer 09940 52830 Fron...

Page 126: ...e out from the oil Keep the front fork vertically and wait 5 6 minutes Fork oil level adjusting Set the oil level gauge with the front fork fully compressed and adjust the oi I level to the specificat...

Page 127: ...ght 14 mm 1 57 in Tighten the fork cap to the specified torque Tightening torque 17 5 22 5 N m 1 75 2 25 kg m 0 0 0 0 lb ft When installing the front fork assembly align the line on the outer tube wit...

Page 128: ...SASSEMBLY Remove the front wheel Refer to page 7 1 Remove the front fork Refer to pages 7 13 or 7 18 Remove the speedometer cable clamp Remove the front fender ITEM CD __ _j Tightening torque N m kg m...

Page 129: ...discon necting the headlight and position light lead wires For conventional front fork model Remove the headlight holder by removing the lower bracket and disconnecting the headlight and position ligh...

Page 130: ...bly Remove the turn signal light Remove the front brake hose guide Disconnect the front brake light switch lead wires Remove the master cylinder with brake lever Remove the throttle cable case Remove...

Page 131: ...eering stem upper bearing race with the special tool 09941 74910 Steering bearing installer and remover Remove the steering stem lower bearing race with the special tools 09941 54911 Bearing outer rac...

Page 132: ...lowing steps Reassemble and remount the steering stem Refer to page 7 16 INNER AND OUTER RACES Press in the upper and lower inner races with the special tool 09941 34513 Steering race installer Instal...

Page 133: ...tem upper bracket rock the front wheel assembly forward and back to ensure that there is no play and that the procedure was accomplished correctly Finally check to be sure that the steering stem moves...

Page 134: ...with the jack or wooden block Loosen the rear axle nut and adjust the drive chain adjusters to loosenest position Remove the rear axle shaft Disengage the drive chain from the rear sprocket and remov...

Page 135: ...OCKET Inspect the sprocket teeth for wear If they are worn as illustrated replace the sprocket and drive chain AXLE SHAFT Refer to page 7 3 WHEEL RIM Refer to page 7 3 REAR TIRE Refer to page 2 13 THR...

Page 136: ...the wheel bearing with the special tools 09924 8451 0 Bearing installer 09924 84521 Bearing installer CAUTION First install the wheel bearing for right side Left side Right side I CD NOTE Left side R...

Page 137: ...REAR BRAKE SG A pply SUZUKI SILICONE GREASE 99000 25100 CHASSIS 7 34...

Page 138: ...s CAUTION Replace the brake pad as a set otherwise braking performance will be adversely affected Reassemble and remount the caliper Refer to page 7 26 CALIPER REMOVAL AND DISASSEMBLY Remove the rear...

Page 139: ...t the piston with a air gun CAUTION Do not use high pressure air to prevent piston damage Remove the dust seal and piston seal CALIPER AND DISC INSPECTION Inspect the caliper cylinder bore wall for ni...

Page 140: ...nd disassembly and also carry out the following steps Reassemble and remount the caliper Refer to page 7 34 CAUTION Wash the caliper components with fresh brake fluid before reassembly Never use clean...

Page 141: ...ke fluid adhering to any part of motorcycle The fluid reacts chemically with paint plastics rubber materials etc Remove the reservoir tank mounting bolt Remove the cotter pin and pin CD Remove the con...

Page 142: ...removal and disassembly and also carry out the follow ing steps CAUTION Wash the master cylinder components with fresh brake fluid before reassembly Never use cleaning solvent or gasoline to wash the...

Page 143: ...M AND SUSPENSION Tightening torque ITEM N m kg m lb ft CD 55 88 5 5 8 8 40 0 63 5 48 72 4 8 7 2 34 5 52 0 70 100 7 0 10 0 50 5 72 5 84 120 8 4 12 0 60 5 87 0 G Apply SUZUKI SUPER GREASE A 99000 25010...

Page 144: ...e 7 31 Remove the chain cover and chain guide Remove the rear brake caliper with the brake hose by separat ing the brake hose from the hose guide Q Remove the chain roller and cushion rod bolt Remove...

Page 145: ...k mounting clamp Remove the cushion lever mounting nut and bolt Remove the rear swingarm with suspension by removing the swingarm pivot shaft Remove the suspension mounting nut and bolt Remove the cha...

Page 146: ...7 43 CHASSIS Remove the dust seal covers CD and spacers Remove the shock absorber Remove the cushion lever Remove the dust seal covers and spacers Remove the dust seal covers and spacer...

Page 147: ...g if there is anything unusual Remove the bearings from the swingarm cushion lever and cushion rod with the speciaI tools 09923 7321 0 Bearing remover 09930 30102 Sliding shaft CAUTION The removed bea...

Page 148: ...steps SWINGARM BEARING Install the new bearing with the suitable socket and special tool 09924 8451 0 Bearing installer NOTE When installing the bearing punch marked side ofbearing faces outside The b...

Page 149: ...Standard spring pre set length 260 mm 10 2 in 09910 60611 Universal clamp wrench CAUTION After adjusting the pre load tighten the spring adjuster lock ring securely SETTING TABLE Spring length STD 260...

Page 150: ...EASSEMBLING INFORMATION Tightening torque ITEM N m kg m lb ft 48 72 4 8 7 2 34 5 52 0 84 120 8 4 12 0 60 5 87 0 70 100 7 0 10 0 50 5 72 5 55 88 5 5 8 8 40 0 63 5 G Apply SUZUKI SUPER GREASE A 99000 25...

Page 151: ...NFORMATION CONTENTS TROUBLESHOOTING 8 1 llli G 1 GilJl 8 j IRE CABLE AND HOSE ROUTING 8 9 Ill llOLilrl i ll CABLE ROUTING 8 11 ffOSl llOUlri G ll 1 SPECIAL TOOLS 8 15 TIGHTENING TORQUE 8 18 SERVICE DA...

Page 152: ...y 1 Fouled spark plug Clean 2 Defective pick up coil primary coil or CDI unit Replace 3 Clogged fuel pipe Replace 4 Clogged jets in carburetor Clean Noisy engine Noise appears to come from piston 1 Pi...

Page 153: ...an or adjust Engine runs poorly in 1 Spark plug gaps too narrow Adjust highspeed range 2 Clogged jets Clean 3 Defective ignition coil Replace 4 Defective pick up coil primary coil or CDI unit Replace...

Page 154: ...ve for operation 4 Filter is clogged Check and clean Overflow and fuel 1 Needle valve is worn or damaged Replace level fluctuations 2 Float is not working properly Check and adjust 3 Foreign matter ha...

Page 155: ...retor Generator does not 1 Open or short in lead wires or loose lead connections Repair replace or retighten charge 2 Shorted grounded or open generator coils Replace 3 Shorted or punctured regulator...

Page 156: ...lean too rapidly 2 Battery is too old Replace BRAKES Complaint Symptom and possible causes Remedy Insufficient brake 1 leakage of brake fluid from hydraulic system Repair or replace power 2 Worn pads...

Page 157: ...Fork oil too viscous Replace stiff 2 Too much fork oil Drain excess oil 3 Front fork adjuster improperly set Inverted front fork Adjust Noisy front 1 Not enough fork oil Refill suspension 2 Loose nut...

Page 158: ...WIRE COLOR B Black L Blue Br Brown G Green Gr Gray Sb Light blue Lg Light green 0 p R w y BBr BL Orange Pink Red White Yellow I I 0 I Black with Brown tracer Black with Blue tracer BG BR BW BY LR LW L...

Page 159: ...BW CC15 31 BW l l2V i 15 ll s i lllll 6 6 I rT fTl i r r r t t t Tl ll i m 1 HAI QL E SW L 0 Orange P Pink R Red W White Y Yellow BBr Black with Brown tracer BL Black with Blue tracer NEUTRAL SW i HUN...

Page 160: ...Rear turn signal R Pass the position light lead wire under the headlight socket boot Clamp Wiring harness Tachometer cable Section A A A Pass the wiring harness under the interference hose Wiring har...

Page 161: ...Fuse Hightension cord Pass the battery EB lead wire between the grooves Battery SERVICING INFORMATION 8 10...

Page 162: ...Throttle cable After touching the speedometer gear box to the stopper tighten the axle shaft Speedometer cable Cable guide Pass the throttle cable to the frame side than wiring harness Clutch cab e Cl...

Page 163: ...the swingarm and kick lever Carburetor overflow hose Clankcase L VIEW A Carburetor overflow hose 11L j j pi l____ ClamP SERVICING INFORMATION 8 12 Clamp Wiring harness Interference hose Oil tank brea...

Page 164: ...he hose Align white mark on the radiator l i with yellow mark on the hose Clamp NOTE Allow mark is tightening direction of the screw Align white mark on the radiator with yellow mark on the hose Set t...

Page 165: ...que After touching the brake hose union to the stopper tighten the union bolt to the specified torque SERVICING INFORMATION 8 14 For Inverted front fork model Lower bracket hose guide F f k Brake hose...

Page 166: ...cket tester 09910 34510 Piston pin puller 09900 06108 Snap ring pliers 09900 20508 Cylinder gauge set 09900 20805 Tire depth gauge 09900 28106 Electro tester 09910 60611 Universal clamp wrench 09900 0...

Page 167: ...ller 09923 73210 Bearing remover 09930 40113 Rotor holder 09940 50113 Front fork oil seal installer 09941 34513 Steering race installer SERVICING INFORMATION 8 16 09913 80112 Bearing installer 09924 8...

Page 168: ...8 17 SERVICING INFORMATION 09941 74910 Steering bearing installer 09941 84510 Bearing remover 09943 74111 Front fork oil level gauge...

Page 169: ...r hose clamp screw 2 2 5 0 2 0 25 1 5 1 8 CHASSIS ITEM N m kg m lb ft Handlebar clamp bolt 18 28 1 8 2 8 13 0 20 0 Front axle shaft 50 80 5 0 8 0 36 0 58 0 Front fork upper clamp bolt 22 35 2 2 3 5 16...

Page 170: ...2 0 2 5 14 5 18 0 Rear sprocket nut 20 30 2 0 3 0 14 5 21 5 Rear brake rod lock nut 15 20 1 5 2 0 11 0 14 5 Brake pad mounting bolt Front Rear 15 20 1 5 2 0 11 0 14 5 TIGHTENING TORQUE CHART For other...

Page 171: ...2nd Approx 5 1 0 20 4 1 0 16 Piston ring end gap 1st 2nd 0 20 0 40 0 80 0 008 0 016 0 031 Piston ring to groove clearance 1st 0 050 0 070 0 0020 0 0028 2nd 0 020 0 060 0 0008 0 0024 Piston pin bore 1...

Page 172: ...kg cm2 pressure 12 8 2 1 psi TRANSMISSION Unit mm in Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3 350 67 20 Final reduction E 02 04 24 2 600 39 15 ratio E 28 2 857 40 14 Gear ratios Low...

Page 173: ...0 6 mm Jet needle J N 60HY36 3rd Needle jet N J N 8 Cut away C A 4 0 Pilot jet P J 35 By pass B P 0 9 mm Pilot outlet P O 0 6 mm Air screw A S 2 turns back Starter jet G S 35 Power jet P W J 80 Valve...

Page 174: ...26 0 at 115 C 239 F Exhaust valve actuator 3 2 7 2 kO W B 0 7 2 kO Y B 4 5 30 0 P Gr Battery Type designation YT4L BS or FT4L BS Capacity 12 V 10 8 kC 3 Ah 1 0 HR Standard elec 1 320 at 20 C 68 F tro...

Page 175: ...83 0 4994 Rear 12 657 12 684 0 4983 0 4994 Brake caliper cylinder bore Front 27 000 27 050 1 0630 1 0650 Rear 30 23 30 28 1 190 1 192 Brake caliper piston diam Front 26 900 26 950 1 0591 1 061 0 Rear...

Page 176: ...oline used should be graded 85 95 oc tane or higher An unleaded or low lead type For the others gasoline is recommended Fuel tank including reserve 9 5 L 2 5 2 1 US Imp gal reserve 1 4 L 1 5 1 2 US Im...

Page 177: ...he TS200RM 91 model NOTE Any differences between TS200RM 91 model and TS200RN 92 model in specifications and service data are clearly indicated with the asterisk marks Please refer to the chapters 1 t...

Page 178: ...ce 2185 mm 86 0 in 880 mm 34 6 in 1245 mm 49 0 in 1425 mm 56 1 in 320 mm 12 6 in 116 kg 256 lbs E02 04 115 kg 254 lbs Others Two stroke water cooled Crankcase reed valve 1 66 0 mm 2 598 in 57 0 mm 2 2...

Page 179: ...d Approx 5 1 0 20 4 1 0 16 Piston ring end gap 1st 2nd 0 20 0 40 0 80 0 008 0 016 0 031 Piston ring to groove clearance 1st 0 050 0 070 0 0020 0 0028 2nd 0 020 0 060 0 0008 0 0024 Piston pin bore 18 0...

Page 180: ...ening 90 15 kPa 0 9 0 15 kg cm2 pressure 12 8 2 1 psi TRANSMISSION Unit mm in Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3 350 67 20 Final reduction E 02 04 24 2 600 39 15 ratio E 28 2 8...

Page 181: ...e J N 6DHY36 3rd Needle jet N J N 8 Cut away C A 4 0 Pilot jet P J 35 By pass B P 0 9 mm Pilot outlet P O 0 6 mm Air screw A S 21f2 turns back Starter jet G S 35 Power jet P W J 80 Valve seat V S 2 5...

Page 182: ...39 F Exhaust valve actuator 3 2 7 2 kfl W B 0 7 2 kfl Y B 4 5 30 n P Gr Battery Type designation YT4L BS or FT4L BS Capacity 12 V 10 8 kC 3 Ah 1 0 HR Standard elec 1 320 at 20 C 68 F trolyte S G Fuse...

Page 183: ...12 684 0 4983 0 4994 Rear 12 657 12 684 0 4983 0 4994 Brake caliper cylinder bore Front 27 000 27 050 1 0630 1 0650 Rear 30 23 30 28 1 190 1 192 Brake caliper piston diam Front 26 900 26 950 1 0591 1...

Page 184: ...Gasoline used should be graded 85 95 oc tar e or higher An unleaded gasoline is The others recommended Fuel tank including reserve 9 0 L 2 4 2 0 US Imp gal reserve 1 4 L 1 5 1 2 US Imp qt Engine oil...

Page 185: ...I Iii Ill l I 11111 Lil d 0 oe ooo 6 11 1 I I I I OA BATTERY LW d Qitii Siil ooc FUSE BOX HANDLE SW L WIRE COLOR B Black L Blue Br Brown G Green Gr Gray Sb Light blue Lg Light green 0 p R w y BBr BL W...

Page 186: ...TS200RP 93 MODEL r CONTENTS SPEC FICA TIONS 10 1 SERVICE DATA 10 2...

Page 187: ...overhaul Coolant 2 185 mm 86 0 in 880 mm 34 6 in 1 245 mm 49 0 in 1 425 mm 56 1 in 320 mm 12 6 in 890 mm 35 0 in 116 kg 256 lbs E04 115 kg 254 lbs E28 113 kg 249 lbs E24 Two stroke liquid cooled Cran...

Page 188: ...nd Approx 5 1 0 20 4 1 0 16 Piston ring end gap 1st 2nd 0 20 0 40 0 80 0 008 0 016 0 031 Piston ring to groove clearance 1st 0 050 0 070 0 0020 0 0028 2nd 0 020 0 060 0 0008 0 0024 Piston pin bore 18...

Page 189: ...pening 90 15 kPa 0 9 0 15 kg cm2 pressure 12 8 2 1 psi TRANSMISSION Unit mm in Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3 350 67 20 Final reduction E 04 24 2 600 39 15 ratio E 28 2 857...

Page 190: ...e J N 6DHY36 3rd Needle jet N J N 8 Cut away C A 4 0 Pilot jet P J 35 By pass B P 0 9 mm Pilot outlet P O 0 6 mm Air screw A S 2Vz turns back Starter jet G S 35 Power jet P W J 80 Valve seat V S 2 5 m...

Page 191: ...at 50 C 122 F Approx 26 0 at 115 C 239 F Exhaust valve actuator 3 2 7 2 kO W B 0 7 2 kO Y B 4 5 30 o P Gr Battery Type designation YT4L BS Capacity 12 V 10 8 kC 3 Ah 10 HR Standard elec 1 320 at 20 C...

Page 192: ...57 12 684 0 4983 0 4994 Rear 12 657 12 684 0 4983 0 4994 Brake caliper cylinder bore Front 27 000 27 050 1 0630 1 0650 Rear 30 23 30 28 1 190 1 192 Brake caliper piston diam Front 26 900 26 950 1 0591...

Page 193: ...d Gasoline used should be graded 85 95 oc tane or higher An unleaded gasoline is The others recommended Fuel tank including reserve 9 0 L 2 4 2 0 US Imp gal reserve 1 4 L 1 5 1 2 US Imp qt Engine oil...

Page 194: ...Prepared by SUZUKI MOTOR CORPORATION Motorcycle Department Overseas Service Division 3rd Ed September 1994 1st Ed October 1990 Part No 99500 21162 0lE Printed in Japan 196...

Page 195: ...SUZUKI MOTOR CORPORATION...

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