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5-14

CHASSIS

BRAKE CALIPER REASSEMBLY AND
REMOUNTING

Reassemble and remount the brake caliper in the reverse order
of removal and disassembly. Pay attention to the following points:

Wash the caliper bores and brake caliper pistons with the
specified brake fluid. Thoroughly wash the dust seal grooves
and piston seal grooves.

Specification and classification: DOT 4

Wash the brake caliper components with new brake
fluid before reassembly.
When washing the components, use the specified
brake fluid. Never use different types of fluid or clean-
ing solvents such as gasoline, kerosine etc.
Do not wipe the brake fluid off after washing the com-
ponents.
Replace the removed piston seals and dust seals
with new ones.
Apply brake fluid to all of the seals, brake caliper
bores and pistons before reassembly.

Tighten the brake caliper housing bolts

1

, brake caliper mount-

ing bolts

2

, and the brake hose union bolt

3

to the specified

torque.

Brake caliper housing bolt: 32 N·m (3.2 kgf-m)
Brake caliper mounting bolt: 26 N·m (2.6 kgf-m)
Brake hose union bolt: 23 N·m (2.3 kgf-m)

NOTE:
Before remounting the brake caliper, push the brake caliper pis-
tons all the way into the brake caliper.

Bleed air from the brake system after reassembling the
brake caliper. (

2-10)

2

1

3

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Summary of Contents for UF50

Page 1: ...9 9 5 0 0 1 0 4 9 1 0 1 E UF50 ...

Page 2: ...s manual and the actual motorcycle Illustrations in this manual are used to show the basic principles of operation and work pro cedures They may not represent the actual motorcycle exactly in detail This manual is written for persons who have enough knowledge skills and tools including special tools for servicing SUZUKI motorcycles If you do not have the proper knowledge and tools ask your authori...

Page 3: ...d on the first page of each sec tion to help you find the item and page you need COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit is its exploded view Work instructions and other service information such as the tightening torque lubricating points and locking agent points are provided Example Front wheel 1 Front axle 2 Spacer 3 Brake disc 4 Bearing 5 Front wheel 6 Spacer 7...

Page 4: ...dicates service data Apply oil Use engine oil unless other wise specified Apply SUZUKI SUPER GREASE A 99000 25010 Apply SUZUKI MOLY PASTE 99000 25140 Apply THREAD LOCK 1342 99000 32050 Apply THREAD LOCK SUPER 1322 99000 32110 Apply THREAD LOCK SUPER 1360 99000 32130 SYMBOL DEFINITION Apply or use brake fluid Measure in voltage range Measure in resistance range Measure in current range Measure in d...

Page 5: ...CAUTION NOTE 1 2 GENERAL PRECAUTIONS 1 2 SUZUKI UF50Y UF50ZY 2000 MODEL 1 4 SERIAL NUMBER LOCATION 1 4 FUEL AND OIL RECOMMENDATIONS 1 4 FUEL 1 4 ENGINE OIL 1 4 FINAL GEAR OIL 1 5 BRAKE FLUID 1 5 BREAK IN PROCEDURES 1 5 INFORMATION LABELS 1 6 SPECIFICATIONS 1 7 1 ...

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

Page 7: ...e nuts and bolts tighten the larger sizes first Always tighten the nuts and bolts from the inside working out diagonally and to the specified torque Whenever you remove oil seals gaskets packing O rings self locking nuts locking wash ers cotter pins circlips and other specified parts be sure to replace them with new ones Also before installing these new parts be sure to remove any left over materi...

Page 8: ...mium quality 2 stroke synthetic engine oil Use only oils which are rated FC under the JASO classification 4 Engine oil tank cap Difference between photographs and the actual motorcycles depends on the markets SERIAL NUMBER LOCATION The frame serial number or V I N Vehicle Identification Number 1 is stamped on the right side of the steering head pipe The engine serial number 2 is located on the end...

Page 9: ...of time BREAK IN PROCEDURES During manufacturing only the best possible materials are used and all machined parts are finished to a very high standard It is still necessary to allow the moving parts to BREAK IN before subjecting the engine to maximum stresses The future performance and reliability of the engine depends on the care and restraint exercised during its early life Refer to the followin...

Page 10: ...1 6 GENERAL INFORMATION INFORMATION LABELS Battery caution label Engine starting label Tire information label Loading cap label General warning label ...

Page 11: ...stem Reed valve Number of cylinders 1 Bore 41 0 mm Stroke 37 4 mm Piston displacement 49 cm3 Corrected compression ratio 7 2 1 Carburetor KEIHIN PWS14 Air cleaner Polyurethane foam element Starter system Electric and kick Lubrication system SUZUKI CCI TRANSMISSION Clutch Dry shoe automatic centrifugal type Gearshifting Automatic variable ratio Gear ratios Variable reduction ratio 2 975 1 033 Final...

Page 12: ...Internal expanding Front tire size 120 70 12 51L Rear tire size 130 70 12 56L ELECTRICAL Ignition type Electronic ignition CDI Spark plug NGK BPR7HS or DENSO W22FPR Battery 12 V 14 4 kC 4 Ah 10 HR Generator Generator Fuse 10 A Headlight 12 V 35 35 W Brake light taillight 12 V 21 5 W Turn signal light 12 V 10 W CAPACITIES Fuel tank 6 0 L Engine oil tank 1 2 L Final gear oil 130 ml NOTE These specif...

Page 13: ...4 CYLINDER HEAD AND CYLINDER 2 5 SPARK PLUG 2 5 CARBURETOR 2 7 FUEL LINE 2 7 FINAL GEAR OIL 2 8 BRAKES 2 8 BRAKE HOSE 2 9 BRAKE FLUID 2 9 STEERING 2 11 FRONT FORK 2 11 REAR SUSPENSION 2 11 TIRES 2 12 CYLINDER HEAD NUTS AND EXHAUST PIPE NUT AND BOLT 2 13 CHASSIS NUTS AND BOLTS 2 13 GENERAL LUBRICATION 2 15 AUTOMATIC CLUTCH INSPECTION 2 16 INITIAL ENGAGEMENT 2 16 CLUTCH LOCK UP 2 17 2 ...

Page 14: ... used under severe conditions PERIODIC MAINTENANCE CHART Interval km Initial 1 000 Every 3 000 Every 6 000 Item months 2 6 12 Battery I I Air cleaner C C Cylinder head and cylinder C C Spark plug C R Carburetor I I I Fuel line I I I Replace every four years Final gear oil I I Brakes I I I Brake hose I I Replace every four years Brake fluid I I Replace every two years Steering I I I Front fork I Re...

Page 15: ...specific gravity reading of 1 22 at 20 C or less means that the battery needs to be recharged Remove the battery from the motorcycle and charge it with a battery charger Standard specific gravity 1 280 at 20 C When removing the battery from the motorcycle be sure to disconnect the battery lead wire first Never charge a battery while it is still in the motor cycle as damage may result to the batter...

Page 16: ...the excess solvent do not twist or wring the ele ments or they will develop tears Immerse the elements in motor oil and squeeze out the ex cess oil The elements should be wet but not dripping Properly install the air cleaner elements into the air cleaner case A Nonflammable cleaning solvent B Motor oil SAE 30 or SAE 10W 40 Inspect the air cleaner element for tears A torn ele ment must be replaced ...

Page 17: ...e every 6 000 km 12 months Remove the left side leg shield 5 3 Disconnect the spark plug cap and remove the spark plug NGK DENSO Standard BPR7HS W22FPR CARBON DEPOSIT Check for carbon deposits on the spark plug If any carbon is deposited on the spark plug remove it using a spark plug cleaner machine or carefully use a tool with a pointed end ...

Page 18: ...rk plug if it has a broken insulator dam aged threads etc Check the tread size and reach when replacing the spark plug If the reach is too short carbon will be de posited on the screw portion of the spark plug hole and engine damage may result SPARK PLUG INSTALLATION To avoid damaging the cylinder head threads first fin ger tighten the spark plug and then tighten it to the specified torque using t...

Page 19: ...Multi circuit tester set THROTTLE CABLE PLAY Throttle cable play A should be 2 4 mm as measured at the throttle grip when turning the throttle grip lightly If the throttle cable play A is incorrect adjust it as follows Loosen the locknut 1 and turn the adjuster 2 in or out until the specified play is obtained Tighten the locknut 1 while holding the adjuster 2 Throttle cable play A 2 4 mm After the...

Page 20: ...y at 1 000 km 2 months and every 3 000 km 6 months thereafter REAR BRAKE LEVER PLAY Turn the adjusting nut 1 until the rear brake lever play A is within specification Rear brake lever play A 15 25 mm REAR BRAKE SHOE WEAR This motorcycle is equipped with a brake lining wear limit indi cator 1 on the brake cam lever To check brake lining wear perform the following steps Make sure that the rear brake...

Page 21: ...brake fluid level Specification and classification DOT 4 The brake system is filled with an glycol based brake fluid which is classified DOT 4 Do not use or mix other types of brake fluid such as silicone based and petroleum based brake fluids when refilling the brake system otherwise serious damage to the brake system will result Do not use any brake fluid taken from old used or unsealed containe...

Page 22: ... valve and insert the free end of the hose into a receptacle Bleed 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 turning it a quarter of a turn so that the brake fluid runs into the receptacle this will remove the tension of the brake lever causing it to touch the handle ...

Page 23: ...ont wheel is off the ground With the wheel facing straight ahead grasp the lower fork tubes near the axle and pull forward If play is found adjust the steering 5 28 and 5 29 FRONT FORK Inspect every 6 000 km 12 months Inspect the front fork for scoring or scratches on the outer sur face of the inner tubes If any damages are found replace the inner tubes with new ones 5 18 and 5 19 REAR SUSPENSION ...

Page 24: ...h gauge TIRE PRESSURE If the tire pressure is too high or too low steering will be ad versely affected and tire wear will increase Therefore maintain the correct tire pressure for good roadability and a longer tire life Cold inflation tire pressure is as follows Cold inflation tire pressure Solo riding Front 125 kPa 1 25 kgf cm2 Rear 175 kPa 1 75 kgf cm2 Dual riding except for UF50Z Front 125 kPa ...

Page 25: ...cified torque Cylinder head nut 10 N m 1 0 kgf m Exhaust pipe nut and bolt 10 N m 1 0 kgf m CHASSIS NUTS AND BOLTS Tighten initially 1 000 km 2 months and every 3 000 km 6 months thereafter Check that all chassis nuts and bolts are tightened to their specified torque Item N m kgf m 1 Front axle nut 42 4 2 2 Steering stem locknut 30 3 0 3 Handlebar set bolt 25 2 5 4 Handlebar clamp nut 50 5 0 5 Fro...

Page 26: ...2 14 PERIODIC MAINTENANCE 1 2 3 4 5 6 7 8 6 9 0 A B C ...

Page 27: ...icated below 1 Rear brake lever holder 2 Center stand pivot and spring hook 3 Front brake lever holder 4 Speedometer cable NOTE Before lubricating each part remove any rust and wipe off any grease oil dirt or grime Lubricate exposed parts which are subject to rust with a rust preventative spray especially whenever the motorcycle has been operated under wet or rainy conditions 1 2 3 4 ...

Page 28: ...on of the drive train Follow the proce dures listed NOTE Warm up the engine INITIAL ENGAGEMENT Remove the trunk 5 4 Connect the multi circuit tester to the high tension cord Start the engine While seated on the machine slowly increase the engine speed and record the speed when the machine begins to move forward 09900 25008 Multi circuit tester Engagement speed 4 100 4 500 r min If the engagement s...

Page 29: ...lly open the throttle for a brief period and note the maxi mum engine speed sustained during the test cycle 09900 25008 Multi circuit tester Lock up speed 5 600 6 200 r min Do not apply full power for more than 10 seconds or damage to the clutch assembly or engine may occur If the lock up speed does not coincide with the standard range refer to the following section to inspect the respective items...

Page 30: ...ER 3 13 PISTON 3 14 CRANKSHAFT AND CONROD 3 16 REED VALVE 3 17 CLUTCH SHOE MOVABLE DRIVEN FACE 3 18 MOVABLE DRIVE FACE 3 23 KICK STARTER 3 25 BEARINGS 3 26 OIL SEALS 3 28 ENGINE MOUNTING BUSHINGS 3 31 ENGINE REASSEMBLY 3 32 CRANKSHAFT 3 32 CRANKCASE 3 32 REAR AXLE SHAFT AND TRANSMISSION 3 34 GENERATOR 3 36 STARTER PINION AND STARTER GEAR 3 37 DRIVE BELT 3 38 PISTON 3 39 CYLINDER 3 40 CYLINDER HEAD...

Page 31: ...drive face 3 9 Movable drive face 3 9 3 38 Clutch housing 3 9 3 38 Clutch shoe assembly 3 9 Drive belt 3 9 3 38 Starter driven gear 3 9 3 37 Starter pinion gear 3 10 3 37 ENGINE RIGHT SIDE PARTS REMOVAL INSTALLATION Exhaust pipe muffler assembly 3 6 3 40 Cooling fan 3 7 Starter motor 3 8 Generator rotor 3 10 3 37 Stator coil 3 10 3 36 Pickup coil 3 10 3 36 Gearbox cover 3 11 3 35 Final driven gear...

Page 32: ...side leg shields and frame covers 5 3 to 5 5 Disconnect the battery lead wire 6 30 Disconnect the fuel hose 1 vacuum hose 2 oil hose 3 and carburetor heater lead wire 4 Remove the carburetor top cap 5 with the throttle cable and throttle valve Disconnect the spark plug cap Disconnect the engine ground wire Disconnect the thermoelement coupler 6 starter motor cou pler 7 and generator coupler 8 4 5 ...

Page 33: ...GINE Remove the rear brake cable holders 1 and adjusting nut 2 Disconnect the air cleaner intake boot Remove the rear shock absorber lower mounting bolt Remove the engine mounting nut shaft and engine 1 1 1 2 ...

Page 34: ...e mounting nut 60 N m 6 0 kgf m NOTE When tightening the engine mounting nut make sure that the front wheel is elevated Tighten the rear shock absorber lower mounting nut 6 to the specified torque Rear shock absorber nut 35 N m 3 5 kgf m Place 65 kg on the seat after installing the engine Check that clearances A and B are equal If clearances A and B are not equal repeat the engine installation pro...

Page 35: ...3 6 ENGINE ENGINE DISASSEMBLY Remove the air cleaner Remove the exhaust pipe muffler assembly Disconnect the oil hoses and remove the oil pump ...

Page 36: ...he oil pump gear 1 intake pipe and carburetor A Twist off bolt Remove the reed valve and gaskets Remove the cylinder cylinder head cover 2 and cooling fan cover 3 Remove the cooling fan Remove the cooling fan case 1 A 2 3 ...

Page 37: ...ove them Remove the cylinder head and gasket Remove the cylinder and gasket Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into the crankcase Then remove the piston pin circlip with long nose pliers Remove the piston pin and piston Remove the starter motor ...

Page 38: ... the kick starter nut 09930 40113 Rotor holder Remove the kick starter 3 fixed drive face 4 movable drive face 5 spacers and washers Hold the clutch housing using the special tool and then re move the clutch housing nut 09930 40113 Rotor holder Remove the clutch housing clutch shoe assembly and drive belt Remove the starter driven gear 2 1 3 5 4 ...

Page 39: ...el pins Drain the final gear oil Hold the generator rotor using the special tool and then re move the generator rotor nut 09930 40113 Rotor holder Remove the generator rotor using the special tool 09920 13120 Crankcase separating tool Remove the stator coil 3 pickup coil 4 and key 5 3 5 4 ...

Page 40: ... brake shoes Remove the brake cam lever 1 return spring 2 brake lining wear limit indicator 3 and brake camshaft 4 Remove the gearbox cover Remove the final driven gear with the rear axle shaft 5 idle shaft gear 6 and dowel pins 7 3 4 2 1 7 5 6 7 ...

Page 41: ...er pin 2 and center stand shaft 3 Remove the center stand 4 Remove the crankcase bolts Separate the left and right crankcases using the special tool 09920 13120 Crankcase separating tool Remove the gaskets and dowel pins Replace the removed gaskets with new ones Remove the crankshaft using the special tool 09920 13120 Crankcase separating tool ...

Page 42: ...he exhaust port and the upper part of the cylinder Take care not to damage the surface of the cylinder wall CYLINDER BORE Measure the cylinder bore with the cylinder gauge at 20 mm from the top of the cylinder If the measurement exceeds the service limit rebore the cylin der and replace the piston with an oversized piston or replace the cylinder with a new one Oversized pistons are available in tw...

Page 43: ... the cylinder and use an oversized piston or replace both the cylinder and the piston with new ones Piston to cylinder clearance Service Limit 0 120 mm CARBON REMOVAL Remove carbon from the crown of the piston and piston ring grooves After cleaning the piston ring grooves install the piston rings and rotate them in their respective grooves to be sure that they move smoothly Carbon in the piston ri...

Page 44: ...GAP Measure the piston ring free end gap using vernier calipers Then fit the piston ring squarely into the cylinder and measure the piston ring end gap using a thickness gauge If any of the measurements exceed the service limit replace the piston ring with a new one 09900 20101 Vernier calipers Piston ring free end gap Service Limit 1st 3 2 mm R 2nd 3 4 mm R 09900 20803 Thickness gauge Piston ring...

Page 45: ...seal CRANKSHAFT RUNOUT Support the crankshaft using V blocks as shown Position the dial gauge as shown and rotate the crankshaft slowly to read the runout If the runout exceeds the service limit correct the runout or replace the crankshaft assembly with a new one 09900 20701 Magnetic stand 09900 20606 Dial gauge 1 100 mm 09900 21304 V block set 100 mm Crankshaft runout Service Limit 0 05 mm ...

Page 46: ...he deflection into specification by replacing the worn parts e g conrod big end bearing and crank pin CONROD SMALL END I D Measure the conrod small end inside diameter using the dial calipers If the conrod small end inside diameter exceeds the service limit replace the conrod with a new one Conrod small end I D Service Limit 14 040 mm 09900 20605 Dial calipers REASSEMBLY When rebuilding the cranks...

Page 47: ...ISASSEMBLY If the engine speed does not coincide with the specified engine speed range disassemble the clutch shoe movable driven face as follows Hold the clutch shoe assembly using the special tools and then loosen the clutch shoe nut 09930 40113 Rotor holder 09930 40131 Rotor holder attachment Remove the clutch shoe nut 1 while holding down the clutch shoe assembly as shown Gradually ease apart ...

Page 48: ...ade screwdriver to pry up the movable driven face spring guide Remove the pins 3 movable driven face 4 and fixed driven face 5 Remove the bearing using the special tools 09923 73210 Bearing remover 09930 30102 Sliding hammer Replace the removed bearing with a new one Remove the circlip ...

Page 49: ...shoe with a new one 09900 20101 Vernier calipers Clutch shoe thickness Service Limit 2 0 mm Inspect the clutch spring for stretched or broken coils If any dam ages are found replace the clutch spring with a new one Replace the clutch shoe and clutch spring as a set Inspect the clutch housing surface for scrolling cracks or un even wear and measure the inside diameter of the clutch hous ing with in...

Page 50: ... and the sliding surface and sliding pins for wear or dam age If any damages are found replace the driven face with a new one DRIVEN FACE Inspect the drive belt contacting surface of both driven faces for any scratches wear or damage If any damages are found re place the driven faces with new ones REASSEMBLY Reassemble the clutch shoe assembly and movable driven face in the reverse order of disass...

Page 51: ...ioned properly Install the pins 1 at three places on the drive face hub Apply sufficient SUZUKI SUPER GREASE A to the cam where the pins are placed and to the surface of the driven face as shown 99000 25010 SUZUKI SUPER GREASE A Position the two O rings 2 Install the movable driven face spring guide NOTE Remove any grease from the movable driven face spring guide after installation Hold the clutch...

Page 52: ... 9 Fixed drive face 0 Washer A Kick starter B Concave washer A Kick starter nut DISASSEMBLY Remove the movable drive face cover 1 and movable drive plate 2 DRIVE FACE Inspect the belt contact surface of the drive faces for wear scratches or any abnormalities If any damages are found re place the drive face with a new one 1 2 ITEM N m kgf m A 50 5 0 ...

Page 53: ... are found or if the width of the drive belt is less than the service limit replace the drive belt with a new one Drive belt width Service Limit 17 4 mm Always keep the drive belt away from grease oil etc REASSEMBLY Mount the three dampers 1 on the movable drive plate 2 and install it onto the movable drive face Install the movable drive face cover 3 NOTE Make sure that the movable drive plate is ...

Page 54: ... pin 6 Gasket 7 Gasket 8 Kick starter lever 9 Kick starter drive gear DISASSEMBLY Remove the kick starter driven gear 1 kick starter shaft spring 2 and kick starter shaft 3 REASSEMBLY Apply SUZUKI SUPER GREASE A onto the inside of the kick starter shaft spacer 99000 25010 SUZUKI SUPER GREASE A 2 3 1 ...

Page 55: ... the kick starter drive gear BEARINGS Wash the bearing with a cleaning solvent and lubricate it with motor oil before inspection Rotate the inner race and check to see that it turns smoothly If it does not turn quietly and smoothly or if there are signs of any abnormalities the bearing is defec tive and must be replaced with a new one REAR AXLE SHAFT BEARING Remove the bearing retainer Remove the ...

Page 56: ...aring remover 09930 30102 Sliding hammer Replace the removed bearings with new ones LEFT DRIVESHAFT BEARING Remove the left driveshaft bearing using the special tool 09921 20220 Bearing remover set Replace the removed bearing with a new one Install the left driveshaft bearing using the special tool 09913 70210 Bearing installer set Install the right driveshaft bearing and idle shaft bearing us ing...

Page 57: ...0 Bearing installer set LEFT CRANKSHAFT BEARING Remove the left crankshaft bearing using the special tools 09923 74510 Bearing remover 09930 30102 Sliding hammer Replace the removed bearing with a new one Install the left crankshaft bearing using the special tool 09913 70210 Bearing installer set OIL SEALS Damage to the lip of the oil seal may result in leakage of the air fuel mixture or gear oil ...

Page 58: ...sing the special tool 09913 50121 Oil seal remover Replace the removed oil seal with a new one Install the rear axle shaft oil seal into the gearbox cover slowly using the special tool 09913 70210 Bearing installer set DRIVE SHAFT OIL SEAL Remove the drive shaft oil seal from the left crankcase using the special tool 09913 50121 Oil seal remover Replace the removed oil seal with a new one Be sure ...

Page 59: ...t crank case using the special tool 09913 50121 Oil seal remover Replace the removed oil seals with new ones NOTE Align the oil seal with the edge A of the crankcase as shown Install the left crankshaft oil seals using the special tool after installing the crankshaft to the crankcase 3 33 Install the crankshaft oil seal into the right crankcase slowly using the special tool 09913 70210 Bearing ins...

Page 60: ...o steel tubes of the appropriate size as shown Replace the removed bushing with a new one Install the engine mounting bushings using two steel tubes of the appropriate size and a vise Press the mounting bush ings 1 and 2 into the crankcase holes as shown NOTE The knurled end 3 should face in Projections A and B should be aligned evenly Crankcase Front side Crankcase Rear side Crankcase 0 5 mm 0 5 ...

Page 61: ...he special tools 09910 32812 Crankshaft installer 09910 20116 Conrod holder Never fit the crankshaft into the crankcase by striking it with a plastic hammer Always use the special tool otherwise the crankshaft may be misaligned CRANKCASE Install the two dowel pins 1 and new gaskets 2 Install the left crankcase onto the right crankcase Tighten the crankcase bolts NOTE After the crankcase bolts have...

Page 62: ...ol 09941 74910 Bearing installer Apply SUZUKI SUPER GREASE A approximately 10 g to the oil pump drive gear on the crankshaft surface side 99000 25010 SUZUKI SUPER GREASE A Install the left crankshaft outer oil seal using the special tool 09913 70210 Bearing installer set 28 5 mm ...

Page 63: ...ox cover 3 Rear axle shaft final driven gear 4 Idle shaft gear 5 Washer 6 Washer 7 Drive shaft Install the idle shaft gear 1 with the thrust washer 2 into the gearbox Install the rear axle shaft final driven gear 3 Install the thrust washer 4 and the O ring 5 3 5 4 ...

Page 64: ...he bolts a little at a time diagonally Apply a light coat of SUZUKI SUPER GREASE A onto the pivoting surface of the brake cam and then install the brake cam into the crankcase 99000 25010 SUZUKI SUPER GREASE A Position the brake cam so that the punch mark A faces the rear axle shaft 2 2 1 A ...

Page 65: ...tighten the brake cam lever nut to the specified torque Brake cam lever nut 10 N m 1 0 kgf m Install the brake shoes and rear wheel Tighten the rear axle nut to the specified torque NOTE Apply final gear oil 10W 40 to the axle nut before tightening it Rear axle nut 120 N m 12 0 kgf m GENERATOR Remove any grease from the tapered portion of the crank shaft and also from the generator rotor Install t...

Page 66: ...in bolt 5 5 N m 0 55 kgf m Add final gear oil until it flows from the final gear oil level hole 2 Final gear oil quantity 130 ml Tighten the final gear oil level bolt to the specified torque Oil level bolt 12 N m 1 2 kgf m Apply SUZUKI SUPER GREASE A onto the starter pinion shaft and install the starter pinion gear assembly 3 99000 25010 SUZUKI SUPER GREASE A Insert the dowel pins 4 Install the st...

Page 67: ...ing the special tool and tighten the clutch housing nut to the specified torque 09930 40113 Rotor holder Clutch housing nut 50 N m 5 0 kgf m Install the movable drive face onto the crankshaft as shown NOTE Thoroughly clean the drive belt contact surface Hold the generator rotor using the special tool and tighten the kick starter nut to the specified torque 09913 40113 Rotor holder Kick starter nut...

Page 68: ...g NOTE The piston rings should be installed with the mark facing up Position the piston ring gaps as shown Before inserting the piston into the cylinder check that the gaps are properly posi tioned Securely install the circlip 1 NOTE The arrow mark 2 on the piston crown should be pointing to wards the exhaust side Apply engine oil onto the piston pin and then install the pis ton CORRECT INCORRECT ...

Page 69: ...ue Cylinder head nut 10 N m 1 0 kgf m OIL PUMP GEAR Apply SUZUKI SUPER GREASE A onto the oil pump gear and then install it 99000 25010 SUZUKI SUPER GREASE A INTAKE PIPE Install the intake pipe and tighten the bolts securely NOTE Be sure to use the special twist off bolt A as shown EXHAUST PIPE MUFFLER Tighten the exhaust pipe mounting nut and bolt to the speci fied torque Exhaust pipe mounting nut...

Page 70: ...ND OIL TANK 4 3 REMOVAL 4 3 REMOUNTING 4 4 FUEL TANK CUSHIONS 4 5 CARBURETOR 4 6 CONSTRUCTION 4 6 I D NO LOCATION 4 6 SPECIFICATIONS 4 7 REMOVAL 4 8 DISASSEMBLY 4 8 CLEANING 4 11 INSPECTION AND ADJUSTMENT 4 11 REASSEMBLY 4 12 REMOUNTING 4 12 OIL PUMP 4 13 AIR BLEEDING 4 13 DISCHARGE RATE CHECK 4 13 ...

Page 71: ...pressure causes the fuel valve diaphragm to compress its spring opening the fuel passageway and allow ing the fuel to flow to the carburetor When the engine has stopped the spring pushes against the valve closing the fuel passageway and stop ping the flow of fuel to the carburetor To carburetor Negative pressure Air vent hose From fuel tank ...

Page 72: ... heat sparks and flames away from gasoline Remove the frame cover 5 4 and 5 5 Disconnect the turn signal light lead wires 1 and license plate light coupler 2 Disconnect the fuel level indicator switch coupler Disconnect the air vent hose 3 and fuel hose 4 Remove the lower fuel tank cover mounting bolts 2 1 3 4 ...

Page 73: ... 1 and fuel tank 2 NOTE After removing the fuel tank reinstall the fuel tank cap Disconnect the oil hose 3 oil level indicator switch coupler 4 and remove the oil tank 5 REMOUNTING Remount the fuel tank and oil tank in the reverse order of re moval 1 2 5 3 4 ...

Page 74: ...FUEL AND LUBRICATION SYSTEM 4 5 FUEL TANK CUSHIONS 15 mm Cushion 80 mm 105 mm 8 mm 1 3 m m 65 mm 40 mm 15 mm 25 mm 6 mm 20 mm 20 mm 15 mm 60 mm 75 mm B A VIEW A VIEW B 45 Cushion ...

Page 75: ...ment 6 Carburetor body 7 Pilot air screw 8 Throttle stop screw 9 Needle valve 0 Float pin A Float B Needle jet C Needle jet holder D Slow jet E Main jet F Float chamber G Thermoswitch A Carburetor heater ITEM N m kgf m A 3 0 3 I D NO LOCATION The carburetor has an I D number A stamped on its body ac cording to its specifications A ...

Page 76: ...TIONS ITEM SPECIFICATION Carburetor type KEIHIN PWS14 Bore size 14 mm I D No 30F0 Idle r min 1 900 200 r min Float height 5 1 0 5 mm Main jet M J 65 Jet needle J N N5GJ 2nd Slow jet S J 42 Air screw A S 2 turns back Throttle cable play 2 4 mm ...

Page 77: ...heater lead wire 2 Disconnect the vacuum hose 3 and fuel hose 4 Loosen the carburetor clamp screw and remove the carbure tor mounting bolts Remove the top cap DISASSEMBLY Remove the throttle cable from the slit in the throttle valve and then remove the throttle valve 1 along with the jet needle and throttle valve spring 2 2 1 3 4 1 2 ...

Page 78: ...d needle valve 5 by removing the float pin 6 When removing the float pin be careful not to damage the carburetor body and float Remove the main jet 7 needle jet holder 8 needle jet 9 and pilot jet 0 Remove the throttle stop screw A and pilot air screw B Do not use wire to clean the passageways valve seat and jets Use compressed air only 2 1 3 4 6 5 8 0 9 7 A B ...

Page 79: ...4 10 FUEL AND LUBRICATION SYSTEM Remove the thermoelement cover 1 and remove the ther moelement 2 Do not disassemble the thermoelement It is not ser viceable Remove the carburetor heater 1 2 ...

Page 80: ...hemi cal manufacturer s instructions for proper use and cleaning of the carburetor components After cleaning reassemble the carburetor with new O rings Replace the removed O rings with new ones INSPECTION AND ADJUSTMENT Check the following items for any damage or clogging If any damages are found replace the damaged parts with new ones Main jet Throttle valve Pilot jet Float Needle jet Needle valv...

Page 81: ...r of disassembly Pay attention to the following points Tighten the carburetor heater to the specified torque Carburetor heater 3 N m 0 3 kgf m Adjust the pilot air screw 4 7 Install the throttle valve with the top cap Align the slit 1 on the throttle valve with the projection 2 on the carburetor body REMOUNTING Remount the carburetor in the reverse order of removal Pay attention to the following p...

Page 82: ...g the procedure Remove the trunk 5 4 Fill the CCI oil gauge with SUZUKI CCI SUPER OIL Connect the oil gauge to the suction side of the oil pump Run the engine at 3 000 r min Keep the engine speed at 3 000 r min and allow the pump to draw for five minutes The measurement on the oil gauge should be within specification 09900 21602 CCI oil gauge Oil discharge amount 0 8 1 2 ml at 3 000 r min for 5 mi...

Page 83: ...ER REMOVAL AND DISASSEMBLY 5 15 MASTER CYLINDER INSPECTION 5 16 MASTER CYLINDER REASSEMBLY AND REMOUNTING 5 17 FRONT SUSPENSION 5 18 CONSTRUCTION 5 18 REMOVAL AND DISASSEMBLY 5 18 INSPECTION 5 20 REASSEMBLY AND REMOUNTING 5 20 HANDLEBAR COVERS AND SPEEDOMETER ASSEMBLY 5 22 CONSTRUCTION 5 22 REMOVAL 5 23 REMOUNTING 5 24 STEERING STEM 5 25 CONSTRUCTION 5 25 REMOVAL AND DISASSEMBLY 5 25 INSPECTION 5 ...

Page 84: ...ASSIS EXTERIOR PARTS CONSTRUCTION 1 Frame cover R 2 Frame cover L 3 Trunk 4 Side leg shield R 5 Side leg shield L 6 Lower leg shield 7 Leg shield 8 Cover 9 Battery holder cover 0 Footboard A Front leg shield ...

Page 85: ... the battery 6 30 Remove the side leg shields 1 Remove the frame cover Remove the footboard 2 Remove the cover 3 Remove the front leg shield mounting screws Disconnect the headlight lead wires 4 and remove the front leg shield 5 1 2 3 4 5 ...

Page 86: ...ove the lower leg shield 1 Remove the ignition switch cap 2 Remove the leg shield 3 SEAT Remove the seat 1 FRAME COVER Remove the seat Remove the side leg shield 5 3 Remove the trunk 1 and fuel tank cap 2 1 2 3 1 2 1 ...

Page 87: ...install the fuel tank cap Remove the passenger grab handle 2 Remove the frame cover mounting screw Disconnect the seat lock cable 3 brake light taillight lead wires 4 and remove the frame cover 5 REMOUNTING Remount the leg shield seat and frame cover in the reverse order of removal 1 2 4 3 5 ...

Page 88: ...ox A Front axle nut B Brake disc bolt ITEM N m kgf m A 42 4 2 B 23 2 3 REMOVAL Disconnect the speedometer cable 1 Remove the front axle nut 2 Raise the front wheel off the ground by raising the motorcycle with a jack or wooden block Remove the front axle and then the front wheel and spacer Remove the speedometer gearbox 1 2 ...

Page 89: ...he inner race by hand to inspect for abnormal noise and smooth rotation If any abnormal noise occurs or rough movement is noted replace the wheel bearings with new ones Remove the wheel bearings as follows Insert the bearing remover attachment 1 into the wheel bear ing Insert the wedge bar 2 from the opposite side and lock it into the slit of the bearing remover attachment Drive out the wheel bear...

Page 90: ... exceeds the service limit replace the front axle with a new one 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block set 100 mm Wheel axle runout Service Limit 0 25 mm TIRE 2 12 REASSEMBLY AND REMOUNTING Reassemble and remount the front wheel in the reverse order of removal and disassembly Pay attention to the following points WHEEL BEARINGS Apply SUZUKI SUPER GREASE A t...

Page 91: ...rake disc mounting bolt 23 N m 2 3 kgf m SPEEDOMETER GEARBOX Apply SUZUKI SUPER GREASE A to the teeth of the speed ometer gear before installing the speedometer gearbox 99000 25010 SUZUKI SUPER GREASE A Align the grooves 1 on the speedometer gearbox with the lugs 2 on the wheel hub FRONT WHEEL Tighten the front axle nut to the specified torque Front axle nut 42 N m 4 2 kgf m 2 1 1 Bearing L 2 Spac...

Page 92: ...e brake system otherwise serious damage to the brake system will result Do not use any brake fluid taken from old used or unsealed containers Do not reuse brake fluid left over from the last servicing or which has been stored for a long period of time When storing brake fluid be sure to seal the container completely and keep it out of the reach of children When replenishing brake fluid be sure not...

Page 93: ... with new ones Brake pad thickness A Service Limit 0 7 mm Replace the brake pads as a set otherwise braking per formance will be adversely affected Install the new brake pads and shims Be sure to properly install the shims 3 as shown in the illustration Tighten the brake caliper mounting bolts 4 to the specified torque Brake caliper mounting bolt 26 N m 2 6 kgf m NOTE After replacing the brake pad...

Page 94: ...ing the brake caliper mounting bolts 3 Never reuse the brake fluid left over from previous servicing or which has been stored for long period of time otherwise serious damage to the brake sys tem will result Brake fluid if it leaks will interfere with safe running and discolor painted surfaces Check the brake hose and hose joints for cracks and oil leakage Connect a clear hose to the air bleeder v...

Page 95: ...essure air to remove the brake caliper pistons otherwise damage to the pistons will result Remove the dust seals and piston seals Do not reuse the dust seals and piston seals to pre vent fluid leakage BRAKE CALIPER INSPECTION BRAKE CALIPER Inspect the brake caliper cylinder wall for nicks scratches or other damage If any damages are found replace the brake cali per with a new one BRAKE CALIPER PIS...

Page 96: ... of fluid or clean ing solvents such as gasoline kerosine etc Do not wipe the brake fluid off after washing the com ponents Replace the removed piston seals and dust seals with new ones Apply brake fluid to all of the seals brake caliper bores and pistons before reassembly Tighten the brake caliper housing bolts 1 brake caliper mount ing bolts 2 and the brake hose union bolt 3 to the specified tor...

Page 97: ...disc runout Service Limit 0 30 mm If either measurement exceeds the service limit replace the brake disc with a new one 5 7 Install the front wheel 5 9 MASTER CYLINDER REMOVAL AND DISASSEMBLY Remove the handlebar cover 5 23 and 5 24 Place a rag underneath the brake hose union bolt on the master cylinder to catch any spilt brake fluid Remove the brake hose union bolt and disconnect the brake hose m...

Page 98: ...ve the piston secondary cup 1 and return spring 2 Remove the master cylinder reservoir cap 3 and diaphragm 4 Drain the brake fluid MASTER CYLINDER INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or other dam age If any damages are found replace the master cylinder with a new one 3 4 2 1 ...

Page 99: ...o not wipe the brake fluid off after washing the com ponents When washing the components use the specified brake fluid Never use different types of fluid or clean ing solvents such as gasoline kerosine etc Apply brake fluid to the master cylinder bore and all of the master cylinder components before reassem bly Specification and classification DOT 4 When remounting the master cylinder on the handl...

Page 100: ...ip 6 Bushing 7 Lower circlip 8 Dust seal 9 Brake caliper bracket A Brake caliper bracket mounting bolt ITEM N m kgf m A 20 2 0 REMOVAL AND DISASSEMBLY Remove the front wheel 5 6 Remove the brake caliper 5 12 Repeat following steps for each fork leg Remove the brake caliper bracket 1 Remove the dust seal 2 1 2 ...

Page 101: ...ip with a new one Remove the lower bushing 2 NOTE When removing the lower bushing 2 pull the inner tube 3 down Remove the upper circlip 4 lower spring 5 and inner tube 6 Replace the removed upper circlip with a new one Remove the upper spring 7 and damper 8 1 2 3 4 6 5 8 7 ...

Page 102: ...r tube with a new one BUSHING Inspect the bushing for wear or damage If any damages are found replace the bushing with a new one REASSEMBLY AND REMOUNTING Reassemble and remount the front suspension in the reverse order of removal and disassembly Pay attention to the following points DAMPER AND SPRING Apply SUZUKI SUPER GREASE A 15 g to the damper and springs 99000 25010 SUZUKI SUPER GREASE A When...

Page 103: ...0 52860 Front fork oil seal installer LOWER CIRCLIP Install the lower circlip 4 into the ring groove 5 Replace the lower circlip with a new one The rounded side on the circlip must face upward After installing the lower circlip make sure that it is properly seated in the groove Tighten the brake caliper bracket mounting bolt to the speci fied torque Brake caliper bracket mounting bolt 20 N m 2 0 k...

Page 104: ...5 22 CHASSIS HANDLEBAR COVERS AND SPEEDOMETER ASSEMBLY CONSTRUCTION 1 Front handlebar cover 2 Rear handlebar cover ...

Page 105: ... mirrors 1 Remove the front handlebar cover 2 Disconnect the front turn signal light lead wires Disconnect the speedometer cable 3 and speedometer cou plers 4 Remove the speedometer assembly 5 Disconnect the handlebar switch couplers 1 2 4 3 5 ...

Page 106: ...5 24 CHASSIS Remove the rear handlebar cover 1 REMOUNTING Remount the handlebar covers and the speedometer assembly in the reverse order of removal 94P50730 1 ...

Page 107: ... Handlebar set bolt C Steering stem locknut ITEM N m kgf m A 50 5 0 B 25 2 5 C 30 3 0 REMOVAL AND DISASSEMBLY Remove the front leg shield and leg shield 5 3 and 5 4 Remove the master cylinder assembly 5 15 Remove the front suspension 5 18 and 5 19 Remove the handlebar cover and speedometer assembly 5 23 and 5 24 Remove the cable clamp Remove the front fender brace 1 and front fender 2 1 2 ...

Page 108: ...e rear brake light switch lead wires 6 Remove the handlebar Remove the steering stem locknut using the special tool 09910 60611 Universal clamp wrench Remove the throttle cable 1 and throttle grip 2 Remove the brake hose 3 and speedometer cable 4 1 2 3 4 6 5 ...

Page 109: ...s are found replace the respective part with a new one Steering race wear and brinelling Worn and damaged steel balls Distortion of steering stem or handlebar Remove the outer lower race using a chisel Drive out the upper and lower races Remove the washer 1 and steering stem nut 2 Remove the steering stem NOTE Hold the steering stem bracket to prevent it from falling 1 2 ...

Page 110: ...nd easily in both direc tions When installing the washer align the tongue 2 of the washer with the groove 3 of the steering stem shaft Tighten the steering stem locknut to the specified torque us ing the special tool Steering stem locknut 30 N m 3 0 kgf m 09910 60611 Universal clamp wrench REASSEMBLY AND REMOUNTING Reassemble and remount the steering stem and handlebar in the reverse order of remo...

Page 111: ...egs move them back and forth and make sure that the steering is not loose After performing the adjustment and installing the handlebar rock the front wheel assembly forward and backward to ensure there is no play and the pro cedure was accomplished correctly Check the steering stem to make sure that it moves freely from left to right with its own weight If play or stiffness is noticeable readjust ...

Page 112: ...M N m kgf m A 120 12 0 B 10 1 0 C 29 2 9 D 35 3 5 1 Rear wheel 2 Brake shoe 3 Brake cam 4 Return spring 5 Brake lining wear indicator plate 6 Brake cam lever 7 Rear shock absorber REMOVAL AND DISASSEMBLY REAR WHEEL AND BRAKE Place the motorcycle on level ground Support the motorcycle using a jack or wooden block Remove the exhaust pipe muffler assembly 3 6 Remove the rear wheel Remove the brake sh...

Page 113: ...icated inside the drum Brake drum I D Service Limit 120 7 mm BRAKE SHOE Inspect the brake shoes for wear or damage If any wear or dam ages are found replace the brake shoes as a set Replace the brake shoes as a set otherwise braking performance will be adversely affected REAR SHOCK ABSORBER Inspect the rear shock absorber for oil leakage or other damage If any oil leakages or damages are found rep...

Page 114: ...PER GREASE A Be careful not to apply too much grease to the brake cam and pin If grease gets on the lining brake slip page will result Tighten the rear axle nut to the specified torque NOTE Apply final gear oil 10W 40 to the axle nut before tightening it Rear axle nut 120 N m 12 0 kgf m Tighten the rear shock absorber upper mounting bolt 1 and lower mounting nut 2 to the specified torque Rear shoc...

Page 115: ...fitted to the original position after repairing the puncture the tire may have to be balanced again since such a repair can cause imbalance INSPECTION WHEELS Clean and check each wheel for the following If any item is ob served replace the wheel with a new one Distortion and crack Nick or scratch on bead Wheel rim runout Wheel rim runout axial and radial Service Limit 2 0 mm TIRES Check each tire ...

Page 116: ... not necessary Inspect the valve core seal 2 for deformation or damage If the valve core seal has abnormal deformation replace the valve with a new one INSTALLATION VALVE Clean any dust or rust around the valve hole 1 Install the valve in the rim NOTE To properly install the valve 2 into the valve hole apply a spe cial tire lubricant or neutral soapy liquid to the valve Be careful not to damage th...

Page 117: ...gasoline to the tire bead When installing the tire make sure that the arrow 1 faces the direction of wheel rotation and align the balancing mark 2 on the tire with the valve 3 as shown For installing the tire onto the wheel refer to the instructions given by the tire changer manufacturer Bounce the tire several times while rotating it This will allow the tire bead to expand outwards making inflati...

Page 118: ... Check the rim line 1 cast on the tire side walls The line must be equidistant from the wheel rim all the way around If the dis tance between the rim line and wheel rim varies this indicates that the bead is not properly seated If this is so deflate the tire completely and unseat the bead on both sides Then coat the bead with lubricant and re seat the tire Adjust the tire pressure to the specifica...

Page 119: ...STARTER MOTOR REASSEMBLY 6 13 STARTER RELAY INSPECTION 6 13 IGNITION SYSTEM 6 14 DESCRIPTION 6 14 TROUBLESHOOTING 6 14 INSPECTION 6 16 FUEL LEVEL INDICATOR SWITCH 6 19 INSPECTION 6 19 OIL LEVEL INDICATOR SWITCH 6 20 INSPECTION 6 20 THERMOELEMENT CARBURETOR HEATER AND THERMOSWITCH 6 21 INSPECTION 6 21 SPEEDOMETER 6 23 REMOVAL AND DISASSEMBLY 6 23 INSPECTION 6 23 LAMPS 6 24 HEADLIGHT 6 24 FRONT AND ...

Page 120: ...each terminal for corrosion and contamination CLAMPS Refer to the WIRE HARNESS CABLE AND HOSE ROUTING section for proper clamping procedures 7 10 to 7 16 Bend the clamp properly as shown in the illustration When clamping the wire harness do not allow it to hang down Do not use wire or any other substitutes for the band type clamp FUSE When a fuse blows always investigate the cause correct the prob...

Page 121: ...ls Install the cover over the battery terminal WIRING PROCEDURE Properly route the wire harness according to the WIRE HAR NESS CABLE AND HOSE ROUTING 7 10 to 7 16 USING THE MULTI CIRCUIT TESTER Properly use the multi circuit tester and probes Improper use can cause damage to the motorcycle and tester If the voltage and current values are not known begin mea suring in the highest range When measuri...

Page 122: ...CTRICAL COMPONENTS 1 Fuel level indicator switch 2 Thermoswitch 3 Oil level indicator switch 4 CDI unit 5 Right handlebar switch 6 Horn 7 Turn signal relay 8 Resistor 9 Regulator rectifier 0 Generator A Starter motor 2 1 3 4 5 6 9 7 8 0 A ...

Page 123: ...ELECTRICAL SYSTEM 6 5 B Left handlebar switch C Ignition switch D Thermoelement E Carburetor heater F Battery G Fuse H Starter relay I Ignition coil B C D E G H F I ...

Page 124: ...t as the generator rotor turns The AC current which is generated in the charging coil is converted by the regulator rectifier into DC current The DC current then charges the battery and the lighting coil uses the regulated AC current to supply the meter light headlight and license plate light W R Y W Y W R B W Y W Regulator rectifier Lighting switch Generator Meter light Headlight Taillight Licens...

Page 125: ...normal driving condition Measure the charging voltage bet ween the battery terminals 6 8 Incorrect Faulty stator coil or disconnected lead wires Check the continuity of the startor coil Continuity Faulty regulator rectifier Inspect the regulator rectifier Correct Short circuit of wire harness Improper coupler contact Faulty battery Inspect the wires Battery overcharges Correct 6 8 6 9 6 9 Faulty r...

Page 126: ...ter Do not turn the ignition switch to the ON position when measuring the current When checking to find the excessive current leakage remove the couplers and connectors one by one checking each part CHARGING OUTPUT Remove the battery holder cover 6 30 Start the engine turn the lighting switch to the on posi tion and run the engine at 5 000 r min Measure the DC voltage between the and battery termi...

Page 127: ...R RECTIFIER Remove the front leg shield 5 3 Disconnect the regulator rectifier coupler 1 Measure the voltage between the terminals using the multi cir cuit tester as indicated in the table below If voltage is not within the specified value replace the regulator rectifier with a new one 09900 25008 Multi circuit tester set Tester knob indication Diode test Unit V Tester probe Tester probe A B C D A...

Page 128: ...TING W Y G B W R W R W R W O W O O R R B W Turn the ignition switch to the ON position Grasp the front or rear brake lever Listen for a click from the starter relay when the starter button is pushed Check if the starter motor runs when its terminal is connected to the battery terminal Do not use a thin wire because a large amount of current flows Starter motor will not run No click Clicks Faulty s...

Page 129: ...ion gear assembly No voltage Incorrect Faulty ignition switch Faulty starter button Faulty brake light switches front and rear brakes Improper connector contact Measure the starter relay voltage at the starter relay connectors between W and Y G when the starter button is pushed Voltage Faulty starter relay Improper starter relay contact Inspect the starter relay Correct 6 13 Open circuit in wire h...

Page 130: ...ages are found replace the armature with a new one If the commutator surface is discolored polish it with 400 sand paper and wipe it using a clean dry cloth If there is no undercut scrape out the insulator 1 with a saw blade ARMATURE COIL Check for continuity between each segment and the armature shaft using the multi circuit tester If there is no continuity be tween the segments or there is conti...

Page 131: ...nals A and B and measure for continuity between terminals C and D as shown If the starter relay clicks and continuity is found the relay is operating correctly 09900 25008 Multi circuit tester set Tester knob indication Continuity test Measure the starter relay resistance between the terminals us ing the multi circuit tester If the resistance is not within the speci fied value replace the starter ...

Page 132: ... coil resulting in a strong spark between the spark plug gap TROUBLESHOOTING W R Br W Y W R R O B W W Bl B W B W B W Battery Generator Regulator rectifier CDI unit Ignition coil Spark Plug Check the ignition system couplers for poor connections No spark or poor spark Correct Correct Looseness Continued on next page Improper coupler connection Measure the battery voltage between input lead wires O ...

Page 133: ...nit Incorrect Incorrect Faulty ignition coil Open circuit in wiring harness Improper ignition coupler connection Inspect the ignition coil Correct Correct Correct Inspect the spark plug Faulty spark plug Incorrect Improper spark plug connection Correct 2 5 and 2 6 6 16 6 17 Measure the pickup coil peak voltage and resistance 6 17 and 6 18 NOTE The pickup coil peak voltage inspection is applicable ...

Page 134: ...erminal probe NOTE Do not disconnect the ignition coil coupler 09900 25008 Multi circuit tester set Before using the multi circuit tester and peak volt adap tor be sure to refer to the appropriate instruction manual Turn the ignition switch to the ON position Pull the brake lever Press the starter button and allow the engine to crank for a few seconds and then measure the ignition coil primary pea...

Page 135: ...ct the CDI unit coil coupler 1 Measure the pickup coil peak voltage in the following procedure Connect the multi circuit tester with the peak volt adaptor as follows Brown Probe White Probe 09900 25008 Multi circuit tester set Before using the multi circuit tester and peak volt adap tor be sure to read the appropriate instruction manual Turn the ignition switch to the ON position Measure the picku...

Page 136: ...in specifica tion but on the CDI unit coupler is not within specification re place the wire harness with a new one If both peak voltages are out of specification replace the pickup coil with a new one Y W W R Br W Gererator Peak volt adaptor 1 PICKUP COIL RESISTANCE Remove the trunk 5 4 Disconnect the generator coupler 1 Measure the resistance between the lead wires using the multi circuit tester ...

Page 137: ...ht comes on the circuit of the fuel level indicator light is in good condition If the fuel level indicator light does not come on replace the indicator bulb or repair the circuit connection If the bulb is in good condition the fuel level indicator switch may be faulty Inspect the fuel indicator switch for any faults If any faults are found replace the fuel indicator switch with a new one Remove th...

Page 138: ...CATOR SWITCH INSPECTION Remove the trunk 5 4 Disconnect the oil level indicator switch coupler and remove the oil level indicator switch 1 Measure the continuity between the lead wires of the oil level indicator switch If there is no continuity between the lead wires when the oil level indicator switch is in the low level position file the contact sur face or replace the oil level indicator switch...

Page 139: ...res to a 12 V battery Wait five minutes and feel the thermoelement to see if it has reached approximately 36 C If the appropriate temperature is not reached replace the thermoelement with a new one NOTE This check should be carried out when the engine is cold B Y B W Y W W R W R W R Y Y R R R Y W Y W Y W Y W B W Y W Y W B W B W Y W Thermo element Regulator rectifier Generator Thermo switch Carbure...

Page 140: ... This check should be carried out when the engine is cold THERMOSWITCH Remove the upper fuel tank cover 5 5 Disconnect the thermoswitch coupler and remove the thermoswitch 1 The temperature at which the thermoswitch closes must be within specification Measure the closing temperature of the thermoswitch as follows Connect the thermoswitch to the multi circuit tester and place it in a container of w...

Page 141: ...dometer assembly 5 23 Disassemble the speedometer as shown INSPECTION Check the continuity between the lead wires using the multi cir cuit tester If there is no continuity replace the respective parts 09900 25008 Multi circuit tester set Tester knob indication Continuity test ...

Page 142: ...T BULB REPLACEMENT Remove the front leg shield 5 3 Remove the headlight bulb If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy wa ter to prevent premature bulb failure Headlight bulb 12 V 35 35 W ...

Page 143: ...lb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy wa ter to prevent premature bulb failure 1 2 3 4 FRONT AND REAR TURN SIGNAL LIGHT FRONT AND REAR TURN SIGNAL LIGHT BULB REPLACEMENT Remove the front turn signal light lens 1 and rear turn signal light lens 2 Turn signal light 12 V 10 W ...

Page 144: ...taillight bulb If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy wa ter to prevent premature bulb failure BRAKE LIGHT TAILLIGHT BULB REPLACEMENT Remove the brake light taillight lens Brake light taillight 12 V 21 5 W ...

Page 145: ...he license plate light bulb If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy wa ter to prevent premature bulb failure LICENSE PLATE LIGHT BULB REPLACEMENT Remove the license plate light case mounting screw License plate light 12 V 5 W ...

Page 146: ...The turn signal relay is located behind the front leg shield 5 3 If the turn signal light does not light inspect the bulb or repair the circuit connection If the bulb and circuit connection are OK the turn signal relay may be faulty replace it with a new one NOTE When making this test make sure that the battery is fully charged ...

Page 147: ...tion Color B Lbl Lg L R STARTER BUTTON Position Color B W Y G PUSH DIMMER SWITCH Position Color Gr Y W HI LO HORN BUTTON Position Color G B W PUSH FRONT BRAKE LIGHT SWITCH Position Color O W ON OFF REAR BRAKE LIGHT SWITCH Position Color O W ON OFF WIRE COLOR B Black Lbl Light blue W White Br Brown Lg Light green G Green O Orange Gr Gray R Red B R Black with Red tracer B W Black with White tracer B...

Page 148: ...6 30 ELECTRICAL SYSTEM BATTERY REMOVAL Remove the battery holder cover 1 Remove the battery NOTE Disconnect the battery lead wire first REMOUNTING Remount the battery in the reverse order of removal 1 ...

Page 149: ...PPER LEVEL line 1 Slowly charge the battery with a battery charger at the speci fied current as described below Maximum charging current 0 4 A The charging time for a new battery is determined by the num ber of months that have elapsed since the date of manufacture The manufacture s date is indicated by the six digit stamp 2 located on the battery The day month and year are each indi cated by two ...

Page 150: ...rging the battery be sure to remove the battery from the motorcycle to protect the regulator rectifier against exces sive voltage Use the following formula to correct the specific gravity read ing to 20 C S20 St 0 0007 t 20 Where S20 corrected value of specific gravity 20 C St value of specific gravity read at temperature t C 0 0007 temperature coefficient of specific gravity t temperature in degr...

Page 151: ... on the surface of the plates If this oc curs replace the battery with a new one STORAGE When a battery is not used for a long period of time sulfation may occur When the motorcycle is not used for more than one month especially during the winter season the battery should be charged at least once a month Before charging the battery remove the seal cap from each cell Keep fire and sparks away from ...

Page 152: ...CTRICAL 7 7 BATTERY 7 8 WIRING DIAGRAM 7 9 WIRE HARNESS CABLE AND HOSE ROUTING 7 10 WIRE HARNESS 7 10 CABLE ROUTING 7 12 FUEL SYSTEM HOSE ROUTING 7 14 BATTERY BREATHER HOSE ROUTING 7 15 FRONT BRAKE HOSE ROUTING 7 16 SPECIAL TOOLS 7 17 TIGHTENING TORQUE 7 19 ENGINE 7 19 CHASSIS 7 19 TIGHTENING TORQUE CHART 7 20 SERVICE DATA 7 21 7 ...

Page 153: ...ce Tighten Replace Replace Replace Clean or replace Clean and dry or replace Replace Replace Replace Replace Clean or replace Clean or replace Replace with needle valve seat Clean or replace Engine stalls easily 1 Fouled spark plug 2 Defective CDI unit 3 Clogged fuel hose 4 Clogged carburetor jet 5 Clogged exhaust pipe Clean or replace Replace Clean Clean Clean Engine is noisy Noise appears to com...

Page 154: ... Replace Replace Regap or replace Replace Replace Replace Adjust float height Clean Clean and prime Clean Dirty or heavy exhaust smoke 1 Incorrect engine oil Change Engine lacks power 1 Worn cylinder 2 Worn piston rings 3 Stiff piston rings 4 Gas leaks from crankshaft oil seal 5 Insufficient spark plug gap 6 Clogged carburetor jet 7 Incorrect float chamber fuel level 8 Clogged air cleaner element ...

Page 155: ...buretor joint vacuum pipe joint or intake pipe 3 Improperly operating thermoelement Check and clean Tighten or replace the defec tive part Replace Medium or high speed trouble 1 Clogged main jet 2 Clogged needle jet 3 Improperly set fuel level 4 Improperly operating throttle valve 5 Clogged fuel filter Check and clean Check and clean Check and adjust float height Check and adjust Clean or replace ...

Page 156: ...the rear shock absorber 6 Worn engine mounting bushing 7 Loose engine mounting nuts or bolts Replace Replace Replace Tighten Tighten Replace Tighten Front suspension too soft 1 Weak springs Replace Front suspension too noisy 1 Insufficient grease on the spring and damper 2 Loose front suspension fastener Add Tighten Rear wheel wobbles 1 Distorted wheel rim 2 Defective or incorrect tire 3 Loose rea...

Page 157: ...eign material in brake fluid 6 Clogged return port of master cylinder 7 Brake shoe surface glazed 8 Loose front axle or rear axle nut 9 Worn brake shoes Clean surface with sandpaper Readjust brake pad position or replace Replace Replace Change brake fluid Disassemble and clean mas ter cylinder Clean surface with sandpaper Tighten Replace Brake lever stroke ex cessive 1 Air in hydraulic system 2 In...

Page 158: ...lead connections 2 Shorted grounded or open generator coil 3 Shorted or punctured regulator rectifier Repair replace or tighten Replace Replace Generator charges but charging rate is below the specifica tions 1 Lead wires tend to get shorted or open circuited or loosely connected at terminal 2 Grounded or open circuited stator coils or generator 3 Defective regulator rectifier 4 Defective battery ...

Page 159: ...5 Foreign matter has entered the battery and has be come mixed with the electrolyte 6 Old battery Check the generator regula tor rectifier and circuit con nections and make neces sary adjustments to obtain specified charging operation Replace and correct the charging system Replace Recharge and adjust electro lyte specific gravity Replace the electrolyte re charge the battery and then adjust speci...

Page 160: ...ATOR LIGHT R TL TURN SIGNAL INDICATOR LIGHT L O I OIL LEVEL INDICATOR LIGHT FU FUEL LEVEL INDICATOR LIGHT HI HIGH BEAM INDICATOR LIGHT Black Blue Brown Green Gray Light blue Light green Orange Red White Yellow Black with White tracer Black with Yellow tracer Blue with White tracer Green with White tracer Red with White tracer White with Blue tracer White with Red tracer Yellow with Black tracer Ye...

Page 161: ...7 10 SERVICING INFORMATION WIRE HARNESS CABLE AND HOSE ROUTING WIRE HARNESS 1 Set the wires under the bracket seat striker and the tube frame ...

Page 162: ...SERVICING INFORMATION 7 11 ...

Page 163: ...ICING INFORMATION CABLE ROUTING 1 Pass the throttle cable behind the front brake hose 2 Pass the throttle cable and the rear brake cable through the cable guide 3 Pass the throttle cable through the cable guide ...

Page 164: ...SERVICING INFORMATION 7 13 ...

Page 165: ...A Fuel valve Fuel hose Vacuum hose To the carburetor To the carburetor Clamp Clamp Air vent hose Fuel hose Fuel valve Vacuum hose Engine oil hose Clamp Oil drain hose Oil drain hose VIEW A VIEW B Fuel hose FUEL SYSTEM HOSE ROUTING ...

Page 166: ...SERVICING INFORMATION 7 15 BATTERY BREATHER HOSE ROUTING Breather hose Battery Forward Forward Cushion 65 mm 15 mm Slit position NOTE The slit on the breather hose must face battery side ...

Page 167: ...hose union bolt so that the hose is parallel to the handlebar 5 Tighten the brake hose union bolt so that the hose is contacting the stopper VIEW A VIEW B VIEW C VIEW D A B C D Master cylinder Wire harness Rear brake cable Front brake hose Clamp Hose guide Speedometer cable Throttle cable Front brake hose Clamp Front brake caliper Front brake disc 3 5 1 4 5 3 4 3 5 1 2 Front brake hose Hose guide ...

Page 168: ... 20205 Micrometer 0 25 mm 09900 20508 Cylinder bore gauge set 09900 20605 Dial calipers 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 20803 Thickness gauge 09900 20804 Thickness gauge 09900 20805 Tire depth gauge 09900 21304 V block 100 mm 09900 21602 CCI oil gauge 09900 25008 Multi circuit tester set 09900 28403 Hydrometer 09910 20116 Conrod holder 09910 32812 Crankshaft instal...

Page 169: ...aller set 09930 30102 Sliding hammer 09930 40113 Rotor holder 09940 52860 Front fork oil seal installer 09941 34513 Steering inner race installer 09941 50111 Bearing remover 09941 74910 Bearing installer 09943 88211 Bearing remover installer 09921 20220 Bearing remover set 09930 40131 Rotor holder attachment ...

Page 170: ... bolt 5 5 0 55 Final gear oil level bolt 12 1 2 Oil pump mounting screw 4 0 4 CHASSIS ITEM N m kgf m Steering stem locknut 30 3 0 Handlebar clamp nut 50 5 0 Handlebar set bolt 25 2 5 Front brake caliper mounting bolt 26 2 6 Front brake hose union bolt 23 2 3 Front brake caliper air bleeder valve 7 5 0 75 Front brake caliper housing bolt 32 3 2 Front brake disc bolt 23 2 3 Front brake master cylind...

Page 171: ...fer to this chart Bolt Diameter Conventional or 4 marked bolt 7 marked bolt A mm N m kgf m N m kgf m 4 1 5 0 15 2 3 0 23 5 3 0 3 4 5 0 45 6 5 5 0 55 10 1 0 8 13 1 3 23 2 3 10 29 2 9 50 5 0 12 45 4 5 85 8 5 14 65 6 5 135 13 5 16 105 10 5 210 21 0 18 160 16 0 240 24 0 Conventional bolt 4 marked bolt 7 marked bolt ...

Page 172: ... 1st 2nd R 0 10 0 25 0 80 Piston ring to piston ring groove clear ance 1st 0 03 0 07 Piston pin bore 10 002 10 010 10 030 Piston pin O D 9 995 10 000 9 980 CONROD CRANKSHAFT Unit mm ITEM STANDARD LIMIT Conrod small end I D 14 003 14 011 14 040 Conrod deflection 3 0 Crank web to web width 36 0 0 05 Crankshaft runout 0 05 OIL PUMP ITEM SPECIFICATION Oil pump reduction ratio 30 000 30 1 Oil pump disc...

Page 173: ...tio 13 812 51 15 65 16 Drive belt width 18 4 17 4 Driven face spring free length 110 104 5 CARBURETOR ITEM SPECIFICATION Carburetor type KEIHIN PWS14 Bore size 14 mm I D No 30F0 Idle r min 1 900 200 r min Float height 5 1 0 5 mm Main jet M J 65 Jet needle J N N5GJ 2nd Slow jet S J 42 Air screw A S 2 turns back Throttle cable play 2 4 mm ...

Page 174: ... resistance 50 90 Ω Battery Type designation CB4L B FB4L B Capacity 12 V 14 4 kC 4 Ah 10 HR Standard electrolyte specific gravity 1 280 at 20 C Fuse size 10 A WATTAGE Unit W ITEM SPECIFICATION Headlight HI 35 LO 35 Brake light Taillight 21 5 Turn signal light 10 Speedometer light 2 Fuel level indicator light 2 Turn signal indicator light 2 Oil level indicator light 2 High beam indicator light 1 2 ...

Page 175: ...OT 4 Wheel rim runout Axial 2 0 Radial 2 0 Wheel axle runout Front 0 25 Wheel rim size Front J12 MT3 50 Rear J12 MT3 50 TIRE ITEM STANDARD SPECIFICATION LIMIT Cold inflation tire pressure Solo riding Front 125 kPa 1 25 kgf cm2 175 kPa 1 75 kgf cm2 Dual riding Except for UF50Z Front 125 kPa 1 25 kgf cm2 Rear 230 kPa 2 30 kgf cm2 Tire type Front BRIDGESTONE HOOP B02 G Rear BRIDGESTONE HOOP B02 Tire ...

Page 176: ...aded 91 octane or higher Unleaded gasoline is recommended Fuel tank capacity 6 0 L Engine oil type Use SUZUKI CCI SUPER OIL If not available use a good quality 2 stroke oil rated FC under JASO classification Engine oil tank capacity 1 2 L Final gear oil type SAE 10W 40 Final gear oil capacity 130 ml ...

Page 177: ...UF50K1 AND UF50ZK1 01 MODEL 8 1 UF50K1 AND UF50ZK1 01 MODEL 8 CONTENTS SPECIFICATIONS 8 2 SERVICE DATA 8 4 WIRE HARNESS ROUTING 8 7 ...

Page 178: ...e system Reed valve Number of cylinders 1 Bore 41 0 mm Stroke 37 4 mm Piston displacement 49 cm3 Corrected compression ratio 7 2 1 Carburetor KEIHIN PWS14 Air cleaner Polyurethane foam element Starter system Electric and kick Lubrication system SUZUKI CCI TRANSMISSION Clutch Dry shoe automatic centrifugal type Gearshifting Automatic variable ratio Gear ratios Variable reduction ratio 2 975 1 033 F...

Page 179: ...ake Internal expanding Front tire size 120 70 12 51L Rear tire size 130 70 12 56L ELECTRICAL Ignition type Electronic ignition CDI Spark plug NGK BPR7HS or DENSO W22FPR Battery 12 V 14 4 kC 4 Ah 10 HR Generator Generator Fuse 10 A Headlight 12 V 35 35 W Brake light taillight 12 V 21 5 W Turn signal light 12 V 10 W CAPACITIES Fuel tank 6 0 L Engine oil tank 1 2 L Final gear oil 130 ml NOTE These sp...

Page 180: ...2 10 010 10 030 Piston pin O D 9 995 10 000 9 980 CONROD CRANKSHAFT Unit mm ITEM STANDARD LIMIT Conrod small end I D 14 003 14 011 14 040 Conrod deflection 3 0 Crank web to web width 36 0 0 05 Crankshaft runout 0 05 OIL PUMP ITEM SPECIFICATION Oil pump reduction ratio 30 000 30 1 Oil pump discharge rate 0 8 1 2 ml for 5 minutes at 3 000 r min CLUTCH Unit mm ITEM STANDARD LIMIT Clutch wheel I D 110...

Page 181: ... primary peak voltage More than 150 V Ground W Bl Generator coil resistance Lighting 0 3 1 5 Ω Y W Ground Charging 0 5 2 0 Ω W R Ground Pick up 120 250 Ω W Br Pick up coil peak voltage More than 5 0 V W Br Regulated voltage 13 5 15 0 V at 5 000 r min Generator Max output 125 W at 5 000 r min Starter relay resistance 50 90 Ω Y G W Battery Type designation CB4L B Capacity 12 V 14 4 kC 4 Ah 10 HR Sta...

Page 182: ...SURE SOLO RIDING Rear 175 kPa 1 75 kgf cm2 25 psi COLD INFLATION TIRE Front 125 kPa 1 25 kgf cm2 18 psi PRESSURE DUAL RIDING Except for UF50Z Rear 230 kPa 2 30 kgf cm2 33 psi Tire size Front 120 70 12 51L Rear 130 70 12 56L Tire type Front BRIDGESTONE HOOP B02 G Rear BRIDGESTONE HOOP B02 Tire tread depth Front 1 6 Rear 1 6 SUSPENSION Unit mm ITEM STANDARD LIMIT Front fork stroke 77 Front fork spri...

Page 183: ...vent hose Generator coupler Oil level indicator switch coupler Ignition coil Clamp Clamp Clamp Clamp Clamp Wire harness Wire harness Wire harness battery terminal battery terminal Fuse box Fuel valve Starter relay Front brake hose Rear brake cable Speedometer cable Throttle cable Generator coupler Fuel valve Rear turn signal light lead wire VIEW VIEW Clamp Wiring harness Wiring harness WIRE HARNES...

Page 184: ...188 Prepared by Motorcycle Service Department 2nd Ed March 2001 1st Ed April 2000 Part No 99500 10491 01E Printed in Japan ...

Page 185: ...Printed in Japan Y K1 ...

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