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Suzuki UG110 2021, Service Manual

The Suzuki UG110 2021 Service Manual is available for free download at manualshive.com. This comprehensive manual provides essential information for servicing and maintaining your Suzuki UG110 2021. Download your copy now to ensure optimal performance and longevity of your vehicle.

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6

ELECTRICAL SYSTEM

CONTENTS

CAUTIONS IN SERVICING ..................................................................  6-  2

CONNECTOR ..................................................................................  6-  2
COUPLER .......................................................................................  6-  2
CLAMP ............................................................................................  6-  2
FUSE ...............................................................................................  6-  2
SEMI-CONDUCTOR EQUIPPED PART ..........................................  6-  2
BATTERY .........................................................................................  6-  3
CONNECTING THE BATTERY ........................................................  6-  3
WIRING PROCEDURE ....................................................................  6-  3
USING THE MULTI CIRCUIT TESTER ............................................  6-  3

LOCATION OF ELECTRICAL COMPONENTS ...................................  6-  4
CHARGING AND LIGHTING SYSTEM ................................................  6-  5

DESCRIPTION ................................................................................  6-  5
TROUBLESHOOTING .....................................................................  6-  6
INSPECTION ...................................................................................  6-  7

STARTER SYSTEM ..............................................................................  6-  9

DESCRIPTION ................................................................................  6-  9
TROUBLESHOOTING .....................................................................  6-10
STARTER MOTOR REMOVAL AND DISASSEMBLY .....................  6-11
STARTER MOTOR INSPECTION ...................................................  6-11
STARTER MOTOR REASSEMBLY .................................................  6-12
STARTER RELAY INSPECTION .....................................................  6-13

IGNITION SYSTEM ..............................................................................  6-14

DESCRIPTION ................................................................................  6-14
TROUBLESHOOTING .....................................................................  6-15
INSPECTION ...................................................................................  6-16

FUEL METER AND FUEL LEVEL GAUGE .........................................  6-19

FUEL METER ..................................................................................  6-19
FUEL LEVEL GAUGE .....................................................................  6-19

OIL LEVEL INDICATOR SWITCH ........................................................  6-21
THERMOELEMENT AND CARBURETOR HEATER ...........................  6-21

INSPECTION ...................................................................................  6-21

SPEEDOMETER ..................................................................................  6-23

REMOVAL AND DISASSEMBLY ....................................................  6-23
INSPECTION ...................................................................................  6-23

LAMPS .................................................................................................  6-24

HEADLIGHT ....................................................................................  6-24
FRONT AND REAR TURN SIGNAL LIGHTS .................................  6-24
LICENSE PLATE LIGHT .................................................................. 6-25
BRAKE LIGHT/ TAILLIGHT ............................................................  6-25
TRUNK LIGHT .................................................................................. 6-26

RELAYS ................................................................................................  6-26

STARTER RELAY ............................................................................  6-26
TURN SIGNAL RELAY ....................................................................  6-26

SWITCHES ...........................................................................................  6-26

IGNITION SWITCH REMOVAL ........................................................ 6-26
INSPECTION .................................................................................... 6-27

BATTERY ..............................................................................................  6-28

REMOVAL .......................................................................................  6-28
REMOUNTING ................................................................................  6-28
SPECIFICATIONS ...........................................................................  6-29
INITIAL CHARGING ........................................................................  6-29
SERVICING .....................................................................................  6-30
RECHARGING OPERATION ..........................................................  6-31

ELECTRICAL SYSTEM   6-1

Summary of Contents for UG110 2021

Page 1: ...UG110 9 9 5 0 0 1 1 1 8 0 0 1 E...

Page 2: ...nual and the actual motorcycle Illustrations in this manual are used to show the basic principles of operation and work procedures They may not represent the actual motorcycle exactly in detail This m...

Page 3: ...e first page of each section 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 serv...

Page 4: ...SE A 99000 25010 Apply SUZUKI SILICONE GREASE 99000 25100 Apply SUZUKI MOLY PASTE 99000 25140 Apply THERMO GREASE 99000 25300 Apply SUZUKI BOND 1215 99000 31110 Apply THREAD LOCK 1322 99000 32110 Appl...

Page 5: ...ZUKI UG110Y 2000 MODEL 1 4 SERIAL NUMBER LOCATION 1 4 FUEL AND OIL RECOMMENDATIONS 1 4 FUEL 1 4 ENGINE OIL 1 5 FINAL GEAR OIL 1 5 BRAKE FLUID 1 5 FRONT FORK OIL 1 5 BREAK IN PROCEDURES 1 5 INFORMATION...

Page 6: ...ted 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 PRECAUTI...

Page 7: ...lts and nuts tighten the larger sizes first Always tighten the bolts and nuts from the inside working out diagonally and to the specified tightening torque Whenever you remove oil seals gaskets packin...

Page 8: ...the crankcase These numbers are required especially for registering the machine and ordering spare parts FUEL AND OIL RECOMMENDATIONS Be sure to use the specified fuel and oils Fuel and oil specifica...

Page 9: ...ring 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 m...

Page 10: ...ION INFORMATION LABELS 1 Warning safety label 2 Engine starting label 3 Warning screen label 4 Tire pressure label 5 Fuel caution plate For E 02 6 Loading capacity label 7 Anti tampering label 8 ID pl...

Page 11: ...ankcase reed valve Number of cylinders 1 Bore 52 5 mm Stroke 52 2 mm Displacement 113 cm3 Corrected compression ratio 6 8 1 Carburetor MIKUNI VM18SH single Air cleaner Polyurethane foam element Starte...

Page 12: ...g 12 BTDC at 1 800 r min Spark plug NGK BPR7HS or DENSO W22FPR Battery 12 V 14 4 kC 4 Ah 10 HR Generator A C generator Fuse 10 A Headlight 12 V 35 35 W Position Parking light 12 V 5 W Brake light Tail...

Page 13: ...GENERAL INFORMATION 1 9 COUNTRY AND AREA CODES The following codes stand for the applicable country ies and area s CODE COUNTRY OR AREA E 02 UK E 04 France E 19 EU...

Page 14: ...ER HEAD NUTS AND EXHAUST PIPE NUTS 2 4 CYLINDER HEAD AND CYLINDER 2 4 SPARK PLUG 2 5 FUEL HOSE 2 6 AIR CLEANER 2 6 CARBURETOR 2 7 OIL PUMP 2 8 FINAL GEAR OIL 2 8 BRAKES 2 9 TIRES 2 11 STEERING 2 12 FR...

Page 15: ...l km 1 000 6 000 12 000 18 000 24 000 miles 600 4 000 7 500 11 000 15 000 Item months 1 6 12 18 24 Cylinder head nuts and exhaust pipe nuts T T T T Cylinder head and cylinder C C C C Spark plug R R R...

Page 16: ...cated below NOTE Before lubricating each part clean off any rusty spots and wipe off any grease oil dirt or grime Lubricate exposed parts which are subject to rust with a rust preventative spray espec...

Page 17: ...6 000 km 6 months thereafter Cylinder head nuts when they are not tightened to the specified torque may result in leakage of the compressed mixture and reduce output Tighten the cylinder head nuts as...

Page 18: ...easure the spark plug gap If out of specification adjust the gap 4 Spark plug gap Standard 0 6 0 7 mm 2 09900 20804 Thickness gauge ELECTRODES Check the condition of the electrodes If the electrode is...

Page 19: ...fuel consumption Check and clean the air cleaner ele ment in the following manner Remove the air cleaner case cover 1 Remove the air cleaner element 2 Fill a washing pan of a proper size with a non f...

Page 20: ...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 i...

Page 21: ...n Check whether the red mark 1 on the oil pump control lever is aligned with the index mark 2 when the throttle grip is posi tioned as above If the marks are not aligned loosen the locknut 3 and turn...

Page 22: ...Do not use or mix different types of fluid such as silicone based and petroleum based fluids Do not use any brake fluid taken from old used or unsealed containers Never reuse brake fluid left over fr...

Page 23: ...alve 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 re...

Page 24: ...he indicator 1 is within the range A embossed on the crankcase If the indicator goes beyond the range the brake shoe assem bly should be replaced with a new set of shoes TIRES Inspect initially at 1 0...

Page 25: ...defects are found replace the defective parts with a new one REAR SUSPENSION Inspect every 12 000 km 12 months Inspect the rear shock absorber for oil leakage and the bushings and crankcases for wear...

Page 26: ...f m 1 Front axle nut 42 4 2 2 Handlebar clamp nut 50 5 0 3 Handlebar set bolt 25 2 5 4 Steering stem locknut 30 3 0 5 Front fork clamp bolt 23 2 3 6 Front brake master cylinder mounting bolt 10 1 0 7...

Page 27: ...2 14 PERIODIC MAINTENANCE...

Page 28: ...check the operation of the drive train Follow the proce dures listed NOTE Warm up the engine INITIAL ENGAGEMENT Connect the multi circuit tester to the high tension cord Start the engine While seated...

Page 29: ...m as possible Fully open the throttle for a brief period and note the maximum engine speed sustained during the test cycle 4 Lock up speed r min 5 100 6 100 r min 5 Do not apply full power for more th...

Page 30: ...PISTON 3 16 CRANKSHAFT AND CONROD 3 18 REED VALVE 3 19 CLUTCH SHOE MOVABLE DRIVEN FACE 3 20 MOVABLE DRIVE 3 25 KICK STARTER 3 27 GEAR BOX COVER 3 29 BEARINGS 3 30 OIL SEALS 3 33 ENGINE MOUNTING BUSHIN...

Page 31: ...44 Fixed drive fan 3 11 Starter driven gear 3 11 Fixed drive face 3 11 Movable drive face 3 12 3 43 Clutch housing 3 12 3 43 Clutch shoe assembly 3 12 Drive belt 3 12 3 43 Kick starter lever 3 27 3 2...

Page 32: ...rubber band 1 Disconnect the battery lead wire 2 Remove the trunk along with the seat 75 6 Remove the frame covers 75 7 Disconnect the starter motor lead wire coupler 3 engine ground wire coupler 4 th...

Page 33: ...r cap 4 with the throttle cable and throttle valve Remove the oil pump cover 5 Loosen the oil pump cable adjuster locknut 6 and remove the oil pump cable from the bracket Disconnect the oil pump cable...

Page 34: ...e the air cleaner case 74 12 Remove the rear shock absorber lower mounting bolt Remove the left and right pillion rider footrests 1 and 2 Remove the engine mounting nut 3 Remove the engine mounting sh...

Page 35: ...he engine mounting nut make sure the front wheel is elevated Tighten the rear shock absorber lower mounting bolt 4 to the specified torque Rear shock absorber lower mounting bolt 32 N m 3 2 kgf m Plac...

Page 36: ...ap 1 Remove the spark plug 2 using the special tool 2 09930 10120 Spark plug socket wrench set Remove the ignition coil 3 Disconnect the air control valve hose 4 and oil hose 5 from the carburetor Rem...

Page 37: ...8 ENGINE Remove the oil pump gear 1 Remove the oil hose guide 2 Disconnect the oil hoses Remove the intake pipe by removing the two bolts and two twist off bolts 3 Remove the reed valve 4 and gaskets...

Page 38: ...9 Disconnect the fuel pump vacuum hose 1 Remove the clutch cover 2 Remove the cooling fan cover 3 Remove the cylinder cover 4 Remove the cooling fan 5 while holding the kick starter with a 32 mm offse...

Page 39: ...or holder Remove the generator rotor using the special tool 2 09920 13120 Crankcase separating tool Remove the key 1 Remove the stator coil 2 and pickup coil 3 Loosen the cylinder head nuts diagonally...

Page 40: ...long nose pliers Remove the piston pin piston and piston pin bearing Remove the starter motor 1 Remove the starter pinion gear assembly 2 Remove the kick starter nut 3 while holding the kick starter w...

Page 41: ...1 and movable drive face 2 Remove the clutch housing nut using the special tool 2 09930 40113 Rotor holder Remove the clutch housing 3 Remove the clutch shoe assembly 3 and drive belt 4 Drain the gear...

Page 42: ...rake shoes 1 Remove the brake cam lever 2 return spring 3 brake lining wear limit indicator 4 and brake camshaft 5 Remove the spacer 6 Remove the gear box cover Remove the driveshaft using the special...

Page 43: ...center stand shaft 4 Remove the center stand 5 Remove the crankcase screws Separate the left and right crankcases using the special tool 2 09920 13120 Crankcase separating tool Remove the shim 6 Remov...

Page 44: ...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...

Page 45: ...e cylinder and use an oversized piston or replace both the cyl inder and the piston with new ones 4 Piston to cylinder clearance Service Limit 0 120 mm CARBON REMOVAL Remove carbon from the crown of t...

Page 46: ...sure the piston pin outside diameter at three positions using the micrometer If any measurement exceeds the service limit replace the piston pin with a new one 2 09900 20205 Micrometer 0 25 mm 4 Pisto...

Page 47: ...eds the service limit correct the runout or replace the crankshaft assembly with a new one 2 09900 20701 Magnetic stand 09900 20606 Dial gauge 1 100 mm 09900 21304 V block set 100 mm 4 Crankshaft runo...

Page 48: ...e 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 cali pers If the c...

Page 49: ...lder Remove the clutch shoe nut 1 while holding down the clutch shoe assembly as shown Gradually ease apart the clutch shoe assembly to counter the clutch spring force Quickly releasing the clutch sho...

Page 50: ...ade screwdriver to pry up the movable driven face spring guide Remove the pins 4 movable driven face 5 and fixed driven face 6 Remove the bearing using the special tools 2 09923 73210 Bearing remover...

Page 51: ...nspect the clutch springs for stretched or broken coils If any damages are found replace the clutch springs as a set 5 Replace the clutch shoes and clutch springs as a set Inspect the clutch housing s...

Page 52: ...and the sliding surface and sliding pins for wear or damage 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...

Page 53: ...UKI SUPER GREASE A to the cam where the pins are placed and surface of the driven face as shown 99000 25010 SUZUKI SUPER GREASE A Position the new two O rings 2 NOTE Clean and free of any grease after...

Page 54: ...ith a new one ROLLER AND SLIDING SURFACE Inspect each roller and its sliding surface for wear or damage If any damages are found replace the rollers as a set 1 Movable drive face 2 Roller 3 Movable dr...

Page 55: ...limit replace the drive belt with a new one 4 Drive belt width Service Limit 18 5 mm 5 Always keep the drive belt away from grease oil etc REASSEMBLY Mount the three dampers 1 on the movable drive pl...

Page 56: ...1 Kick starter shaft 2 Kick starter spring 3 Spacer 4 Circlip 5 Kick starter lever 6 Kick starter drive gear DISASSEMBLY Remove the oil separator 1 Remove the kick starter lever Remove the circlip fro...

Page 57: ...pply SUZUKI SUPER GREASE A onto the inside of the kick starter shaft spacer 99000 25010 SUZUKI SUPER GREASE A Apply a light coat of SUZUKI SUPER GREASE A onto the end of the kick starter shaft 99000 2...

Page 58: ...10 SUZUKI SUPER GREASE A Install the kick starter drive gear 1 Align the projection A with the groove of the clutch cover Install the kick starter lever to the kick starter shaft as shown GEAR BOX COV...

Page 59: ...a new one RIGHT REAR AXLE SHAFT BEARING Remove the bearing retainer 1 Remove the right rear axle shaft bearing using the special tool 2 09921 20220 Bearing remover set 20 mm 5 Replace the removed bear...

Page 60: ...haft bearing using the special tool 2 09913 70210 Bearing installer set 30 mm LEFT DRIVESHAFT BEARING Remove the left driveshaft bearing using the special tool 2 09921 20220 Bearing remover set 17 mm...

Page 61: ...1 20220 Bearing remover set 15 mm Install the left idle shaft bearing using the special tool 2 09913 70210 Bearing installer set 25 mm RIGHT CRANKSHAFT BEARING Remove the right crankshaft bearing usin...

Page 62: ...esult in leakage of the fuel air mixture or gear oil Inspect the oil seal and if it is damaged replace it with a new one Install the oil seals into the crankcases and gear box cover as shown below 5 R...

Page 63: ...d oil seal with a new one Install the drive shaft oil seal into the left crankcase slowly using the special tool 2 09913 70210 Bearing installer set 30 mm CRANKSHAFT OIL SEALS Remove the left cranksha...

Page 64: ...t crankcase slowly using the special tool 2 09913 70210 Bearing installer set 25 mm NOTE Align the oil seal with the edge A of the crankcase as shown Install the left crankcase oil seal using the spec...

Page 65: ...new one Press out the each bushing in a vise using two steel tubes of the appropriate size as shown 5 Replace the removed bushing with a new one Install the bushings using two steel tubes of the appro...

Page 66: ...HIM SELECTION After mounting the crankshaft into the right crankcase mea sure the length A between the right crankcase end and left end of the crank web Measure the length B between the left crankcase...

Page 67: ...aft installer 09910 20116 Conrod holder 09911 11310 Crankshaft installer attachment Tighten the crankcase screws diagonally NOTE After the crankcase screws have been tightened make sure that the crank...

Page 68: ...KI SUPER GREASE A Install the new left crankcase oil seal 1 using the special tool 2 09951 16080 Bearing installer CENTER STAND Apply grease to the spring hooks and center stand shaft sliding surfaces...

Page 69: ...e shaft gear 1 with the thrust washer 2 into the gear box Install the rear axle shaft final driven gear 3 Install the thrust washer 4 and the new O ring 5 1 Gear box cover 2 O ring 3 Rear axle shaft 4...

Page 70: ...e bolts to the specified torque in the ascending order of numbers Gear box cover bolt 22 N m 2 2 kgf m Install rear axle shaft spacer 3 in the correct direction Apply a light coat of SUZUKI SUPER GREA...

Page 71: ...to the brake cam Install the return spring and brake cam lever onto the brake cam 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 7...

Page 72: ...ace to provide the maximum drive belt clearance 5 The drive belt should be installed so that the arrows on the drive belt periphery point in the normal turning direction The drive belt contact surface...

Page 73: ...nd without slipping PISTON Install the piston rings onto the piston 1st Keystone ring 2nd Keystone ring and Expander ring NOTE The piston rings should be installed with the mark facing up Position the...

Page 74: ...n the cylinder head nuts diagonally as shown and to the specified torque Cylinder head nut 23 N m 2 3 kgf m GENERATOR Remove any grease from the tapered portion of the crankshaft and also from the gen...

Page 75: ...enerator lead wire CLUTCH COVER Install the dowel pins 1 and new gasket 2 Install the clutch cover NOTE Install the wire clamp with the bolt A INTAKE PIPE Install the clamps as shown NOTE Be sure to u...

Page 76: ...jection 1 into the groove 2 EXHAUST PIPE MUFFLER Tighten the exhaust pipe nuts to the specified torque Exhaust pipe nut 23 N m 2 3 kgf m Tighten the muffler mounting bolts to the specified torque Muff...

Page 77: ...4 7 FUEL VALVE 4 8 INSPECTION AND REMOVAL 4 8 REMOUNTING 4 8 FUEL PUMP 4 9 INSPECTION AND REMOVAL 4 9 REMOUNTING 4 9 CARBURETOR 4 10 CONSTRUCTION 4 10 SPECIFICATIONS 4 11 I D NO LOCATION 4 11 REMOVAL...

Page 78: ...nt excessive supply FUEL PUMP Vacuum pulsations from the crankcase are used to operate the pump diaphragm A When vacuum is applied to the diaphragm A fuel is drawn from the fuel valve into the diaphra...

Page 79: ...pressure causes the fuel valve diaphragm to compress its spring opening the fuel passageway and allowing the fuel to flow to the fuel pump When the engine has stopped the spring pushes against the va...

Page 80: ...jet and the air control valve is metered by the pilot screw to produce air fuel mixture most appropriate for the current atmospheric temperature and then jetted into the main bore When temperature is...

Page 81: ...sparks and flames away from gasoline Remove the leg shield cover rear leg shield 75 9 Disconnect the fuel level gauge coupler 1 Remove the frame pipe 2 Remove the fuel tank mounting bolts Disconnect t...

Page 82: ...R If the fuel filter is dirty with sediment fuel will not flow smoothly and loss in engine power may result Clean the fuel filter with compressed air Also check the fuel filter for cracks REMOUNTING R...

Page 83: ...t the oil hose 2 NOTE Insert a suitable plug into the hole of the oil tank Remove the oil tank INSPECTION OIL LEVEL INDICATOR SWITCH 7 7 7 7 76 22 REMOUNTING Remount the oil tank in the reverse order...

Page 84: ...oint Properly route the fuel valve hoses 77 12 Remove the lower leg shield 75 5 Disconnect the fuel valve vacuum hose 1 from the carburetor Disconnect the fuel hose 2 from the fuel pump Apply negative...

Page 85: ...flows FUEL PUMP INSPECTION AND REMOVAL Gasoline is highly flammable and explosive Keep heat sparks and flames away from gasoline Disconnect the fuel hose 1 from the carburetor and then put it into a r...

Page 86: ...p cap 2 Throttle valve spring 3 Jet needle 4 Throttle valve 5 Thermoelement 6 Air screw 7 Throttle stop screw 8 Pilot jet 9 Needle jet 0 Main jet A Needle valve B Float C O ring D Float chamber E Ther...

Page 87: ...c cording to its specifications SPECIFICATIONS ITEM SPECIFICATIONS Carburetor type MIKUNI VM18SH Bore size 18 mm I D No 16F1 Idle r min 1 800 200 r min Float height 9 5 0 5 mm Main jet M J 75 Jet need...

Page 88: ...se 3 from the carburetor Remove the carburetor top cap 4 Disconnect the carburetor heater terminal lead wire 5 Disconnect the air control valve hose 6 Disconnect the thermoelement lead wire coupler 7...

Page 89: ...n the throttle valve 2 and then remove the throttle valve 2 along with the jet needle 3 and throttle valve spring 4 Separate the jet needle 3 and throttle valve 2 5 Spring retainer 6 Spring Disconnect...

Page 90: ...d pilot jet 8 5 Do not use wire to clean the passages and jets Only use compressed air Remove the throttle stop screw 9 and air screw 0 NOTE Before removing the air screw 9 its setting must be determi...

Page 91: ...lar trouble will occur Conversely if the needle valve sticks the gasoline will not flow into the float chamber Clean the float chamber and float parts with gasoline If the needle valve is worn as show...

Page 92: ...asoline in the carburetor Remove air completely from the fuel level gauge With the level gauge held vertical lower the gauge slowly and align the datum point 1 with the gauge graduation Wait until the...

Page 93: ...to the specified torque 99000 25300 THERMO GREASE Carburetor heater 3 N m 0 3 kgf m Install the throttle valve with the top cap Align the slit 1 on the throttle valve with the projection 2 on the carb...

Page 94: ...shown If air does not flow out replace the air control valve with a new one Carry out the above inspection under the conditions that the air control valve temperature is 20 C and when it is 0 C Check...

Page 95: ...ring the proce dure Remove the trunk 75 6 Disconnect the oil hose 1 from the oil tank Connect the suitable plug to the outlet of the oil tank Fill the CCI oil gauge with SUZUKI CCI SUPER OIL Connect t...

Page 96: ...he trunk 75 6 Remove the oil strainer 1 Inspect the oil strainer for clogging If the oil strainer is clogged replace it with a new one Install the oil strainer 1 in the correct direction as shown NOTE...

Page 97: ...AKE DISC INSPECTION 5 20 MASTER CYLINDER REMOVAL AND DISASSEMBLY 5 20 MASTER CYLINDER INSPECTION 5 21 MASTER CYLINDER REASSEMBLY AND REMOUNTING 5 22 FRONT FORK 5 24 CONSTRUCTION 5 24 REMOVAL AND DISAS...

Page 98: ...ASSIS EXTERIOR PARTS CONSTRUCTION Front leg shield cover Front leg shield Brace To frame Leg shield cover Lower leg shield Fuel lid Right side leg shield Left side leg shield Maintenance lid Rear leg...

Page 99: ...stener core 1 Pull out the fastener INSTALLATION Push the bottom A of fastener core as shown Right frame cover Insert the fastener into the installation hole securely Push in the head of fastener core...

Page 100: ...INSTALLATION Push the bottom A of fastener core as shown Insert the fastener into the installation hole securely and then push the faster core REMOVAL FRONT LEG SHIELD COVER Remove the front leg shiel...

Page 101: ...side leg shields 75 4 Remove the lower leg shield 1 Hooked part FRONT LEG SHIELD Remove the front leg shield cover and side leg shields 75 4 Disconnect the headlight coupler 1 Remove the screws 2 Rem...

Page 102: ...eat using the key Remove the seat 1 TRUNK Remove the rear carrier 1 Remove the bolts and screws Remove the oil tank cap 2 Disconnect the engine oil drain hose 3 Disconnect the trunk light lead wire co...

Page 103: ...ve the trunk 75 6 Remove the left and right side leg shields 75 4 Remove the lower leg shield 75 5 Remove the stand grip 1 Disconnect the brake light taillight lead wire coupler 2 Remove the frame cov...

Page 104: ...5 8 CHASSIS Separate the left frame cover right frame cover and upper frame cover REAR FENDER Remove the frame covers 75 7 Remove the CDI unit 1 Remove the rear fender 2 Hooked part...

Page 105: ...h shutter 2 Remove the side leg shields and lower leg shileds 75 4 and 5 Remove the frame covers 75 7 Remove the leg shield cover rear leg shield 3 Separate the reg shield covers 1 2 and rear leg shie...

Page 106: ...peedometer gearbox 8 Brake disc A Front axle nut B Brake disc bolt REMOVAL Disconnect the speedometer cable 1 ITEM N m kgf m A 42 4 2 B 23 2 3 Remove the front axle nut 2 Raise the front wheel off the...

Page 107: ...rotation If any abnormal noise occurs or rough movement is noted replace the wheel bearings with new ones Remove the wheel bearings as follows Remove the dust seal using the special tool 2 09913 5012...

Page 108: ...nout exceeds the service limit replace the front axle with a new one 2 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block set 100 mm 4 Wheel axle runout Service Limit 0 25...

Page 109: ...disc is clean and free of any grease Apply THREAD LOCK SUPER 1360 to the brake disc bolts and tighten them to the specified torque 99000 32130 THREAD LOCK SUPER 1360 Brake disc mounting bolt 23 N m 2...

Page 110: ...5 14 CHASSIS Have the stopper 1 on the speedometer gearbox touch the lug 2 on the right front fork leg FRONT AXLE Tighten the front axle nut 1 to the specified torque Front axle nut 42 N m 4 2 kgf m...

Page 111: ...o get dust into the fluid When washing brake components use new brake fluid Never use cleaning solvent A contaminated brake disc or brake pad reduces braking performance Discard contaminated pads and...

Page 112: ...perates correctly and then check the brake fluid level BRAKE FLUID REPLACEMENT Place the motorcycle on a level surface and keep the handle bars straight Remove the wind screen 75 32 Remove the master...

Page 113: ...of the in spection window 5 Bleed air from the brake fluid circuit 72 10 BRAKE CALIPER REMOVAL AND DISASSEMBLY Disconnect the brake hose from the brake caliper by removing the brake hose union bolt 1...

Page 114: ...ay attention to the following points Wash the caliper bore and brake caliper piston with new brake fluid Thoroughly wash the dust seal groove and piston seal groove Specification and classification DO...

Page 115: ...e caliper mounting bolts 1 and the brake hose union bolt 2 to the specified torque Brake caliper mounting bolt 1 26 N m 2 6 kgf m Brake hose union bolt 2 23 N m 2 3 kgf m NOTE Before remounting the br...

Page 116: ...runout Service Limit 0 30 mm If either measurement exceeds the service limit replace the brake disc with a new one 75 11 and 13 Install the front wheel 75 13 and 14 MASTER CYLINDER REMOVAL AND DISASSE...

Page 117: ...09900 06108 Snap ring pliers Remove the washer 5 piston secondary cup 6 and return spring 7 Remove the master cylinder reservoir cap 8 and diaphragm 9 MASTER CYLINDER INSPECTION MASTER CYLINDER Inspe...

Page 118: ...brake fluid before reassembly Do 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 s...

Page 119: ...NOTE When remounting the master cylinder onto the handlebars tighten the upper clamp bolt first After touching the brake hose union to the stopper A tighten the brake hose union bolt 2 to the specifie...

Page 120: ...16 Remove the front wheel 75 10 Remove the front fender 1 1 Cap 2 O ring 3 Front fork spring 4 Damper rod ring 5 Damper rod 6 Spring 7 Inner tube 8 Dust seal 9 Oil seal stopper ring 0 Oil seal A Bushi...

Page 121: ...nt fork cap bolt 2 Remove the spring 3 Invert the front fork and stroke it several times to drain out the fork oil Hold the front fork in the inverted position for a few minutes to allow the fork oil...

Page 122: ...ch set 09940 34520 T handle Remove the damper rod 2 and rebound spring 3 from the inner tube Separate the inner tube from the outer tube Remove the rubber bushing 4 Remove the oil seal by using the sp...

Page 123: ...ew one 4 Front fork spring free length Service Limit 267 mm INNER AND OUTER TUBES Inspect the inner tube sliding surface and outer tube sliding sur face for any scuffing or damage If any damages are f...

Page 124: ...be Apply THREAD LOCK 1342 to the damper rod bolt 2 and then tighten it to the specified torque with the special tools 99000 32050 THREAD LOCK 1342 2 09900 00410 Hexagon wrench set 09940 34520 T handle...

Page 125: ...fied fork oil into the inner tube 3 99000 99044 10G SUZUKI FORK OIL G10 10 4 Front fork oil capacity each leg 81 ml Hold the front fork leg in a vertical position and adjust the fork oil level using t...

Page 126: ...all the front fork to the motorcycle Align the upper surface of the inner tube A with the upper surface of the steering stem B Tighten the front fork clamp bolts 3 to the specified torque Front fork c...

Page 127: ...CHASSIS 5 31 HANDLEBAR COVERS CONSTRUCTION 1 Wind screen 2 Center handlebar cover 3 Front handlebar cover 4 Rear handlebar cover...

Page 128: ...e the screws Remove the front handlebar cover 1 Hooked part Remove the wind screen 2 Remove the center handlebar cover 3 Hooked part Remove the handlebar right switch screws Disconnect the throttle ca...

Page 129: ...speedom eter assembly REMOUNTING Remount the handlebar covers and wind screen in the reverse order of removal Pay attention to the following points Install the handlebar right switch NOTE Apply SUZUKI...

Page 130: ...assembly 75 20 Remove the front fork 75 24 Remove the cable clamp 1 ITEM N m kgf m A 50 5 0 B 25 2 5 C 30 3 0 Remove the rear view mirror 2 Remove the handlebar left switch 1 Handlebars 2 Washer 3 Ste...

Page 131: ...lead wire couplers Remove the handlebars Remove the steering stem locknut using the special tool 2 09910 60611 Universal clamp wrench Remove the washer 1 and steering stem nut 2 Remove the steering s...

Page 132: ...o 2 1 Remove the speedometer cable guide 2 INSPECTION Inspect the removed parts for the following abnormalities If any damages are found replace the respective part with a new one Steering race wear a...

Page 133: ...3 Steering inner race installer Press in the lower inner race using the special tool 2 09941 74910 Bearing installer Apply grease to the upper and lower outer races 99000 25010 SUZUKI SUPER GREASE A I...

Page 134: ...hen tighten them to the specified torque Set bolt 4 25 N m 2 5 kgf m Clamp nut 5 50 N m 5 0 kgf m NOTE Hold the front fork legs move them back and forth and make sure the steering is not loose 5 After...

Page 135: ...sing a jack or wooden block Remove the exhaust pipe muffler assembly 73 7 ITEM N m kgf m A 75 7 5 B 10 1 0 C 32 3 2 Remove the rear axle nut 1 Remove the rear wheel 1 Rear wheel 2 Brake shoe 3 Brake c...

Page 136: ...one The value of this limit is indicated inside the drum 4 Brake drum I D Service Limit 110 7 mm BRAKE SHOE Inspect the brake shoes for wear or damage If it is worn or dam aged replace the brake shoes...

Page 137: ...k absorber in the reverse order of removal and disassembly Pay attention to the following points Apply SUZUKI SUPER GREASE A to the brake cam and pin and then install the brake shoes 99000 25010 SUZUK...

Page 138: ...alve position Even though the tire is refitted to the original position after repair ing the puncture the tire may have to be balanced again since such a repair can cause imbalance INSPECTION WHEEL Wi...

Page 139: ...ot 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 t...

Page 140: ...r 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 installin...

Page 141: ...adjustment NOTE 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 distance between the rim line and wheel rim varies this indi...

Page 142: ...RELAY INSPECTION 6 13 IGNITION SYSTEM 6 14 DESCRIPTION 6 14 TROUBLESHOOTING 6 15 INSPECTION 6 16 FUEL METER AND FUEL LEVEL GAUGE 6 19 FUEL METER 6 19 FUEL LEVEL GAUGE 6 19 OIL LEVEL INDICATOR SWITCH 6...

Page 143: ...oseness or bends Inspect each terminal for corrosion and contamination CLAMP Refer to WIRE CABLE AND HOSE ROUTING for proper clamping procedures 7 9 to 15 Bend the clamp properly as shown in the illus...

Page 144: ...to disconnect the battery lead wire first When connecting the battery lead wires be sure to connect the battery lead wire first If the terminal is corroded remove the battery pour warm water over it a...

Page 145: ...tery 2 Fuse 3 Turn signal relay 4 Horn 5 Oil level indicator switch 6 Carburetor thermo switch 7 CDI unit 8 Carburetor heater 9 Thermoelement 0 Fuel level gauge A Ignition switch B Starter relay C Ign...

Page 146: ...AC current as the generator rotor turns The AC current which is generated in the charging coil flows to the regulator rectifier where it is changed to the DC current The DC current then charges the ba...

Page 147: ...6 6 ELECTRICAL SYSTEM 6 7 6 7 6 8 6 8 TROUBLESHOOTING...

Page 148: ...to avoid tester damage Do not turn the ignition switch to the ON position when measuring the current When checking to find the excessive current leak remove the couplers and connectors one by one chec...

Page 149: ...4 1 0 REGULATOR RECTIFIER Remove the right side leg shield 5 4 Disconnect the regulator rectifier coupler 1 and remove the regulator rectifier 2 Measure the voltage between the terminals using the mu...

Page 150: ...ear brakes ignition switch and battery Pressing the starter button while squeezing the front or rear brake lever energizes the starter relay causing the contact points to close thus completing the cir...

Page 151: ...lever when pushing the starter button Y G 6 13 Correct 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...

Page 152: ...ER MOTOR INSPECTION CARBON BRUSH Inspect the carbon brushes for abnormal wear cracks or smooth ness in the brush holder If any damages are found replace the brush assembly with a new one 1 Starter mot...

Page 153: ...the armature shaft If there is no continuity between the segments or there is conti nuity between the segments and shaft replace the armature with a new one 09900 25008 Multi circuit tester set Tester...

Page 154: ...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 k...

Page 155: ...nergy is released in a single surge at the specified ignition timing point and the current flows through the primary side of the ignition coil A high voltage is induced in the secondary windings of th...

Page 156: ...W at the CDI unit with the ignition switch in the ON position 6 16 2 5 Faulty CDI unit Faulty CDI unit Faulty ignition coil Improper spark plug cap connection Improper ignition coupler connection Brok...

Page 157: ...0 25008 Multi circuit tester set When using the multi circuit tester and peak volt adap tor refer to the appropriate instruction manual Turn the ignition switch to the ON position and grasp the front...

Page 158: ...e multi circuit tester Connect the multi circuit tester with the peak volt adaptor as follows Probe White lead wire Probe Brown lead wire 09900 25008 Multi circuit tester set When using the multi circ...

Page 159: ...the peak voltage on the pickup coil lead wire is within specifi cation but on the CDI unit coupler is not within specification replace the wire harness with a new one If both peak voltages are out of...

Page 160: ...ermine the accuracy of the fuel meter in the E empty and F full positions Connect a 90 ohm resistor between the Y B and B W lead wires The fuel meter is operating correctly if the needle moves to E em...

Page 161: ...level gauge with a new one The relation between the position of the fuel level gauge float and the resistance is shown in the following table Float position Resistance A F Full 4 10 B E Empty 90 100...

Page 162: ...T Remove the trunk 5 6 Disconnect the thermoelement coupler 1 Connect the thermoelement 2 lead wires to a 12 V battery Wait five minutes and feel the thermoelement to see if it has reached approximate...

Page 163: ...is cold CARBURETOR THERMO SWITCH The temperature at which the thermo switch closes must be within specification Measure the closing temperature of the thermo switch as follows Disconnect the carburet...

Page 164: ...and 33 Remove the speedometer assembly 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 th...

Page 165: ...ou touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure Unhook the headlight bulb socket holder spring 2 and remove t...

Page 166: ...ur hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure BRAKE LIGHT TAILLIGHT BULB REPLACEMENT Remove the brake light taillight lens 1 Remove the b...

Page 167: ...h 09930 11930 Torx bit JT30H 09930 11940 Bit holder RELAYS STARTER RELAY The starter relay is located behind the leg shield cover 6 13 TURN SIGNAL RELAY The turn signal relay is located behind the fro...

Page 168: ...r W B White with Black tracer Y G Yellow with Green tracer Y W Yellow with White tracer IGNITION SWITCH Position Color R O Bl W B W Gr Br ON C OFF LOCK P LIGHTING SWITCH Position Color O Gr Y W OFF S...

Page 169: ...STEM BATTERY REMOVAL Remove the front leg shield cover 5 4 Remove the battery rubber band 1 Remove the battery NOTE First disconnect the battery lead wire REMOUNTING Remount the battery in the reverse...

Page 170: ...te container After completely filling the battery with electrolyte use the caps 2 from the electrolyte container to seal the battery filler holes Insert the nozzles of the electrolyte container 4 into...

Page 171: ...from that of a conventional battery Only use the specified MF battery Do not remove the caps once they are installed in the battery Measure the battery voltage using a tester The tester should indicat...

Page 172: ...10 hours Be careful not to permit the charging current to exceed 5 A at any time After recharging wait at least 30 minutes and then measure the battery voltage using a tester If the battery voltage is...

Page 173: ...GRAM 7 8 WIRE HARNESS CABLE AND HOSE ROUTING 7 9 WIRE ROUTING 7 9 CABLE ROUTING 7 10 FUEL HOSE ROUTING 7 12 ENGINE OIL DRAIN HOSE ROUTING 7 14 FRONT BRAKE HOSE ROUTING 7 15 CENTER STAND SET UP 7 16 FU...

Page 174: ...5 Clogged fuel hose Clean or replace 6 Clogged fuel filter Clean or replace Engine stalls easily 1 Fouled spark plug Clean or replace 2 Defective pick up coil or CDI unit Replace 3 Clogged fuel hose o...

Page 175: ...fuel supply Clean and prime to the carburetor 10 Clogged fuel valve Clean Exhaust smoke is dirty or 1 Incorrect engine oil Change thick Engine lacks power 1 Worn cylinder Replace 2 Worn piston rings R...

Page 176: ...an or replace with needle valve seat 5 Incorrect float chamber fuel level Adjust float height CHASSIS Complaint Symptom and possible causes Remedy Steering is heavy 1 Overtightened steering stem nut A...

Page 177: ...play Adjust Brake squeaks 1 Carbon adhesion on brake pad surface Clean surface with sandpaper 2 Tilted brake pad Readjust brake pad position or replace 3 Damaged wheel bearings Replace 4 Worn brake p...

Page 178: ...Repair replace or tighten charge 2 Shorted grounded or open generator coils Replace 3 Shorted or punctured regulator rectifier Replace Generator charges 1 Lead wires tend to get shorted or open circu...

Page 179: ...their active Replace the battery and material as a result of overcharging correct the charging system 3 Internally shorted battery Replace 4 Old battery Replace Reversed battery polarity 1 Improperly...

Page 180: ...W W R R O Gr Br W Br W Lbl O Lbl Y W W B B O Y G Lg W Lbl LIGHTING SWITCH FRONT BRAKE LIGHT SWITCH STARTER BUTTON IGNITION COIL FUEL GAUGE OIL LEVEL SWITCH REGULATOR RECTIFIER CDI UNIT TRUNK BOX LIGHT...

Page 181: ...ion coil Ground wire Starter motor Wiring harness Wiring harness Throttle cable Wiring harness License plate light Rear turn signal light R Thermo switch Clamp Wiring harness Engine ground wire Starte...

Page 182: ...the rear brake cable inside the bracket Throttle cable Clamp securely Rear brake cable Pass the rear brake cable through the cable guide Rear brake cable Throttle cable Throttle cable Wiring harness...

Page 183: ...SERVICING INFORMATION 7 11 Cable guide Speedometer cable Cable guide Speedometer cable Cable guide Speedometer gear box...

Page 184: ...ar brake cable Fuel valve vacuum hose Carburetor Carburetor Air vent hose Air vent hose Fuel drain hose Fuel drain hose Fuel valve Fuel hose Fuel hose Fuel hose Fuel pump Fuel pump Hose guide Fuel val...

Page 185: ...ICING INFORMATION 7 13 VIEW A A B VIEW B Upward Carburetor Carburetor Fuel pump vacuum hose Fuel pump Fuel pump Fuel pump vacuum hose Fuel hose Carburetor overflow hose Upward Clamp Clamp 1 0 0 1 2 0...

Page 186: ...ender Fuel valve vacuum hose Engine oil drain hose Throttle cable guide Trunk Align the white mark with the guide Pass through the engine oil drain hose between the left side of trunk and the guide Re...

Page 187: ...r Wiring harness Speedometer cable Rear brake cable Throttle cable Front brake hose Insert the stopper into the hole of steering stem Front brake hose Clamp Clamp the brake hose firmly Clamp the brake...

Page 188: ...7 16 SERVICING INFORMATION CENTER STAND SET UP Inner spring Inner spring Outer spring Outer spring Cushion Center stand Center stand FUEL TANK CUSHION ADHERING Cushion Cushion...

Page 189: ...pliers 09900 06108 Snap ring pliers 09900 09003 Impact driver set 09900 20606 Dial gauge 09900 20803 Thickness gauge 09900 20605 Dial calipers 09900 20701 Magnetic stand 09900 20805 Tire depth gauge 0...

Page 190: ...940 52861 Front fork oil seal installer set 09941 34513 Steering inner race installer 09941 50111 Bearing remover 09943 74111 Fork oil level gauge NOTE When order the special tool please confirm wheth...

Page 191: ...3 Starter motor mounting bolt 10 1 0 Spark plug 28 2 8 CHASSIS ITEM N m kgf m Handlebar clamp nut 50 5 0 Handlebar set bolt 25 2 5 Steering stem locknut 30 3 0 Front fork clamp bolt 23 2 3 Front fork...

Page 192: ...er 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...

Page 193: ...n pin O D 13 995 14 000 13 980 CONROD CRANKSHAFT Unit mm ITEM STANDARD LIMIT Conrod small end I D 18 000 18 008 18 040 Conrod deflection 3 0 Crank web to web width 40 0 0 1 Crankshaft runout 0 05 OIL...

Page 194: ...der bore Front 11 000 11 043 Master cylinder piston diam Front 10 957 10 984 Brake caliper cylinder bore Front 30 230 30 306 Brake caliper piston diam Front 30 150 30 200 Brake fluid type DOT 4 Wheel...

Page 195: ...l peak voltage More than 150 V Ground B Bl Generator coil resistance Charging 0 4 1 0 W R Ground Lighting 0 3 0 8 Y W Ground Pick up 140 230 Br W Generator no load voltage More than 40 V AC at 5 000 r...

Page 196: ...ded FUEL OIL ITEM STANDARD SPECIFICATION NOTE Fuel type Fuel tank capacity 6 0 L Engine oil type Engine oil tank capacity 1 2 L Final gear oil type SAE 10W 40 Final gear oil capacity 130 ml Use SUZUKI...

Page 197: ...Prepared by Motorcycle Service Department November 1999 Part No 99500 11180 01E Printed in Japan 200...

Page 198: ...Printed in Japan Y TK...

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