Suzuki Vinson LT-A500F Service Manual Download | Manualshive

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1-2 GENERAL INFORMATION

WARNING/CAUTION/NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol

and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes-
sages highlighted by these signal words.

A WARNING

Indicates a potential hazard that could result in death or injury.

ACAUTIOINT

Indicates a potential hazard that could result in vehicle damage.

NOTE:
Indicates special information to make maintenance easier or instructions clearer.

Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all
potential hazards relating to the servicing, or lack of servicing, of the vehicle. In addition to the WARNINGS

and CAUTIONS stated, 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.

G E N E R A L PRECAUTIONS

A W A R N I N G

* Proper service and repair procedures are important for the safety of the service mechanic

and the safety and reliability of the vehicle.

* When two or more persons work together, pay attention to the safety of each other.
* When it is necessary to run the engine indoors, make sure that exhaust gas is forced out-

doors.

* When working with toxic or flammable materials, make sure that the area you work in is well

ventilated and that you follow all of the manufacturer's instructions.

* Never use gasoline as a cleaning solvent.
* To avoid getting burned, do not touch the engine, engine oil, radiator, and exhaust system

until they have cooled.

* After servicing the fuel, oil, engine coolant, exhaust or brake systems, check all of the lines,

and fittings related to the system for leaks.

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Summary of Contents for Vinson LT-A500F

Page 1: ...S U Z U K I LT A500F SERVICE MANUAL ...

Page 2: ...in this manual are used to show the basic principles of operation and work procedures They may not represent the actual vehicle exactly in detail This manual is written for persons who have enough knowledge skills and tools includ ing special tools for servicing SUZUKI vehi cles If you do not have the proper knowledge and tools ask your authorized SUZUKI motorcycle dealer to help you A WARNING Ine...

Page 3: ...here is an exploded view which provides work instructions and other service information e g tightening torque lubricating points and locking agent points Example Front brake Master cylinder reservoir cap Diaphragm Master cylinder clamp Boot Piston cup set Cup Spring Master cylinder Brake hose No 1 Brake hose No 2 Brake hose No 3 Brake pipe joint Brake pipe RH Brake pipe LH Piston Piston seal Dust ...

Page 4: ...ine oil and SUZUKI MOLY PASTE in a ratio of 1 1 Apply or use brake fluid Apply SUZUKI SUPER GREASE A 99000 25030 For USA 99000 25010 For the other countries Measure in voltage range Apply SUZUKI SILICONE GREASE 99000 25100 Measure in resistance range Apply SUZUKI MOLY PASTE 99000 25140 Measure in current range Apply WATER RESISTANCE GREASE 99000 25160 Measure in diode test range 12Q7B Apply SUZUKI...

Page 5: ...UKI LT A500FY 2000 MODEL 1 4 SERIAL NUMBER LOCATION 1 4 FUEL OIL AND ENGINE COOLANT RECOMMENDATIONS 1 4 FUEL 1 4 ENGINE OIL 1 5 DIFFERENTIAL GEAR AND FINAL BEVEL GEAR OIL 1 5 BRAKE FLUID 1 5 ENGINE COOLANT 1 5 BREAK IN PROCEDURES 1 6 INFORMATION LABELS 1 7 SPECIFICATIONS 1 8 COUNTRY AND AREA CODES 1 10 ...

Page 6: ...t 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 A WARNING Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the vehicle When two or more persons work together pay attention to the s...

Page 7: ...case nuts and bolts tighten the larger sizes first Always tighten the nuts and bolts from the inside working out diagonally and to the speci fied 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 ma...

Page 8: ...r 91 octane or higher rated by the Research Method SUZUKI recommends that customers use alcohol free unleaded gasoline whenever possible Use of blended gasoline containing MTBE Methyl Tertiary Butyl Ether is permitted Use of blended gasoline alcohol fuel is permitted provided that the fuel contains not more than 10 eth anol Gasoline alcohol fuel may contain up to 5 methanol if appropriate cosolven...

Page 9: ... if the vehicle is operated where the ambient temperature is below 0 C 32 F BRAKE FLUID Specification and classification DOT 4 A WARNING This vehicle uses a glycol based brake fluid Do not use or mix different types of brake fluid such as silicone based and petroleum based fluids for refilling the system otherwise serious damage will result to the brake system Never use any brake fluid taken from ...

Page 10: ...ssible 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 following break in engine speed recommendations Keep to these brake in en...

Page 11: ...General warning label o o o o General warning label o Warning no passenger label o o o o Age 16 label o o o o Age 16 label and gearshift label o Manual notice label o o Max AMP caution label o o o o Max AMP caution label o Fuel caution label o Gearshift label o o o o Front carrier warning label o o o Front carrier warning label o Rear carrier warning label o o o Rear carrier warning label o Traile...

Page 12: ...displacement 493 cm3 30 1 cu in Compression ratio 8 5 1 Carburetor MIKUNI BST34SS Air cleaner Polyurethane foam element Starter system Electric and recoil starter Lubrication system Wet sump Idle speed 1 500 100 r min TRANSMISSION Clutch Wet shoe automatic centrifugal type Transmission Automatic variable ratio with reverse and 2 speed transmission Gearshift pattern Forward Hand lever operated Reve...

Page 13: ...e wishbone coil spring oil damped spring preload 5 way adjustable 4 link rigid axle coil spring oil damped spring preload 5 way adjustable Inside 38 Outside 26 17 mm 0 67 in 3 0 m 9 8 ft Disc brake Internal expanding mechanically operated AT25 x 8 12 r AT25 x 10 12 r r 150 mm 5 9 in 150 mm 5 9 in Electronic ignition CDI 10 BTDC at 1 500 r min NGK CR6E DENSO U20ESR N 12 V 50 4 kC 14 Ah 10 HR Three ...

Page 14: ...ENERAL INFORMATION COUNTRY AND AREA CODES The following codes stand for the applicable countries and areas C O D E C O U N T R Y O R A R E A E 03 USA E 17 Sweden E 24 Australia E 28 Canada E 33 California USA ...

Page 15: ... OIL FILTER 2 8 DIFFERENTIAL GEAR AND FINAL BEVEL GEAR OIL 2 10 ENGINE COOLANT 2 11 RADIATOR HOSES 2 72 DRIVE BELT 2 72 SPARK ARRESTER 2 74 BRAKES 2 75 BRAKE FLUID 2 16 BRAKE HOSES 2 77 TIRES 2 78 STEERING 2 73 SUSPENSIONS 2 19 CHASSIS NUTS AND BOLTS 2 20 GENERAL LUBRICATION 2 22 COMPRESSION PRESSURE CHECK 2 23 COMPRESSION TEST PROCEDURE 2 23 OIL PRESSURE CHECK 2 24 OIL PRESSURE TEST PROCEDURE 2 2...

Page 16: ...leaner C C Exhaust pipe nuts and muffler bolts T T T Valve clearance I I Spark plug I Spark plug Replace every 6 000 km 4 000 miles Fuel hose I I Fuel hose Replace every four years Throttle cable I I I Engine idle speed I I I Engine oil and oil filter R R Differential gear and final bevel gear oil I Differential gear and final bevel gear oil Replace every two years Engine coolant Replace every two...

Page 17: ...with a non flammable clean ing solvent Immerse the air cleaner element in the cleaning solvent and wash it Press the air cleaner element between the palms of both hands to remove the excess solvent do not twist or wring the element or it will tear Immerse the element in motor oil and then squeeze out the excess oil leaving the element slightly wet Non flammable cleaning solvent Motor oil SAE 30 or...

Page 18: ...00 km 600 miles 3 months thereafter Remove the rear fender CU3 7 7 Tighten the exhaust pipe nuts muffler connection bolt 2 and muffler mounting bolts to the specified torque H Exhaust pipe nut 23 Nm 2 3 kgf m 16 5 Ib ft Muffler connection bolt 23 N m 2 3 kgf m 16 5 Ib ft Muffler mounting bolt 23 N m 2 3 kgf m 16 5 Ib ft ...

Page 19: ...he engine is cold The intake and exhaust valves must be checked and adjusted when the piston is at Top Dead Center TDC of the compres sion stroke Turn the generator rotor until the piston is at TDC on the compression stroke by turning the starter cup Turn the rotor until the line on the rotor is aligned with the mark on the crankcase Insert the thickness gauge to check the clearance between the va...

Page 20: ...nted end SPARK PLUG GAP Measure the spark plug gap using a thickness gauge If the spark plug gap is out of specification adjust the gap mm Standard Spark plug gap 0 7 0 8 mm 0 028 0 031 in IT55L1 09900 20803 Thickness gauge ELECTRODE Check the condition of the electrode If the electrode is extremely worn or burnt replace the spark plug with a new one Also replace the spark plug if it has a broken ...

Page 21: ...very 1 000 km 600 miles 3 months Replace every four years Inspect the fuel hose for damage and fuel leakage If any dam ages are found replace the fuel hoses with a new one When replacing the fuel hoses remove the front fender CT3 7 6 THROTTLE CABLE PLAY Inspect initially at 200 km 100 miles 1 month and every 1 000 km 600 miles 3 months thereafter Adjust the throttle cable play as follows Loosen th...

Page 22: ...s should be done together with the engine oil change ENGINE OIL REPLACEMENT Place an oil pan below the engine and then drain the oil by removing the engine oil drain plug and engine oil filler cap Tighten the engine oil drain plug to the specified torque and then pour the new oil through the oil filler When per forming an oil change without oil filter replacement the engine will hold about 2 3 L 2...

Page 23: ...TE To properly tighten the oil filter use the special tool Never tighten the oil filter by hand Add new engine oil and check the oil level c T3 2 8 WBEH Engine oil capacity Oil change Oil and filter change Engine overhaul A CAUTION 2 3 L 2 4 US qt 2 0 Imp qt 2 5 L 2 6 US qt 2 2 Imp qt 3 0 L 3 2 US qt 2 6 Imp qt ONLY USE A GENUINE SUZUKI MOTORCYCLE OIL FILTER Other manufacturer s oil filters may di...

Page 24: ...t the drain plug and pour the specified oil in through the filler hole until it over flows ErtSSS Differential gear oil capacity 150 ml 5 1 US oz 5 3 Imp oz 5 Differential gear oil drain plug 23 N m 2 3 kgf m 16 5 Ib ft Differential gear oil filler cap 23 N m 2 3 kgf m 16 5 Ib ft FINAL BEVEL GEAR OIL Place an oil pan below the final gear case and then drain the oil by removing the drain plug and f...

Page 25: ...olant gets into the eyes or contacts the skin flush the eyes or wash the skin thoroughly with plenty of water If engine coolant is swallowed induce vomiting and call a physician immediately Flush the radiator with fresh water if necessary Tighten the drain plug securely Pour the specified engine coolant into the reservoir 33 Engine coolant Use an antifreeze designed for aluminum radiators mixed wi...

Page 26: ...y 1 000 km 600 miles 3 months Replace every 2 000 km 1 200 miles 6 monts REMOVAL Remove the front fender and rear fender 7 6 and 7 7 Remove the footrest mounting bolt and disconnect the rear brake cable Remove the cooling duct connector Remove the drive belt cover Hold the movable drive face using the special tool and remove the movable drive face nut ItSSlJ 09930 40113 Rotor holder Hold the movab...

Page 27: ...e belt as low as possible between the mov able driven face to provide the maximum drive belt clearance before installing Install the movable driven face with drive belt to the drive shaft and temporally tighten the nut A CAUTION The drive belt should be installed so that the arrows on the drive belt periphery point in the normal turn ing direction The drive belt contact surface of the driven face ...

Page 28: ...t is properly seated and both the drive and driven face rotate together smoothly and without slipping H r SPARK ARRESTER Clean every 2 000 km 1 200 miles 6 months Put the range lever into neutral and set the parking brake Remove the drain bolts Start the engine and fully open the throttle several times to blow out the accumulated carbon particles Stop the engine and replace the drain bolts w A WAR...

Page 29: ...rake pedal Turn the adjuster in or out until the pedal height to the specification after loosening the locknut Make sure to tighten the locknut securely Turn the adjuster in or out until the free play of the brake pedal is between 20 30 mm 0 8 1 2 in B Brake pedal height 70 mm 2 8 in Brake pedal play 20 30 mm 0 8 1 2 in Rear brake lever After adjusting the brake pedal check the rear brake lever pl...

Page 30: ...00 km 600 miles 3 months Replace every two years BRAKE FLUID LEVEL Place the handlebar straight Check the brake fluid level by observing the lower limit line on the front brake fluid reservoir When the brake fluid level is below the lower limit line replenish with brake fluid that meets the following specifica tion Specification and classification DOT 4 A WARNING The brake system of this vehicle i...

Page 31: ...e the lever fully without releasing it Loosen the air 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 handlebar grip Then close the air bleeder valve pump and squeeze the lever and open the valve Repeat this process until the fluid flowing into the receptacle no longer contains ...

Page 32: ... increase Therefore main tain the correct tire pressure for good roadability and a longer tire life Cold inflation tire pressure is as follows COLD INFLATION TIRE PRESSURE kPa kgf cm2 psi FRONT 35 0 35 5 1 REAR 30 0 30 4 4 VEHICLE LOAD CAPACITY LIMIT 172 kg 380 lbs A CAUTION To minimize the possibility of tire damage from over inflation we strongly recommended that a manual type air pump be used r...

Page 33: ...rward position Place a load of 75 kg 165 lbs on the seat Measure the distance and of the front wheels with a toe in gauge as shown and calculate the difference between and M T o e i n 7 15 mm 0 28 0 59 in If the toe in is out of specification bring it into the specified range CZT 7 42 SUSPENSIONS Inspect every 2 000 km 1 200 miles 6 months Support the machine using a jack and wooden blocks Remove ...

Page 34: ...6 0 Steering knuckle pinch bolt upper and lower 50 5 0 36 0 Front shock absorber mounting nut upper and lower 60 6 0 43 5 Tie rod end nut 32 3 2 23 0 Tie rod locknut 45 4 5 32 5 Front brake air bleeder valve 7 5 0 75 5 5 Front brake caliper mounting bolt 26 2 6 19 0 Footrest bolt M8 26 2 6 19 0 Footrest bolt M10 55 5 5 40 0 Front brake master cylinder mounting bolt 10 1 0 7 0 Front brake hose unio...

Page 35: ...PERIODIC MAINTENANCE 2 21 ...

Page 36: ...e gets on the brake lin ings brake slippage will result Steering shaft holder Drive shaft joint spline Speedometer cable Brake cam Brake lever holder and throttle lever Speedometer gear box Brake pedal Drive belt cover bearing inner race Propeller shaft joint spline NOTE Before lubricating each part remove any rust and wipe off any grease oil dirt or grime Lubricate exposed parts which are subject...

Page 37: ...tive cylinder head gasket NOTE When the compression pressure goes below specification check the engine for conditions listed above COMPRESSION TEST PROCEDURE NOTE Before testing the engine for compression pressure make sure that the cylinder head nuts are tightened to the speci fied torque values and the valves are properly adjusted Warm up the engine before testing Make sure that the battery is f...

Page 38: ... passage Damaged O ring Defective oil pump Combination of the above items HIGH OIL PRESSURE Engine oil viscosity is too high Clogged oil passage Combination of the above items OIL PRESSURE TEST PROCEDURE Connect a tachometer Remove the main oil gallery plug Install the oil pressure gauge and adaptor into the main oil gallery Warm up the engine as follows Summer 10 minutes at 2 000 r min Winter 20 ...

Page 39: ...hly check the operation of the drive train Perform the following Check the oil level EZr 2 8 Warm up the engine INITIAL ENGAGEMENT INSPECTION Connect the tachometer onto the spark plug lead Start the engine Shift the range lever to the High position Slowly open the throttle and note the engine speed r min when the vehicle begins to move forward gW Engagement speed 1 800 2 400 r min If the engageme...

Page 40: ... as firmly as possible Fully open the throttle for a brief period and note the maxi mum engine speed sustained during the test cycle EBBS Lock up speed 3 300 3 900 r min A CAUTION Do not apply full power for more than 10 seconds or damage to the clutch or engine may occur If the lock up speed r min does not coincide with the standard range inspect the following items for any abnormalities Clutch s...

Page 41: ...SSION 3 49 BEARINGS 3 53 OIL SEALS 3 58 ENGINE REASSEMBLY 3 61 WATER PUMP DRIVEN GEAR 3 61 CRANKSHAFT 3 62 BALANCER SHAFT 3 63 SECONDARY DRIVEN OUTPUT SHAFT 3 63 GEARSHIFT CAM AND FORK 3 64 CRANKCASE 3 65 GEARSHIFT CAM STOPPER BOLT 3 66 WATER PUMP DRIVE GEAR 3 66 STARTER CLUTCH AND GENERATOR ROTOR 3 67 OIL PUMP 3 67 CAM CHAIN 3 68 CLUTCH SHOE 3 68 ONE WAY CLUTCH 3 68 NEUTRAL SWITCH 3 69 CLUTCH HOU...

Page 42: ... 14 3 71 ENGINE RIGHT SIDE PARTS REMOVAL INSTALLATION Movable drive driven face 3 15 3 16 3 69 3 70 Neutral switch 3 16 3 69 Clutch shoe 3 17 3 68 One way clutch 3 16 3 68 Oil pump assembly 3 17 3 67 Oil pump drive driven gear 3 17 3 67 3 68 ENGINE CENTER PARTS REMOVAL INSTALLATION Carburetor 5 8 5 13 Cam chain tension adjuster 3 11 3 76 3 77 Cylinder head cover 3 12 3 76 Camshaft automatic decomp...

Page 43: ...explained in the following steps Shift the range lever to the Neutral position Remove the front fender and rear fender CZT3 7 6 and 7 7 Drain the engine oil 2 8 Remove the carburetor CT3 5 8 Remove the muffler Remove the center exhaust pipe cover and exhaust pipe Remove the cooling duct connector and cooling ducts Cooling duct No 1 Cooling duct No 2 Cooling duct No 3 ...

Page 44: ...ator rectifier coupler and remove the regulator rectifier Remove the carburetor intake pipe Disconnect the air cleaner case breather hose Remove the air cleaner assembly Disconnect the starter motor read wire and remove the starter motor 0 ...

Page 45: ...he aligning points of the gearshift arm and camshaft before removing the gearshift arm Disconnect the engine coolant temperature switch connector 0 and spark plug cap 5 Disconnect the clamp and radiator hoses Remove the left and right footrests Remove the clip and disconnect the rear brake cable ...

Page 46: ...dometer cable Disconnect the clamps neutral switch coupler erator couplers Remove the front propeller shaft joint bolts Remove the rear propeller shaft joint bolts Disconnect the ignition coil coupler and ignition wire gen coil lead ...

Page 47: ...ENGINE 3 7 Remove the engine under plate Remove the engine from the right side ...

Page 48: ...the nut has been removed it is no longer of any use Be sure to use new nuts and then tighten them to the specified torque H 23 N m 2 3 kgf m 16 5lb ft 26 N m 2 6 kgf m 19 0lb ft Hold the bolt head with a wrench and then tighten the engine mounting nuts to the specified torque LENGTH ITEM Nm kgf m Ib ft 40 4 0 29 0 55 5 5 40 0 55 5 5 40 0 55 5 5 40 0 Bolt 60 mm 2 4 in Bolt 180 mm 7 1 in Bolt 235 mm...

Page 49: ...J33 99000 32050 THREAD LOCK 1342 5 Front propeller shaft joint bolt 45 N m 4 5 kgf m 32 5 Ib ft Install the gearshift arm to the camshaft NOTE Make sure to align the marks made on the gearshift arm and the camshaft when installing the gearshift arm Install the gearshift arm as shown NOTE Make sure the transmission is in the neutral position Tighten the exhaust pipe nut to the specified torque H Ex...

Page 50: ...9 21 Pour 3 0 L 3 2 US qt 2 6 Imp qt of an API service classified SF or SG engine oil that has a viscosity rating of SAE 10W 40 into the engine after overhauling it Start the engine and allow it to run for a few minutes at idle speed Turn off the engine and wait about three minutes and then check the oil level on the dipstick WM Engine oil capacity Oil change 2 3 L 2 4 US qt 2 0 Imp qt Oil and fil...

Page 51: ...l starter Remove the Top Dead Center TDC plug Turn the generator rotor until the line 3 on the generator rotor is aligned with the mark 4 on the crankcase NOTE When removing the cylinder head cover the piston must be at TDC of the compression stroke Remove the valve inspection caps 5 and spark plug ...

Page 52: ...lts diagonally and remove the cylinder head cover Remove the camshaft end cap and dowel pins 2 Flatten the lock washer and remove the two camshaft sprocket bolts Remove the camshaft and sprocket Remove the four cylinder head bolts diagonally BlfBl ...

Page 53: ...the cylinder head nuts and then remove the cylin der head If the cylinder head does not come off lightly tap it using a plastic mallet Remove the cylinder head gasket 0 and dowel pins 2 Remove the radiator hose ...

Page 54: ...me off lightly tap it using a plastic mallet Remove the cylinder gasket 3 and dowel pins Place a clean rag over the cylinder base to prevent the pis ton pin circlip from dropping into the crankcase Remove the piston pin circlip Draw out the piston pin and remove the piston Remove the speedometer gearbox Remove the starter cup ...

Page 55: ...ter driven gear shaft 2 starter drive gear and starter drive gear shaft 0 Remove the oil filter using the special tool IT55LI 09915 40610 Oil filter wrench Remove the drive belt cover Hold the movable drive face using the special tool and remove the movable drive face nut IT55LI 09930 40113 Rotor holder ...

Page 56: ...vable driven face using the special tool and Remove the fixed drive face plate and spacer Remove the clutch housing case and clutch housing 2 Remove the neutral switch 0 switch contacts 0 and springs Remove the one way clutch ...

Page 57: ...The clutch shoe nut has left hand threads Remove the clutch shoe assembly and cam chain Hold the generator rotor using a 36 mm offset wrench and then remove the oil pump drive gear bolt Remove the washer oil pump drive gear pin and spacer Remove the circlip washer pin and oil pump driven gear Remove the oil pump ...

Page 58: ...ver attachment until the left surface of the crankshaft seats the attachment IT55LI 09930 31920 Rotor remover Remove the generator rotor using the special tool 09930 30721 Rotor remover NOTE Do not hit the generator rotor with a hammer Remove the key starter clutch gear and washer Remove the circlip water pump drive gear and pin ...

Page 59: ...ankcase securing bolts Separate the crankcase using the special tool 09920 13120 Crankcase separating tool NOTE Fit the crankcase separating tool to the right side so that the tool plate is paralleled with the end face of the crankcase Remove the reverse idle gear reverse idle gear shaft bushing and washers ...

Page 60: ...ntershaft assembly and driveshaft assembly Remove the secondary driven output shaft assembly NOTE Refer to chapter 4 when inspecting the secondary driven output shaft Remove the balancer driven gear and key Remove the crankshaft from the crankcase using the special tool 09920 13120 Crankcase separating tool ...

Page 61: ...er pump driven gear pin and washer Remove the transmission output shaft housing Unlock the caulking as pointed and remove the transmis sion output shaft nut using the special tool 09930 73160 Output shaft holder Remove the transmission output shaft assembly tup ...

Page 62: ...3 22 ENGINE Remove the oil sump filter cap 0 and oil sump filter 2 ...

Page 63: ... of the cylinder head cover for distor tion using a straightedge and thickness gauge Take clearance readings at several places If any reading exceeds the service limit replace the cylinder head cover with a new one 09900 20803 Thickness gauge EKffiS Cylinder head cover distortion Service Limit 0 05 mm 0 002 in ROCKER ARM SHAFT O D Measure the rocker arm shaft diameter at three different loca tions...

Page 64: ...e rocker arm shafts tighten the set bolts to the specified torque H Rocker arm shaft set bolt 28 N m 2 8 kgf m 20 0 Ib ft A CAUTION Use a new gasket on the set bolt to prevent oil leakage C Y L I N D E R H E A D DISASSEMBLY A CAUTION Identify the position of each removed part Organize the parts in their respective groups i e exhaust or intake so that they can be reinstalled in their original posit...

Page 65: ...ve guide servicing CYLINDER HEAD DISTORTION Decarbonize the combustion chamber Check the gasket surface of the cylinder head for distortion using a straightedge and thickness gauge Take clearance readings at several places If any clearance reading exceeds the service limit replace the cylinder head with a new one 09900 20803 Thickness gauge mm Cylinder head distortion Service Limit 0 05 mm 0 002 i...

Page 66: ...TEM DEFLECTION Lift the valve about 10 mm 0 39 in from the valve seat Mea sure the valve stem deflection in two directions X and Y perpendicular to each other Position the dial gauge as shown If the deflection exceeds the service limit determine whether the valve or the guide should be replaced with a new one IT55L1 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand Valve stem deflection S...

Page 67: ...e r J 09916 34580 Valve guide reamer 10 8 mm 09916 34542 Reamer handle Oil the stem hole of each valve guide and drive the guide into the guide hole using the valve guide installer T H 09916 44310 Valve guide remover installer A CAUTION Failure to oil the valve guide hole before driving the new guide into place may result in a damaged guide or head After fitting the valve guides refinish their gui...

Page 68: ...35 0 043 in If the valve seat is out of specification re cut the seat VALVE SEAT SERVICING The valve seats for both the intake and exhaust valves are machined to two different angles The seat contact surface is cut at 45 INTAKE EXHAUST 45 N 229 N 229 15 N 229 N 121 For USA 2 Valve seat cutter N 121 and N 229 Solid pilot N 140 5 0 IN N 100 5 0 EX For the other countries 09916 21110 Valve seat cutte...

Page 69: ...e seat using the 45 cutter Rotate the cutter one or two turns Measure the valve seat width after every cut If the valve seat is pitted or burned use the 45 cutter to con dition the seat some more NOTE Cut only the minimum amount necessary from the seat to pre vent the possibility of the valve stem becoming too close to the rocker arm for correct valve contact angle ...

Page 70: ...the 45 cutter very lightly to clean up any burrs caused by the previous cutting operations A CAUTION DO NOT use a lapping compound after the final cut is made The finished valve seat should have a velvety smooth finish but not a highly polished or shiny fin ish This will provide a soft surface for the final seat ing of the valve which will occur during the first few seconds of engine operation NOT...

Page 71: ...e with a new one WM Valve stem end length Service Limit 1 8 mm 0 07 in VALVE SPRING The force of the coil spring keeps the valve seat tight A weak ened spring results in reduced engine power output and accounts for the chattering noise coming from the valve mecha nism Check the valve springs for proper strength by measuring their free length and also by the force required to compress them If the s...

Page 72: ...l Install the valve spring with the smaller pitch facing the cylinder head Larger pitch Down Install the valve spring retainer by pressing down the spring using the valve lifter Fit the cotter halves to the stem end and release the lifter to allow the cotter to wedge between the retainer and the valve stem Be sure that the rounded lip of the cotter fits snugly into the groove in the stem end 09916...

Page 73: ...KI BOND 1207B For the other countries 99000 31140 SUZUKI BOND 1207B 5 Engine coolant temperature switch 7 5 N m 0 75 kgf m 5 5 Ib ft C A M S H A F T A U T O M A T I C D E C O M P R E S S I O N A S S E M B L Y A CAUTION Do not attempt to disassemble the camshaft auto matic decompression assembly It is not serviceable AUTOMATIC DECOMPRESSION Move the automatic decompression weight by hand to inspect...

Page 74: ... specified torque NOTE Make sure the gasket surface of the cylinder head and cylinder head cover are clean and free of any bond or other material H Cylinder head cover bolt 10 N m 1 0 kgf m 7 0 Ib ft NOTE Do not rotate the camshaft with the plastigauge in place Remove the cylinder head cover and read the width of the com pressed plastigauge with the envelope scale This measure ment should be taken...

Page 75: ...y clearance reading exceeds the service limit replace the cylinder block with a new one T 09900 20803 Thickness gauge Effil Cylinder distortion Service Limit 0 05 mm 0 002 in CYLINDER BORE Inspect the cylinder wall for any scratches nicks or other dam age Measure the cylinder bore diameter at six places 09900 20508 Cylinder gauge set ifi q Cylinder bore Standard 87 500 87 515 mm 3 4449 3 4455 in P...

Page 76: ... 51 2 53 mm 0 0988 0 0996 in WM Piston ring thickness Standard 1st 0 97 0 99 mm 0 0382 0 0390 in 2nd 1 17 1 19 mm 0 0461 0 0469 in PISTON RING FREE END GAP AND PISTON RING END GAP Measure the piston ring free end gap using the vernier calipers first and then fit the piston ring squarely into the cylinder and measure the piston ring end gap using the thickness gauge If any measurement exceeds the s...

Page 77: ...e conrod with a new one TOSL 09900 20605 Dial calipers Conrod small end I D Service Limit 23 040 mm 0 9071 in CONROD DEFLECTION AND BIG END SIDE CLEARANCE Wear on the big end of the conrod can be estimated by checking the movement of the small end of the rod This method can also be used to check the extent of wear on the parts of the conrod s big end IT55LI 09900 20701 Magnetic stand 09900 20606 D...

Page 78: ...Also check the depth of the grooves on the clutch shoes If there is no groove at any part of the shoes replace the shoes as a set NOTE The clutch shoes must always be changed as a set CLUTCH WHEEL Inspect the condition of the inner clutch wheel surface for scuffs scratches cracks or uneven wear If any damages are found replace the clutch wheel with a new one ONE WAY CLUTCH Inspect the one way clut...

Page 79: ...l to the starter clutch Apply THREAD LOCK SUPER 1303 to the hexagon bolts and then tighten them to the specified torque while holding the rotor and using a 36 mm offset wrench tti3 99000 32030 THREAD LOCK SUPER 1303 H Starter clutch bolt 26 N m 2 6 kgf m 19 0 Ib ft Install the starter gear to the starter clutch Check that the rotor turns in the direction of the arrow on the rotor while holding the...

Page 80: ...ut Ring nut H ITEM N m kgf m Ib ft 115 11 5 83 0 115 11 5 83 0 100 100 72 5 Movable drive face plate Damper 4 pes Spacer Roller 8 pes Oil seal 2 pes Movable drive face Drive belt Fixed drive face Fixed driven face Oil seal 2 pes Movable driven face Pin 4 pes Spacer 4 pes O ring 2 pes Spring seat Spring Spring plate ...

Page 81: ...re found replace the rollers as a set NOTE The rollers must always be changed as a set OIL SEAL Inspect the lip of the oil seal for wear or damage If any dam ages are found replace the oil seal with a new one MOVABLE AND FIXED DRIVE FACE Inspect the drive faces for any abnormal conditions such as stepped wear or discoloration caused by burning If any damages are found replace the drive faces with ...

Page 82: ...other countries 99000 25010 SUZUKI SUPER GREASE A A CAUTION Wipe off any excess grease thoroughly Take care not to apply grease to the contact surface of the drive belt Position the eight rollers on the movable drive face Mount the damper on the movable drive face plate Position the movable drive plate on the movable drive face Install the spacer NOTE Press down the movable drive face plate so as ...

Page 83: ...en face assembly and compress the movable driven face assembly by turning in the special tool handle NOTE Make sure to insert the projection of the movable driven face assembly into the slot of the special tool as shown Remove the movable driven face nut r J 09922 31430 Clutch spring compressor A WARNING Since a high spring force applies to the movable driven face care must be used so as not to ca...

Page 84: ...pring with a new one Movable driven face spring free length Service Limit 145 4 mm 5 72 in MOVABLE AND FIXED DRIVEN FACE Inspect the driven face for any abnormal condition such as stepped wear or discoloration caused by burning If any dam ages are found replace the movable driven face with a new one REASSEMBLY Install the new O rings Apply SUZUKI SUPER GREASE A to the oil seal lips O rings and mov...

Page 85: ...For the other countries 99000 25010 SUZUKI SUPER GREASE A Install the pin to the pin hole with the roller fitted A CAUTION Before installing the pins so that the flat position of the fixed driven face threads is aligned with the hole D on the movable driven face as shown Install the movable driven face spring to the movable driven face by aligning the projection on the spring with the hole on the ...

Page 86: ...1 Ring nut socket wrench 09924 52420 Holder 5 Movable driven face nut 100 N m 10 0 kgf m 72 5 Ib ft D R I V E B E L T INSPECTION Check that the drive belt is free from any greasy substance Inspect the contact surface of the drive belt for cracks or dam age and measure the width of the drive belt using the vernier calipers If any damages are found or the measurement exceeds the service limit replac...

Page 87: ...ase securing screw is applied with SUZUKI THREAD LOCK SUPER 1303 If an attempt is made to overhaul the oil pump assembly the screw may be damaged Only the oil pump unit is available as a replacement t4ssl 99000 32030 THREAD LOCK SUPER 1303 ...

Page 88: ...pective gear using the thickness gauge If the clearance exceeds specification replace the fork its respective gear or both IT55LI 09900 20803 Thickness gauge 09900 20101 Vernier calipers EffiS Gearshift fork groove clearance Service Limit 0 50 mm 0 020 in Checking clearance ESS Shift fork groove width Transmission and reverse Standard 5 50 5 60 mm 0 217 0 220 in Checking groove width V M Shift for...

Page 89: ...Washer Spacer Reverse idle gear shaft Bearing Countershaft Bearing Bearing Washer Transmission drive gear Circlip Reverse gear dog Circlip Washer Spacer Bearing Reverse driven gear Washer Lock washer Drive shaft Washer Spacer Bearing Low driven gear Circlip High Low selection dog High driven gear Washer Bearing ...

Page 90: ...shaft it should be discarded and a new circlip must be installed When installing a new circlip do not expand the end gap larger than required to slip the circlip over the shaft After installing a new circlip make sure it is com pletely seated in its groove and securely fitted NOTE When reassembling the transmission attention must be given to the locations and positions of the washers and circlips ...

Page 91: ...ENGINE 3 51 Countershaft Driveshaft Reverse idle shaft Front ...

Page 92: ...circlip pay attention to the direction of the circlip Fit it to the side where the thrust is as shown The rounded side should be against the gear surface Thrust B Sharp edge Fit the claw of the lock washer to the groove of the washer 2 ...

Page 93: ...emove the right and left countershaft bearings using the special tools j 09923 74510 Bearing remover 09930 30102 Sliding hammer ACAUTIQINT Replace the removed bearings with new ones Install the right and left countershaft bearings using the spe cial tool J 09913 70210 Bearing installer set RIGHT DRIVESHAFT BEARING Remove the right driveshaft bearing using the special tool f 09921 20220 Bearing rem...

Page 94: ...HAFT BEARING Remove the right and left crankshaft bearings using the spe cial tools 09941 64511 Bearing remover 09930 30102 Sliding hammer A CAUTION Replace the removed bearings with new ones Install the right and left crankshaft bearing using the special tool IT55LI 09913 70210 Bearing installer set OUTPUT SHAFT BEARINGS Remove the bearing retainer Remove the right and left output shaft bearings ...

Page 95: ...0 32110 THREAD LOCK SUPER 1322 RIGHT BALANCER SHAFT BEARING Remove the right balancer shaft bearing using the special tools 09923 74510 Bearing remover 09930 30102 Sliding hammer A CAUTION Replace the removed bearing with a new one Install the right balancer shaft bearing using the special tool f l 09913 70210 Bearing installer set LEFT BALANCER SHAFT BEARING Remove the left balancer shaft bearing...

Page 96: ...ater pump bearing 2 A CAUTION Replace the removed bearing and circlip with new ones Install the water pump bearing and circlip LEFT CLUTCH HOUSING BEARING Remove the bearing retainer Remove the left clutch housing bearing using the special tools 09941 64511 Bearing remover 09930 30102 Sliding hammer A CAUTION Replace the removed bearing with a new one ...

Page 97: ...ON Replace the removed bearing with a new one Install the drive belt cover bearing using the special tool 09913 70210 Bearing installer set STARTER CUP BEARING Remove the starter cup oil seal d r 3 3 59 and 3 60 Remove the starter cup bearing using the special tools frSgh 09923 74510 Bearing remover 09930 30102 Sliding hammer A CAUTION Replace the removed bearing with a new one Install the starter...

Page 98: ...wing points ACAUTIOINT Replace the removed oil seals with new ones Apply SUZUKI SUPER GREASE A to the lip of the oil J S I 99000 25030 SUZUKI SUPER GREASE A For the other countries 199000 25010 SUZUKI SUPER GREASE A COUNTERSHAFT OIL SEAL Remove the countershaft oil seal from the right crankcase using the special tool IT55L1 09913 50121 Oil seal remover A CAUTION Replace the removed oil seal with a...

Page 99: ... 09913 70210 Bearing installer set CLUTCH HOUSING OIL SEAL Remove the bearing CZ 3 3 56 Remove the clutch housing oil seal from the clutch housing case using the special tool IT55LI 09913 70210 Bearing installer set A CAUTION Replace the removed oil seal with a new one Install the clutch housing oil seal into the clutch housing case slowly using the special tool ITSSLI 09913 70210 Bearing installe...

Page 100: ...3 60 ENGINE Remove the starter cup oil seal using the special tool Install the starter cup oil seal using the special tool IT55LI 09913 70210 Bearing installer set ...

Page 101: ...SHAFT Hold the transmission output shaft using the special tool and tighten the transmission output shaft nut to the specified torque 09930 73160 Output shaft holder 5 Transmission output shaft nut 100 N m 10 0 kgf m 72 5 Ib ft Bend the collar of the shaft nut into the notch of the output shaft W A T E R P U M P D R I V E N G E A R When installing the water pump driven gear and align the pin with ...

Page 102: ...idth Standard 71 1 0 1 mm 2 795 0 004 in When mounting the crankshaft in the crankcase it is neces sary to pull its left end into the crankcase by using the spe cial tool T L 09910 32812 Crankshaft installer 09940 52861 Attachment A CAUTION Never fit the crankshaft into the crankcase by striking it with a plastic hammer Always use the special tool otherwise the accuracy of the crankshaft alignment...

Page 103: ...own as A CAUTION Install the balancer springs at crisscross position Install the balancer shaft with key Install the balancer driven gear aligning the matching marks S E C O N D A R Y D R I V E N O U T P U T S H A F T Install the secondary driven output shaft into the left crank case NOTE Be sure to install the bearing C ring as shown Also make sure the pins on the front side and rear side bearing...

Page 104: ...seal Reverse gearshift fork Transmission gearshift fork Gearshift fork shaft Install the gearshift forks into the gearshifting grooves in the correct position and direction Install the gearshift fork shaft NOTE After the gearshift fork shaft and gearshift forks have been fitted make sure the gears can engage normally If gear change is not obtained disassemble the gears to find and fix the mistake ...

Page 105: ...r through it to dry it off Fit the O ring into the O ring groove as shown A CAUTION Replace the removed O ring with a new one to prevent oil leakage Install the dowel pins to the left crankcase Apply engine oil to the conrod big end and to the transmis sion gears Apply grease to the lip of oil seals 99000 25160 WATER RESISTANCE GREASE Apply SUZUKI BOND 1207B to the mating surface of the right cran...

Page 106: ...shaft countershaft driveshaft transmission output shaft rear final driven shaft and secondary driven output shaft rotate smoothly If a large resistance is felt to rotation try to free the shafts by tapping them with a plastic hammer G E A R S H I F T C A M S T O P P E R B O L T Tighten the gearshift cam stopper bolts to the specified torque H Gearshift cam stopper bolts 23 N m 2 3 kgf m 16 5 Ib ft...

Page 107: ...nch 439 99000 32030 THREAD LOCK SUPER 1303 H Generator rotor nut 160 N m 16 0 kgf m 115 5 Ib ft O I L P U M P Before mounting the oil pump apply engine oil to the sliding surfaces of the oil pump case outer rotor inner rotor and shaft Apply a small quantity of THREAD LOCK 1342 or 1322 to the threaded parts of the oil pump mounting screws and then tighten them For USA 433 99000 32050 THREAD LOCK 13...

Page 108: ...ed torque H Oil pump drive gear bolt 50 N m 5 0 kgf m 36 0 Ib ft C A M C H A I N Install the cam chain onto the sprocket C L U T C H S H O E Hold the generator rotor using the 36 mm offset wrench and then tighten the clutch shoe nut to the specified torque H Clutch shoe nut 70 N m 7 0 kgf m 50 5 Ib ft O N E W A Y C L U T C H A Install the one way clutch with the OUT SIDE mark facing JH out as show...

Page 109: ... clutch housing case bolt to the specified torque H Clutch housing case bolt 11 N m 1 1 kgf m 8 0 Ib ft M O V A B L E D R I V E D R I V E N F A C E A N D D R I V E B E L T Insert the drive belt as low as possible between the mov able driven face while pulling out the driven face to provide the maximum drive belt clearance A CAUTION The drive belt should be installed so that the arrows on the drive...

Page 110: ...the specified torque ITSSLI 09930 40113 Rotor holder H Movable drive face nut 115 N m 11 5 kgf m 83 0 Ib ft Movable driven face nut 115 N m 11 5 kgf m 83 0 Ib ft Turn the fixed drive face until the drive bolt is properly seated and both the drive and driven faces rotate together smoothly and without slipping ...

Page 111: ...asket to prevent oil leakage Apply SUZUKI SUPER GREASE A to the new O ring install the starter cup and then tighten the mounting nut to the specified torque For USA 99000 25030 SUZUKI SUPER GREASE A For the other countries 99000 25010 SUZUKI SUPER GREASE A H Starter cup nut 33 N m 3 3 kgf m 24 0 Ib ft S P E E D O M E T E R G E A R B O X Fit the gasket to the speedometer gearbox A CAUTION Use a new...

Page 112: ...gnated top and bottom They can be installed in any position A CAUTION When installing the spacer be careful not to allow its two ends to overlap in the groove 0 INCORRECT ECORRECT Position the piston ring gaps as shown Before inserting the piston into its cylinder check that the gaps are properly posi tioned Exhaust side Intake side 2nd ring and lower side rail Upper side rail 1st ring and spacer ...

Page 113: ...e which will occur with a bent one Apply molybdenum oil solution to the small end of the con rod Apply engine oil to the sliding surface of the piston and big end of the conrod Install the dowel pins and new gasket onto the crank case A CAUTION Use a new gasket to prevent oil leakage Hold each piston ring with the piston ring sections positioned correctly and put it into the cylinder Make sure the...

Page 114: ...facing up as shown With the head snugly seated on the cylinder secure it by tightening the bolts diagonally Tighten the cylinder head bolts to the specified torque H Cylinder head bolt Initial 25 N m 2 5 kgf m 18 0 Ib ft Final 38 N m 3 8 kgf m 27 5 Ib ft After tightening the cylinder head bolts to specification tighten the cylinder head nuts and cylinder base nuts to the specified torque H Cylinde...

Page 115: ... Engage the chain on the cam sprocket with the locating pin hole at two o clock position NOTE Do not rotate the generator rotor while doing this When the sprocket is not positioned correctly turn the sprocket When installing the camshaft into the cam sprocket pay attention not to dislodge the locating pin or it may fall into the crankcase Install the C ring into the groove of the cylinder head Ins...

Page 116: ...drive chain Install the two dowel pins to the cylinder head side Install the camshaft end cap Install a gasket shown to each cylinder head cover bolt as A CAUTION Use a new gasket to prevent oil leakage NOTE When tightening the cylinder head cover bolts the piston posi tion must be at TDC on the compression stroke Lightly tighten the cylinder head cover bolts diagonally and then tighten them to th...

Page 117: ... adjuster body to the cylinder and then tighten the two alien bolts to the specified torque H Chain tension adjuster bolt 10 N m 1 0 kgf m 7 0 Ib ft Turn the adjusting screw counterclockwise with a flat bladed screwdriver to unlock Tighten the cap bolt to the specified torque H Cap bolt 8 N m 0 8 kgf m 6 0 Ib ft V A L V E C L E A R A N C E After tightening the head cover bolts check and adjust the...

Page 118: ...l Spiral spring Rope S Bolt DISASSEMBLY After removing the nut take out the recoil starter related parts from the housing Nut Friction plate Ratchet guide Ratchet Spring cover Spring Spacer Pin 9 Reel A WARNING Wear hand and eye protection when removing the reel since the spring may quickly unwind and cause an injury ...

Page 119: ... 99000 25030 SUZUKI SUPER GREASE A For the other countries 99000 25010 SUZUKI SUPER GREASE A Turn the starter rope on the reel properly After installing the spiral spring engage the part of the reel with the part of the spiral spring Apply SUZUKI SUPER GREASE A to the shaft and ratchet For USA 99000 25030 SUZUKI SUPER GREASE A For the other countries 5 H99000 25010 SUZUKI SUPER GREASE A Spiral spr...

Page 120: ...INAL ASSEMBLY AND REMOUNTING 4 9 REASSEMBLY INFORMATION 4 10 DIFFERENTIAL BEVEL GEARS 4 11 CONSTRUCTION 4 11 REMOVAL 4 12 DISASSEMBLY 4 13 INSPECTION 4 16 REASSEMBLY AND ADJUSTMENT 4 18 REMOUNTING 4 27 REASSEMBLY INFORMATION 4 28 FINAL BEVEL GEARS 4 29 CONSTRUCTION 4 29 REMOVAL AND DISASSEMBLY 4 30 INSPECTION 4 32 REASSEMBLY AND ADJUSTMENT 4 34 REMOUNTING 4 40 REASSEMBLY INFORMATION 4 41 ...

Page 121: ...output yoke nut H ITEM N m kgf m Ib ft 100 10 0 72 5 100 10 0 72 5 100 100 72 5 Front propeller shaft joint yoke Washer Plate Plate O ring Spacer Oil seal Bearing Shim Secondary driven front shaft Washer Secondary drive bevel gear Shim Secondary driven bevel gear Ring Circlip Secondary driven output shaft Bearing Oil seal Output joint frange Washer ...

Page 122: ...se c 3 3 11 to 3 19 Remove the front and rear secondary driven output shaft Remove the transmission output shaft 3 21 Separate the front and rear secondary driven output shafts D I S A S S E M B L Y FRONT SECONDARY DRIVEN OUTPUT SHAFT Remove the circlip Remove the secondary driven bevel gear and bearing ...

Page 123: ...op the needle rollers from the cage Remove the front drive output yoke nut by holding the yoke using the vise A CAUTION Replace the removed nut with a new one Remove the washer yoke oil seal bearing and shim A CAUTION Replace the removed oil seal with a new one REAR SECONDARY DRIVEN OUTPUT SHAFT Remove the rear output joint nut by holding the joint using the vise A CAUTION Replace the removed nut ...

Page 124: ...ne Inspect the front and rear secondary driven output shafts for distortion If distortion is found replace the front or rear second ary driven output shaft with a new one Inspect the secondary drive and driven bevel gears for wear or damage If any wear or damage is found replace the second ary drive or driven bevel gears with a new one R E A S S E M B L Y Reassemble the front and rear secondary dr...

Page 125: ...2 5 Ib ft Bend the collar of the nut into the notch in the shaft FRONT SECONDARY DRIVEN OUTPUT SHAFT Tighten the new front drive output yoke nut to the specified torque 5 Front drive output yoke nut 100 N m 10 0 kgf m 72 5 Ib ft NOTE When installing the universal joint take care not to drop the needle rollers from the cage A CAUTION Replace the removed C ring with a new one ...

Page 126: ...s not within specification the shim thickness must be changed and the backlash checked until it is within specifica tion Refer to the chart at the right for the appropriate shim thickness EHEKS Secondary bevel gear backlash Standard 0 03 0 15 mm 0 001 0 006 in NOTE Adjust the backlash by referring to the chart at the right and using the thickness of the old shims as a guide Backlash Shim thickness...

Page 127: ...oth con tact has been adjusted since it may have changed Adjust the tooth contact and backlash until they are both within specification If the correct tooth contact cannot be maintained when adjusting the backlash replace the secondary drive and driven bevel gears Tooth contact Shim thickness Contact at tooth top Increase shims Contact at tooth root Decrease shims List of shims D available for the...

Page 128: ...teeth and lubricate the teeth with engine oil Tighten the front drive output yoke nut and transmission out put shaft nut to the specified torque H Front drive output yoke nut 100 N m 10 0 kgf m 72 5 Ib ft Transmission output shaft nut 100 N m 10 0 kgf m 72 5 Ib ft IT55L1 09930 73160 Output shaft holder Bend the collar of the nut into the notch in the shaft NOTE Before installing the front secondar...

Page 129: ... 19B00 030 Thickness 0 30 mm 24935 19B00 035 Thickness 0 35 mm 0 60 24935 19B00 025 Thickness 0 25 mm 24935 19B00 030 Thickness 0 30 mm 24935 19B00 035 Thickness 0 35 mm 0 65 24935 19B00 025 Thickness 0 25 mm 24935 19B00 030 Thickness 0 30 mm 24935 19B00 035 Thickness 0 35 mm 0 70 24935 19B00 025 Thickness 0 25 mm 24935 19B00 030 Thickness 0 30 mm 24935 19B00 035 Thickness 0 35 mm 0 75 24935 19B00...

Page 130: ...vel gear Differential drive bevel gear housing O ring Shim Differential driven bevel gear case Oil seal Bearing Ring Differntial assembly Shim Differential driven bevel gear Shim Sliding dog Bearing Bearing O ring Driven bevel gear bearing case Oil seal Gasket Cam cover Drive bevel gear housing bolt Drive bevel gear nut Oil drain plug Driven bevel gear bearing case bolt H ITEM N m kgf m Ib ft 23 2...

Page 131: ...e the differential gear case covers Remove the front drive shaft using the special tools L 09930 30102 Sliding hammer 09924 21940 Wheel hub remover 09924 21930 Drive shaft remover Remove the front propeller shaft joint bolt Disconnect the selection lever cable and breather hose Remove the differential gear case mounting bolt ...

Page 132: ...n the position of the front propeller shaft joint yoke Separate the front propeller shaft joint yoke and differential drive bevel gear yoke Remove the bearing from the differential drive bevel gear yoke by the same manner as the front propeller shaft joint yoke NOTE When removing the bearing take care not to drop the needle rollers from the cage Remove the differential drive bevel gear housing ...

Page 133: ...ferential drive bevel gear yoke and differential drive bevel gear Remove the oil seal using the special tool IT55LI 09913 50121 Oil seal remover A CAUTION Replace the removed oil seal with a new one Remove the differential drive bevel gear bearing using the special tool 09941 84510 Bearing remover Remove the outer race using the special tool 09941 54911 Bearing outer race remover 09913 84510 Beari...

Page 134: ...DRIVE AND DIFFERENTIAL 4 15 DIFFERENTIAL DRIVEN BEVEL GEAR AND DIFFERENTIAL ASSEMBLY Remove the driven bevel gear bearing case Remove the cam cover Remove the washer and spring 2 Remove the cam and washer ill ...

Page 135: ...OUSING Inspect the removed parts for the following abnormalities If any damages are found replace the respective part with a new one Bearing race wear and brinelling Worn or damaged bearing Differential drive bevel gear housing brinelling Insert the bearing into the universal joint and check the play by turning the bearing If excessive play is noted replace the bearing with a new one NOTE Make sur...

Page 136: ... in the differential case Rotate the inner race by hand to inspect for abnormal noise and smooth rotation If anything unusual is found replace the bearing with a new one NOTE Make sure to check each bearing in the same manner Remove the front driven output shaft bearing using the spe cial tool 09913 70210 Bearing installer set Remove the driven bevel gear bearing using a suitable tool Remove the d...

Page 137: ...a new one Inspect the spline of the differential assembly for wear If any wear is found replace the differential assembly with a new one REASSEMBLY AND ADJUSTMENT DIFFERENTIAL DRIVE BEVEL GEAR HOUSING NOTE Apply hypoid gear oil to all moving parts before assembling Install the outer race using the special tool IT55LI 09924 84510 Bearing installer Install a new differential drive bevel gear bearing...

Page 138: ...o seat the bearings EEffll Bearing preload Standard 30 70 Ncm 3 0 7 0 kgf cm 2 6 6 1 Ib in If the bearing preload is not within specification tighten the gear nut to the specified torque and bring the preload within specification H Differential drive bevel gear nut 90 110 N m 9 0 11 0 kgf m 65 0 79 5 Ib ft A CAUTION Make sure to check the backlash and tooth contact when changing the gear bearing a...

Page 139: ...mark side of the bearing with the bearing installer Install a new front driven output shaft bearing using the spe cial tool 09913 70210 Bearing installer set 09924 74520 Bearing installer NOTE When installing the bearing tap on the punched mark side of the bearing using the bearing installer Install a new differential driven bevel gear housing right bear Install new oil seals using the special too...

Page 140: ...n the differential bevel gear hub Install the differential driven bevel gear on the differential Install the removed shim on the drive bevel gear housing Install the drive bevel gear into the differential driven bevel gear housing and tighten its bolts to the specified torque 3 Front drive bevel gear housing bolt 23 N m 2 3 kgf m 16 5 Ib ft ...

Page 141: ...ntial bevel gear backlash Standard 0 01 0 05 mm 0 0004 0 0020 in Without bearing case specification 0 07 0 15 mm 0 0028 0 0059 in Bearing case assembled specification NOTE Adjust the backlash by referring to the chart at the right and using the thickness of the old shims as a guide Backlash Shim thickness Under 0 01 mm 0 0004 in Increase 0 01 0 05 mm 0 0004 0 0020 in Correct Over 0 05 mm 0 0020 in...

Page 142: ...tedge and special tools IT55L1 09900 20602 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21203 Surface plate 09900 21304 V block set 100 mm Decide the prpper shim thickness by the following formula 0 10 mm Shim thickness B 0 10 mm Proper clearance Proper shim thickness EXAMPLE 2 5 00 mm 4 00 mm 5 00 4 00 0 10 0 90 So 0 90 is the proper shim size Select the 0 90 mm shims 0 50 0 40 mm from th...

Page 143: ...ted teeth Remove the differential drive bevel gear and compare the coated teeth to the examples shown in and If the tooth contact pattern is correct example go to the Final Assembly sub section on p 4 27 to complete installa tion Incorrect contact at tooth top Correct Incorrect contact at tooth root If tooth contact is found to be incorrect examples and the shim thickness between the differential ...

Page 144: ...st s dye or paste from the gear teeth and lubricate the teeth with hypoid gear oil Install new O rings to the differential driven gear bearing case and differential drive bevel gear housing Apply SUZUKI SUPER GREASE A to the O rings For USA 199000 25030 SUZUKI SUPER GREASE A For the other countries 99000 25010 SUZUKI SUPER GREASE A Install the differential drive bevel gear housing into the differ ...

Page 145: ...f camshaft with punched mark of cam Install the dog and shift fork into the driven gear bearing case Install the driven gear bearing case and then tighten the securing bolts to the specified torque H Driven gear bearing case bolt 23 N m 2 3 kgf m 16 5 Ib ft ...

Page 146: ...ever with the mark on the camshaft as shown Apply THREAD LOCK SUPER 1303 or 1322 to the threads of the propeller shaft joint bolts and then tighten them to the specified torque For USA t 9 99000 32030 THREAD LOCK SUPER 1303 For the other countries 453 99000 32110 THREAD LOCK SUPER 1322 J Propeller shaft joint bolt 45 N m 4 5 kgf m 32 5 Ib ft Apply SUZUKI SUPER GREASE A to the universal joint For U...

Page 147: ...t of shims List of shims List of shims Part No Shim thickness mm 27326 19B00 035 0 35 27326 19B00 040 0 40 27326 19B00 050 0 50 27326 19B00 060 0 60 Part No Shim thickness mm 27327 34200 0 35 27327 34210 0 40 27327 34220 0 50 27327 34230 0 60 Part No Shim thickness mm 27445 19B00 015 0 15 27445 19B00 030 0 30 27445 19B00 035 0 35 27445 19B00 040 0 40 ...

Page 148: ...al gear oil drain plug Final gear stopper Final drive bevel gear nut Final drive shaft housing nut Final gear bearing case R O ring Oil seal Bearing Shim Final bevel gear set Washer Shim Final bevel gear case Bearing O ring Final bearing case L Oil seal Bearing Shim Bearing Oil seal O ring Final drive shaft coupling Washer Final drive shaft Circlip Bearing Final drive shaft housing Spacer Dust sea...

Page 149: ...ain the final bevel gear oil CCT3 2 10 Remove the rear axle shaft OT 7 54 Disconnect the final bevel gear case breather hose Remove the rear propeller shaft joint bolt Remove the final drive shaft housing Remove the circlips Remove the final drive shaft assembly ...

Page 150: ...special tool and then remove the final drive gear nut IT55LI 09924 61810 Final drive gear coupling holder Remove the washer and final drive shaft coupling Remove the bearing stopper pin Remove the O ring final drive gear and shim A CAUTION Replace the removed O ring with a new one ...

Page 151: ...r bearing case using the suitable 5 mm bolts Remove the shims and final driven bevel gear Remove the shims 3 and washer INSPECTION Inspect the final drive shaft and ball joint assembly for wear or damage If any damages are found replace the final drive shaft and ball joint with a new one ...

Page 152: ...ve shaft and drive gear and then tapping the tool with a hammer A CAUTION Replace the removed bearing with a new one Remove the final drive pilot bearing using a suitable tool A CAUTION Replace the removed bearing with a new one Remove the right final driven gear bearing and oil seal using the special tool 09913 70210 Bearing installer set A CAUTION Replace the removed oil seal with a new one Remo...

Page 153: ...using the special tool TSSL 09913 50121 Oil seal remover ACAUTIOINT Replace the removed oil seal with a new one REASSEMBLY AND ADJUSTMENT BEARINGS Install the new drive shaft bearing and drive gear bearing using a suitable tool Install the new final drive pilot bearing using the suitable tool Install the new right final driven gear bearing using the spe cial tools T L 09913 70210 Bearing installer...

Page 154: ...earing using the special tool IT55L1 09913 70210 Bearing installer set Install the new oil seals using the special tool J 09913 70210 Bearing installer set Place the removed shims on the final driven bevel gear Install the final driven bevel gear on the final bevel gear case ...

Page 155: ...g case specification 0 08 0 13 mm 0 0031 0 0051 in Bearing case assembled specification NOTE Adjust the backlash by referring to the chart at the right and using the thickness of the old shims as a guide Backlash Shim thickness Under 0 02 mm 0 0008 in Increase 0 02 0 06 mm 0 0008 0 0024 in Correct Over 0 06 mm 0 0024 in Decrease FINAL GEAR BEARING CASE SHIM CLEARANCE Measure the clearance between ...

Page 156: ...te 09900 21304 V block set Decide the proper shim thickness by the following formula 0 1 0 m m S h i m thickness 0 10 mm Proper clearance Proper shim thickness EXAMPLE 10 00 mm 9 00 mm 10 00 9 00 0 10 0 90 Select the 0 90 mm shims from the right table Since it is the proper shim thickness List of shims available bearing shims d r 3 4 41 Part No Shim thickness mm 27327 34200 0 35 27327 34210 0 40 2...

Page 157: ... the final drive bevel gear and compare the coated teeth to the examples shown in and If the tooth contact is found to be correct example go to the Final Assembly sub section on p 4 42 to complete instal lation Incorrect contact at tooth top Correct Incorrect contact at tooth root If tooth contact is found to be incorrect examples and the shim thickness between the final drive gear bearing and fin...

Page 158: ...0 25010 SUZUKI SUPER GREASE A Apply THREAD LOCK SUPER 1303 or 1322 to the bear ing case bolt and tighten them to the specified torque For USA tjSS 99000 32030 THREAD LOCK SUPER 1303 For the other countries 433 99000 32110 THREAD LOCK SUPER 1322 H Bearing case bolt 23 N m 2 3 kgf m 16 5 Ib ft Tighten the final gear stopper to the specified torque using the special tool Sjj 09924 41820 Final gear st...

Page 159: ...using For USA HhsZI 99104 31140 SUZUKI BOND 1207B For the other countries 99000 31140 SUZUKI BOND 1207B Tighten the final drive shaft housing nut to the specified torque H Final drive shaft housing nut 23 N m 2 3 kgf m 16 5 Ib ft REMOUNTING Remount the final bevel gear case in the reverse order of removal Pay attention to the following point Tighten the rear propeller shaft joint bolts to the spec...

Page 160: ... List of shims Part No Shim thickness mm 27326 18A00 030 0 30 27326 18A00 035 0 35 27326 18A00 040 0 40 27326 18A00 050 0 50 27326 18A00 060 0 60 Part No Shim thickness mm 27327 34200 0 35 27327 34210 0 40 27327 34220 0 50 27327 34230 0 60 Part No Shim thickness mm 27445 18B00 030 0 30 27445 18B00 035 0 35 27445 18B00 040 0 40 27445 18B00 050 0 50 27445 18B00 060 0 60 ...

Page 161: ...VALVE 5 4 REMOVAL AND INSPECTION 5 4 FUEL STRAINER 5 4 REMOUNTING 5 4 FUEL LEVEL GAUGE 5 5 REMOVAL 5 5 INSPECTION 5 5 REMOUNTING 5 5 CARBURETOR 5 6 CONSTRUCTION 5 6 SPECIFICATIONS 5 7 I D NO LOCATION 5 7 REMOVAL 5 8 DISASSEMBLY 5 8 CLEANING 5 77 INSPECTION 5 72 REASSEMBLY 5 73 REMOUNTING 5 73 LUBRICATION SYSTEM 5 74 ENGINE LUBRICATION SYSTEM CHART 5 74 ...

Page 162: ...lines fuel tank and fuel tank cap for damage and fuel leakage If any damages are found replace the defec tive parts with new ones REMOVAL Remove the front fender 7 6 Drain the fuel completely Turn the fuel valve to the ON position Disconnect the fuel hose and vacuum hose A WARNING Gasoline is highly flammable and explosive Keep heat sparks and flames away from gasoline ...

Page 163: ...FUEL AND LUBRICATION SYSTEM 5 3 Remove the fuel tank REMOUNTING Remount the fuel tank in the reverse order of removal ...

Page 164: ...and explosive Keep heat sparks and flames away from gasoline Replace the removed O ring with a new one to pre vent fuel leakage FUEL STRAINER If the fuel strainer is dirty with sediment or rust fuel will not flow smoothly and loss in engine power may result Clean the fuel strainer with compressed air REMOUNTING Remount the fuel valve in the reverse order of removal ...

Page 165: ...plosive Extreme care must be taken INSPECTION Inspect the float of the fuel gauge assembly moves smoothly Inspect that the needle moves correctly as the float of the fuel gauge assembly moves up and down as shown in the illustra tion Approx 70 mm J F Approx 107 mm 1 2 Approx 136 mm Float REMOUNTING Remount the fuel level gauge in the reverse order of removal ...

Page 166: ...ing Jet needle Diaphragm Piston valve Needle jet Pilot air jet Main jet Needle valve assembly Pilot jet Pilot screw Float Float pin Gasket Float chamber Starter plunger Spring Holder Cap Gasket Side cap Throttle cable guide Throttle stop screw Vacuum hose Air vent hose ...

Page 167: ...in Main jet M J 135 B5 Jet needle J N 4D35 3rd 4D36 Needle jet N J 0 6 0 6 Throttle valve Th V 105 Pilot jet P J 60 ED Pilot screw P S 2 turns back PRE SET Pilot air jet P A J 155 Throttle cable play pulling cable 1 3 mm 0 04 0 12 in Starter enricher plunger cable play 0 5 1 0 mm 0 02 0 04 in E 03 USA E 24 Australia E 28 Canada E 33 California USA I D NO LOCATION Carburetor has an I D number 0 pri...

Page 168: ...he starter cable Remove the carburetor side cap Disconnect the throttle cable 2 Remove the carburetor DISASSEMBLY Remove the fuel hose air vent hoses hose 5 and throttle stop screw vacuum Remove the top cap A CAUTION Do not use compressed air on the carburetor body before removing the diaphragm this may damage the diaphragm ...

Page 169: ...M 5 9 Remove the spring stopper plate diaphragm jet needle and Remove the float chamber Remove the O ring A CAUTIOISr Replace the removed O ring with a new one to prevent fuel leakage Remove the float pin float and needle valve ...

Page 170: ... 8 size drill bit with a drill stop to remove the pilot screw plug Set the drill stop 6 mm from the end of the bit to prevent drilling into the pilot screw Carefully drill through the plug Thread a self tapping sheet metal screw into the plug Pull on the screw head with pliers to remove the plug Carefully clean any metal shavings from the area Slowly turn the pilot screw clockwise and count the nu...

Page 171: ... carburetor body with a spray type cleaner If necessary soak each cir cuit in a dip type cleaning solution to loosen dirt and varnish Dry the carburetor body using compressed air A CAUTIOINT Do not use wire to clean the jets or passageways If wire is used the jets and passageways may become damaged If the components cannot be cleaned with a spray type cleaner it may be necessary to soak the compon...

Page 172: ...at and needle valve are worn beyond the permissible limits similar 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 shown replace it and the valve seat with and a new one Clean the fuel passage of the mixing chamber using compressed air u CORRECT INCORRECT ...

Page 173: ...umber of turns counted during disassembly Pilot screw Carburetor body A CAUTION Replace the removed O ring with a new one Install the diaphragm NOTE When installing the diaphragm make sure the tab of the dia phragm is aligned with the convex section of the carburetor body s rim REMOUNTING Remount the carburetor assembly in the reverse order of removal After the carburetor assembly has been remount...

Page 174: ...Y ZD i O C O o LL_ C O o 111 6 O CD o C C cc o LU o 00 C O cc o o C C LU O C C O Q C O x LU ACE L i 2 CAM CO cc cc o o o o LU LU cc C C HAI R H n n RH SIDE LU 1 1 CAMS SIDE OILGA CAMS UNDE VER UNDE CYLII OILGA CAMS CY CO CY OILGA 5 C C LU b JL Gl Q _ 1 o C O o 2 o3 C O C C C O s AR 1 LU A C Ar CD ESH RSE LU cc LU o C C C O cc LU CD LU O Q ...

Page 175: ...ESERVOIR 6 6 INSPECTION 6 6 REMOVAL 6 7 REMOUNTING 6 8 COOLING FAN THERMO SWITCH 6 9 REMOVAL 6 9 INSPECTION 6 10 INSTALLATION 6 10 ENGINE COOLANT TEMPERATURE SWITCH 6 11 REMOVAL 6 11 INSPECTION 6 11 INSTALLATION 6 11 THERMOSTAT 6 12 REMOVAL 6 12 INSPECTION 6 12 INSTALLATION 6 13 WATER PUMP 6 14 REMOVAL AND DISASSEMBLY 6 14 INSPECTION 6 14 REASSEMBLY 6 15 ...

Page 176: ...ntrol over the flow of engine coolant through the radiator The valve is actuated by the temperature sensitive wax contained in the pellet Referring to the following illustration the thermostat is in the closed condition so that engine coolant recir culates through the route comprising pump engine by pass hole of the thermostat and radiator in the reg ulated condition As the coolant temperature ris...

Page 177: ...STEM 6 3 CONSTRUCTION Radiator cap Radiator inlet hose Radiator outlet hose Water pump inlet hose Water pump outlet hose Radiator bypass hose Water hose joint pipe Reservoir cap Reservoir Inlet hose Overflow hose ...

Page 178: ...6 4 COOLING SYSTEM Radiator O ring Cooling fan assembly Cooling fan Cooling fan thermo switch ...

Page 179: ...e of anti freeze is above or below this range the coolant s frost protection and rust inhibiting capabilities will be reduced Always keep the antifreeze content above 50 even if the atmospheric temperature does not go below the freezing point ESffl Engine coolant capacity 2 000 ml 2 1 US qt 1 8 Imp qt Antifreeze density Freezing point 50 31 C 24T 55 40 C 40 F 60 55 C 67 F F C 302 150 284 140 poini...

Page 180: ...n the filler to prevent the engine coolant from spray ing out A CAUTION Do not exceed the radiator cap release pressure or the radiator cap and subsequently the radiator can be damaged Check the radiator cap using a radiator tester Attach the radiator tester to the radiator cap as shown Slowly apply pressure to the radiator cap do not exceed 110 0 15 kPa 1 1 0 15 kgf cm2 15 6 2 1 psi If the radiat...

Page 181: ... fender CZT 7 6 Drain the engine coolant CJT 2 11 Remove the clamp Disconnect the cooling fan thermo switch coupler 2 and fan motor coupler 3 A WARNING Do not open the radiator cap when the engine is hot as you may be injured by escaping hot liquid or vapor The engine must be cool before servicing the cool ing system Engine coolant may be harmful if swallowed or if it comes in contact with the ski...

Page 182: ...fan Disconnect the engine coolant reservoir hoses Remove the engine coolant reservoir REMOUNTING Remount the radiator cooling fan and engine coolant reservoir in the reverse order of removal After remounting the radiator be sure to add engine coolant c 3 2 11 ...

Page 183: ... engine coolant is low but closes when the temperature reaches approximately 88 C 190T setting the cooling fan in motion Main IG switch fuse Fuse B O B R Thermo switch Fan motor B W Battery WIRE COLOR R Red B O Black with Orange tracer B R Black with Red tracer B W Black with White tracer REMOVAL Remove the front fender ZZT 7 6 Disconnect the cooling fan thermo switch coupler and remove the coolin...

Page 184: ...FF Approximately 82 C 180T INSTALLATION Install the cooling fan thermo switch in the reverse order of removal Pay attention to the following points Apply SUZUKI SUPER GREASE A to the O ring For USA 99000 25030 SUZUKI SUPER GREASE A For the other countries M 99000 25010 SUZUKI SUPER GREASE A Tighten the cooling fan thermo switch to the specified torque H Cooling fan thermo switch 17 N m 1 7 kgf m 1...

Page 185: ...r set PHBS Engine coolant temperature switch specification OFF ON Approximately 115 C 239T ON OFF Approximately 108 C 226 F INSTALLATION Install the engine coolant temperature switch in the reverse order of removal Pay attention to the following points Apply SUZUKI BOND 1207B to the thread portion of the engine coolant temperature switch and tighten it to the spec ified torque For USA 4 E 99104 31...

Page 186: ...omes in contact with the skin or eyes If engine coolant gets into the eyes or contacts the skin flush the eyes or wash the skin thoroughly with plenty of water If engine coolant is swallowed induce vomiting and call a physician immediately Disconnect the thermostat case T and remove the thermo stat INSPECTION Inspect the thermostat for cracks or damage If any damages are found replace the thermost...

Page 187: ...ve should have lifted at least 3 0 mm 0 12 in EEffiJ Thermostat valve lift over 3 0 mm at 90 C over 0 12 in at194T If the thermostat is faulty in either of these two checks replace it I N S T A L L A T I O N Install the thermostat in the reverse order of removal Pay attention to the following points Apply SUZUKI SUPER GREASE A to the rubber seal on the thermostat For USA J 99000 25030 SUZUKI SUPER...

Page 188: ... into the eyes or contacts the skin flush the eyes or wash the skin thoroughly with plenty of water If engine coolant is swallowed induce vomiting and call a physician immediately Disconnect the radiator hoses and remove the water pump assembly Remove the water pump cover I N S P E C T I O N WATER PUMP BEARING Inspect the inner race play of the water pump bearing by hand while they are in the wate...

Page 189: ...al for damage If any dam ages are found replace the mechanical seal with a new one Remove the mechanical seal A CAUTIOINT Replace the removed mechanical seal with a new one R E A S S E M B L Y Reassemble and remount the water pump in the reverse order of removal and disassembly Pay attention to the following points Install the water pump bearings using the special tool irSSh 09913 70210 Bearing in...

Page 190: ... REASSEMBLY AND REMOUNTING 7 26 FRONT SUSPENSION 7 28 CONSTRUCTION 7 28 REMOVAL AND DISASSEMBLY 7 29 INSPECTION 7 30 REASSEMBLY AND REMOUNTING 7 33 STEERING 7 36 CONSTRUCTION 7 36 REMOVAL AND DISASSEMBLY 7 37 INSPECTION 7 39 REASSEMBLY AND REMOUNTING 7 40 TOE IN ADJUSTMENT 7 42 FRONT WHEEL FRONT BRAKE FRONT SUSPENSION AND STEERING REASSEMBLING INFORMATION 7 43 REAR BRAKE 7 44 CONSTRUCTION 7 44 REM...

Page 191: ...7 2 CHASSIS EXTERIOR PARTS C O N S T R U C T I O N 0 Fuel tank cover Front fender side cover Front carrier Lid Front fender Radiator cover Front mudguard Front mudflap Mudflap inner ...

Page 192: ...CHASSIS 7 3 ...

Page 193: ...7 4 CHASSIS REMOVAL SEAT Remove the seat FRONT CARRIER Remove the front carrier FRONT GRIP BAR Remove the differential case cover Disconnect the clamps and headlight couplers Remove the front grip bar 2 ...

Page 194: ...T 7 4 Remove the radiator cover LID Remove the lid FRONT FENDER SIDE COVERS Remove the seat CU3 7 4 Remove the selection lever knob Remove the front fender side covers 2 FUEL TANK COVER Remove the front fender side cover cCr 7 5 Remove the range lever knob ...

Page 195: ...ct mounting bolt Remove the fuel tank cover FRONT FENDER Remove the seat front carrier front grip bar radiator cover front fender side covers and fuel tank cover d r 7 4 to 7 6 Remove the front fender REAR CARRIER Remove the rear carrier m ...

Page 196: ...ers fuel tank cover and rear carrier T 7 5 and 7 6 Remove the front seat hook plate and rear seat hook plate Remove the battery NOTE Disconnect the 0 battery lead wire first Remove the air cleaner duct Disconnect the taillight couplers Remove the rear fender ...

Page 197: ...front fender rear carrier and rear fender in the reverse order of removal Pay attention to the following point Apply THREAD LOCK SUPER 1303 or 1322 to the range lever knob mounting screw and selection lever knob mounting screw For USA tfi9 99000 32030 THREAD LOCK SUPER 1303 For the other countries tjssl 99000 32110 THREAD LOCK SUPER 1322 ...

Page 198: ... set nuts Support the vehicle with a jack or wooden block and remove the front and rear wheels R E M O U N T I N G Remount the wheels in the reverse order of removal Pay atten tion to the following point Tighten the wheel set nuts to the specified torque J Front and rear wheel set nut 50 N m 5 0 kgf m 36 0 Ib ft Rear wheel ...

Page 199: ... Never apply grease oil or gasoline to the tire bead because they will deteriorate the tire A CAUTION The standard tire fitted on this vehicle is AT25 x 8 1 2 for the front and AT25 x 10 12i r for the rear The use of tires other than the standard may cause instability It is highly recommended to use the speci fied tire Mount the tire on the rim by hand as shown NOTE Inspect the sealing portion of ...

Page 200: ...ine and the wheel rim varies this indi cates that the bead is not properly seated If this is so deflate the tire completely and unseat the tire bead on both sides Then coat the bead with clean water and re seat the tire Adjust the tire pressure to specification ESSJCold inflation tire pressure Front 35 kPa 0 35 kgf cm2 5 1 psi Rear 30 kPa 0 30 kgf cm2 4 4 psi E5SGS Vehicle load capacity 172 kg 380...

Page 201: ...oot set Snap ring Circlip Differential Differential Wheel side Wheel side shaft assembly side joint set side boot set side outer boot clamp side inner boot clamp side outer boot clamp side inner boot clamp inner boot clamp outer boot clamp R E M O V A L Remove the front drive shaft dT 4 12 D I S A S S E M B L Y Clean the front drive shaft ...

Page 202: ...ap ring from the outer race Separate the outer race from the front drive shaft Wipe off any grease and remove the circlip from the cage on the front drive shaft Remove the cage and boot from the front drive shaft ACAUTIOINT Do not disassemble the wheel side joint double offset joint If any damage is found replace the wheel side joint with a new one ...

Page 203: ... except for the boot After washing completely dry the parts using compressed air Clean the boots with a cloth A CAUTION Wash all parts before installation clean the inside and outside of the boot with a cloth Do not wash the boots in any commercially avail able degreaser such as gasoline or kerosene Washing in a degreaser causes deterioration of the boot Fit a boot on the drive shaft end fitting t...

Page 204: ...ide Differential side Quantity 45 g 80 g NOTE The tube of joint grease is included in the wheel side boot set or wheel side joint assembly of spare parts Insert the cage into the outer race and fit a snap ring in the groove of the outer race ACAUTIOINT Locate the opening of the snap ring 0 so that the opening is not lined up with a ball ...

Page 205: ...oot so that the air pressure in the boot becomes the same as the atmospheric pressure at the positions indicated in the illustration 1 5 1 1 6 1 mm 5 9 6 3 in Fix the boot on the outer race with a boot band taking care not to distort the boot Rotation direction Right side Left side R E M O U N T I N G Install the front drive shaft C r 5 4 27 ...

Page 206: ...e glycol based DOT 4 brake fluid Do not use or mix different types of fluid such as silicone based or petroleum based brake fluids Do not use any brake fluid taken from old used or unsealed containers Never reuse brake fluid left over from the last servicing or which has been stored for long periods of time When storing brake fluid seal the container completely and keep it away from children When ...

Page 207: ...e the brake pads as a set otherwise braking performance will be adversely affected Install the new brake pads Tighten the brake pad mounting pins and brake caliper mounting bolts 5 to the specified torque H Brake pad mounting pin 18 N m 1 8 kgf m 13 0 Ib ft Brake caliper mounting bolt 26 N m 2 6 kgf m 19 0 Ib ft NOTE After replacing the brake pads pump the brake lever a few times to check for prop...

Page 208: ...lve and disconnect the clear hose Fill the reservoir with new brake fluid to the upper end of the inspection window A CAUTIOINT Bleed air from the brake system 2 16 and 2 17 B R A K E C A L I P E R R E M O V A L A N D D I S A S S E M B L Y Disconnect the brake hose from the brake caliper by remov ing the brake hose union bolt and allow the brake fluid to drain into a suitable receptacle Remove the...

Page 209: ...iper piston damage Remove the dust seals and piston seals A CAUTION Do not reuse the dust seals and piston seals to pre vent fluid leakage B R A K E C A L I P E R I N S P E C T I O N BRAKE CALIPER Inspect each brake caliper cylinder wall for nicks scratches or other damage If any damages are found replace the brake caliper with a new one BRAKE CALIPER PISTONS Inspect the brake caliper pistons for ...

Page 210: ...n DOT 4 A CAUTION Wash the brake caliper components with new brake fluid before reassembly Do not wipe the brake fluid off after washing the components When washing the components use the specified brake fluid Never use different types of fluid or cleaning solvents such as gasoline kerosine etc Replace the removed piston seals and dust seals with new ones Apply brake fluid to all of the seals brak...

Page 211: ...e brake caliper pistons all the way into the caliper A CAUTION Bleed air from the system after reassembling the brake caliper cir 2 16 and 2 17 B R A K E D I S C R E M O V A L A N D D I S A S S E M B L Y Remove the front wheel dT 7 9 Remove the cotter pin A CAUTION Replace the removed cotter pin with a new one Loosen the axle nut by applying the front brake Remove the brake caliper CIT3 7 19 Remov...

Page 212: ...ess Service Limit 3 0 mm 0 12 in Measure the runout using the dial gauge If the runout exceeds the service limit replace the brake disc with a new one 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand Effl Brake disc runout Service Limit 0 3 mm 0 012 in If either measurement exceeds the service limit replace the brake disc with a new one CC73 7 22 and 7 23 B R A K E D I S C R E A S S E M ...

Page 213: ... Brake disc bolt 23 N m 2 3 kgf m 16 5 Ib ft Install the wheel hub A CAUTION When installing the wheel hub make sure the spacer 0 is properly positioned Tighten the front wheel set nuts and hub nut to the specified torque H Front wheel set nut 50 N m 5 0 kgf m 36 0 Ib ft Front hub nut 100 N m 10 0 kgf m 72 0 Ib ft NOTE First remount the front wheels and lower the jack and then tighten the front hu...

Page 214: ...union bolt and disconnect the brake hose A CAUTIOINT Immediately wipe off any brake fluid contacting any part of the vehicle The brake fluid reacts chemically with paint plastics rubber materials etc and will damage them severely Remove the master cylinder assembly Remove the brake lever Remove the reservoir cap and diaphragm Drain the brake fluid Pull the dust boot out and remove the circlip 0 ...

Page 215: ...iston set with a new one M A S T E R C Y L I N D E R R E A S S E M B L Y A N D R E M O U N T I N G Reassemble and remount the master cylinder in the reverse order of removal and disassembly Pay attention to the follow ing points A CAUTION Wash the master cylinder components with new brake fluid before reassembly Do not wipe the brake fluid off after washing the components When washing the componen...

Page 216: ... upper clamp bolt first H Master cylinder clamp bolt 10 N m 1 0 kgf m 7 0 Ib ft Master cylinder Master cylinder upper clamp bolt Handlebar Clearance Tighten the brake hose union bolt to the specified torqe H Brake hose union bolt 23 N m 2 3 kgf m 16 5 Ib ft A CAUTION Bleed air from the brake system after reassembling the master cylinder c T3 2 16 and 2 17 ...

Page 217: ... Steering knuckle Inner dust seal Spacer Hub bearing Outer dust seal Washer Lower wishbone arm Steering knuckle end Bushing Shock absorber mounting nut Wishbone arm pivot nut Steering knuckle pinch bolt Steering knuckle end bolt H ITEM N m kgf m Ib ft 60 6 0 43 5 65 6 5 47 0 50 5 0 36 0 145 14 5 105 0 ...

Page 218: ...brake hose retainer Remove the cotter pin and tie rod end nut A CAUTION Replace the removed cotter pin with a new one Remove the wishbone arm pivot bolts and shock absorber upper mounting bolt Remove the front suspension assembly Remove the front shock absorber Remove the upper wishbone arm and lower wishbone arm ...

Page 219: ...emove the brake disc cover I N S P E C T I O N FRONT SHOCK ABSORBER Inspect the shock absorber for oil leakage or damage If any damages are found replace the front shock absorber with a new one KNUCKLE END Inspect the knuckle end boot for wear or damage If any dam ages are found replace the knuckle end with a new one ...

Page 220: ... the brake disc cover for wear or damage If any dam ages are found replace the brake disc cover with a new one BUSHING Inspect the rubber bushing shock absorber wishbone arm for wear or other damage If any damages are found replace the bushing with a new one Apply THREAD LOCK SUPER 1303 or 1322 to the outer surface of bushing when replacing the bushing of the wish bone arm For USA 493 99000 32030 ...

Page 221: ...A CAUTION Replace the removed dust seal with a new one HUB BEARINGS Inspect the inner race play of the hub bearing by hand while it is in the steering knuckle Rotate the inner race by hand to inspect for abnormal noise and smooth rotation If there is anything unusual replace the bearing with a new one NOTE Make sure to check each bearing in the same manner Play Ip R j P l a y U Remove the hub bear...

Page 222: ...I SUPER GREASE A to the hub bearings and the lip of the dust seals before installing them For USA 199000 25030 SUZUKI SUPER GREASE A For the other countries 199000 25010 SUZUKI SUPER GREASE A Install the hub bearings using the special tool J 09924 84510 Bearing installer set NOTE Install the outer bearing the spacer 2 and then the inner bearing Make sure the sealed side of the bearing faces out wa...

Page 223: ...r ing knuckle pinch bolts and then tighten it to the specified torque For USA 463 99000 32030 THREAD LOCK SUPER 1303 For the other countries rfsB 99000 32110 THREAD LOCK SUPER 1322 5 Steering knuckle pinch bolt 50 N m 5 0 kgf m 36 0 Ib ft Apply THREAD LOCK SUPER 1303 or 1322 to the wish bone arm pivot bolts and then tighten the nuts 0 to the specified torque For USA t S 99000 32030 THREAD LOCK SUP...

Page 224: ...tie rod end nut to the specified torque H Tie rod end nut 32 N m 3 2 kgf m 23 0 Ib ft NOTE After installing the tie rod end nut insert a new cotter pin into the tie rod end FRONT SHOCK ABSORBER STANDARD POSITION 2 5 ...

Page 225: ...andlebar lower clamp Steering shaft Steering shaft holder Dust seal Cable guide Bushing Dust seal Dust seal Tie rod end inside Tie rod end outside Handlebar clamp bolt Steering shaft holder bolt Steering shaft nut Tie rod end nut Tie rod locknut H ITEM N m kgf m Ib ft 23 2 3 16 5 23 2 3 16 5 49 4 9 35 5 32 3 2 23 0 45 4 5 32 5 ...

Page 226: ... E M B L Y Remove the front fender 7 6 Remove the front wheel 7 9 Remove the master cylinder assembly 7 25 Remove the speedometer assembly cZr 8 23 Remove the throttle lever case Disconnect the rear brake cable and remove the handle bar switch 2 ...

Page 227: ...ering shaft nut A CAUTION Replace the removed cotter pins with new ones Remove the clips and steering shaft holder bolts Remove the steering shaft A CAUTION Replace the removed clips with new ones Remove the dust seals from the steering shaft Remove the dust seal and O ring from the frame A CAUTION Replace the removed O ring with a new one ...

Page 228: ...r damage If any damages are found replace the tie rod with a new one TIE ROD END Inspect the tie rod end and boots for smooth movement If there are any abnormalities replace the tie rod end with a new one STEERING SHAFT AND HOLDER Inspect the steering shaft for distortion or bends If any dam ages are found replace the steering shaft with a new one Inspect the two steering shaft holders for wear or...

Page 229: ... torque H Steering shaft nut 49 N m 4 9 kgf m 35 5 Ib ft NOTE After installing the steering shaft nut install a new cotter pin into the steering shaft Apply SUZUKI SUPER GREASE A to the steering shaft holders and dust seals before remounting the steering shaft holders For USA 5 H99000 25030 SUZUKI SUPER GREASE A For the other countries 199000 25010 SUZUKI SUPER GREASE A A CAUTION To prevent the en...

Page 230: ...he tie rod comes out A CAUTION The locknuts have left hand threads HANDLEBAR When setting the handlebar lower clamps to the steering shaft face the white mark on its clamp to forward Set the handlebar to match its punched mark to the mat ing face of the handlebar clamps First tighten the bolts to the specified torque and then tighten the bolt 0 H Handlebar clamp bolt 23 N m 2 3 kgf m 16 5 Ib ft Al...

Page 231: ...peci fication adjust the tie rod to the right or left until the toe in is within the specified range Toe in L i i f r m T f i l Toe in Standard 7 15 mm 0 28 0 59 in Temporarily tighten the four locknuts Check that the distances and are equal as shown If the distances are not equal adjust the tie rod to the right or left until the toe in is within specification Check the toe in again by measuring d...

Page 232: ...NT SUSPENSION AND STEERING REASSEMBLING INFORMATION H ITEM Nm kgf m Ib ft ITEM Nm kgf m Ib ft 23 2 3 16 5 100 10 0 72 5 23 2 3 16 5 50 5 0 36 0 49 4 9 35 5 50 5 0 36 0 65 6 5 47 0 60 6 0 43 5 145 14 5 105 0 32 3 2 23 0 23 2 3 16 5 45 4 5 32 5 ...

Page 233: ...ake panel Brake cam lever Brake drum cover bolt Brake panel bolt Brake cam lever nut ITEM Nm kgf m Ib ft 23 2 3 16 5 23 2 3 16 5 11 1 1 8 0 R E M O V A L A N D D I S A S S E M B L Y Remove the rear wheel CZT 7 9 Remove the cotter pin A CAUTION Replace the removed cotter pin with a new one Remove the axle nut by applying the rear brake ...

Page 234: ...CHASSIS 7 45 Disconnect the rear brake breather hose ...

Page 235: ...brake camshaft I N S P E C T I O N BRAKE DRUM Inspect the brake drum and measure the brake drum inside diameter to determine the extent of wear If the measurement exceeds the service limit replace the brake drum with a new one The brake drum inside diameter is indicated inside the drum Brake drum I D Service Limit 180 7 mm 7 11 in ...

Page 236: ...one A CAUTION Replace the removed dust seal and O rings with new ones Inspect the seal ring mounted on the brake drum for any scuff ing or damage If any damages are found replace the brake drum with a new one R E A S S E M B L Y A N D R E M O U N T I N G Reassemble and remount the rear brake in the reverse order of removal and disassembly Pay attention to the following points Apply SUZUKI SUPER GR...

Page 237: ...all quantity of THREAD LOCK 1342 to the rear brake panel bolt and then tighten it to the specified torque 423 99000 32050 THREAD LOCK 1342 H Rear brake panel bolt 23 N m 2 3 kgf m 16 5 Ib ft A WARNING Be careful not to apply too much grease to the brake camshaft and pin If grease gets on the lining brake slippage will result Install the brake shoes and brake drum Tighten the brake drum cover bolt ...

Page 238: ...the rear brake H Rear hub nut 100 N m 10 0 kgf m 72 5 Ib ft NOTE First remount the rear wheels and lower the jack and then tighten the rear axle nut to the specified torque After installing the rear axle nut insert a new cotter pin into the axle shaft After installing the rear brake adjust the following items Brake pedal play d7 2 15 Rear brake lever play C r 3 2 15 ...

Page 239: ...ng left side Bushing Bushing Bushing Bushing Rear suspension arm RH Rear suspension arm RH Rear suspension arm LH Resr suspension arm LH Rear shock absorber mounting nut Rear shock absorber mounting bolt Suspension arm bolt Suspension arm pivot nut ITEM Nm kgf m Ib ft 60 6 0 43 5 55 5 5 40 0 50 5 0 36 0 80 8 0 58 0 60 6 0 43 5 ...

Page 240: ...d remove the clamps Remove the suspension arms I N S P E C T I O N REAR SHOCK ABSORBER Inspect the rear shock absorber for oil leakage or damage If any damages are found replace the shock absorber with a new one SUSPENSION ARM Inspect the suspension arm for distortion or damage If any damages are found replace the suspension arm with a new one ...

Page 241: ...ints Apply THREAD LOCK SUPER 1303 or 1322 to the sus pension arm pivot nuts and rear suspension arm bolts and tighten the rear suspension arm bolts and nut For USA tjS3 99000 32030 THREAD LOCK SUPER 1303 For the other countries tjas 99000 32110 THREAD LOCK SUPER 1322 H Rear suspension arm bolt and nut 60 N m 6 0 kgf m 43 5 Ib ft Tighten the shock absorber mounting bolt and nut to the specified tor...

Page 242: ... O N Circlip Bearing Rear axle shaft right side Rear axle housing right side Final bevel gear case cover Trailer towing Rear axle housing left side Rear axle shaft left side Dust seal Rear axle housing mounting bolt H ITEM Nm kgf m Ib ft 50 5 0 36 0 ...

Page 243: ...21940 Wheel hub remover 09930 30102 Sliding hammer Remove the final bevel gear case cover Support the final bevel gear case with a stand or wooden blocks Remove the rear axle housings and trailer towing Remove the rear axle shafts I N S P E C T I O N REAR AXLE HOUSING Inspect the rear axle housing for distortion or damages If any damages are found replace the rear axle housings with new ones ...

Page 244: ...lace the dust seal with a new one Remove the dust seal using the special tool IT55LI 09913 50121 Oil seal remover HUB BEARING Inspect the inner race play of the hub bearing by hand while it is in the rear axle housing Rotate the inner race by hand to inspect for abnormal noise and smooth rotation If there is anything unusual replace the bearing with a new one NOTE Make sure to check each bearing i...

Page 245: ... removal and disassembly Pay attention to the following points Apply SUZUKI SUPER GREASE A to the hub bearings and dust seals before installing them For USA fl 99000 25030 SUZUKI SUPER GREASE A For the other countries JigH99000 25010 SUZUKI SUPER GREASE A Install the hub bearings using the special tool ITS5LI 09913 70210 Bearing installer set Install the dust seal using the special tool 09913 7021...

Page 246: ...s grooved line on its shaft Apply SUZUKI BOND 1207B to the mating surface of the rear axle housings For USA 3 99104 31140 SUZUKI BOND 1207B For the other countries m s Z H 99000 31140 SUZUKI BOND 1207B Install the rear axle housings and trailer towing and then tighten them to the specified torque 5 Rear axle housing mounting nut and bolt 50 N m 5 0 kgf m 36 0 Ib ft REAR SHOCK ABSORBER STANDARD POS...

Page 247: ...7 58 CHASSIS REAR WHEEL REAR BRAKE REAR SUSPENSION AND REAR AXLE SHAFT REASSEMBLING INFORMATION ...

Page 248: ...CHASSIS 7 59 SHIFT LEVERS C O N S T R U C T I O N Remove the selection shift lever bracket ...

Page 249: ...ction shift lever holder Remove the O rings and spacer A CAUTION Replace the removed O rings with new ones INSPECTION Inspect the selection shift lever assembly for wear or damage If any damages are found replace the selection shift lever assembly with a new one ...

Page 250: ...acer mating surface of the selection shift lever and O rings For USA 99000 25030 SUZUKI SUPER GREASE A For the other countries 99000 25010 SUZUKI SUPER GREASE A NOTE Adjust the selection lever cable after installing the selection shift lever and its cable CZT 7 63 and 7 64 RANGE LEVER REMOVAL AND DISASSEMBLY Remove the front fender 7 6 Disconnect the range lever cable Remove the range lever bracke...

Page 251: ...ssemble and remount the range lever in the reverse order of removal and disassembly Pay attention to the following point Apply SUZUKI SUPER GREASE A to the spacer mating surface of the range lever and O rings For USA 99000 25030 SUZUKI SUPER GREASE A For the other countries 99000 25010 SUZUKI SUPER GREASE A Align the slit in the range lever arm with the punch mark on the range lever NOTE Adjust th...

Page 252: ...e differential camshaft Install the selection lever onto the differential camshaft and then tighten the bolt securely Set the selection lever to the lower 4WD position on the differential case and the selection shift lever to the front 4WD position on the selection shift lever case bracket Install the cable and clip differential case side to the stopper located on the A CAUTION Make sure the insta...

Page 253: ...ing and damage to the cable selection shift lever or selection lever Fasten the selection lever cable and selection shift lever by installing the selection lever cable washer and E ring NOTE Direction of the eye rod is determined by the side differential case or crankcase side it is installed on A CAUTION Be sure to install the selection lever eye rod accu rately and that the end face of the selec...

Page 254: ... crankcase camshaft as shown and then tighten the bolt securely Set the range lever to the front low position on the crankcase and the range shift lever to the front low posi tion on the range lever case bracket Install the cable and clip to the stopper located on the crankcase side A CAUTION Make sure the installation angle of the range lever is accurate and its position is adjusted properly Do n...

Page 255: ...nd damage to the cable selection lever or range lever Fasten the range lever cable and range lever arm by install ing the range shift lever cable washer and E ring NOTE Direction of the eye rod is determined by the side differential case or crankcase side it is installed on A CAUTION Be sure to install the range lever eye rod accurately and that the end face of the selection lever contacts the fla...

Page 256: ... SYSTEM 8 12 DESCRIPTION 8 12 TROUBLESHOOTING 8 12 STARTER MOTOR REMOVAL AND DISASSEMBLY 8 13 STARTER MOTOR INSPECTION 8 14 STARTER MOTOR REASSEMBLY AND REMOUNTING 8 15 STARTER RELAY INSPECTION 8 16 NEUTRAL RELAY INSPECTION 8 17 IGNITION SYSTEM 8 18 DESCRIPTION 8 18 TROUBLESHOOTING 8 18 INSPECTION 8 20 BACK UP LIGHT RELAY FOR E 17 8 22 SPEEDOMETER 8 23 REMOVAL 8 23 DISASSEMBLY 8 24 LAMPS 8 25 HEAD...

Page 257: ...ect each terminal for corrosion and contamination CLAMPS Refer to the WIRE HARNESS CABLE AND HOSE ROUT ING section for proper clamping procedures T 9 12 to 9 21 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 substitutes for the band type clamp FUSES When a fuse blows always investigate the cause correct the pr...

Page 258: ...ery is different from that of a conventional battery Do not replace the MF battery with a conventional battery CONNECTING THE BATTERY When disconnecting terminals from the battery for disassem bly or servicing be sure to disconnect the 0 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 ...

Page 259: ...le and tester If the voltage and current values are not known begin mea suring in the highest range When measuring the resistance make sure no voltage is applied If voltage is applied the tester will be damaged After using the tester turn the switch to the OFF position A CAUTION Before using the multi circuit tester read its instruc tion manual ...

Page 260: ...ELECTRICAL SYSTEM 8 5 LOCATION OF ELECTRICAL COMPONENTS Battery Ignition coil Ignition switch Speedometer Handlebar switch Starter motor Neutral switch Regulator rectifier ...

Page 261: ...8 6 ELECTRICAL SYSTEM Cooling fan Cooling fan thermo switch Engine coolant temperature switch Fuse box Neutral relay CDI unit Main fuse Starter relay Generator ...

Page 262: ...egulator rectifier into DC current The regulator rectifier is one unit which has two functions The regulator prevents overcharging of the battery by grounding the exces sive AC current The rectifier changes the AC current which is produced by the generator to the DC cur rent All of these components work together to maintain a correct and constant voltage and to prevent the battery from overchargin...

Page 263: ...orrect Inspect the regulator rectifier 8 11 Correct _ L _ Inspect the wires Correct Others Accessories are installed Current leaks Correct No continuity Incorrect Incorrect Incorrect Remove accessories Short circuit of the wire harness Loose or disconnected wires Faulty battery Faulty battery Abnormal driving condition Faulty stator coil or disconnected lead wires Faulty generator Faulty regulator...

Page 264: ...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 seat cOr 7 4 Start the engine turn the ignition switch to light and the dimmer switch to HI and run the engine at 5 000 r min Measure the DC voltage between the and battery termi nals u...

Page 265: ...er set Tester knob indication Resistance Q Stator coil resistance Standard 0 1 1 0 Q Yellow Yellow AC GENERATOR NO LOAD PERFORMANCE Remove the rear fender J 7 7 Disconnect the stator coil lead wire coupler Start the engine and run it at 5 000 r min Measure the AC voltage between the lead wires of the genera tor using the multi circuit tester If the voltage is under the specified value replace the ...

Page 266: ...Tester probe B R B R2 B1 B2 B3 B W1 B W2 B R1 0 0 4 0 7 0 4 0 7 0 4 0 7 0 5 1 2 0 5 1 2 obe B R2 0 0 4 0 7 0 4 0 7 0 4 0 7 0 5 1 2 0 5 1 2 _ CL S _ Bi 1 4 1 5 1 4 1 5 1 4 1 5 1 4 1 5 0 4 0 7 0 4 0 7 C D G O C D B2 1 4 1 5 1 4 1 5 1 4 1 5 1 4 1 5 0 4 0 7 0 4 0 7 F B3 1 4 1 5 1 4 1 5 1 4 1 5 1 4 1 5 0 4 0 7 0 4 0 7 F B W1 1 4 1 5 1 4 1 5 1 4 1 5 1 4 1 5 1 4 1 5 0 B W2 1 4 1 5 1 4 1 5 1 4 1 5 1 4 1 5...

Page 267: ...er motor draws about 80 amperes to start the engine R Starter Engine stop Ignition button switch switch TROUBLESHOOTING Starter motor will not run The transmission is in neutral Turn on the igni tion switch with the engine stop switch in the RUN position Listen for a click from the starter relay when the starter button is pushed Clicks No click Continued on next page Check if the starter motor run...

Page 268: ...ty neutral relay Faulty starter button Improper connector contact Open circuit in wire harness Check the starter relay C73 8 16 I Correct Incorrect Faulty starter relay Improper starter relay contact Others Engine does not turn though the starter motor runs Faulty starter clutch STARTER MOTOR REMOVAL AND DISASSEMBLY Remove the rear fender d r 5 7 7 Disconnect the starter motor lead wire and engine...

Page 269: ...discoloration abnormal wear or undercut If abnormal wear is found replace the armature with a new one If the commutator surface is discolored polish it with 400 sandpaper and wipe it using a clean dry cloth If there is no undercut scrape out the insulator with a saw blade ARMATURE COIL INSPECTION Check for continuity between each segment and between each segment and the armature shaft using the mu...

Page 270: ...N Replace the removed O rings with new ones to pre vent oil leakage and moisture Apply SUZUKI SUPER GREASE A to the lip of the oil seal For USA Jif 99000 25030 SUZUKI SUPER GREASE A For the other countries Jjfn99000 25010 SUZUKI SUPER GREASE A Apply a small quantity of SUZUKI MOLY PASTE to the armature shaft 4 W 99000 25140 SUZUKI MOLY PASTE Align the match marks on the starter motor case with the...

Page 271: ...arter relay clicks and continuity is found the relay is ok ITC 5L1 09900 25008 Multi circuit tester set Tester knob indication Continuity test A CAUTION Do not apply battery voltage to the starter relay for more than five seconds This may overheat and damage the relay coil Measure the relay coil resistance between the terminals using the multi circuit tester If the resistance is not within the spe...

Page 272: ...tral relay from the starter relay holder Apply 12 V to terminals and to and to and check the continuity between and using a multi circuit tester If there is no continuity found replace the neutral relay with a new one 09900 25008 Multi circuit tester set Tester knob indication Continuity test 1 r r ...

Page 273: ...it CDI unit Ignition power source circuit CPU Wave form arrangment circuit Ignition coil TROUBLESHOOTING No spark or poor spark Check the ignition sysl connections em couplers for poor 1 Correct Measure the battery v lead wires O W and E with the ignition switch Dltage between input W at the CDI unit in the ON position Make sure the transmission is in the neutral position and the engine stop switc...

Page 274: ...ect Faulty spark plug Inspect the ignition coil CIT3 8 21 Improper spark plug connection Incorrect Faulty ignition coil Correct Measure the pickup coil and power source coil peak voltage and resistance Xlr3 8 21 and 8 22 NOTE The pickup coil and power source coil peak voltage inspection is applicable only with the multi circuit tester and the peak volt adaptor Incorrect Faulty pickup coil Correct ...

Page 275: ...900 25008 Multi circuit tester set A CAUTION When using the multi circuit tester and peak volt adaptor refer to the appropriate instruction manual Shift the transmission into neutral and turn the ignition switch to the ON position Press the starter button and allow the engine to crank for a few seconds and then measure the ignition coil primary peak voltage Repeat the above procedure a few times a...

Page 276: ...TAGE NOTE Make sure all of the couplers are connected properly Disconnect the generator coupler at the CDI unit Measure the pickup coil and power source coil peak voltage in the following procedure Connect the multi circuit tester with the peak volt adaptor as follows Pickup coil Blue Probe Green Probe Power source coil Yellow Probe White Probe IT55LI 09900 25008 Multi circuit tester set A CAUTION...

Page 277: ...fied value the pickup coil and power source coil must be replaced 09900 25008 Multi circuit tester set j Tester knob indication Resistance 12 EBKJ Pickup coil resistance 170 250 Q Blue Green Power source coil resistance 0 05 0 5 Q Yellow White BACK UP LIGHT R E L A Y For E 17 Remove the back up light relay 2 Rear box Ckeck that no continuity exists between the terminals D and If continuity is foun...

Page 278: ...3 SPEEDOMETER REMOVAL Remove the front fender Zr 7 6 Remove the lower meter cover Disconnect the speedometer cable speedometer coupler and ignition switch coupler Remove the upper meter cover Remove the speedometer assembly ...

Page 279: ...8 24 ELECTRICAL SYSTEM DISASSEMBLY Disassemble the speedometer as shown CD Speedometer Damper Braket Pilot box reflector Upper case pilot box Pilot lens Bulb Bulb Socket assembly ...

Page 280: ...soapy water to prevent premature bulb failure BULB REPLACEMENT Remove the headlight guard unit Remove the rubber cap Push in the bulb socket turn it to the left and then remove it Remove the bulb Install the new bulb in the reverse order of removal ACAinTOINT If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failu...

Page 281: ...with alcohol or soapy water to prevent premature bulb failure BULB REPLACEMENT Remove the taillight lens Push in on the bulb turn in to the left and then pull it out Remove the bulb Install the new bulb in the reverse order of removal A CAUTION If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure ...

Page 282: ...r Light r Light ON o o OFF DIMMER SWITCH C o l o r P o s i t i o n Y w Gr HI HI LO o o ENGINE STOP SWITCH C o l o r P o s i t i o n 0 o w RUN o O OFF STARTER BUTTON C o l o r P o s i t i o n o w Y G PUSH o o HORN BUTTON For E 24 C o l o r P o s i t i o n G B W PUSH o o WIRE COLOR G Green Gr Gray O Orange R Red Y Yellow W White B W Black with White tracer O W Orange with White tracer Y G Yellow wit...

Page 283: ...minum tape which seals the battery filler holes Remove the caps from the electrolyte container NOTE Do not remove or pierce the sealed areas of the electro lyte container After completely filling the battery with electrolyte use the caps from the electrolyte container to seal the battery filler holes Insert the nozzles of the electrolyte container into the electrolyte filler holes of the battery H...

Page 284: ...caps firmly into the filler holes so that the top of the caps do not protrude above the upper surface of the top cover of the battery A CAUTION The charging system for an MF battery is different 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 the multi circuit tester If the battery...

Page 285: ... the bat tery Recharging time 1 4 A for 5 to 10 hours or 7 A for 1 hour A CAUTION Be careful not to permit the charging current to exceed 7 A at any time After recharging wait at least 30 minutes and then measure the battery voltage using the multi circuit tester If the battery voltage is less than 12 5 V recharge the battery again If the battery voltage is still less than 12 5 V after recharging ...

Page 286: ... 9 12 WIRE HARNESS ROUTING 9 12 CABLE ROUTING 9 14 DIFFERENTIAL AND FINAL BEVEL GEAR HOSE ROUTING 9 16 REAR BRAKE BREATHER HOSE ROUTING 9 17 FUEL SYSTEM HOSE ROUTING 9 18 COOLING SYSTEM HOSE ROUTING 9 19 FRONT BRAKE HOSE ROUTING 9 20 HEAT SHIELD ADHESIVE POSITION 9 21 SPECIAL TOOLS 9 22 TIGHTENING TORQUE 9 25 ENGINE 9 25 DIFFERENTIAL 9 26 CHASSIS 9 26 TIGHTENING TORQUE CHART 9 27 SERVICE DATA 9 28...

Page 287: ...eplace 2 Wet spark plug Clean and dry or replace 3 Defective ignition coil Replace 4 Open or short in high tension cord Replace 5 Defective generator Replace 6 Defective CDI unit Replace No fuel reaching the carburetor 1 Clogged fuel tank vent hose Clean or replace 2 Clogged or defective fuel valve Clean or replace 3 Defective carburetor needle valve Replace 4 Clogged fuel hose Clean or replace 5 ...

Page 288: ...ft 1 Rattling bearing Replace 2 Worn or burnt crank pin bearing Replace 3 Excessive thrust clearance Replace thrust bearing Noise s e e m s to come from the movable drive and driven face 1 Worn or slipping drive belt Replace 2 Worn rollers in movable drive face Replace Noise s e e m s to come from the transmission 1 Worn or rubbing gear Replace 2 Worn driveshaft spline Replace driveshaft 3 Worn be...

Page 289: ...ce Replace Regap or replace Adjust Replace Adjust float height Clean or replace Clean and prime Replace Exhaust smoke is dirty or thick 1 Excessive amount of engine oil 2 Worn piston ring 3 Worn valve guide 4 Scored or scuffed cylinder wall 5 Worn valve stem 6 Defective valve stem oil seal Check level and drain Replace Replace Replace Replace valve Replace Engine lacks power 1 Insufficient valve c...

Page 290: ...place Replace Adjust Replace Replace Replace CARBURETOR Complaint Symptom and possible c a u s e s Remedy Starting difficulty 1 Clogged starter jet 2 Clogged starter jet passage 3 Air leaking from joint between starter body and carburetor 4 Improperly working starter enricher plunger Clean Clean Tighten adjust or replace gasket Adjust Idling or low speed trouble 1 Clogged or loose pilot jet 2 Clog...

Page 291: ...e pressure 2 Worn steering linkage connections 3 Loose suspension system bolts Regulate Replace Tighten Tires rapidly or unevenly wear 1 Worn or loose front wheel hub bearings 2 Improper front wheel alignment Replace Adjust Steering too noisy 1 Loose nuts and bolts 2 Damaged or worn front wheel hub bearings 3 Insufficiently lubricated Tighten Replace Lubricate Suspension too soft 1 Weak spring 2 S...

Page 292: ...on lining surface 2 Titled pad 3 Loose front wheel axle or rear wheel axle 4 Worn brake pads and linings 5 Foreign material in brake fluid 6 Clogged return port of master cylinder 7 Wrongly fixed spring 8 Caliper binding on caliper axles Repair surface with emery paper Modify pad fitting Tighten to specified torque Replace Replace brake fluid Disassemble and clean master cylinder Set correctly Cle...

Page 293: ...type spark plug Tune up Tighten Adjust carburetor Generator does not charge 1 Open or short in lead wires or loose lead connections 2 Shorted grounded or open generator coil 3 Shorted or punctured regulator rectifier Repair replace or connect properly Replace Replace Generator charges but charging rate is below specification 1 Lead wires tend to get shorted open circuited or loosely connected at t...

Page 294: ...ier circuit connections and make necessary adjustments to obtain specified charging operation Replace the battery and correct the charging system Replace Replace Reversed battery polarity 1 Improperly connected battery leads i e 0 to a n d t o Replace the battery and be sure to connect it properly Battery discharged too rapidly 1 Dirty container top and sides 2 Old battery Clean Replace Battery su...

Page 295: ...9 10 SERVICING INFORMATION WIRING DIAGRAM E 03 24 28 and 33 JflJJuIlilJJlJ j S fHl 1 i iiiiiiiiiliSjiiiifiim l ai j Slll llSlSlllgg mm ...

Page 296: ...SERVICING INFORMATION 9 11 E 17 5 uj 5 5 i S i S f f l S 0 0 L I S lllijliil iiilMiiIIillIMIMiiiii l i oii S lIllalSlllI g ...

Page 297: ...SE ROUTING WIRE HARNESS ROUNTING Clamp Wiring harness Clamp Wiring harness Clamp Wiring harness Clamp Handlebar switch L Clamp Ignition switch Handlebar switch Speedometer Horn button E 24 Emergency switch E 17 battery lead wire Q battery lead wire Clamp ...

Page 298: ...SERVICING INFORMATION 9 13 J1207B r Engine ground lead wire Starter motor lead wire Right crankcase Clamp o Generator lead wire Neutral switch Generator lead wire ...

Page 299: ...er cable Throttle cable Brake hose Pass the throttle cable behind the brake hose and rear brake lever cable Rear brake lever cable Water pump inlet hose Speedometer cable Rear brake Rear brake pedal cable Clamp Rear brake lever cable Rear brake pedal cable ...

Page 300: ...SERVICING INFORMATION 9 15 ...

Page 301: ...9 16 SERVICING INFORMATION ...

Page 302: ...SERVICING INFORMATION 9 17 REAR BRAKE BREATHER HOSE ROUTING ...

Page 303: ...9 18 SERVICING INFORMATION FUEL SYSTEM HOSE ROUTING Steering head cover ...

Page 304: ...SERVICING INFORMATION 9 19 ...

Page 305: ...rake hose union to the stopper tighten the union bolt to the specified torque Brake hose Blake caliper R Brake caliper L After touching the brake hose union to the stopper tighten the union bolt to the specified torque Brake caliper L After touching the brake hose union to the stopper tighten the union bolt to the specified torque Brake caliper R ...

Page 306: ...SERVICING INFORMATION 9 21 ...

Page 307: ...0 mm 0 25 mm 09900 20508 Cylinder gauge set 1 100 mm 40 80 mm 09900 20602 Dial gauge 1 1000 mm 09900 20605 Dial calipers 1 100 mm 10 34 mm 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 20803 Thickness gauge 09900 20805 Tire depth gauge 09900 21203 Surface plate 09900 21304 V block set 100 mm 09900 22301 Plastigauge 09900 22302 Plastigauge 09900 22403 Small bore gauge 18 35 mm 09...

Page 308: ...set 09916 24311 Solid pilot N 100 5 0 09916 22410 Solid pilot N 140 5 0 09916 27720 Valve seat cutter N 229 09916 34542 Reamer handle 09916 34570 Valve guide reamer 5 0 mm 0 9 9 1 Valve guide reamer 10 8 mm 09916 44310 Valve guide remover installer V 09916 84511 Tweezers 09917 14920 Valve adjuster driver 09917 23711 Ring nut socket wrench 09920 13120 Crankcase separat ing tool 09921 20220 Bearing ...

Page 309: ...aller 09924 84510 Bearing installer set 09930 30102 Sliding hammer 09930 30721 Rotor remover 09930 31920 Rotor remover 09930 40113 Rotor holder 09930 73160 Output shaft holder 09941 50111 Bearing remover 09941 54911 Bearing outer race remover 09941 64511 Bearing remover 09941 84510 Bearing remover NOTE When ordering a special tool please confirm whether it is available or not ...

Page 310: ...h bolt 6 5 0 65 4 5 T D C plug 23 2 3 16 5 Clutch shoe nut 70 7 0 50 5 Movable drive face nut 115 11 5 83 0 Movable driven face nut 115 11 5 83 0 Movable driven face spring nut 100 10 0 72 5 Generator rotor nut 160 16 0 115 5 Oil pump drive gear bolt 50 5 0 36 0 Gearshift cam stopper 23 2 3 16 5 Exhaust pipe nut 23 2 3 16 5 Muffler mounting bolt 23 2 3 16 5 Muffler clamp bolt 23 2 3 16 5 Engine oi...

Page 311: ...il filler plug 23 2 3 16 5 Final gear oil drain plug 23 2 3 16 5 CHASSIS ITEM N m kgf m Ib ft Handlebar clamp bolt 23 2 3 16 5 Steering shaft holder bolt 23 2 3 16 5 Steering shaft nut 49 4 9 35 5 Steering knuckle end bolt 145 14 5 105 0 Steering knuckle arm pinch bolt Upper Lower 50 5 0 36 0 Steering knuckle arm pinch bolt 50 5 0 36 0 Tie rod end nut 32 3 2 23 0 Tie rod locknut 45 4 5 32 5 Front ...

Page 312: ...nut and bolt 60 6 0 43 5 Trailer towing mounting bolt 50 5 0 36 0 TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page refer to this chart Bolt Diameter mm Conventional or 4 marked bolt 7 marked bolt Bolt Diameter mm N m kgf m Ib ft N m kgf m Ib ft 4 1 5 0 15 1 0 2 3 0 23 1 5 5 3 0 3 2 0 4 5 0 45 3 0 6 5 5 0 55 4 0 10 1 0 7 0 8 13 1 3 9 5 23 2 3 16 5 10 29 2 9 21 0 50 ...

Page 313: ... 014 Valve guide I D IN EX 5 000 5 012 0 1969 0 1973 Valve stem O D IN 4 975 4 990 0 1959 0 1965 EX 4 955 4 970 0 1951 0 1957 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve stem end length IN EX 1 8 0 07 Valve seat width IN EX 0 9 1 1 0 035 0 043 Valve head radial runout IN EX 0 03 0 001 Valve spring free length IN EX INNER 35 0 1 38 OUTER 37 8 1 49 Valve spring tensi...

Page 314: ...cker arm shaft O D IN EX 11 973 11 984 0 4714 0 4718 Cylinder head distortion 0 05 0 002 Cylinder head cover distortion 0 05 0 002 CYLINDER PISTON PISTON RING Unit mm in ITEM STANDARD LIMIT Compression pressure Automatic decomp actuated 800 kPa Approx 8 0 kgf cm2 114 psi Piston to cylinder clearance 0 030 0 040 0 0012 0 0016 Cylinder bore 87 500 87 515 3 4449 3 4455 Nicks or Scratches Piston diam ...

Page 315: ...0 9061 23 040 0 9071 Conrod deflection 3 0 0 12 Conrod big end side clearance 0 10 0 45 0 004 0 018 1 00 0 039 Conrod big end width 24 95 25 00 0 982 0 984 Crank web to web width 71 0 0 1 2 795 0 004 Crankshaft runout 0 08 0 003 OIL PUMP ITEM STANDARD LIMIT Oil pump reduction ratio 1 450 29 20 Oil pressure at 60 C 140 F Above 190 kPa 1 9 kgf cm2 27 psi Below 250 kPa 2 5 kgf cm2 36 psi at 3 000 r m...

Page 316: ... gear backlash 0 03 0 15 0 001 0 006 Final drive bevel gear backlash 0 08 0 13 0 0031 0 0051 Front differential drive bevel gear backlash 0 07 0 15 0 0028 0 0059 Front differential drive bevel gear pre load 30 70 N cm 3 7 kgf cm 2 6 6 1 Ib in THERMOSTAT RADIATOR FAN ENGINE COOLANT ITEM STANDARD SPECIFICATION LIMIT Thermostat valve opening temperature 73 5 76 5 C 164 170 F Thermostat valve lift Ove...

Page 317: ... 031 Spark performance Over 8 0 3 at 1 atm Ignition coil resistance Primary 0 1 0 8 Q Terminal Ground Secondary 1 0 15 kQ Plug cap Ground Generator coil resistance Pick up 170 250 Q B l G Power source 0 05 0 5 Q Y W Charging 0 1 1 0 Q Y Y Generator no load voltage When engine is cold More than 60 V AC at 5 000 r min Generator Max output Approx 325 W at 5 000 r min The rotation of the generator Reg...

Page 318: ... 1 2 Rear brake pedal height 70 2 8 Brake drum I D Rear 180 7 7 11 Brake disc thickness Front 3 5 0 2 0 138 0 008 3 0 0 12 Brake disc runout Front 0 3 0 012 Master cylinder bore Front 14 000 14 043 0 5512 0 5529 Master cylinder piston diam Front 13 957 13 984 0 5495 0 5506 Brake caliper cylinder bore Front 25 400 25 450 1 0000 1 0020 Brake caliper piston diam Front 25 335 25 368 0 9974 0 9987 Brak...

Page 319: ...ssible E 03 33 Fuel type Use only unleaded gasoline of at least 87 pump octane R A method or 91 octane or higher rated by the Research Method E 28 Fuel type Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended E 17 24 Fuel tank including reserve 12 5 L 3 3 2 7 US Imp gal reserve 3 8 L 1 0 0 8 US Imp gal Engine oil type SAE 10W 40 API SFor SG Engine oil capacity Ch...

Page 320: ...erisk marks Please refer to the chapter 1 through 9 for details which are not given in this chapter CONTENTS SPECIFICATIONS 10 2 SERVICE DATA 10 4 PERIODIC MAINTENANCE CHART 10 11 MAINTENANCE PROCEDURES 10 12 SPARK ARRESTER 10 12 DRIVE BELT 10 12 ENGINE MOUNTING BRACKET 10 13 FINAL BEVEL GEARS 10 14 CONSTRUCTION 10 14 REMOVAL AND DISASSEMBLY 10 15 INSPECTION 10 17 REASSEMBLY AND ADJUSTMENT 10 20 R...

Page 321: ...8 in Piston displacement 493 cm3 30 1 cu in Compression ratio 8 5 1 Carburetor MIKUNI BST34SS Air cleaner Polyurethane foam element Starter system Electric and recoil starter Lubrication system Wet sump Idle speed 1 500 100 r min TRANSMISSION Clutch Wet shoe automatic centrifugal type Transmission Automatic variable ratio with reverse and 2 speed transmission Gearshift pattern Forward Hand lever o...

Page 322: ...N Battery 12 V 50 4 kC 14 Ah 10 HR Generator Three phase A C generator Main fuse 30 A Headlight 12 V 30 30 W 12 V 35 36 5 W E 17 24 Taillight 1 2 V 5 W Brake light Taillight 12 V 7 3 4 W E 17 Back up light 12 V 21 W E 17 Speedometer light 12V1 7W Reverse indicator light 12 V 3 4 W Neutral indicator light 12 V 3 4 W High beam indicator light 12 V 1 7 W Engine coolant temp indicator light 12 V 3 4 W...

Page 323: ...014 Valve guide I D IN EX 5 000 5 012 0 1969 0 1973 Valve stem O D IN 4 975 4 990 0 1959 0 1965 EX 4 955 4 970 0 1951 0 1957 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve stem end length IN EX 1 8 0 07 Valve seat width IN EX 0 9 1 1 0 035 0 043 Valve head radial runout IN EX 0 03 0 001 Valve spring free length IN EX INNER 35 0 1 38 OUTER 37 8 1 49 Valve spring tensio...

Page 324: ...r arm shaft O D IN EX 11 973 11 984 0 4714 0 4718 Cylinder head distortion 0 05 0 002 Cylinder head cover distortion 0 05 0 002 CYLINDER PISTON PISTON RING Unit mm in ITEM STANDARD LIMIT Compression pressure Automatic decomp actuated 800 kPa Approx 8 0 kgf cm2 114 psi Piston to cylinder clearance 0 030 0 040 0 0012 0 0016 Cylinder bore 87 500 87 515 3 4449 _ 3 4455 Nicks or Scratches Piston diam 8...

Page 325: ... 9061 23 040 0 9071 Conrod deflection 3 0 0 12 Conrod big end side clearance 0 10 0 45 0 004 0 018 1 00 0 039 Conrod big end width 24 95 25 00 0 982 0 984 Crank web to web width 71 0 0 1 2 795 0 004 Crankshaft runout 0 08 0 003 OIL PUMP ITEM STANDARD LIMIT Oil pump reduction ratio 1 450 29 20 Oil pressure at 60 C 140 F Above 190 kPa 1 9 kgf cm2 27 psi Below 250 kPa 2 5 kgf cm2 36 psi at 3 000 r mi...

Page 326: ...gear backlash 0 03 0 15 0 001 0 006 Final drive bevel gear backlash 0 08 0 13 0 0031 0 0051 Front differential drive bevel gear backlash 0 07 0 15 0 0028 0 0059 Front differential drive bevel gear pre load 30 70 N cm 3 7 kgf cm 2 6 6 1 Ib in THERMOSTAT RADIATOR FAN ENGINE COOLANT ITEM STANDARD SPECIFICATION LIMIT Thermostat valve opening temperature 73 5 76 5 C 164 170 F Thermostat valve lift Over...

Page 327: ...e Primary 0 1 0 8 Q Terminal Ground Ignition coil resistance Secondary 1 0 1 5 kQ Plug cap Ground Generator coil resistance Pick up 1 7 0 250 Q B l G Generator coil resistance Power source 0 05 0 5 Q Y W Generator coil resistance Charging 0 1 1 0 Q Y Y Generator no load voltage When engine is cold More than 60 V AC at 5 000 r min Generator Max output Approx 325 W at 5 000 r min The rotation of the...

Page 328: ...2 Rear brake pedal height 70 2 8 Brake drum I D Rear 180 7 7 11 Brake disc thickness Front 3 5 0 2 0 138 0 008 3 0 0 12 Brake disc runout Front 0 3 0 012 Master cylinder bore Front 14 000 14 043 0 5512 0 5529 Master cylinder piston diam Front 13 957 13 984 0 5495 0 5506 Brake caliper cylinder bore Front 25 400 25 450 1 0000 1 0020 Brake caliper piston diam Front 25 335 25 368 0 9974 0 9987 Brake f...

Page 329: ... with appropriate cosolvents and corrosion inhibitor is permissible E 03 28 33 Fuel type Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended E 17 24 Fuel tank including reserve 12 5 L 3 3 2 7 US Imp gal reserve 3 8 L 1 0 0 8 US Imp gal Engine oil type SA E 10W 40 API SF or SG Engine oil capacity Change 2 300 ml 2 4 2 0 US Imp qt Engine oil capacity Filter change ...

Page 330: ...gine idle speed I I I Engine oil and oil filter R R Differential gear and final bevel gear oil I Differential gear and final bevel gear oil Replace every two years Engine coolant Re place every two years Radiator hoses I Drive belt I Spark arrester C Brakes I I I Brake fluid I I Brake fluid Replace every two years Brake hoses I Brake hoses Replace every four years Tires I Steering I I I Suspension...

Page 331: ...A CAUTION Clean every 2 000 km 1 200 miles 6 months Remove the muffler end cover Remove the spark arrester Remove the carbon deposits Install the spark arrester securely o 1 y i i J t o z DRIVE BELT A CAUTION Inspect every 2 000 km 1 200 miles 6 monts T7 2 12 to 14 ...

Page 332: ...LT A500FK1 01 MODEL 10 13 ...

Page 333: ...r oil filler plug Final gear oil drain plug Final gear stopper Final drive bevel gear nut Final drive shaft housing nut Final gear bearing case R O ring Oil seal Bearing Shim Final bevel gear set Washer Shim Final bevel gear case Bearing Oil seal Bearing Shim Bearing Oil seal O ring Final drive shaft coupling Washer Final drive shaft Final drive shaft housing Bearing Circlip Oil seal Oil seal coll...

Page 334: ...r oil Disconnect the final drive shaft boot Remove the final bevel gear case assembly 2 Remove the final drive shaft housing Remove the oil seal collar 5 Remove the oil seal using the special tool 1 T 5 5 L 1 09913 50121 Oil seal remover A CAUTION Replace the removed oil seal with a new one Remove the circlip and bearing ...

Page 335: ...24 61810 Final drive gear coupling holder Remove the washer and final drive shaft coupling Remove the bearing stopper pin ft Remove the final drive gear bearing stopper using the special tool 09921 21820 Final gear stopper remover A CAUTION Replace the removed oil seal and O ring with a new one Remove the final drive gear 3 and shim r D ...

Page 336: ...LT A500FK1 01 MODEL 10 17 Remove the final gear right case bolts INSPECTION Inspect the final drive shaft for wear or damage If any damages are found replace the final drive shaft ...

Page 337: ...nspect the oil seal for wear or damages If any damages are found replace the oil seal with a new one FINAL GEAR CASE BEARINGS AND OIL SEAL Remove the final driven gear oil seal using the special tool Irogll 09913 50121 Oil seal remover A CAUTION Replace the removed oil seal with a new one Remove the final driven gear bearing using the special tool IT55LI 09913 70210 Bearing installer set Remove th...

Page 338: ...ing installer set Install the new final drive pilot bearing using the special tool 09924 84521 Bearing installer set A FINAL GEAR RIGHT CASE BEARING AND OIL SEAL Remove the bearing and oil seal using the special tool 09913 70210 Bearing installer set A CAUTION Replace the removed oil seal with a new one Install the new oil seal and then bearing using the special tool j 09913 70210 Bearing installe...

Page 339: ...coupling in each direction and securely holding the final driven gear If the backlash is not within specifi cation the shim thickness must be changed and the backlash checked until it is within specification Refer to the chart at the right for the appropriate shim thickness LttMrJ Final drive gear backlash Standard 0 02 0 06 mm 0 0008 0 0024 in Without bearing case specification 0 08 0 13 mm 0 003...

Page 340: ...ing surface of the gear case and driven gear back side using the straightedge and special tool ITOSLI 09900 20602 Dial gauge 09900 20701 Magnetic stand 09900 21203 Surface plate 09900 21304 V block set Decide the proper shim thickness by the following formula 2 0 10 mm Shim thickness 0 10 mm Proper clearance Proper shim thickness EXAMPLE 2 10 00 mm 9 00 mm 10 00 9 00 0 10 0 90 Select the 0 90 mm s...

Page 341: ...rive bevel gear and compare the coated teeth to the examples shown in 2 and 3 If the tooth contact is found to be correct example 2 go to the Final Assembly sub section on p 32 to complete installa tion Incorrect contact at tooth top 2 Correct 3 Incorrect contact at tooth root If tooth contact is found to be incorrect examples and 3 the shim thickness between the final drive gear bearing and final...

Page 342: ...UZUKI SUPER GREASE A Apply THREAD LOCK SUPER 1303 or 1322 to the bearing case bolt and tighten them to the specified torque For USA t 99000 32030 THREAD LOCK SUPER 1303 For the other countries fiH 99000 32110 THREAD LOCK SUPER 1322 H Bearing case bolt 23 N m 2 3 kgf m 16 5 Ib ft 7 t Tighten the final gear stopper to the specified torque using the special tool IT55LI 09921 21820 Final gear stopper ...

Page 343: ...ely Install the oil seal 3 using a suitable tool A CAUTION Do not press the lip of oil seal when installing it Apply approximately 4 5 cm3 of SUZUKI SUPER GREASE A to the lip of oil seal 10 26 For USA 99000 25030 SUZUKI SUPER GREASE A For the other countries a H 99000 25010 SUZUKI SUPER GREASE A Install the oil seal collar using the special tool 09913 70210 Bearing installer set NOTE Set the suita...

Page 344: ...15 or 1207B to the mating surface of the final drive shaft housing For USA rf207B 99104 31140 SUZUKI BOND 1207B For the other countries rfias 99000 31110 SUZUKI BOND 1215 Tighten the final drive shaft housing nut to the specified torque H Final drive shaft housing nut 23 N m 2 3 kgf m 16 5 Ib ft Apply SUZUKI SUPER GREASE A to the spline of the final drive shaft REMOUNTING Remount the final bevel g...

Page 345: ...rt No Shim thickness mm Part No Shim thickness mm Part No Shim thickness mm 27326 09F70 030 0 30 27326 18A00 035 0 35 27445 24A01 030 0 30 27326 09F70 035 0 35 27326 18A00 040 0 40 27445 24A01 035 0 35 27326 09F70 040 0 40 27326 18A00 050 0 50 27445 24A01 040 0 40 27326 09F70 050 0 50 27326 18A00 060 0 60 27445 24A01 050 0 50 27326 09F70 060 0 60 27445 24A01 060 0 60 ...

Page 346: ...LT A500FK1 01 MODEL 10 27 WIRING DIAGRAM F o r E 0 3 24 28 3 3 SS2IS51I v OJ m v v v v Cra o groro a J g 3 g O m m m o o o c r m m m m m m o o o _J 0 O z o O LU ...

Page 347: ...A500FK1 01 MODEL For E 17 LU O N N 5 v _v _v _v s 0 0 0 0 g a a o o o o o a a c c c l S o _o m m a a o c c m m m m m m m o o o o a m m o a o c c m m m m m m m d b 6 O t t C O i ui z pi x O DC t Z O lil LuQo 2 1 ...

Page 348: ...Z c 0 cn o T 3 1 C O 0 0 c t f J Z J Z 0 g co O _0 0 0 0 0 J Z J Z O O 9 9 o o o o Q g 0 0 J Z J Z o o o o 0 0 0 0 O i s O O O w Q _ C O C O C O C O o o o o D T 3 CO CO Q 0 0 4 J Z J Z 0 0 0 J Z J Z J Z 0 3 CO 0 0 J Z J Z 0 0 J Z J Z 0 0 0 0 0 0 0 O O O O O O O 2 l LL L L l L L L L ...

Page 349: ...Prepared by SUZUKI MOTOR CORPORATION Motorcycle Service Department 2nd Ed December 2000 1st Ed July 1999 Part NO 99500 44032 01E Printed in Japan ...

Page 350: ...SUZUKI MOTOR CORPORATION Printed in Japan TK Y K1 ...

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