Suzuki VX800L Manual Download

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Summary of Contents for VX800L

Page 1: ...nt of 5Occ or greater are subject to Environmental Pro tee tion Agent y emission regula tions These regulations set specific standards for exhaust emission output levels as well as particular servicing requirements This manual includes specific information required to properly inspect and service VX800 in accordance with all EPA regulations It is strongly recommended that the chapter on Emission C...

Page 2: ...VIEW OF SUZUKI VX8OOL LEFT SIDE RIGHT SIDE www ClassicCycles org ...

Page 3: ... 1 FUEL OIL AND COOL ANT RECOMMENDA TION I 1 BREAK IN PROCEDURES l_ 3 CYLINDER DENT FICA T ON I_ 3 SPECIAL MATERIALS l_ 4 PRECAUTIONS AND GENERAL INSTRUCTIONS l 7 SPECIFICA TIONS l_ g COUNTRY OR AREA 1 11 Classic Cycles Technical Resources ...

Page 4: ...leaded gasoline of at least 87 pump octane by the F method or 91 octane or higher rated by the Research method alcohol fuel may contain up to 5 methanol if appropriate cosolvents and corrosion inhibitors are present in it 5 If the performance of the vehicle is unsatisfactory while using blended gasoline alcohol fuel you should switch to alcohol free unleaded gasoline 6 Failure to follow these guid...

Page 5: ...ARNING Since the brake system of this motorcycle is filled with a glycol based brake fluid by the manufacturer do not use or mix different types of fluid such as silicone based and petroleum based fluid for refilling the system otherwise serious damage will result Do not use any brake fluid taken from old or used or unsealed containers Never reuse brake fluid left over from a previous servicing wh...

Page 6: ...high standard but 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 exercise during its early life The general rules are as follows _ l Keep to these break in engine speed limits Initial 800 km 500 miles Below 4000 r min Up to 1600 km 1000 miles Below 60...

Page 7: ... other models SUZUKI BRAKE FLUID DOT3 DOT4 99000 23110 SUZUKI GOLDEN CRUISER 1200NA 99000 99032 10x SUZUKI SUPER GREASE A 99000 25010 T Brakes 2 Coolant 2 Brake pedal pivot Footrest pivot Gearshift lever pivot Side stand pivot and spring hook Center stand pivot and spring hook 2 O ring of oil jet Secondary bevel gear case oil seal and O ring Final driven gear oil seal Final driven bevel gear coupl...

Page 8: ...0 3 37 3 43 3 56 3 45 3 58 3 60 7 12 SUZUKI MOLY PASTE SUZUKI MOLY PASTE 99000 25140 99000 25140 l Oil pressure switch 3 17 y t i gear case SUZUKI BOND NO 1207B SUZUKI BOND NO 1215 99104 31140 99000 311 IO l Cylinder head cover 3 60 zy SUZUKI BOND NO 1216 99104 31160 SUZUKI BOND NO 1216 99000 31160 l Secondary driven bevel gear housing bolt l Gearshift and stopper l Cam sprocket bolt l Final drive...

Page 9: ...earshift cam stopper bolt l Gearshift cam driven gear bolt l Gearshift cam guide nut and paw1 lifter screw l Oil pump securing bolt l Brake pedal boss bolt l Front footrest bolt 3 45 3 49 3 50 3 50 3 51 8 25 8 39 THREAD LOCK SUPER THREAD LOCK SUPER 1333B 1 322 99000 32020 99000 32 110 l Crankcase bearing retainer screw and bolt 3 18 THREAD LOCK SUPER 1303 THREAD LOCK SUPER 1324 99000 32030 99000 3...

Page 10: ...ft it should be discarded and a new When installing a new circlip care must be taken not to expand the end gap larger than required to slip the circlip over the shaft After installing a circlip always insure that it is completely seated in its groove and securely fitted Tighten cylinder head and case bolts and nuts beginning with larger diameter and ending with smaller diameter from inside to out ...

Page 11: ...es CAUTION Use of replacement parts which are not equivalent in quality to genuine SUZUKI parts can lead to performance problems and damage ASBESTOS INFORMATION Note the following when handling a supply part with this WARNING LABEL orany part in the partslist which contains asbestos Operate if possible out of doors in a well ventilated place Preferably use hand tools or low speed tools equipped if...

Page 12: ...cement Compression ratio Carburetor Front Rear Air cleaner Starter system Lubrication system Four stroke water cooled OHC TSCC 45 V twin 0 08 0 13 mm 0 003 0 005 in 2 83 0 mm 3 268 in 74 4 mm 2 929 in 805 cm3 49 12 cu in 10 0 1 MI KUN I BDS36SS single MI KUN I BS36SS single Polyester fiber element Electric starter motor Wet sump TRANSMISSION Clutch Transmission Gearshift pattern Primary reduction ...

Page 13: ...damping force 4 way adjustable EOl 03 28 33 compression damping force 4 way adjustable and rebound damping force 4 way adjustable Others 150 mm 5 9 in 118 mm 4 6 in EOl 03 28 33 119 mm 4 7 in Others 59 143 mm 5 63 in EOl 03 28 33 142 mm 5 59 in Others 35 right left 3 2 m 10 5 ft Disc Disc 110 80 18 58H tubeless 150 70B17 69H tubeless Fully transistorized 5 B T D C below 1650 r min and 30 B T D C a...

Page 14: ...Imp qt Front fork oil each leg 388 ml 13 1 13 7 US Imp oz E01 03 28 33 392 ml 13 2 13 8 US Imp oz Others These specifications are subject to change without notice COUNTRY OR AREA The series of symbols on the left stand for the countries and areas on the right SYMBOL COUNTRY or AR EA E 01 General market Export standard model E 02 England E 03 U S A except California E 04 France E 15 Finland E 16 No...

Page 15: ...URES 2 3 BATTERY 2 3 AIR CLEANERS 2_ 4 VALVE CLEARANCE 2 5 SPARK PLUGS 2 7 ENGINE OIL AND OIL FILTER 2_ B FUEL LINES 2 9 CARBURETORS 2_ g COOLING SYSTEM 2 10 CLUTCH 2 10 FINAL GEAR OIL 2 11 BRAKES 2_ 72 TIRES 2 14 STEERING 2 15 FRONT FORKS 2 15 REAR SHOCK ABSORBERS 2_ 15 CHASSIS BOLTS AND NUTS a 2_15 Classic Cycles Technical Resources ...

Page 16: ...ic service work necessary keep the motorcycle operating at peak performance and economy Mileages are expressed in terms kilometer miles and time for your convenience PERIODIC MAINTENANCE CHART to of INTERVALS THIS INTERVAL SHOULD BE km 1000 6000 12000 18000 24000 JUDGED BY ODOMETER READING OR miles 600 4000 7500 11000 15000 MONTHS WHICHEVER COMES FIRST months 2 12 24 36 48 Battery Specific gravity...

Page 17: ...brication points are indicated below q Clutch lever holder and clutch cable I ElCenter stand pivot I El Side stant pivot and spring hook and spring hook q Oil ra q Footrest phot NOTE Before lubricating each part clean off any rusty spots and wipe off any grease oil dart or grime Lubricate exposed parts which are subject to rust with oil or grease Classic Cycles Technical Resources ...

Page 18: ...checking specific gravity use a hydrometer to deter mine the charged condition 09900 28403 Hydrometer Standard specific gravity 1 28 at 20 C 68 F An S G reading of 1 22 at 20 C or under means that the battery needs recharging Remove the battery from the ma chine and charge it with a battery charger CAUTION Never charge a battery while still in the machine as damage may result to the battery or reg...

Page 19: ...ur screws and pull out the rear side air cleaner element Photo F Carefully use an air hose to blow the dust from the air cleaner elements Photo G CAUTION Always apply an air pressure on the outside of the air cleaner elements If air pressure is applied on the inside dirt will be forced into the pores of the cleaner element thus restricting air flow through the cleaner element l Reinstall the clean...

Page 20: ...esults in valve damage and reduced power Check and adjust the clearance to the specification Valve clearance when cold IN EX 0 08 0 13 mm 0 003 0 005 in NOTE The clearance specification is for COLD state Both intake and exhaust valves must be checked and adjust ed when the piston is at Top Dead Center TDCI of the compression stroke l Remove the seat and the fuel tank l Remove the following parts F...

Page 21: ...clearance is out of the specification bring it into the specified range by using the special tool 09917 10410 Valve adjust driver CAUTION Both right and left valve clearances should be as closely set as possible l Rotate the generator rotor 450 degrees 1 X turns and align the FT line on the rotor with the center of hole on the generator cover Rotation angle 450 degrees 480 degrees l 1 4 turns for ...

Page 22: ...d be selected to meet the requirements of speed actual road fuel etc If the plugs need to be replaced it is recommended that ones having a heat range closest to the standard plug in the table be selected When remove the plugs inspect the insulators Proper heat range would be indicated if all insulators were light brown in color If they are blackened by carbon they should be replaced with hotter ty...

Page 23: ...tighten the filter by hand Fit the drain plug 0 securely and add fresh oil through the oil filler The engine will hold about 2 8 L 3 0 2 5 US Imp qt of oil Use an API classification of SE or SF oil with SAE lOW 40 viscosity Refit the filler cap 2 Start up the engine and allow it to run for several minutes at idling speed Turn off the engine and wait about one minute then check the oil level throug...

Page 24: ...eed should be adjusted when the engine is hot l Connect a tachometer l Start up the engine and set its speed at idle speed 1000 and 1200 r min by turning throttle stop screw 0 Engine idle speed 1100 100 r min for E 01 and others 1200 50 r min for E 03 33 1200 O r min for E 18 THROTTLE CABLE PLAY There should be 0 5 1 0 mm 0 02 0 04 in play on the throttle cable Adjust the throttle cable play with ...

Page 25: ...th fresh water if necessary Tighten the drain plug securely and remove the air bleeder plug 8 Pour the specified coolant up to the radiator inlet and tighten the air bleeder plug 0 Tightening torque Coolant drain plug 10 12 N m 1 0 1 2 kg m 7 0 8 5 lb ft Air bleeder plug IO 12 N m 1 0 1 2 kg m 7 0 8 5 lb ft NOTE For coolant information refer to page 5 2 l Close the radiator cap 0 securely l After ...

Page 26: ...rovide a clutch lever play 8 of 4 mm 0 16 in and tighten the lock nut Clutch cable play 4 mm 0 16 in l Tighten the lock nut to secure the adjuster 0 FINAL GEAR OIL Replace at initial 1000 km 600 miles or 2 months and inspect every 12000 km 7500 miles or 24 months Place the motorcycle on the center stand Place an oil pan below the final gear case and drain oil by removing filler cap 0 and drain plu...

Page 27: ...troleum based Do not use any brake fluid taken from old used or unsealed containers Never reuse brake fluid left over from the last servicing or stored for long periods WARNING Brake fluid if it leaks will interfere with safe running and immediately discolor painted surfaces Check the brake hoses and hose joints for cracks and oil leakage before riding BRAKE PADS The extent of brake pad wear can b...

Page 28: ...he master cylinder reservoir to the upper end of the inspection window for front brake and UPPER line for rear brake Replace the reservoir cap Attach a pipe to the caliper bleeder valve and insert the free end of the pipe into a receptacle Squeeze and release the brake lever several times in rapid succession and squeeze the level fully without releasing it Loosen the bleeder valve by turning it a ...

Page 29: ...cycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation It is highly recommended to replace a tire when the remaining depth of tire tread reaches the following specifica tion Tire tread depth limit FRONT 1 6 mm 0 06 in REAR 2 0 mm 0 08 in TIRE PRESSURE If the tire pressure is too high or too low steering will be adversely affected and tire wea...

Page 30: ...steering will cause poor stability Check that there is no play in the front fork assembly by supporting the motorcycle so that the front wheel is off the ground with the wheel straight ahead grasp the lower fork tubes near the axle and pull forward If play is found perform steering bearing adjust ment as described in page 8 18 of this manual FRONT FORKS Inspect at initial 1000 km 600 miles or 2 mo...

Page 31: ... 3 0 14 5 21 5 Front brake master cylinder mounting bolt 5 8 0 5 0 8 3 5 6 0 I Front brake caliper mounting bolt 30 48 3 0 4 8 21 5 34 5 Brake hose union bolt 15 20 I 1 5 2 0 I 11 0 14 5 I Air bleeder valve 6 9 0 6 0 9 4 5 6 5 Front and rear disc bolt 18 28 1 8 2 8 13 0 20 0 I Front footrest bracket mounting bolt I Swingarm pivot nut Rear shock absorber upper lower mounting nut 1 27 43 I 2 7 4 3 I...

Page 32: ...2 17 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES www ClassicCycles org ...

Page 33: ...MBL Y 3_ 5 ENGINE COMPONENTS INSPECTION AND SERVICING 3 20 CYLINDER HEAD COVER 3_20 CYLINDER HEAD 3_24 CYLINDER 3_30 PISTON 3_31 PISTON RING 3_32 PISTON PIN AND PIN BORE 3 33 CONROD 3_34 CRANKSHAFT 3_37 CLUTCH 3 39 GENERATOR 3_41 STARTER CLUTCH 3 4 1 OIL PUMP 3_42 TRANSMISSION 3_42 ENGINE REASSEMBLY 3_44 CAMSHAFT TIMING 3 57 VALVE ROCKER ARM AND SHAFT 3_50 Classic Cycles Technical Resources ...

Page 34: ...l the engine in the following cases Compression pressure in one of the cylinders is less than 1100 kPa I 1 kg cm 156 psi Difference in compression pressure between two cylinders is more than 200 kPa 2 kg cm2 28 psi All compression pressure are below 1300 kPa 13 kg cm 184 psi even when they measure more than 1100 kPa 11 kg cm2 156 psi COMPRESSION TEST PROCEDURE NOTE Before testing the compression o...

Page 35: ... Pick up coil 7 7 Secondary driven bevel gear 3 15 Water pump case 3 3 Water pump assembly 5 7 ENGINE CENTER See page Radiator 3 3 Exhaust pipe and muffler 3 3 Oil filter 3 12 Carburetor 3 3 Oil sump filter 3 12 Oil pressure switch 3 l 7 Starter motor assembly 3 l 2 engine from the frame Refer ENGINE RIGHT SIDE See page Clutch cover 3 9 B Clutch pressure drive and z driven plates 3 9 d Oil pump dr...

Page 36: ...ver 11 Remove the clutch release cam assembly 12 Remove the radiator by removing the radiator protector radiator hose clamps and radiator cooling fan 13 Remove the left footrest 14 Remove the gearshift lever 15 Remove the water pump case 16 Loosen the shaft drive boot clamp 17 Remove the coolant reservoir tank 18 Disconnect the choke cables and throttle cables 19 Disconnect the rear carburetor fue...

Page 37: ...Install the brackets spacer bolts and nuts properly as shown in the following illustration NOTE The engine mounting nuts are self locking Once the nut has been removed it is no longer of any use Be sure to use new nuts and tighten them to the specified torque 1 Classic Cycles Technical Resources ...

Page 38: ...dling adjustment 2 9 Balancing carburetors 6 15 Rear brake pedal height 2 l 2 Pour 3 3 L 3 5 2 9 US Imp qt of engine oil SAE lOW 40 graded SE or SF into the engine after overhauling engine Start up the engine and allow it run for several minutes at idle speed About several minutes after stopping engine check that the oil level remains between the marks of oil level inspection window Change 2400 ml...

Page 39: ...ion and lay the parts out in groups so that each will be restored to the original location during assembly l Remove the valve inspection caps l Remove the cylinder head covers NOTE When removing the cylinder head covers the piston must be at top dead center on the compression stroke No 2 FRONT No 1 REAR Classic Cycles Technical Resources ...

Page 40: ...the camshaft sprocket bolts l Remove the camshafts and sprockets l Remove the water pipe water hose by removing the water pipe bolts and loosening the water hose clamp screw l Remove the cylinder head bolts l Remove the front and rear cylinder heads along with the respective cylinders www ClassicCycles org ...

Page 41: ...t and chain tensioner body Separate the respective cylinder heads and cylinders l Check the F and R piston marks Place a clean rag over the cylinder base to prevent piston pin circlips from dropping into crankcase Remove the piston pin circlips with long nose pliers Drive out the piston pins by using proper drift Classic Cycles Technical Resources ...

Page 42: ... bolts diagonally l Remove the pressure plate l Remove the clutch push piece thrust washer bearing and push rod l Remove the clutch drive and driven plates l Remove the clutch sleeve hub nut by using the special tool 09920 50710 Clutch sleeve hub holder l Remove the back torque limiter c along with the clutch sleeve hub 0 www ClassicCycles org ...

Page 43: ...pump drive chain and oil pump driven gear l Remove the thrust washer and spacer l Remove the primary drive gear bolt while holding the primary drive gear with the special tool and remove the primary drive gear 09930 40113 Rotor holder CAUTION This bolt has left hand thread Turning it counter clockwise it may cause damage Classic Cycles Technical Resources ...

Page 44: ...e paw1 lifter and cam guide by removing the nuts and screws 0 09900 09003 Impact driver set l Remove the gearshift cam driven gear retaining bolt l Remove the gearshift cam driven gear 0 NOTE When removing the gearshift cam driven gear do not lose gearshift pawl pin and spring 0 l Unhook the gearshift cam stopper spring 0 gearshift cam stopper plate and washer 8 www ClassicCycles org ...

Page 45: ...er by using the special tool 09915 40611 Oil filter wrench l Remove the starter motor cover l Remove the starter motor l Remove the generator cover l Remove the oil sump filter cap and oil sump filter Classic Cycles Technical Resources ...

Page 46: ...r remover For the other models 09930 34970 Rotor remover l Remove the key iJ l Remove the starter driven gear l Remove the cam chain guide and cam chain l Loosen the rotor bolt NOTE When removing the rotor do not remove the rotor bolt after loosening the bolt The rotor bolt is used in conjunction with the rotor remover www ClassicCycles org ...

Page 47: ...ead wire Install the universal joint into the secondary driven gear Remove the driveshaft bolt and secondary drive gear shaft nut while holding the universal joint CAUTION Driveshaft bolt 0 has left hand thread bevel bevel l Remove the secondary driven bevel gear housing bolts and secondary bevel gear case bolts Classic Cycles Technical Resources ...

Page 48: ...separating tool NOTE Fit the crankcase separating tool so that the tool plate is parallel with the end face of the crankcase The crankshaft and transmission components must remain in the left crankcase half Remove the gearshift fork shafts and gearshift forks Remove the gearshift cam Remove the driveshaft assembly countershaft assembly and secondary reduction gear Remove the crankshaft www Classic...

Page 49: ...NSMISSION DISASSEMBLY l Disassemble the transmission gears as shown in the illustration Reduction drive gear Low driven gear 4th driven gear 3rd driven gear Driveshaft Top driven gear 2nd driven gear CountershaftlLow drive gear 4th drive gear 3rd drive gear Top drive gear 2nd drive gear Classic Cycles Technical Resources ...

Page 50: ...l pressure switch NOTE When reinstalling the oil pressure switch apply the SUZUKI BOND NO 1207B NO 1215 to thread part For U S A model 99104 31140 SUZUKI BOND NO 1207B For the other models 99000 31110 SUZUKI BOND NO 1215 l Check the oil jet fitted on the crankcase for clogging NOTE When installing the oil jet apply the motor oil to the oil jet O ring www ClassicCycles org ...

Page 51: ...CK SUPER 1303 1324 to bearing retainer bolts or screws For U S A model 99000 32030 TH READ For the other models 99000 32120 THREAD LOCK SUPER 1303 LOCK SUPER 1324 l Remove the bearings and oil seal by using the special tools 09914 79610 Bearing remover 09923 73210 Bearing remover 09930 30102 Sliding shaft Classic Cycles Technical Resources ...

Page 52: ...COOLING SYSTEM RELATED PARTS NOTE When reinstalling each cover check that the O ring is installed www ClassicCycles org ...

Page 53: ...r to page 3 60 for reassembly CYLINDER HEAD COVER DISTORTION After removing sealant SUZUKI BOND NO 1216 from the fitting surface of the cylinder head cover place the cylinder head cover on a surface plate and check for distortion with a thickness gauge Check points are shown in Fig Service Limit 0 05 mm 0 002 in 09900 20803 Thickness gauge If the distortion exceeds the limit replace the cylinder h...

Page 54: ...hafts should be checked for wear and also for runout of cams and journals if the engine has been noted to produce abnormal noise or vibration or to lack output power Any of these malconditions could be caused by a worn camshafts The camshaft can be distinguished by the embossed letters F and R on the camshaft F Front No 2 camshaft R Rear No 1 camshaft FRONT CYLINDER TDC I Exhaust close I BDC I REA...

Page 55: ...rance which is specified as follows Camshaft journal oil clearance Service Limit 0 15 mm 0 006 in o Tighten the cylinder head cover bolts evenly and diagonally to the specified torque Cylinder head cover tightening torque Length N m kg m lb ft 140 mm 21 25 2 1 235 2 5 15 0 18 0 mm The others 9 11 09900 22301 Plastigauge 0 9 1 1 6 5 8 0 NOTE To properly measure the oil clearance with plastigauge al...

Page 56: ...ed or ratchet mechanism is faulty replace the chain tensioner assembly with a new one The cam chain tensioner can be distinguished by the embossed letters F and RI on the cam chain tensioners I I F Front No 2 cam chain tensioner R Rear No 1 cam chain tensioner CAM CHAIN GUIDE Two kinds of cam chain guide are used on the respective cam drive chains I I F Front No 2 cam chain guide R Rear No 1 cam c...

Page 57: ...assembling work If valve guides have to be removed for replacement after inspect ing related parts carry out the steps shown in valve guide servicing Refer to page 3 30 for reassembly CYLINDER HEAD DISTORTION l Decarbonize the combustion chambers Check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge taking a clearance reading at several places indic...

Page 58: ...1304 V block VALVE HEAD RADIAL RUNOUT Place the dial gauge at right angles to the valve head face and measure the valve head radial runout If it measures more than limit replace the valve Service Limit 0 03 mm 0 001 in 09900 20701 Magnetic stand 09900 20606 Dial gauge I IO0 mm 09900 2 1304 V block VALVE GUIDE TO VALVE STEM CLEARANCE Measure the clearance in two directions X and Y per pendicular to...

Page 59: ...DE SERVICING l Using the valve guide remover 0 drive the valve guide out toward intake or exhaust rocker arm side 0991644910 Valve guide remover installer l Re finish the valve guide holes in cylinder head with a 10 8 mm reamer and handle 09916 34580 Valve guide hole reamer 09916 34541 Reamer handle NOTE Discard the removed valve guide subassemblies Only oversized valve guide is available l Lubric...

Page 60: ...lve seat with prussian blue uniformly Fit the valve and tap the coated seat with the valve face in a rotating manner in order to obtain a clear impression of the seating contact In this operation use the valve lapper to hold the valve head The ring like dye impression left on the valve face must be continuous without any break In addition the width of the dye ring which is the visualized seat widt...

Page 61: ...ment and T handle l Using the 45 cutter descale and cleanup the seat with one or two turns l Inspect the seat by the previous seat width measurement procedure If the seat is pitted or burned additional seat conditioning with the 45 cutter is required CAUTION Cut only the minimum amount necessary from the seat to prevent the possibility of the valve stem becoming too close to the cam for correct va...

Page 62: ...the valve stem end may be resurfaced providing that the length will not be reduced to less than 4 0 mm 0 15 in If this length becomes less than 4 0 mm 0 15 in the valve must be replaced After installing a valve whose stem end has been ground off as above check to ensure that the face of the valve stem end is above the totters 0 VALVE SPRING The force of the two coil springs keeps the valve seat ti...

Page 63: ...ing retainer and using the valve spring com pressor press down the spring fit the two cotter halves to the stem end and release the compressor to allow the cotter to wedge in between seat and stem Be sure that the rounded lip of the cotter fits snugly into the groove in the stem end CAUTION Be sure to restore each spring valve and spring retainer to their original positions CYLINDER DISTORTION Che...

Page 64: ...eter measure the piston outside diameter at the place shown in Fig If the measurement is less than the limit replace the piston Piston oversize 0 5 1 O mm Service Limit 82 880 mm 3 2630 in 09900 20204 Micrometer 75 100 mm PISTON TO CYLINDER CLEARANCE As a result of the above measurement if the piston to cylinder clearance exceeds the following limit overhaul the cylinder and use an oversize piston...

Page 65: ...70 1 190 mm 0 0461 0 0469 in PISTON RING FREE END GAP AND END GAP Before installing piston rings measure the free end gap of each ring using vernier calipers Next fit the ring in the cylinder and measure each ring end gap using a thickness gauge If any ring has an excess end gap replace the ring Piston ring free end gap Piston ring Service Limit 1st R 8 4 mm 0 33 in 2nd R 9 4 mm 0 37 in 09900 2010...

Page 66: ... to identify the side rail as there is no mark or numbers on it PISTON PIN AND PIN BORE Using a small bore gauge measure the piston pin bore inside diameter and using a micrometer measure the piston pin outside diameter If the reading exceeds the following limit replace both piston and piston pin Piston pin bore I D Service Limit 20 030 mm 0 7886 in 09900 20602 Dial gauge l 1000 mm 1 mm 0990022403...

Page 67: ... in 09900 20803 Thickness gauge Standard 09900 20205 Micrometer 0 25 mm 09900 20605 Dial calipers 10 34 mm CONROD CRANK PIN BEARING SELECTION l Loosen the bearing cap nuts and tap the bolt end lightly with plastic hammer to remove the bearing cap l Remove the rods and mark them to identify the cylinder position l Inspect the bearing surfaces for any sign of fusion pitting burn or flaws If any repl...

Page 68: ...i gauge is in the clearance l Remove the caps and measure the width of compressed plastigauge with envelope scale This measurement should be taken at the widest part Crank pin bearing oil clearance Service Limit 0 080 mm 0 0031 in If oil clearance exceeds the service limit select the specified bearings from the following table Check the corresponding conrod I D code number 0 1 2 or 3 Check the cor...

Page 69: ...1 6135 1 6137 in 09900 20202 Micrometer 25 50 mm CAUTION Bearing should be replaced as a set Bearing thickness Color Part No Thickness Green 1 485 I 488 mm 12 164 45COO OAO 0 0585 0 0586 in Black I 488 I 491 mm I 2164 45COO 060 0 0586 0 0587 in Brown I 491 I 494 mm 12164 45COO OCO 0 0587 0 0588 in Yellow I 494 1 497 mm I 2164 45COO ODO 0 0588 0 0589 in Blue 1 497 I 500 mm 12164 45COO OEO 0 0589 0 ...

Page 70: ...ward l Tighten the conrod fitting nuts with specified torque after applying engine oil to the nut thread Tightening torque Initial 22 28 N m 2 2 2 8 kg m 16 0 20 0 lb ft Final 49 53 N m 4 9 5 3 kg m 35 5 38 5 lb ft l Check the conrod movement for smooth turning CRANKCASE CRANKSHAFT BEARING SELECTION l Inspect the crankshaft and crankshaft journal bearings for any damage l Measure the crankshaft jo...

Page 71: ...s by hydraulic press Hone the new journal bearings with the specified value by honing machine CAUTION When honing the new journal bearings be sure to mate the left and right crankcases Crankshaft journal bearing I D 48 000 48 015 mm 1 8898 1 8904 in CRANKSHAFT THRUST CLEARANCE Install the crankshaft in the right crankcase half after installing the thrust shim on the crankshaft NOTE The oil grooved...

Page 72: ...thickness 1 09160 48001 I 1 925 1 950 0 0758 0 0768 1 I 09160 48002 1 1 950 1 975 0 0768 0 0778 I 09 160 48003 1 975 2 000 0 0778 0 0787 09 160 48004 2 000 2 025 0 0787 0 0797 1 09 160 48005 I 1 I 2 025 2 050 0 0797 0 0807 1 I 09 160 48006 2 050 2 075 0 0807 0 0817 09 160 48007 2 075 2 100 0 0817 0 0827 09 160 48008 2 100 2 125 0 0827 0 0837 09 160 48009 2 125 2 150 0 0837 0 0847 09 160 48010 2 15...

Page 73: ... free length of each coil spring with a vernier calipers and compare the elastic strength of each with the specified limit Replace all the springs if any spring is not within the limit Clutch spring free length Service Limit No 1 24 6 mm 0 97 in No 2 23 3 mm 0 92 in CLUTCH BEARING Inspect clutch push piece bearing for any abnormality particu larly cracks upon removal from the clutch to decide whet...

Page 74: ...T type hexagon wrench 6 mm l When fitting the one way clutch to the guide position flange side of one way clutch to the rotor side l Apply THREAD LOCK SUPER 1303 1305 to the securing bolts and tighten them to the specified torque while holding the rotor with off set wrench For U S A model 99000 32030 THREAD LOCK SUPER 1303 For the other models 99000 32100 THREAD LOCK SUPER 1305 09914 25811 T type ...

Page 75: ...E 3 42 OIL PUMP CAUTION Do not attempt to disassemble the oil pump assembly The oil pump is available only as an assembly TRANSMISSION TRANSMISSION GEARS AND RELATED PARTS Classic Cycles Technical Resources ...

Page 76: ...30 4 40 mm 0 169 0 173 in COUNTERSHAFT AND DRIVESHAFT REASSEMBLY Assemble the countershaft and driveshaft in the reverse order of disassembly Pay attention to following points NOTE Always use new circlips NOTE Before installing the gears coat lightly moly paste or engine oil to the driveshaft and countershaft 99000 25140 SUZUKI MOLY PASTE CAUTION Never reuse a circlip After a circlip has been remo...

Page 77: ...RS l When installing the 3rd driven gear onto the driveshaft install the lock washer No 2 I onto the driveshaft and turn and fit it into the groove l Then fit the lock washer No 1 in the lock washer No 2 0 ENGINE REASSEMBLY This engine is reassembled by carrying out the steps of disassembly in the reverse order but there are a number of steps which demand special descriptions or precautionary meas...

Page 78: ...e specified torque WARNING Never hit the secondary drive bevel gear Maybe secondary drive bevel gear circlip will be detached Tightening torque 18 28 N m l lnstal reduc 0 lnstal cam l lnstal I the countershaft assembly driveshaft assembly and tion driven gear I the gearshift forks gearshift fork shafts and gearshift I a new O ring 0 I 8 2 8 kg m 13 0 20 0 lb ft l Install the new O rings 0 l Apply ...

Page 79: ...15 No 1207B to the oil hole oil groove and bearing Apply to distorted surfaces as it forms a comparatively thick film Place the gaskets as shown in Fig Fit the engine ground wire to the correct position as shown in Fig Check that shafts turn smoothly CAUTION Use new gasket to prevent oil leakage l When securing the right and left crankcases tighten each bolt a little at a time to equalize the pres...

Page 80: ... make these surfaces completely dry Install the rotor onto the crankshaft Apply THREAD LOCK SUPER 1303 1305 to the rotor bolt and tighten it to the specified torque Tightening torque 140 160 N m 14 0 16 0 kg m 101 5 115 5 lb ft For U S A model 99000 32030 THREAD LOCK SUPER 1303 For the other models 99000 32100 THREAD LOCK SUPER 1305 l Install the starter driven gear and its idle gear l Fit the dow...

Page 81: ...l the secondary driven bevel gear assembly correct shims and a new O ring Apply engine oil to the bearing and gears NOTE Be sure to align the bearing pin with the bearing pin hole l Apply SUZUKI BOND NO 1207B NO 1215 to the secon dary bevel gear case CAUTION Be careful not to block the oil passage 0 For U S A model 99104 31140 SUZUKI BOND NO 12079 For other models 99000 31110 SUZUKI BOND NO 1215 l...

Page 82: ...dary drive bevel gear shaft nut and driveshaft bolt to the specified torque while holding the universal joint Tightening torque Secondary drive bevel gear nut 80 110 N m 8 0 11 O kg m 58 0 79 5 lb ft Driveshaft bolt 60 70 N m 6 0 7 0 kg m 43 5 50 5 lb ft CAUTION Driveshaft bolt has left hand thread l Install the washer on the gearshift cam NOTE When replacing the gearshift cam stopper 0 apply THRE...

Page 83: ...33B For the other models 99000 32110 THREAD LOCK SUPER 1322 l Hook the gearshift cam stopper spring l Install the gearshift shaft return spring properly l install the gearshift shaft Match the center teeth of the gear on the gearshift shaft with the center teeth on the cam driven gear as shown NOTE When replacing the gearshift arm stopper 0 apply a small quantity of THREAD LOCK SUPER 1303 to its t...

Page 84: ... For the other models 99000 32110 THREAD LOCK SUPER 1322 l Install the thrust washer onto the crankshaft NOTE The chamfer side of thrust washer faces crankcase side l Align the punch mark on the crankshaft with the punch mark on the camshaft drive sprocket l Install the cam chain and cam chain guide l Tighten the cam chain guide set bolt Cam chain guide set bolt Tightening torque 8 12 N m 0 8 1 2 ...

Page 85: ...e oil to the primary driven gear bearing and spacer l Engage the oil pump drive chain onto the oil pump drive gear l Install the primary driven gear assembly onto the counter shaft l Engage the oil pump drive chain onto the oil pump driven gear and fix the oil pump driven gear with circlip 09900 06107 Snap ring pliers l Install the thrust washer onto the countershaft NOTE The groove of thrust wash...

Page 86: ... kg m 36 0 50 5 lb ft 09920 50710 Clutch sleeve hub holder Install the clutch push rods into the countershaft so that the long push rod touches clutch push piece Install the clutch push piece bearing and thrust washer in that order Apply engine oil to the bearing Install the wave washer seat 0 wave washer and drive plate No 2 thicker plate as shown in the figure NOTE Install the clutch drive plate...

Page 87: ...B bolt L 35 mm 1 4 in Spring L 24 5 mm 0 96 in Spacer L 24 1 mm 0 95 in l Fit the new clutch cover gasket and dowel pins l Install the clutch cover NOTE Fit the new gaskets to thecorrect positions as shown in Fig CAUTION Use a new gasket to prevent oil leakage Apply engine oil lightly to the gasket of the new filter before installation Install the new filter turning it by hand until you feel that ...

Page 88: ...ylinder CAUTION Use a new gasket to prevent gas leakage l Assemble each cylinder head and cylinder and tighten the cylinder head nuts and bolts to the specified torque Tightening torque Cylinder head nuts 8 12 N m 0 8 1 2 kg m 6 0 8 5 lb ft Cylinder head bolts 9 11 N m 0 9 1 1 kg m 6 5 8 0 lb ft Install the piston rings in the order of oil ring 2nd ring and top ring Top ring and 2nd middle ring di...

Page 89: ...e so located l Rub a small quantity of SUZUKI MOLY PASTE onto the piston pin 99000 25140 SUZUKI MOLY PASTE Place a clean rag over the cylinder base to prevent the piston pin circlips from dropping into the crankcase When fitting the piston turn the triangle mark on the piston head to exhaust side Fit the piston pin circlips with long nose pliers CAUTION Use new piston pin circlip to prevent circli...

Page 90: ...ox wrench and align T line 0 on the magneto rotor with the center of generator cover hole keeping the camshaft drive chain pulled upward CAUTION If crankshaft is turned without drawing the camshaft drive chain upward the chain will be caught between crankcase and cam chain drive sprocket NOTE Apply grease on the cam pin in to the camshaft No 1 REAR ENGINE sprocket locating pin and install the l En...

Page 91: ...eased l Apply SUZUKI MOLY PASTE to the camshaft journals and cam faces 99000 25140 SUZUKI MOLY PASTE No 2 FRONT ENGINE l At this position engage the chain on the cam sprocket with the locating pin hole at the nine half o clock position NOTE Do not rotate the magneto rotor while doing this When the sprocket is not positioned correctly turn the sprocket When installing the camshaft into the cam spro...

Page 92: ...o 1 REAR engine posi tion is positioned at T D C CAMSHAFT TIMING Turn the crankshaft so that the rear engine is positioned at T D C Engraved line mark Engraved line mark FRONT LA Aligning mark on cranksh Iaft Aligning ma k on the drive sprocket www ClassicCycles org ...

Page 93: ...r head surface For U S A model 99104 31160 SUZUKI For the other models 99000 31160 SUZUKI NOTE BOND NO 1216 BOND NO 1216 Do not apply SUZUKI BOND NO 1216 to the camshaft end cap NOTE When tightening the cylinder head cover bolts the piston must be at top dead center on the compression stroke NOTE Do not forget the plate on No 1 rear cylinder head cover l Lightly tighten the cylinder head cover bol...

Page 94: ... CYLINDER HEAD BOLT L Length Unit mm LOCATION OF CYLINDER HEAD COVER BOLT Front cylinder head cover L 20 Rear cylinder head cover L 235 Before installing the stud bolt L 55 apply Bond No 1216 to the thread of cylinder head cover side L Length Unit mm Apply Bond No 1215 to the thread of bolt www ClassicCycles org ...

Page 95: ...e pipe use a new O ring to prevent sucking air from the joint l Coat the O ring with grease VALVE INSPECTION CAP AND CAM TIMING INSPECTION CAP l Before installing the valve inspection caps and cam timing inspection cap coat the respective O rings with grease CAUTION Replace the respective O rings with new ones Classic Cycles Technical Resources ...

Page 96: ...TING 4_ 7 REASSEMBLY INFORMATION 4 7 FINAL BEVEL GEARS CONSTRUCTION 4_ 6 FINAL GEAR CASE BREATHER CIRCUIT 4_ g AIR AND GEAR OIL FLOW IN FINAL GEAR CASE BREATHER CIRCUIT 4_ g REMOVAL AND DISASSEMBLY 4 10 lNSPECTlON 4 13 REASSEMBLY 4 13 FINAL GEAR SHIM ADJUSTMENT 4 16 FINAL GEAR BEARING CASE SHIM CLEARANCE 4 16 BACKLASH 4 16 TOOTH CONTACT 4 16 FINAL ASSEMBL Y AND REMOUNTING 4 19 REASSEM_BLY iNFORM_A...

Page 97: ...4 1 SHAFT DRIVE SHAFT DRIVE _ Classic Cycles Technical Resources ...

Page 98: ...clip 8 y og rln Bolts 8 giy 5 kinds rln 8 iynsg 5 kinds rln Oil seal housing Oil seal Bearing retainer Bolts Secondary bevel gear set Tiahtenina toraue w Item N m kg m lb ft 18 28 1 8 2 8 13 0 20 0 _ iD 18 28 1 8 2 8 13 0 20 0 1 8 1 90 120 1 9 0 12 0 165 0 87 0 1 www ClassicCycles org ...

Page 99: ...EAR l Remove the secondary driven bevel gear assembly See page 3 l 5 l Remove the bearing retainer with the special tool l Remove the oil seal 0 oil seal housing and O ring 0 CAUTION The removed oil seal and O ring should be replaced with new ones INSPECTION Inspect the removed parts for the following abnormalities The drive and driven bevel gears must be inspected thoroughly for excessive wear or...

Page 100: ...PDCACC A J L lNl3 rL Lr 3L For the other models _ 99000 25010 SUZUKI SUPER GREASE A CAUTION Always use a new oil seal and O ring 0 Tighten the bearing retainer to the specified torque Tightening torque 90 120 N m 9 0 12 0 kg m 65 0 87 0 lb ft 09921 21820 Bearing retainer wrench SECONDARY GEARS SHIM ADJUSTMENT BACi ip eii l Install the secondary drive bevel gear assembly and removed shims and tight...

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