Suzuki AY50 Service Manual Download

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Summary of Contents for AY50

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Page 2: ...our customers of fast and reliable service This manual has been prepared on the ba sis of the latest specifications at the time of publication If modifications have been made since then differences may exist between the content of this manual and the actual motorcycle Illustrations in this manual are used to show the basic principles of operation and work procedures They may not represent the actu...

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Page 132: ... with the multi circuit tester 09900 25008 Multi circuit tester set Tester knob indication Diode test Unit V More than 1 4 V tester s battery voltage NOTE If the tester reads under 1 4 V disconnect the tester probes from the wire leads and then replace the multi circuit tester s battery Standard resistance Y Ground 0 1 1 2 Ω Tester prove Tester prove A B C D E A 0 1 3 1 6 1 3 1 6 B 0 1 3 1 6 1 3 1...

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Page 214: ...IAGRAM 11 17 CONTENTS This chapter describes specification service data and servicing procedures which differ from those of the AY50Y WRY 00 MODEL NOTE Any differences between AY50Y WRY 00 MODEL and AY50K1 WRK1 01 MODEL in specifications and service data are clearly indicated with the asterisk marks Please refer to the chapters 1 through 10 for details which are not given in this chap ter COUNTRY ...

Page 215: ... Variable 2 768 1 005 P 22 Variable 2 768 0 871 P 02 39 Variable 2 975 1 140 The others Final reduction ratio 14 960 51 15 66 15 P 02 22 39 13 812 51 15 65 16 The others Drive system V belt drive CHASSIS Front suspension Inverted telescopic coil spring Rear suspension Swingarm type coil spring oil damped Steering angle 45 right left Caster 25 18 Trail 76 7 mm Turning radius 1 9 m Front brake Disc ...

Page 216: ...975 0 781 P 02 18 22 Variable 2 975 1 140 The others Final reduction ratio 16 271 51 15 67 14 P 02 18 22 13 812 51 15 65 16 The others Drive system V belt drive CHASSIS Front suspension Inverted telescopic coil spring Rear suspension Swingarm type coil spring oil damped Steering angle 45 right left Caster 25 18 Trail 76 7 mm Turning radius 1 9 m Front brake Disc brake Rear brake Disc brake Front t...

Page 217: ...on ring to 1st 0 03 0 07 groove clearance 2nd 0 02 0 06 Piston pin bore 10 002 10 010 10 030 Piston pin O D 9 995 10 000 9 980 CONROD CRANKSHAFT Unit mm ITEM STANDARD LIMIT Conrod small end I D 14 003 14 011 14 040 Conrod deflection 3 0 Crank web to web width 36 0 0 05 Crankshaft runout 0 05 OIL PUMP ITEM SPECIFICATION Oil pump reduction ratio 30 000 30 1 Oil pump discharge rate 0 9 1 1 ml for 5 m...

Page 218: ...3 P 02 Carburetor type KEIHIN PWS14 Bore size 14 mm I D No 35EE 35E2 Idle r min 1 900 200 r min 1 700 200 r min Float height 5 1 0 5 mm Main jet M J 70 60 Jet needle J N N4WA 3rd Pilot jet P J 48 45 Air screw A S 1 turns back 1 3 8 turns back Throttle cable play 2 4 mm ITEM SPECIFICATION P 22 P 34 P 39 Carburetor type KEIHIN PWS14 KEIHIN PWS12 Bore size 14 mm 12 mm I D No 35EJ 35EG 35EB Idle r min...

Page 219: ...istance 50 90 Ω Battery Type FB4L B P 53 designation YT4L BS The others Capacity 12 V 14 4 kC 4 Ah 10 HR P 53 12 V 10 8 kC 3 Ah 10 HR The others Standard electrolyte S G 1 280 at 20 C P 53 Fuse size 10 A WATTAGE Unit W ITEM SPECIFICATION Headlight HI 35 LOW 35 Brake light Taillight 21 5 Turn signal light 10 Speedometer light 1 2 2 Fuel meter light 1 2 Turn signal indicator light 2 Oil level indica...

Page 220: ...fork spring free length 124 7 122 Rear wheel travel 60 TIRE PRESSURE P 26 34 COLD INFLATION SOLO RIDING TIRE PRESSURE kPa kgf cm2 psi FRONT 125 1 25 18 REAR 175 1 75 25 The others COLD INFLATION SOLO RIDING DUAL RIDING TIRE PRESSURE kPa kgf cm2 psi kPa kgf cm2 psi FRONT 125 1 25 18 125 1 25 18 REAR 175 1 75 25 230 2 30 33 FUEL OIL ITEM SPECIFICATION NOTE Fuel type Fuel tank capacity 6 8 L Engine o...

Page 221: ...on ring to 1st groove clearance 2nd 0 01 0 05 Piston pin bore 12 002 12 010 12 030 Piston pin O D 11 996 12 000 11 980 CONROD CRANKSHAFT Unit mm ITEM STANDARD LIMIT Conrod small end I D 16 003 16 011 16 040 Conrod deflection 3 0 Crank web to web width 38 0 0 05 Crankshaft runout 0 05 OIL PUMP ITEM SPECIFICATION Oil pump reduction ratio 30 000 30 1 Oil pump discharge rate 0 8 1 0 ml for 5 minutes a...

Page 222: ...8 22 39 Variable 2 975 0 781 P 04 26 34 53 Variable 2 975 1 140 Final reduction ratio P 02 18 22 39 16 271 51 15 67 14 P 04 26 34 53 13 812 51 15 65 16 Drive belt width 18 4 17 4 Driven face spring free length 110 104 5 CARBURETOR ITEM SPECIFICATION P 04 26 53 P 34 P 18 Carburetor type KEIHIN PWS14 KEIHIN PWS12 Bore size 14 mm 12 mm I D No 35EC 35EH 35EB Idle r min 1 900 200 r min 1 700 200 r min ...

Page 223: ...R6HS Type DENSO W20FPR Gap 0 6 0 7 P 02 18 22 Type NGK BPR7HS DENSO W22FPR Gap 0 6 0 7 P 04 26 34 53 Spark performance Over 8 at 1 atm Ignition coil resistance Plug cap Secondary 4 10 kΩ B W lead wire terminal Generator coil resistance Charging 0 2 1 5 Ω Y Ground Pick up 100 270 Ω R Ground Regulated voltage 13 5 15 5 V at 5 000 r min Generator Max output 100 W at 5 000 r min Starter relay resistan...

Page 224: ... 2 3 5 Rear 4 0 0 2 3 5 Brake disc runout Front Rear 0 30 Master cylinder bore Front 11 000 11 043 Rear 12 000 12 043 Master cylinder piston diam Front 10 957 10 984 Rear 11 957 11 984 Brake caliper cylinder bore Front 30 230 30 306 Rear 30 230 30 306 Brake caliper piston diam Front 30 150 30 200 Rear 30 150 30 200 Brake fluid type DOT 4 Wheel rim runout Axial 2 0 Radial 2 0 Wheel axle runout Fron...

Page 225: ...DING DUAL RIDING TIRE PRESSURE kPa kgf cm2 psi kPa kgf cm2 psi FRONT 125 1 25 18 125 1 25 18 REAR 175 1 75 25 230 2 30 33 FUEL OIL ITEM SPECIFICATION NOTE Fuel type Fuel tank capacity 6 8 L Engine oil type Engine oil tank capacity 1 2 L Final gear oil type SAE 10W 40 Final gear oil capacity 130 ml Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended Use SUZUKI CCI...

Page 226: ...wallowed or if it comes in contact with the skin or eyes If engine cool ant gets into the eyes or contacts the skin flush eyes or wash the skin throughly with plenty of water If en gine coolant is swallowed induce vomiting and call a physician immediately Remove the thermostat cover 1 Remove the thermostat 2 INSPECTION Inspect the thermostat for cracks or damage If any damages are found replace th...

Page 227: ... valve should have lifted at least 3 mm Thermostat valve lift Over 3 mm at 80 C If the thermostat is faulty in either of these two checks replace it with a new one INSTALLATION Install the thermostat in the reverse order of removal After installing the thermostat be sure to add engine coolant ENGINE COOLANT TEMP SWITCH For AY50WRK1 REMOVAL Remove the trunk Drain engine coolant Disconnect the lead ...

Page 228: ...t temp switch is operated 09900 25008 Multi circuit tester set Engine coolant temp switch specification OFF ON Approx 125 C ON OFF Approx 118 C INSTALLATION Install the engine coolant temp switch in the reverse order of removal Pay attention to the following points Apply SUZUKI BOND No 1215 to the thread portion of the engine coolant temp switch 99000 31110 SUZUKI BOND No 1215 Tighten the engine c...

Page 229: ...e tester reads under 1 4 V disconnect the tester probes from the wire leads and then replace the multi circuit tester s battery Tester probe CDI IGNITION COIL Measure the voltage between the terminals using the multi circut tester as indicated in the table below If the voltage is not within the specified value replace the CDI ignition coil with a new one 09900 25008 Multi circuit tester set Tester...

Page 230: ...Y W Y G Y G B W B W O W B W B W Bl W Bl B R B R P B W B W O W B W B Y W Y W Y Y O Lb Lbl Bl W Bl W B W B W G W G W B W B W Y B Y B B W B W Y B Y B B W B W Bl W Bl W B W B W Y W Y W Y W Y W Lg Lg W B W B B W B W Br Br B B W B W B W B W Lg Lg B B W B W Lg Lg B W B W Y B W B W W B B W B W Gr Gr W Y B Lb Lbl Lg Lg G B W B W R B W B W Y W Y W B W B W R Y W Bl W Bl B W B W Y W Y W Y G Y G W B W B R R W ...

Page 231: ...l W Bl W Y G W G W Gr Gr Y W Y W Y G Y G B W B W O W B W B W Bl W Bl B R B R P B W B W O W B W B Y W Y W Y Y O Lb Lbl Bl W Bl W B W B W G W G W B W B W Y B Y B B W B W Y B Y B B W B W Bl W Bl W B W B W Y W Y W Y W Y W Lg Lg W B W B B W B W Br Br B B W B W B W B W Lg Lg B B W B W Lg Lg B W B W Y B W B W W B B W B W Gr Gr W Y B Lb Lbl Lg Lg G B W B W R B W B W Y W Y W B W B W R Y W Bl W Bl B W B W Y...

Page 232: ...l W Y G W G W Gr Gr Y W Y W Y G Y G B W B W O W B W B W Bl W Bl B R B R P B W B W O W B W B Y W Y W Y Y O Lb Lbl Bl W Bl W B W B W G W G W B W B W Y B Y B B W B W Y B Y B B W B W Bl W Bl W B W B W Lg Lg W B W B B W B W Br Br B B W B W B W B W Lg Lg B B W B W Lg Lg B W B W Y B W B W W B B W B W Gr Gr W Y B Lb Lbl Lg Lg G B W B W R B W B W Y W Y W B W B W R Y W Bl W Bl B W B W Y W Y W Y G Y G W B W ...

Page 233: ...Bl B Bl B B G B G O W B W B O W B W B W Bl W Bl B R B R P B W B W Y W Y W Y Y Y W Y W Y W Y W Y B Y B B W B W G W G W B W B W Bl W Bl W B W B W Bl W Bl W B W B W O Lb Lbl B G B G Y B Y B B W B W Y B Y B Gr Gr B W B W O Lg Lg B Bl W Bl W B G B G Y Gr Gr W Y B R B R B W B W Bl B Bl B O R Gr Gr Br Br B r B r R B R B B W B W Bl W Bl W O R Gr Gr Br Br B Lb Lbl Lg Lg G B W B W O G R B W B W Y W Y W B W ...

Page 234: ... Y G B W B W Bl W Bl W Bl B Bl B B G B G O W B W B O W B W B W Bl W Bl B R B R P B W B W Y W Y W Y Y Y W Y W Y W Y W Y B Y B B W B W G W G W B W B W Bl W Bl W B W B W Bl W Bl W B W B W O Lb Lbl B G B G Y B Y B B W B W Y B Y B Gr Gr B W B W O Lg Lg B Bl W Bl W B G B G Y B R B R B W B W Bl B Bl B O R B R B R R B R B B W B W Bl W Bl W O R Gr Gr W Y B Lb Lbl Lg Lg G B W B W O G R B W B W Y W Y W B W B...

Page 235: ... G B W B W Bl W Bl W Bl B Bl B B G B G O W B W B O W B W B W Bl W Bl B R B R P B W B W Y W Y W Y Y Y W Y W Y W Y W Y Y B Y B B W B W G W G W B W B W Bl W Bl W B W B W Bl W Bl W B W B W O Lb Lbl B G B G Y B Y B B W B W Y B Y B Gr Gr B W B W O Lg Lg B Bl W Bl W B G B G Y B R B R B W B W Bl B Bl B O R B R B R R B R B B W B W Bl W Bl W O R Gr Gr W Y B Lb Lbl Lg Lg G B W B W O G R B W B W Y W Y W B W B...

Page 236: ...om those of the AY50K2 WRK2 02 MODEL NOTE Please refer to the chapters 1 through 11 for details which are not given in this chapter SPECIFICATIONS 12 2 AY50 AND AY50S 12 2 AY50W AND AY50WS 12 3 SERVICE DATA 12 4 AY50 AND AY50S 12 4 AY50W AND AY50WS 12 8 WIRING DIAGRAM 12 13 AY50 AND AY50S 12 13 AY50W AND AY50WS 12 15 OIL HOSE ROUTING 12 17 COUNTRY OR AREA P 02 UK P 19 EU ...

Page 237: ...element Starter system Electric and Kick Lubrication system SUZUKI CCI Idle speed 1 900 200 r min DRIVE TRAIN Clutch Dry shoe automatic centrifugal type Gearshifting Automatic variable ratio Gear ratio variable Variable reduction ratio 2 768 1 005 Final reduction ratio 14 960 51 15 65 15 Drive system V belt drive CHASSIS Front suspension Inverted telescopic coil spring Rear suspension Swingarm coi...

Page 238: ...eadlight 12V 35 35W Brake light Taillight 12V 21 5W Turn signal light 12V 10W Speedometer light 12V 1 2W 2 Fuel level gauge light 12V 1 2W High beam indicator light 12V 1 2W Turn signal indicator light 12V 2W Oil level indicator light 12V 2W Trunk light 12V 2W CAPACITIES Fuel tank 6 8 L 1 8 1 5 US Imp gal Engine oil tank 1 2 L 1 3 1 1 US Imp qt Final gear oil oil change 120 ml 4 1 4 2 US Imp oz ov...

Page 239: ...r system Electric and Kick Lubrication system SUZUKI CCI Idle speed 1 900 200 r min DRIVE TRAIN Clutch Dry shoe automatic centrifugal type Gearshifting Automatic variable ratio Gear ratio reduction ratio Variable reduction ratio 2 975 1 033 Final reduction ratio 16 271 51 15 67 14 Drive system V belt drive CHASSIS Front suspension Inverted telescopic coil spring Rear suspension Swingarm coil sprin...

Page 240: ...ght 12V 21 5W Turn signal light 12V 10W Speedometer light 12V 1 2W 2 Fuel level gauge light 12V 1 2W Turn signal indicator light 12V 2W High beam indicator light 12V 1 2W Oil level indicator light 12V 2W Coolant temperature check light 12V 2W Trunk light 12V 2W CAPACITIES Fuel tank 6 8 L 1 8 1 5 US Imp gal Engine oil tank 1 2 L 1 3 1 1 US Imp qt Final gear oil oil change 120 ml 4 1 4 2 US Imp oz o...

Page 241: ...ap 1st R Approx 4 0 3 2 2nd R Approx 4 3 3 4 Piston ring end gap 1st 2nd R 0 10 0 25 0 80 Piston ring to groove clearance 1st 0 03 0 07 2nd 0 02 0 06 Piston pin bore 10 002 10 010 10 030 Piston pin O D 9 995 10 000 9 980 ITEM STANDARD LIMIT Conrod small end I D 14 003 14 011 14 040 Conrod deflection 3 0 Crank web to web width 36 0 0 05 Crankshaft runout 0 05 ITEM SPECIFICATION Oil pump reduction r...

Page 242: ... 5 1 0 5 mm Main jet M J 65 Jet needle J N N5GJ 3rd Pilot jet P J 40 Air screw A S 1 turns back Throttle cable play 2 4 mm ITEM SPECIFICATION NOTE Spark plug Type NGK BPR6HS DENSO W20FPR U Gap 0 6 0 7 Spark performance Over 8 at 1 atm Ignition coil resistance Secondary 4 10 kΩ Plug cap B W lead wire terminal Generator coil resistance Charging 0 2 1 5 Ω Y Ground Pick up 100 270 Ω R Ground Regulated...

Page 243: ...ckness Front 4 0 0 2 3 5 Brake disc runout Front 0 30 Master cylinder bore Front 11 000 11 043 Master cylinder piston diam Front 10 957 10 984 Brake caliper cylinder bore Front 30 230 30 306 Brake caliper piston diam Front 30 150 30 200 Brake fluid type DOT 4 Wheel rim runout Axial 2 0 Radial 2 0 Wheel axle runout Front 0 25 Wheel rim size Front J12 MT3 50 Rear J12 MT3 50 Tire size Front 120 70 12...

Page 244: ...m2 psi FRONT 125 1 25 18 125 1 25 18 REAR 175 1 75 25 230 2 30 33 ITEM SPECIFICATION NOTE Fuel type Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended Fuel tank capacity 6 8 L Engine oil type Use SUZUKI CCI SUPER OIL If they are not avail able use a good quality 2 stroke oil rated FC under JASO classification Engine oil tank capacity 1 2 L Final gear oil type SA...

Page 245: ...p 1st 2nd T Approx 4 5 3 6 N Approx 3 0 2 4 Piston ring end gap 1st 2nd T N 0 08 0 18 0 80 Piston ring to groove clearance 1st 2nd 0 01 0 05 Piston pin bore 12 002 12 010 12 030 Piston pin O D 11 996 12 000 11 980 ITEM STANDARD LIMIT Conrod small end I D 16 003 16 011 16 040 Conrod deflection 3 0 Crank web to web width 38 0 0 05 Crankshaft runout 0 05 ITEM SPECIFICATION Oil pump reduction ratio 30...

Page 246: ... OFF Approx 118 C Engine coolant type Use an anti freeze coolant compatible with alumi num radiator mixed with distilled water only at the ratio of 50 50 Engine coolant including reserve 1 200 ml ITEM STANDARD LIMIT Reduction ratio Variable 2 975 1 033 Final reduction ratio 16 271 51 15 67 14 Drive belt width 18 4 17 4 Driven face spring free length 110 104 5 ITEM SPECIFICATION Carburetor type KEI...

Page 247: ...Y Ground Pick up 100 270 Ω R Ground Regulated voltage 13 5 15 5 V at 5 000 r min Generator Max output 100 W at 5 000 r min Starter relay resistance 50 90 Ω Battery Type designation YT4L BS Capacity 12 V 10 8 kC 3 Ah 10 HR Fuse size 10 A ITEM SPECIFICATION Headlight HI 35 LO 35 Brake light Taillight 21 5 Turn signal light 10 Speedometer light 1 2 2 Fuel meter light 1 2 Turn signal indicator light 2...

Page 248: ...150 30 200 Rear 30 150 30 200 Brake fluid type DOT 4 Wheel rim runout Axial 2 0 Radial 2 0 Wheel axle runout Front 0 25 Wheel rim size Front J12 MT3 50 Rear J13MC MT3 50 Tire size Front 120 70 12 51L Rear 130 60 13 M C 53L Tire type Front METZELER ME 7 TEEN Rear METZELER ME 7 TEEN Tire tread depth Front 1 6 Rear 1 6 ITEM STANDARD LIMIT Front fork stroke 77 Front fork spring free length 124 7 122 R...

Page 249: ... 91 octane or higher An unleaded gasoline is recommended Fuel tank capacity 6 8 L Engine oil type Use SUZUKI CCI SUPER OIL If they are not avail able use a good quality 2 stroke oil rated FC under JASO classification Engine oil tank capacity 1 2 L Final gear oil type SAE 10W 40 Final gear oil capacity 130 ml ...

Page 250: ...NDICATOR LIGHT OI OIL LEVEL INDICATOR LIGHT HI HIGH BEAM INDICATOR LIGHT FUEL CDI IGNITION COIL BRAKE LIGHT SWITCH REAR BRAKE LIGHT SWITCH FRONT STARTER BUTTON THERMO SWITCH OIL LEVEL INDICATOR LIGHT SWITCH CARBURETOR HEATER TURN SIGNAL RELAY FUEL LEVEL GAUGE SP TU OI HI PUSH ON OFF ON OFF ON OFF ON OFF LO HI L R PUSH PUSH P LOCK OFF C ON Y B Gr B W O Lg B Bl W B G Y Y B Y W B W O Lg B Bl W B G Y ...

Page 251: ...CH REAR BRAKE LIGHT SWITCH FRONT STARTER BUTTON THERMO SWITCH OIL LEVEL INDICATOR LIGHT SWITCH CARBURETOR HEATER TURN SIGNAL RELAY FUEL LEVEL GAUGE SP TU OI HI PUSH ON OFF ON OFF ON OFF ON OFF LO HI L R PUSH PUSH ON C OFF LOCK Y B Gr B W O Lg B Bl W B G Y Y B Y W B W O Lg B Bl W B G Y Y G B W O W B O W B W Bl B R P B W Y W Y Y Y W Y W O Lbl Bl W B W Y B B W Y B B W Bl W B W Y W W Y B Lbl Lg G B W ...

Page 252: ... FRONT STARTER BUTTON DIODE THERMO SWITCH OIL LEVEL INDICATOR LIGHT SWITCH CARBURETOR HEATER TURN SIGNAL RELAY FUEL LEVEL GAUGE SP TU OI WT HI WATER TEMP SWITCH PUSH ON OFF ON OFF ON OFF ON OFF LO HI L R PUSH PUSH P LOCK OFF C ON Y B Gr B W O Lg B Bl W B G Y Y B Y W B W O Lg B Bl W B G Y Y G B W O W B Bl W Bl B B G O W B W Bl B R P B W Y W Y Y Y W Y W B G O Lbl Bl W B W Y B B W Y B B W Bl W B W Y ...

Page 253: ...ITCH FRONT STARTER BUTTON DIODE THERMO SWITCH OIL LEVEL INDICATOR LIGHT SWITCH CARBURETOR HEATER TURN SIGNAL RELAY FUEL LEVEL GAUGE SP TU OI WT HI WATER TEMP SWITCH PUSH ON OFF ON OFF ON OFF ON OFF LO HI L R PUSH PUSH ON C OFF LOCK Y B Gr B W O Lg B Bl W B G Y Y B Y W B W O Lg B Bl W B G Y Y G B W O W B Bl W Bl B B G O W B W Bl B R P B W Y W Y Y Y W Y W B G O Lbl Bl W B W Y B B W Y B B W Bl W B W ...

Page 254: ...03 MODEL 12 19 OIL HOSE ROUTING Clip Clip Clip Clip Clip Clip Oil hose Oil hose Oil hose Oil hose Oil hose to the oil tank Filter Face the arrow mark on the filter to the oil pump when installing the filter Oil pump Clamp ...

Page 255: ...bes specifications service data and servicing procedures which differ from those of the AY50K3 WRK3 03 MODEL NOTE Please refer to the chapters 1 through 12 for details which are not given in this chapter SPECIFICATIONS 13 2 AY50 13 2 AY50W 13 3 SERVICE DATA 13 4 AY50 13 4 AY50W 13 8 ...

Page 256: ...ed telescopic coil spring Rear suspension Swingarm coil spring oil damped Front suspension stroke 77 mm 3 0 in Front wheel travel 70 mm 2 8 in Rear wheel travel 60 mm 2 4 in Caster 25 20 Trail 76 mm 2 99 in Steering angle 45 left and right Turning radius 1 9 m 6 2 ft Front brake Disc brake Rear brake Drum brake Front tire size 120 70 12 51L tubeless Rear tire size 130 70 12 56L tubeless ELECTRICAL...

Page 257: ...ingarm coil spring oil damped Front suspension stroke 77 mm 3 0 in Front wheel travel 70 mm 2 8 in Rear wheel travel 60 mm 2 4 in Caster 25 20 Trail 76 mm 2 99 in Steering angle 45 left and right Turning radius 1 9 m 6 2 ft Front brake Disc brake Rear brake Disc brake Front tire size 120 70 12 51L tubeless Rear tire size 130 60 13 M C 53L tubeless ELECTRICAL Ignition type Electronic ignition CDI I...

Page 258: ...Approx 4 0 3 2 2nd R Approx 4 3 3 4 Piston ring end gap 1st 2nd R 0 10 0 25 0 80 Piston ring to groove clearance 1st 0 03 0 07 2nd 0 02 0 06 Piston pin bore 10 002 10 010 10 030 Piston pin O D 9 995 10 000 9 980 ITEM STANDARD LIMIT Conrod small end I D 14 003 14 011 14 040 Conrod deflection 3 0 Crank web to web width 36 0 0 05 Crankshaft runout 0 05 ITEM SPECIFICATION Oil pump reduction ratio 30 0...

Page 259: ...5 mm Main jet M J 65 Jet needle J N N5GJ 3rd Pilot jet P J 40 Air screw A S 1 3 4 turns back Throttle cable play 2 4 mm ITEM SPECIFICATION NOTE Spark plug Type NGK BPR6HS DENSO W20FPR U Gap 0 6 0 7 Spark performance Over 8 at 1 atm Ignition coil resistance Secondary 4 10 kΩ Plug cap B W lead wire terminal Generator coil resistance Charging 0 2 1 5 Ω Y Ground Pick up 100 270 Ω R Ground Regulated vo...

Page 260: ...sc thickness Front 4 0 0 2 3 5 Brake disc runout Front 0 30 Master cylinder bore Front 11 000 11 043 Master cylinder piston diam Front 10 957 10 984 Brake caliper cylinder bore Front 30 230 30 306 Brake caliper piston diam Front 30 150 30 200 Brake fluid type DOT 4 Wheel rim runout Axial 2 0 Radial 2 0 Wheel axle runout Front 0 25 Wheel rim size Front J12 MT3 50 Rear J12 MT3 50 Tire size Front 120...

Page 261: ...0 2 30 33 ITEM SPECIFICATION NOTE Fuel type Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended Fuel tank capacity 6 8 L Engine oil type Use SUZUKI CCI SUPER OIL If they are not avail able use a good quality 2 stroke oil rated FC under JASO classification Engine oil tank capacity 1 2 L Final gear oil type SAE 10W 40 Final gear oil capacity 130 ml ...

Page 262: ...T Approx 4 5 3 6 N Approx 3 0 2 4 Piston ring end gap 1st 2nd T N 0 08 0 18 0 80 Piston ring to groove clearance 1st 2nd 0 01 0 05 Piston pin bore 12 002 12 010 12 030 Piston pin O D 11 996 12 000 11 980 ITEM STANDARD LIMIT Conrod small end I D 16 003 16 011 16 040 Conrod deflection 3 0 Crank web to web width 38 0 0 05 Crankshaft runout 0 05 ITEM SPECIFICATION Oil pump reduction ratio 30 000 30 1 ...

Page 263: ...prox 118 C Engine coolant type Use an anti freeze coolant compatible with alumi num radiator mixed with distilled water only at the ratio of 50 50 Engine coolant including reserve 1 200 ml ITEM STANDARD LIMIT Reduction ratio Variable 2 975 1 033 Final reduction ratio 16 271 51 15 67 14 Drive belt width 18 4 17 4 Driven face spring free length 110 104 5 ITEM SPECIFICATION Carburetor type KEIHIN PWS...

Page 264: ... 100 270 Ω R Ground Regulated voltage 13 5 15 5 V at 5 000 r min Generator Max output 100 W at 5 000 r min Starter relay resistance 50 90 Ω Battery Type designation YT4L BS Capacity 12 V 10 8 kC 3 Ah 10 HR Fuse size 10 A ITEM SPECIFICATION Headlight HI 35 LO 35 Brake light Taillight 21 5 Turn signal light 10 License plate light 5 Speedometer light 1 2 2 Fuel meter light 1 2 Turn signal indicator l...

Page 265: ...Brake caliper piston diam Front 30 150 30 200 Rear 30 150 30 200 Brake fluid type DOT 4 Wheel rim runout Axial 2 0 Radial 2 0 Wheel axle runout Front 0 25 Wheel rim size Front J12 MT3 50 Rear J13MC MT3 50 Tire size Front 120 70 12 51L Rear 130 60 13 M C 53L Tire type Front METZELER ME 7 TEEN Rear METZELER ME 7 TEEN Tire tread depth Front 1 6 Rear 1 6 ITEM STANDARD LIMIT Front fork stroke 77 Front ...

Page 266: ...octane or higher An unleaded gasoline is recommended Fuel tank capacity 6 8 L Engine oil type Use SUZUKI CCI SUPER OIL If they are not avail able use a good quality 2 stroke oil rated FC under JASO classification Engine oil tank capacity 1 2 L Final gear oil type SAE 10W 40 Final gear oil capacity 130 ml ...

Page 267: ...274 Prepared by 7th Ed February 2004 1st Ed March 1997 Part No 99500 10457 01E Printed in Japan ...

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