-

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r l,

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 FOREWORO A WARNING Indicates a potentia l hazard
that cou ld result in death or injury .
This manual is presented as a means whereby .4. CAUTION Indicates a potential hazard
you can maintain your RM250 in top working that could result in motorcycle damage.
condition at all times . Your riding skill and the NOTE: Indicates special information to make
maintenance steps outlined in this manual will maintenance easier or instruc tions clearer.
assure you of top performance from your
machine under any type of competition. COMPETITION MOTORCYCLES
The Suzuki RM250 is a high-perfo rmance ,
We sin cerely wish you and your Suzuki motor- competition-only motorcycle. It is not designed
cycle a successful partnership for many years or approved for gene ral off-highway riding , as
of happy riding . it does not meet U.S. Environmental Protection
Agency off -highway motorcycle noise standa rs
All information, illustration, photographs and and does not have a U.S. Forest Service ap-
specifications contained in the manual are based proved spark arrester . It is also not designed or
on the latest product information available at the approved for riding on publ ic roads, as it does
time of publication. Due to improvements or not meet Federal Motor Vehicle Safety Stan-
other changes, there may be some discrepan - da rds for on -highway motorcycles.
cies in this manual. Suzuki reserves the right to
make production changes at any time , witihout General considerations:
notice and without incurring any obligation to • Before each use, perform an inspection per
make the same or similar changes to vehicles " Periodic Inspection" section starting on
previously built or sold . page 2 - 1.
• Suzuki RMs are designed for the rider only
Suzuki Motor Corporation believes in conserva- - NO PASSENGERS .
tion and protection of Earth 's natural resources . • Always ride within the boundaries of your
To that end, we encourage every veh icle own- own skills. Knowing these limits and staying
er to recycle , trade in , or properly dispose of , within them wi ll help you avoid accidents.
as appropriate, used motor oil , engine coolant, Ride only in events app ropriat e for your ex-
and other fluid , and tires . perience .
• Safely competing on a mot orcycle requires
that your mental and physical ski lls are fully
part of the experience . You should not at-
tempt to operate a motor vehicle , especially
one with two wheels , if you are tired or un-
der the influence of alcohol or other drugs.
WARNING /CAUTION / NOTE Alcohol , illegal drugs , and even some
Please read this manual and follow its instruc- prescription and over-the-counter drugs can
tions ca refully . To emphasize special informa- cause drowsiness , loss of coordination . loss
tion , the symbol £ and the words WARNING, of ba lance, and loss of good judgement. If
CAUTION , and NOTE have special meanings. you are tired or under the influence of alco-
Pay special attention to the messages highlight- hol or other drugs, PLEASE DO NOT RIDE
ed by these signal words : your motorcycle.

Mayall of your rides on your new Suzuki be win-

ning rides!

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 WARNINGS FOR SERVICING

A WARNING A WARNING

Never run the engine indoors or in a garage . Fuel can catch on fire if you do not handle it
Exhaust gas contains carbon monoxide. a gas properly . Gasoline vapors can catch fire
that is colorless and odorless and can cause easily .
death or severe injury . Do not smoke when servicing the machine .
Only run the engine outdoors where there is Do not service the machine in an area where
fresh air . there are open flames or sparks .

\')
o
o

A WARNING A WARNING

Hot engine and muffler can burn you . Brake fluids and engine coolant can be
hazardous to humans and pets. Brake fluid
Wait until the engine and muffler cools before
servicing .
and engine coolant are harmful or fatal if swal -
lowed, and harmful if it comes in contact with
your skin or eyes.
Keep brake fluid and engine coolant away
from children . Call your doctor immediately
if swallowed, and induce vomiting , Flush eyes
or skin with water if either brake fluid or
engine coolant gets in eyes or comes in
contact with skin.

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 A WARNING A WARNING

Servicing the machine with engine running Servicing the machine without proper clothes
can be hazardous . You can be caught in the and protective gear can be hazardous . You
moving parts such as the drive chain, sprock· can be injured if you do not wear Rroper
ets etc. clothes and protective gear.

Be sure to s top the engine when servicing the Be sure to wear proper clothes and shoes for
machine. servicing and wear protective glasses. mask
or gloves as necessary .

' ~:P/
III "

PRECAUTIONS FOR SERVICING REPLACEMENT PARTS

• Replace gaskets, eire lips, a-rings and cotter Use on ly genuine SUZUKI replacement parts or
pins with new ones. thei r equivalent . Genuine SUZUKI parts are high
• Take care not to expand the end gap larger quality parts which are designed and built spe -
than required to slip the circl ip over the shaft cially for SUZUKI vehicles .
when installing a circlip.
• Use special tools where specified. NOTE: Use of replacement parts which are not
• Use genuine SUZUKI parts and recommend - equivalent in quality to genuine SUZUKI parts can
ed oil. lead to performance problems and damage.
• When two or more persons work together ,
pay attention to the safety of each other.
• After reassembly , inspect parts for tightness
and ope ration .

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 SYMBOL MARKS AND MATERIALS

SYMBO L MARK MATERIALS

SUZUKI SUPER GREASE" A"

99000-25030

;
_....
.. .

-
SUZUKI SILICONE GREASE
99000-25100

THREAD LOCK SUPER" 1303"

99000-32030

SUZUKI BOND 1207B

99104-31140

Use or apply OOT4 brake fluid .

FROtIT
FIIIKDlL
SUZUKI FORK OIL 55-05
99000-99001-555

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 SYMBOL MARK MATERIALS

UI
___ -.l
1
I

SUZUKI REAR SUSPENSION OIL 55-25

99000-99001 -525

Use engine coolant.

Apply engine oil or transmission oil.

Tighten a nut or bolt to the specified

torque.

Replace a part with a new one when

ressembling .

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J
 - MEMO -

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 TABLE OF CONTENTS
,----------------------------------------
GENERAL INSTRUCTIONS

PERIODIC MAINTENANCE

TROUBLESHOOTING

MACHINE TUNING

ENGINE DISMOUNTING AND MOUNTING

CYLINDER, PISTON AND EXHAUST VALVE

CLUTCH

KICK STARTER

TRANSMISSION AND CRANKSHAFT

FUEL SYSTEM

COOLING SYSTEM

ELECTRICAL SYSTEM

FRONT AND REAR WHEELS

FRONT AND REAR BRAKES

FRONT FORK AND STEERING

REAR SUSPENSION

SERVICE DA TA

SPECIAL TOOLS

WIRE, CABLE AND HOSE ROUTING

SPECIFICA TIONS

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 1·1 GENERAL INSTRUCTIONS

LOCATION OF PARTS

CDClutch lever
@ Engine kill switch
@ Throttle grip
@ Front brake lever

® Fuel tank cap

® Choke/idle adjust knob
Q) Gearshift lever

® Kick starter lever

® Rear brake peda l

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 GENERAL INSTRUCTIONS 1·1

FUEL
This motorcycle is of the two-stroke design, which requires
n I~I,
a premixture of gasoline and oil. 5:0 156
10.0 312
Gasol ine: Unleaded gasoline minimum 90 pump UA + M) /2) 15.0 46B
octane. 20.0 624
Engine oil: SUZUKI CCI SUPER 2-CYCLE MOTOR LUBR I-
CANT or equivalent T wo Cycle Racing Gasoline Oil
I gal. I I qt I
Lubricant .
Mixing ratio : 32 : 1 1.0 1/8
Fuel tank capacity : 7.5 L (2.0 US gal) 2 .0 1 /4
3.0 3/8
.A CAUTION 4 .0 1/ 2
A mixture containing too little oil will cause piston sei- 5.0 5 /8
zure. Too much oil will cause excessive carbon formation
resulting in preignition . fouled spark plug and loss of en-
gine power.
M ix fuel and the engine oil at the ratio of 32:1 .

NOTE:
• Mix gasoline and the engine oil thoroughlv when the tem-
perature is below aoe
(32 OF). Vegetable -based oils can
separate easier than mineraloils.
• Use premixture oil as soon as possible after mixing, or
lubrication performance of the engine oil can decrease.
• Do not mix vegetable-based 011 and mineral oil.
• Insert the end of the breather hose into the steering stem
head after refueling .

NOTE: Fuel tank cap has directional breather hose. Fit the
breather hose correctly as shown in the illustration.

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 1·J GENERAL INSTRUCTIONS

OPERATING INSTRUCTIONS
Starting th e Engine
ON OFF
Inspect the transmission oil level, coolant level and air cleaner
condition before starting t he engine.

When the engine is cold:

1 ) Turn the fuelcock lever to the "ON" posit ion.
2) Shift the transmission into neut ral.
3) Pu ll the choke /idle adjust knob.
4) Close the throttle grip co m ple tely and depress t he kick
starter lever forcefu lly.
5) Return the choke/idle adjust knob when the engine revs
at steady speed.

When the engine is warm:

1 ) Turn the fuelcock lever to the "ON" pasitan .
2) Shift the transmission into neutral.
3) Open the throttle 1/8 - 1/4 turn and depress t he ki ck
starter lever forcefu ll y,

To restart afte r t he moto rcycle has fal len:

1 ) Shift th e t ransmission into neu t ral.
2) Open the t hrottle comple tely and depress the kick start-
er lever fo rcefully.
3) Close the throttle gradua lly as engine speed increases.
4) Wait un t il engine revs smoothly.

Stopping the Engine

1 ) Shift the transmission into neu t ral.
2) Turn the fuel cock lever to t he "OFF" posit ion.
3) Push the engine ki ll swit ch to stop the engine.

A WARNING
Leaving the fuelcock in the " ON " position may cause car-
buretor overflow . Thi s can cause a fire or severe engine
damage when y ou start the engine.

Alw ay s leave th e fuel cock in the " OFF " position when
the engine is not running .

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 GENERAL INSTRUCTIONS 1·4

CHOKEIIOLE ADJUST KNOB

CHOKE ON
The choke/idle adjust knob is used to work the choke sys-
tem and to adjust the engine idle speed. The choke system
works by pulling up the knob. The engine idle speed is ad-
justed by turning the knob. Turn the knob clockwise to Idle speed
decrease
t CHOKE OFF
Idle speed
increase
decrease engine idle speed and turn the knob counterclock-
wise to increase engine idle speed.

TRANSMISSION
This motorcycle has a 5-speed transmission. Neutral is lo -
cated between low and 2nd. Engage first gear by pressing
the lever down from the neutral position. You can shift into
higher gears by lifting on the shift lever once for each gear.
When neutral is desired, press or Jjft the lever to a position
halfway between low and 2nd gear.

BREAK -IN
When the Motorcycle Is New
1 , Warm up the engine before starting off.
2) Ride for 10 minutes using less than 1 /2 throttle opening
with various throttle opening.
3) Ride for 20 minutes using less than 3/4 throttle opening
with various threat le opening.

NOTE:
• The break·in period is the period of greatest wear.
• The bolts and nuts of the new machine can be loosened
earlier. Be sure to retighten the bolts and nuts during the
break·,n period.

When Engine Parts Are Replaced

Follow the same procedure when any of the following parts
are replaced:
Piston
Piston ring
Cylinder
Crankshaft
Crankshaft bearing

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 2·' PERIODIC MAINTENANCE

PERIODIC MAINTENANCE
INSPECTION BEFORE PRACTICE

WHAT TO CHECK CHECK FOR

Spark plug • Heat range , fouled electrode . tightness
• Loose high-tension cord
Air cleaner element Lubrication
Transmission oil Oil level
Coolant Coolant fevel
Cooling system • Radiator hose damage
• Coolant leak
Clutch Smooth operation
Throttle • Play
• Smooth operation
Brake fluid Fl uid level
Brakes • Brake lever/pedal play
• Operation
Drive chain Slack , lubrication, chain 'oint clip condi t ion
Drive chain uide/buffer Wea r, dama e
Suspension • Smooth operation
• Front fork air pressure
Wheels • Spoke tension
• Rim lock ti hteness
Tires Tire pressure
Steerin Smoothness, play
Exhaust pi e Firm fjxation
Bolts and nuts Tightening torque

INSPECTION BEFORE RACE

WHAT TO CHECK CHECK FOR

All items of inspection
before practice above plus .
Air cleaner Cleanliness
Clutch Clutch disc plates wear and distortion
Brake pad s Wear
Sprockets Wea r
Fuel tank • Leakage
• Fuel filter clogging
Fuel line Damage
Exhaust pipe Dama e
Piston and Cylinder • Combustion Chamber carbon deposit
• Piston head carbon deposit
• Piston and cylinder wear
Front fork Air pressure

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 PERIODIC MAINTENANCE 2·2

PERIOOIC MAINTENANCE CHART

It is very important to inspect and maintain the machine regularly . Follow the guideline in the chart.
The life of parts varies depending on the riding conditions . Perform more often than shown in the
cha rt if you use the motorcycle under severe conditions. D
~I races Every Every Every
race 3 races 5 races
Remarks
Servic Ever~1 !h - Ever"H4 IA- Every7 1h-
Item HRS
2 RS 6 RS 10 HRS
Spark plug I I R
Air cleaner C C C Replace air cleaner element as
necessary .
Transmission oil - R - Change after 1st initial break-in.
I & C I & C I & C
Replace radiator hose and coolant
Cooling-system every year .
Flushing for overhaul or storage .
Clutch I I I Replace clutch plates as necessary.
Throttle and
clutch cable I I R
Carburetor I I I
I I I
Fuel line
Replace every 4 years.
Piston - - R
Piston ring - R -
Cylinder head ,
cylinder, exhaust - C -
valve and muffler
- R -
Drive chain Adjust slack every 30 minutes.
Clean and lubricate after every race.
Engine sprocket - - R
Check and retighten sprocket bolts
Rear sprocket - R - at initial and subsequent 10 minutes
of riding and each race thereafter .
Drive chain buffer - R -
Drive chain guide - R -
Kick starter lever Apply orease after every race .
Replace brake hose and fluid every
Brake I I I year.
Front fork oil - R - Change after 1st initial break-in .
Check abnormality for front fork in~~~
Front fork I I I tube frequently and equalize the for
air pressure to the atmospheric pressure.
Rear suspension Check rear suspension system
system pivoting I I I frequently and apply grease to the
portion pivotinQ portion as necessary.
Tire I I I
Inspect every 20 min. up to initial
Spoke nipple 2 hours then check before each ride. First loosen then tighten .
Steering I I I
Bolts and nuts T T T Retighten every , hour.

NOTE: R = Rep/ace, C = Clean, T= Tighten, /=Inspect and clean, adjust lubricate

or replace if necessary.

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 2·3 PERIODIC MAINTENANCE

SPARK PLUG
Inspect t he spark plug condition, electrode color, ca rbon
deposits, spark plug gap, and washe r damage. after re mov-
ing the spark pl ug.
NOTE: Remove the dirt around the spark plug before
removing the spark plug to prevent dirt from entering the
combustion chamber.
Inspect the po rcelain tip color.

Porcelain tip color Cause

• Hot t ype spark plug

W hite (overheated)
• Advanced ign it ion t iming
• Lea n ai r/fu el mixtu re
• Deteriorated f uel

• Cold type spa rk plug

Black (fouled)
• Retarded ig nition timing
• Rich ai r/fuel mixture
• Rich oil/gasol ine mixture

Clean the spark plug with a brush or wi re and check t he spark

plug ga p with a thickness gauge.
Spark plug gap : 0 .55 - 0 .65 mm (0 .022 - 0 .026 in)

Stand ard Spark plug

0.55 - 0.65 mm
NGK R411 BS· B (0.022 - 0.026 in)

A CAUTION
Changing the spark plug heat range improperly can
damage the engine .

Select the spark plug heat rang e only after adjusting the
ignition timing . carburetor setting and oil/gasoline mixture.

Tighten the spark plug with specif ied t ighteing torque after
tighteni ng the spark pl ug tem porari ly with fingers.

Tightening torque : 2S N.m (2 .S kg-m . 20 .0 Ib -ft)

AIR CLEANER
Air Cleaner Element Removal
• Remove the seat.
• Remove the air clea ner ca p.
• Remove sc rew CD.

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 PERIODIC MAINTENANCE 2·4

• Remove outer element ® and inner element @ from

the element holder.

-I
':Y ---
;g - ~...
Washing
• Fill a washing pan large enough to hold the el ement
w ith a non-flam mable cleaning solvent ®. Immerse
~
the element in the solvent and wash it. ,,
• Squeeze the elemen t by grasping it t o remove excess

~
solvent. Do not twist or wring the element or it will

~r
develop cracks. \ '--...I I
• Dry the element in a plastic bag, pour in some foam
filter oil @and work the oil into the element . Qf
• SQueeeze the elemen t to remove excess. oil.

NOTE: Both inner and outer elements should be cleaned

in the same manner,

In stallation
• Apply grease to the element holder where it contacts
the element .
• Install the inner and outer elements onto the element
holder as triangle mark @ faces the screw .

.II. CAUTION
Improper element installation allows dust and dirt to enter
the combustion chamber . It can result in piston and
cylinder wear.
Be sure to check the element seals properly after in stall·
ing the elements .

• Install the air cl eaner cap properly as sho w n.

NOTE: Running the engine without the air cleaner cap can
vary carburetion. Do not remove the air cleaner cap. Left ..,. ~ Rig ht

NOTE: Fit the attached sponge as shown in the iIIustra·

tion to avoid water running into the air cleaner box when
E7o.. Muffler

going across a deep puddle.

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 1·5 PERIODIC MAINTENANCE

NOTE: Follow the instructions below to keep the air cleaner

element dry when cleaning the motorcycle.
• Cover the element with vinyl bag.
• Install the seat.
• Do not spray high pressure water to the air cleaner box. ~ \
i .i \
~

TRANSMISSION OIL
Transmission Oil Level Inspection and Replenishment
• Place the motorcycle on level ground and hold the
motorcycle vertically.
• Run the engine for a few minutes and stop it. Wait 2 - 3
minutes .
• Remove the oil level screw @ . Check th at oil comes
out of the hole.
• 1f oil does not come out of the hole, open oil filler cap
<D and add the specified oil until oil comes out of t he
oil level hole .
• Tighten the filler cap and oil level sc rew firmly.
Transmission Oil Change
• Warm up the engine.
• Place the motorcycle on the level ground and hold the
motorcycle vertically.
• Remove filler cap G) and drain plug @ . Drain oi l
thoroughly.
• Tighten the drain plug fi rmly.
• Pour specified amount of oil.
Oil change .. . 750 ml (0.8 US qt)
Overhaul .... 850 ml (0.9 US qt)
• Tighten the filler cap.
• Run the engine for a few minutes and stop it. Wait 2- 3
minut es.
• Inspect the oil level.
Suzuki recommends the use of SUZUKI PERFORMANCE 4
MOTOR OIL or an oil wh ich has 1OW - 40 viscosi ty rating.

ENGINE COOLANT
Engine Coolant level Check rr
r
A WARNING
You ca n be injured by scalding fluid or steam if you open
the radiator cap when the engine is hot.
Do not open the radiator cap when the engine is hot. Wait
until engine cools.

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 PERIODIC MAINTENANCE 2·6

• Remove the radiator cap.

• Check that t he engine coolant level is at the bottom
of the inlet hole, replenish t he radiator wi th specified
engine coolant.
• Tig hten the radiator cap secu rely.

A CAUTION
Improperly tightening the radiator cap cannot obtain the
specified pressure in the c ooling system and it will cau se
engine coolant overflow.
Tighten the radiator c ap until it locks firmly .

NOTE:
• This motorcycle does not have an overflow tank at the
end of breather hose. Therefore, engine coolant level
may decrease while riding. Check the engine coolant
level every time before riding.
• When replenishing engine coo/ant, be sure to use en-
gine coolant mixed with distilled water at the ratio of
50 : 50. Adding only water will dilute engine coolan t
and it may' decrease cooling performance.

Engine Coolant
Use SUZUK I GOLDE N CRU ISER 1200NA or equ ivalent anti·
freeze and Summer coolant w hi ch is compatible with alu·
SUZUKI GOLDEN CRUISER
minum radiator, mixed w ith distilled water at the ratio of 1200NA
50: 50. (Non · Amine Ivpe)( 2 .0LI
99000 - 24120

NOTE: The radiator, cylinder and cylinder head are made

of aluminum al/oy. Using non·recommended engine coolant
may corrode aluminum alloy and may clog the coolant pas-
sageways.

A WARNING
Engine coolant is harmful if swallowed or if it comes in
contact with your skin or eyes.
Keep engine coolant away from children and pets . Call
your doctor immediately if engine coolant is swallowed
and induce vomiting . Flush eyes or skin with water if en·
gine coolant gets in eyes or comes in contact with skin .

Cooling System Inspection

Inspect the following items before practice and races.
• Engine coolant leakage
• Rad iat or hose cracks and deterioration
• Rad iator mounting condition
• Radiator breather hose condit ion
• Radiator fin conditio n

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 2·) PERIODIC MAINTENANCE 1
CLUTCH
Adjust the clutch cable playas follows:
Major Adjustment
• Loosen lock nut CD.
• Turn adjuster @ so the clutch lever has 10 - ' 5 mm
(0.4-0.6 in) play at the cl utch lever end before pressu re
is felt .
• Tighten lock nut G) .

Minor Adjustment
• Loosen lock nut @.
• Turn adjuster @) so the clutch lever has 10 - 15 mm
(0.4-0.6 in) play at the clutch lever end before pressu re
is felt.
• Tighten lock nut @.

THROTTLE CABLE
Adjust the throttle cable playas follows:
• Loosen lock nut <D,
• Turn adjuster ® so the throttle grip has 2-4 mm
(0.08-0. 16 in) play.
• Tighten lock nut CD.

• Remove the throttle housing cover.

• Apply oil to the throttle cable.
• Apply grease to the th rottle cable spool.

FUEL HOSE
Aepalce fuel hose every four yea rs.

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 PERIDDIC MAINTENANCE 2·8

CYLINDER HEAD. CYLINDER AND PISTDN

Cylinder Head
• Remove the cylinder head. (c:r 6-2)
• Remove carbon deposits from combustion chamber
surface.
• Inspect for pinholes, cracks and other damage.

Cylinder
• Remove the cylinder. ( c:r 6-2)
• Remove carbon deposits from the exhaust port and the
exhaust va lve chamber.
• Check for scratches and wear on the cylinder sleeve.

Piston
• Remove the piston. ( c::r 6 -2)
• Remove carbon deposits from the t op surface of the
piston.
• Check for scratches, cracks, and wear around the piston
bosses.
• Remove minor scu ffs w ith # 1000 - # 1 200 sand paper.
• Check piston ring wea r. Remove ca rbon deposits from the
piston ring groove.

EXHAUST VALVE

• Remove the exhaust valve. ( CT 6-3)

• Remove carbon deposits from the exhaust valve and ex·
haust valve guide.
• Check for wear and damage .

EXHAUST SILENCER
Silencer In spection and Replacement
• Remove the seat and the right frame cover.
• Remove three bolts and extract the black frontal part from
the alum inum case.
• Check if the glasswool sil encer is clogged with carbon
deposit or tar.
• Replace the glass wool silencer with new one if necessary.

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 2·9 PERIODIC MAINTENANCE

Silencer Reassembly
• Fit the glasswool silencer and the frontal part to the alu-
minum case. Tighten three bolts.

NOTE: To seal between the frontal part and the aluminum

case, apply SUZUKI BOND 12078 to the cantact area of the
frontal part.

DRIVE CHAIN AND SPROCKETS

Drive Chain Slack
• Place the motorcycle on the side stand.
• Inspect the drive chain slack at the middle point between
the t wo sprockets.
Drive chain slack: 45-55 mm (1.8-2.2 in) € ~
'iJ'
45 - 55 mm
8
Drive Chain Adjustment
• Remove cotter pin CD and loosen axle nut @.
• Loosen lock nut @ and adjust the drive chain slack to the
specification by turning adjuster 0.
• Check that both right and left alignment mark ® are at
the same position .
• Tighten the axle nut. Replace the cotter pin with a new one.
Tightening torque : 100 N .m (10 .0 kg-m . 72.5 Ib·ft)

• Tighten the lock nut @ securely.

NOTE: Pull the upper drive chain tight and lock it by plac- 012 20
ing a bar between the drive chain and rear sprocket while 00000000 ••• 00000000 0

tightening the axle nut. This will help prevent the chain ad- (L
justers from loosening.

20th Pitch Length

Pull the drive chain tight and measu re the 20th pitch length.
Service limit: 323 .8 mm 112.75 in)

Drive Chain Lubrication

• Remove the chain clip and master link from the drive chain
and remove the drive chain.

NOTE: Be careful not to bend the chain clip.

Inspect for wear and damage of the drive chain and replace
it jf necessary.

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 PERIODIC MAINTENANCE 2·10

• Clean the drive chain with non-flammable cleaning

solvent.
• Do not u se gasoline to clean the drive chain.
• Dry t he drive chain.
• Apply Suzuki Chain Lube or an equivalent to the link plates
and rollers.
• Reassemble the drive chain.

NOTE: Reassemble the drive chain clip so the slit end faces
opposite the direction of rotation.
___ Direction of travel
• Adjust the drive chain slack.

Sprocket Inspection
Inspect the engine sprocket and rear sprocket for wear and
cracks. Replace the sprockets as necessary.

NOTE: When replacing a worn sprocket, it is likely that the

drive chain will need ta be rep/aced as well.

DRIVE CHAIN GUIDE, BUFFER , TENSIONER ROLLER

Drive Ch ain Guide
Inspect the drive chain guide CD for bends and damage .

NOTE: The drive chain can hit a bent guide causing noise
and drive chain wear.

In spect the chain guide defense @ for wear.

Drive Chain Guide Buffe r

Inspe ct the drive chain guide buffer @) for wear and cracks.

NOTE: The drive chain can touch the swing arm directlv
if the chain guide buffer is worn out. This will cause drive
chain and swing arm damage.

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 2-11 PERIODIC MAINTENANCE

Drive Chain Tensioner Roller

• Inspect the drive chain tensioner rollers @) for wear .
• Inspect the tensioner rolle r bolts for tightness .

BRAKES
Brake Fluid level
Inspect the brake fluid level in both front and rear reservoi rs.
If the brake fluid level is lowe r th an LOWER mark, repl eni sh
the reservoir w ith the specified brake fluid to the UPPER lev-
el. Inspect brake pad wear and brake fluid leakage if the
brake fluid level decreases.
Brake fluid : DOT4

A WARNING
Brake fluid can be hazardous to humans and pets. Brake
fluid is harmful or fatal if swallowed. and harmful if it
comes in contact with your skin or eyes .
Keep brake fluid away from children . Call your doctor im -
mediately if brake fluid is swallowed . and induce vomit-
ing . Flush eyes or skin with water if brake fluid gets in
eyes or comes in contact with skin .

A WARNING
The use of any fluid except DOT4 brake fluid from a sealed
containter can dam age the brake system and lead to an
accident.
Use only DOT4 brake fluid from a sealed container. Never
use or mix different types of brake fluid .

.. CAUTION
Spilled brake fluid can damage painted surface and plas-
tic parts .
Be careful not to spill any fluid when filling the brake fluid
reservoir . Wipe spilled fluid up immediately.

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 PERIODIC MAINTENANCE 2-12

Brake Pad
Inspect the brake pads for wear. If t he brake pads are worn ,
replace them w ith new ones . ( r:::r 14-3 )
Brake pad w ear limit : 1 .0 mm (0 .04 in)

NOTE:
• Pump the brake lever/pedal several times to restore the
brake pads after replacing the brake pads. 1.0 mm
• Replace both right and left pads together when rep/acing
the brake pads.

Front Brake leve r Adjustm ent

Adjust t he brake lever pl ayas foll ows :
• Loosen lock nut <D.
• Turn in or out adjuster @ to obta in the specified play .

Brake lever play : 5 - 20 mm 10 .20 - 0.79 in)

• Tighten t he lock nut cD .

.. CAUTION
Brake lever play less than 5 mm (0 .20 in) can cause brake
dragging .
Do not adju st the bra ke lever pl ay less th an 5 mm (0 .20
in ).

Brake Pedal Height Adjustment

Adjust the rea r brake pedal height as follows:
• Loosen lock nut CD.
• Ad just the brake pedal height by turning the adjuster ®
to locate t he pedal 10 mm (0 .4 in) below the t op face of
the foot rest.
• Tighten lock nut CD.
• Loosen lock nut @ .
• Turn adjuste r @ t o obtain t he brake pedal play of 5 - 15
mm (0.20 - 0.59 in) at the pedal end .
• Tighten lock nut @ .

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 2·13 PERIODIC MAINTENANCE

FRONT FORK
• Move the front fork up and down several times and in-
spect for smooth movement.
• In spect for damage and oil leaks.
• In spect the bolts and nuts for t ightness.

REAR SUSPENSION
• Move the rear suspension up and down several times and
inspect for smooth movement.
• Inspect for damage and oil leaks.
• Inspect the bolts and nuts for t ightness.

WHEELS ANO TIRES

Wheel Rim
• Inspect the wheel bearing for rattles . Replace the bear-
ings jf necessary. ( a 13-3)
• Inspect the w heel rim runout . (C7 13-3 )

Spoke Nipple and Rim Lock

• Inspect the spokes for tension. Retighten the spoke nip-
ples with a spoke nipple wrench so as all spokes have
same tension.
• Inspect the rim lock for tightness.

Tire Pressure
• Inspect front and rear tire pressure .
Cold inflation tire
pressure : 70 - 110kPa(O.7 - 1.1 kg /cm 2 , 10 - 16psi J

STEERING
• Inspect the steering by moving the front fork up and down,
and right and left. If the steering has play or bind s, inspect
steering stem head nut tightness and steering bearings.
10- 15- 111

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 I
PERIODIC MAINTENANCE 2·14

LUBRICAT ION
Apply grease or oil to the moving parts to increase durability and prevent wear.

No. ITEM LUBRICANT FREOUENCY COMMENTS

1. Inner cable A Pre-race and between Run oil through cables. Unit it
ends. lever every race exists the lower end. Lube the
cable ends where they pivot.
2. Throttle grip , A Pre-race Lightly oil the inside of throttle
throttle hous- spool, Keep free from dirt.
inQ, cable
3. Rear brake C Pre -race Grease the brake pedal pivot.
pedal
4. Swing arm C Every 3 races/ More Clean and pack the bearings.
often according to con- Keep seals fresh.
ditions
5. Rear suspen- C Every 3 races/More Clean and pack the bearings.
sian linkage often according to con- Keep seals fresh .
pivot points ditons
6. Steering stem C Every 5 races/More Clean and pack the bearings .
bearings often according to con- Keep seals fresh .
ditions
7. Choke/idle Lightly oil the choke/idle adjust
A Pre-race
adjust knob knob shaft.
8. Drive chain B Pre-race and between Keep chain thoroughly lubed at
every moto all t imes. Always check wear
and alignment.

The following materials are necessary:

A. Lightweight oil such as WD-40 or penetrating oil.
B. Aerosol type Suzuki Chain Lube or equivalent lube.
C. Water-proof wheel bearing grease.

Follow the schedule closely. The disassembly necessary to lubricate many components is in itself
valuable preventative maintenance. It allows you to inspect for wear, fatigue, adjustment and fastener
tightness and it allows you to clean out the grit which otherwise cannot be gotten out.

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 2·15 PERIODIC MAINTENANCE

TIGHTENING TORQUE

PART N.m kg-m Ib·1t

Cylinder head nuts 25 2.5 18.0
Magneto rotor nut 35 3.5 25.5
Cylinder nuts 38 3.8 27.5
Clutch sleeve hub nut 90 9.0 65.5
Primary drive gear bolt 70 7 .0 51.0
Exhaust valve arm bolt 5 0.5 4.0
Spark plug 28 2 .8 20.0
Handlebar clamp bolts 25 2 .5 18.0
Front fork upper clamp bolts (right and left) 30 3.0 20.0
Front fork lower clamp bolts (right and leftl 25 2.5 18 .0
Steering stem head nut 90 9.0 65. 5
Front fork cap bolts 35 3.5 25.5
Front fork center bolt 65 6.5 47.0
Frok cylinder inner rod lock not 20 2.0 14.5
Front fork cap-Fork cylinder 80 8.0 58.0
Master cylinder set bolt (front) 10 1.0 7.5
Master cylinder set bolt (rear) 10 1.0 7.5
Master cylinder rod lock nut (A) 18 1.8 13.0
Brake hose union bolt (front master cylinder) 18 1.8 13.0
Brake hose union bolts (front and rear) 23 2.3 16 .5
Brake pad mounting bolts (front and rear) 20 2.0 14.5
Brake caliper mounting bolts (front) 23 2.3 16 .5
Brake bleeder plugs (front and rear) 8 0.8 5.5
Disk plate screw (front and rear) 9 0 .9 6.0
Front axle holder nuts 10 1.0 7.5
Front axle shaft 65 6 .5 47.0
Engine mounting nuts (front and upper) 43 4.3 31 .0
Engine mounting nuts (lower) 35 3.5 25.5
Rear axle nut 100 10.0 72.5
Rear sprocket nuts 35 3. 5 25.5
Spoke nipples 3 0.3 2.0
Rear swingarm pivot nut (engine mounting) 70 7.0 51.0
Rear shock absorber fitting nuts
60 6.0 43.0
(upper and lower)
Rear cushion lever center nut 100 10.0 72. 5
Rear cushion lever front nut 80 8.0 58 .0
Rear cushion rod nut 100 10.0 72. 5

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 PERIODIC MAINTENANCE 2·16

For other bolts and nuts not listed in the table , refer to this cha rt .

Bolt Conventional or "4" marked bolt " 7 " marked bolt

Diameter
(mm) N.m kg-m Ib-It N.m kg-m Ib-ft

4 2.0 0.2 1.5 2.0 0.2 1. 5

5 3 .0 0 .3 2.0 5.0 0.5 3.5
6 6 .0 0 .6 4 .5 10 .0 1.0 7.0
8 13.0 1.3 9.5 15 .0 1.5 11.0

10 29 .0 2.9 21.0 50.0 5.0 36.0

12 45.0 4 .5 32.5 85.0 8 .5 61.5
14 65.0 6.5 47 .0 135.0 13.5 97.5
16 105.0 10.5 76 .0 210 .0 21 .0 152.0
18 160.0 16.0 1 15.5 240 .0 24 .0 173.5

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 3-1 TROUBLESHOOTING

TROUBLESHOOTING
ENGINE

Complaint Possible Cause Remedy

Engine does not Fuel deterioration Replace
start or hard to No fuel flow to the carburetor
start • Fuelcock clogged Clean
• Fuel hose clogged Clean or replace
• Fuel tank cap breather hose clogged Clean
• Carburetor float valve malfunction Replace
Carburetor overflow pipe clogging Clean
Carburetor air vent pipe clogging Clean
Too rich air/ fuel mixture in combustion chamber Scavange
Incorrect ignition timing Adjust
No spark at spark plug 0 12-2
Low compression
• Piston ring worn or stuck Replace
• Cylinder worn Replace
• Air leak from cylinder gasket Replace
• Air leak from crankshaft oil seal Replace
Engine stalls Fuel deterioration Replace
Fouted spark plug Clean or replace
Fuel hose clogged Clean or replace
Air cleaner clogged Clean or replace
Carburetor jets clogged Clean
low compression
• Piston ring worn or stuck Replace
• Cylinder worn Replace
• Air leak from cylinder gasket Replace
• Air leak from crankshaft oil seat Replace
Incorrect ignition timing Adjust
Carburetor fuel level maladjustment Adjust
Insufficient Fuel deterioration Replace
power Brake dragging Adjust
Exhaust pipe cracked or clogged with carbon Replace or clean
Exhaust va lve maladjustment Adjust
Exhaust valve ca rbon deposits Clean
Air cleaner element clogged Clean or replace
Carburetor jets clogged Clean or replace
Incorrect fuel level in carburetor Adjust
Incorrect spark plug gap Adjust or replace
Cylinder or piston ring worn Replace
Reed valve malfunction Replace
Incorrect ignition timing Adjust

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 TROUBLESHOOTING 3-2

Complaint Possible Cause Remedy

Engine runs poorly Wide spark plug gap Adjust or replace
in low speed range Carburetor air screw maladjustment Adjust
Incorrect carburetor fuel level Adjust
Improper jet needle size Adjust
In correct ignition timing Adjust
CO l unit malfunction Replace
Ignition coil damage Replace
Magneto malfunction Replace
Magneto short circuit Replace
Engine runs poorly Narrow spark plug gap Adjust or replac e
in high speed range Incorrect carburetor fuel level Adjust
Retarded ignition timing Adjust
COl unit malfunction Replace
Ignition coi l damage Replace
Air cleaner element clogged Clean or replace
Magneto short circuit Replace
Exhaust pipe cracked Replace
E)(haust valve malfunction Clean . adjust or
replace
Piston ring stuck Replace
Engine speed does Too high engine idle speed Adjust
no t return smooth ly
Exhaust valve does Ca rbon deposits on exhaust valve Clean
not work Exhaust valve damage Replace
Governer damage Replace
Exhaust valve shaft damage Replace
Valve spring damage Replace
Spark plug does Ignition coil malfunction Replace
not ignite Spark plug malfunction Replace
Magneto malfunction Replace
COl unit malfunction Replace
Wide spark plug gap Adjust
Engine kill switch malfunction Repair or replace
Carbon deposits on Too rich air/fuel mixtu re Adjust
spa rk plug porcelain Too rich oil/gasoline mixture Adjust
Improper spark plug heat range Replace
Spark plug Improper spark plug heat range Replace
electrode damage Overheating CT 3-3
Incorrect ignition timing Adjust
Loose spark plug Tighten
Too lean ai r/fuel mixture Adjust

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I
 3-3 TROUBLESHOOTING

Complaint Possible Cause Remedy

Overheating Low engine coolant level Replenish
Engine coolant teak Repair
Too lean air/fuel mixture Adjust
Incorrect ignition timing Adjust
Water pump malfunction Adjust or replace
Cylinder head carbon deposits Clean
Exhaust pipe carbon deposits Clean or replace
Improper spark plug heat range Replace
Fuel deterioration Replace
Clutch slipping Adjust or replace
Radiator cap loose Tighten
Radiator fins damaged Repair or replace
Excessive coolant Radiator hose cracked or damaged Replace
level decrease Loose radiator hose connection Repair
Radiator cracked or damaged Repair or replace
Water pump cover mating surface damage Replace
Water pump cover crack Replace
Water pump cover gasket damage Replace
Water seal wear or damage Replace
Radiator cap seal damage Replace
Incorrect radiator cap va lve pressure Replace
Cylinder or cylinder head cracked Replace
Cylinder or cylinder head O-rings damage Replace
Clutch does not Clutch lever play maladjustment Adjust
disengage Clutch spring damage Replace
Clutch plates distortion Replace
Clutch slipping Clutch cable play maladjustment Adjust
Weakened clutch spring Replace
Clutch pressure plate wear Replace
Clutch plate distortion Replace
Clutch plates worn Replace
In sufficient clutch capacity • Use optional parts
Transmission does Gearshift cam damage Replace
not shift Gearshift fork distortion Replace
Gearshift pawl wear Replace
Transmission gears Gearshift fork groove wear or damage Replace
jump out Gearshift fork distortion or wear Replace
Gearshift cam stopper damage Replace
Gearshift lever Weakened gearshift return spring Replace
does not return Gearshfit lever sticking Repair or replace

• Air larger capac ity optional clutch set is avail ad Ie at your SUZUKI dealer.

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 TROUBLESHOOTING 3-4

CHASSIS

Complaint Possible Cause Remedy

Heavy handling Steering stem nut ove rtightened Adjust
Steering head bearings damaged or rusted Repla ce
Steering stem distortion Replace
Front wheel Loose spoke nipples Adjust
w obbling Wheel distortion Replace
Front wheel bearing damage Replace
Incorrect tightening axle torque Retighten
Rear wheel Loose spoke nipples Adjust
wobbling Wheel distortion Replace
Rear wheel bearing damage Replace
Sw ing arm pivot bearing damage Replace
Incorrect tightening axle torque Retighten
Incorrect tightening swing arm torque Retighten
Soft front Weakened spring Replace
suspension low oil level Replenish
Lo w fork oil viscosity Replace
Damping force maladjustment Adjust
Damping valve malfunction Replace
Standard spring too soft · Use optional spring
Hard front High fork oi l level Adjust
suspension High fork oil viscosity Replace
Damping force maladjustment Adjust
Inner tube distortion Replace
Soft rear Weakened spring Replace
suspension Damping force maladjustment Adjust
Low gas pressure Adjust
Standard spring too soft • Use optional spring
Hard rear Damping force maladjustment Ad just
suspension Damper rod distortion Replace
Rear suspension pivoting portion out of grease Lubricate
Standard spring too hard ·Use optional spring
Poor braking Brake pads worn Replace
Improper ai r bleeding Bleed air
Dirty pads and disc Clean
Brake fluid leak Repair
Brake noise Brake pads worn Replace
Brake disc worn Replace
Dirty brake pads and disc Clean

• An optional sprin g is available at your SUZUKI dealer.

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 4- 1 MACHINE TUNING

MACHINE TUNING PRINCIPLES OF CARBURETOR TUNING

CARBURETOR Carburetor Components and Functions
The carburetion of your motorcycle is carefully The carburetor consists of a number of parts as
selected after extensive testing . You wi ll find shown below, The asterisk (*) marked parts are
that the carburetion will function smoothly un· precisely machined, w hich meter the intake air
der many varied operating conditions. For best (oxygen) and fuel so that the air/fuel mixture ra-
results we recommend that the adjustments and tio is controlled accurately. They can be divid-
carburetion jetting be left " as is " from the ed by three operation-related groups; pilot (slow)
factory . system , intermediate system and main system,
and they achieve their functions in each cor-
Some riders may operate their motorcycle un- responding throttle opening range , It is neces-
der extreme operating conditions such as; very sary to have a full understanding of them for
high altitudes or extreme cold and hot temper- proper carbu retor tuning,
atures . In these circumstances the jetting of the
carburetor or other adjustments may need to be
altered slightly . Riders who are not familiar with
the operation and jetting procedures of the
KEIHIN carburetor should have their local autho-
rized Suzuki dealer perform these alterations,
Mechanically experienced riders can alter the
carburetor settings based on the following in-
formation and specifications .

Carburetor Specifications

Bore 38 mm
Main jet # 180
Jet needle R14 70NS-3rd
Cut-aw ay #5
Slow jet #52
Air screw 1-1f2turns out
Float height 16,0 mm (0.55 in)

Setting parts # 175.# 178. # 185 and

main jet: #1 90

5. Choke/idle adjust
knob
6. * Air screw
7. *Main jet
1. Top cap 8. *Slow jet
2. Spring 9. Float
3 . *Jet needl e 10. Needle valve ass 'y
4 . Throttle valve 11 . Clip

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 MACHINE TUNING 4·2

As shown below, each of the asterisk (*) marked parts is located bet ween the air/fuel passage and
has its own air/fuel mixture adjustable range in terms of the throttle valve opening. The chart indi-
cates that the carburetor can supply correct air/fuel mixture to the engine in any range because of
the overlapping adjustable range of the each part .

TUNING PARTS THROTTLE VALVE OPENING

MAIN JET

JET NEEDEL CLIP POSITION

JET NEEDLE 0.0 .

SLOW JET AND AIR SCREW

THROTTLE OPENING
'I'
CD MAIN SYSTEM ® INTERMEDIATE SYSTEM ® SLOW SYSTEM

When performing carburetor tuning first find out Air Screw

in what throttle opening range an improper
air/fuel mixture is supplied, by checking the color
of exhaust smoke, spark plug , throttle response ,
power, etc. Second , replace or adjust the part(s)
related to the throttle opening range by refer-
ring to the following instructions . The sizes
referred to in the illustrations are those of stan-
dard setting.

Slow Jet

The air screw is located in the inlet air passage

and meters the air for the slow system. As it has
a right-hand thread, tightening it makes the pas- .
sage narrower, allowing less amount of intake
air to flow and resulting in richer air/fuel mix-
ture . Air flow adjustment is effective within a
range of 1/2 - 2 turns out.

The slow jet meters the fuel supplied to the slow

system , Each jet size is indicated by a number.
Larger number means a larger bore diameter and
fitting a larger numbered slow jet en riches the
air/fuel mixture.

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 4·3 MACHINE TUNING

Needle Clip Position Jet Needle

Lean ii ~ Needle
0.0. of Needle

3 ~ clip ~
Rich 145 Clip

Taper angle

\
Needle number
The jet needle is linked to the th rottle valve by
means of the needle clip. Its lower part is ta- R 1470 NS
L

r
pered and it has five grooves cut in the upper Some alplabets are stamped
part w here the needle clip fits . \ on the jet needle insted of "5".
0.0. 2.705 mm
To adjust the air/fuel mixture with the jet nee-
dle , c hange position of the needle clip w hich is Taper angle 1 0 45 '
~

set in the 3rd groove. The lower groove the clip Changing the needle itself controls air/fuel mix -
is moved to , the higher the jet needle rises and ture ratio particulary on lower mid-throttle open-
the la rger the clearance with the needle jet be - ing. The smaller the D.O., the riche r the air/fuel
comes, resulting in a richer air/fuel mixture ratio. mixture becomes.

The needle clip position can be changed by half EX .

to fine-tune the setting. To change the needle
clip position by half, change jet needle from NS Needle Number Taper Angle 0.0 .
type to MS type. This change w ill move the nee- Rl469 NS 10 45' 2.695 mm
dle position by half to t he ri cher side. MS type
Rl470NS 1 0 45' 2.705 mm
jet needles can be available as optional parts.
Rl471 NS 1 0 45' 2.715mm

Air/fuel mixture Needle type and clip Main Jet

position
l ean
R1470MS-lst
Rl4 70NS-2nd
R1470MS-2nd
R1470NS-3rd
R1 470MS-3rd
R1470NS-4th
R14 70MS-4th
The main jet, like the slow jet, meters fuel flo w.
R1470NS-5th Each jet size is indicated by a number. Larger
Ri ch R1 470MS-5th number means a larger bore diameter and fitting
a larger numberd main jet enriches the air/ fuel
mixture.

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 MACHINE TUNING 4-4

CARBURETOR TUNING IN PRACTICE

In the previous section. basic principles of carburetor tuning have been discussed. Described in this
section are the bases for carburetor tuning required when copying with variation in air (oxygen) con-
centration.
Variation in Air (Oxygen ) Concentration and Carbu retor Condition s
As the air, affected by the temperature, altitude and hum idity, gets expanded or compressed , air
(oxygen) concentration varies accordingly . Each of these three factors affects the air in different
w ays , and the following graphs show their effects respectively in terms of the oxygen concentration .

~~-------------'r----------------'r----------------, I%I

100 100
"i
z 90
Q
~ BO 80
'"z
>-
w
u
z
8
z
w
~
~
o
-10 a 10 20 30 40 tOCI 500 1000 1500 2000 2500 Iml 20 40 60 80 100 (%,
10 30 50 70 90 110 rGF! 1600 3200 5000 6600 8200 Iftl
ATMOSPHERIC TEMPERATURE AL T ITUOE HUM ID ITY

In the above graphs, oxygen concentration is graduated on the vertical axis while the temperature ,
altitude and humidity are on the horizontal axis respectively. Oxygen concentration is set 100% un-
der the conditions of 20 ° C 168 ° F) , 0 m (0 ft) and 50 % humidity. The standard carburetor setting
is chosen to obtain the best engine performance under these conditions.

The graph at the left shows that the oxygen concentration cha nges about 10% in the 0 ° to 40°C
temperature difference , the one in the center shows about 20% change in the 0 to 2 OOOm altitude
difference and the one at the right shows about 5 % change in the 0 to 100% humidity difference.
As for humidity, its normal range is from 20 to 95 %. Therefore the possible effect of humidity 01'\
the oxygen concentration is so little that it can be disregarded. Consequently , we can say that the
oxygen concentration varies by as much as 20% depending on the temperature and altitude under
normal riding conditions . On the other hand, different from the air , the fuel (gasoline) hardly changes
in volume even when such envi ronmental conditions change. There fore , increase in oxygen concen-
tration will make the ai r/fuel mixture richer and decrease will make it lean .

As the carbu retor mixes gasoline and air , which are metered by each jet in varying proportions to
suit throttle opening , the air/fuel mixture is affected if the air concentration itself varies as described
above . Then proper engine power output can not be attained and , should the mixture become too
lean, a piston seizure may result. To compensate for such change in the air concentration , it is re-
quired to carry out carburetor tuning beforehand . This requirement applies to all models of motorcy-
cles and ATVs if they are used in areas where temperature and altitude range widely. The next section
describes the procedure of the above tuning in detail.

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 4·5 MACHINE TUNING

Judging Air/Fuel Mixture Setting Parts and Option al Parts

For proper carburetor tuning , it is necessary to
know how to judge the ai r/fuel mi xture made Main je t
in the carburetor ; whether too rich, too lean or
properly mixed. Given below are the symptoms Air/fuel
SIZE P/ND
observed when the engine is not supplied w ith mixture
the proper air/fuel mixture ratio from the carbu·
Lea n # 170 09491 -34010
retor. Check each item as referen ce for judging
the air/fuel mixture condition. # 172 09491 -3 4011
,. # 175 09491 -35009
When air/fuel mixture is too rich
,. # 1 78 09491 -35010
1 ) The engin e noise is dut! and intermittent.
2) The engine co ndition becomes wo rse w hen #180 09491-36008
the choke is applied. • # 185 0949 1-3 7008
3) Th e engine condition becomes w orse as it is
,. # 190 09491-3801 1
wa rm ed up.
4) The engine condition improves when the air # 195 09491 -39001
cleaner is removed .
#200 09491-400 13
5) The spark plug is fouled with carbon (wet and
oily) . #205 09491-4100 1
6) The exhaust ga s produ ces hea v y smoke. # 210 0949 1-42006
#215 09491 -43001
W hen air/fuel mixture is too lea n
1 ) Th e engine overheats . #220 09491 -44006
2) The engine co ndition improves when the #225 09491 -45003
choke is applied.
Rich #230 09491 -46004
3) Acceleration is poor.
4) The spark plug is burned white.
Slow jet
5) The speed of the engine fluctuates and lack
of powe r is noti ced.
Air/fuel
6) Detonation and pinging are experienced . SIZE P/ND
mixture
Tuning Procedure Lean #35 09492-35019
Th e following indicates the correct tuning proce-
# 40 09492-40022
dure for this motorcyc le. Understand the proce-
dure by first riding the motorcycle where it will #45 09492-45032
be used and adjust the engine to the best con- #50 09492-50023
dition after judging the air/fuel mixture .
#52 09492-52011
Ca rburetor sta ndard setting #55 09492-5 5017
Main jet : # 180 Rich #60 09492-60016
Jet needle : R1470NS-3rd
Slow jet #52
Air screw 1-1/2 turns is out
Cut-away #5

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 MACHINE TUNING 4-6

Jet needle
Ex _ Main jet # 1 80
Air/fuel If air/fuel mixture is rich , replace it with
SIZE P/NO
mixture # 178 main jet. If air/fuel mixture is
lean, repla ce it with # 185 main jet.
Lean R1473 NS 13383-28E90
R1473 MS 13383-28 E80
1 a-
R1472 NS 13383-28E70 @ Adjustment of inte rmediate system
R1472 MS 13383-28 E60
R1471 NS 13383-28E50
~1 I L.an
R1471 MS 13383-28 E40
?? 3' ··· ·STD
R1470 NS
R1470MS
13383-28E30
13383-28E20
•
5
I A;"

R1469 NS 13383-28 E10 '----

Ri ch R1469 MS 13383-28EOO

Monitor the air/fuel mixture condition and adjust

NOTE:
the intermediate syste m by changing the needle
SHADED : STANDARD
cl ip position.
• : ATTACHED SETTING PARTS
NONE : OPTIONAL PARTS
® Final adjustment of slow system
After a proper standard setting has been obtained
CD Adjustment of slow system by the procedure CD
through ®.
fine tune the car-
l ) Set the air sc re w as specified . buretar according to the actual race conditions .
2) See if the selected slow jet is correct or not
by judging the air/fuel mixture. If air/fuel mix-
1 ) Adjust the air/fuel mixture by turning the air
ture is rich , repla ce it with smaller one. If
scre w within 1/ 2 - 2 turns out.
air/fuel mixture is lean , replace it w ith larger
1/2 turn out
one .
1-1f.! turns out
2 turns out
2) If the mixture can not be adjusted by the air
Ex. Slow jet # 52 screw within 1/2 - 2 turns out range, readjust
If air/fuel mixture is ri ch, replace it with the slow system ®.
# 50 slow jet. If air/fuel mixture is lean.
repla ce it wi th # 55 slow jet. ® Final adjustment of intermediate system

Fine tune the intermediate system by changing

® Adjustment of main system
the needle type and clip position .
With the throttle opened 3/4 to fu ll. make main
system adjustment monitoring the air/fuel mix-
ture condition after completion of slow system
settings .
• Make sure to adjust the main system before
adjusting the intermdiate system .

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 4-) MACHINE TUNING

- MEMO -

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 MACHINE TUNING 4·8

FRONT FORK
The front fork compression and rebound damping force. oil
level is adjustable for rider's preference, riders weight and
course condition.

NOTE:
• Break-in new front forks before attempting adjustment.
(= 1-4)
• 8e sure to adjust both right and left front forks equally.

Rebound Damping Force Adjustment

• Turn the adjuster screw clockwise until it stops that is S----"H
fu ll hard.

NOTE: To set the adjuster, you must gently turn the ad-
juster surew clockwise until it stops, then back i1 out the
recommended number of turns. Do not force the adjuster
screw past the stopped position or you may damage the ad-
juster.

• Turn the adjuster screw counterclockwise and the 15th

position is the standard position.
Standard setting: 15th cli ck

Compression Damping Force Adj u stm ent

• Turn the adjuster screw clockwise until it stops that is
full hard.

NOTE: To set the adjuster, you must gently turn the ad-
juster screw clockwise until it stops, then back it out the
recommended number of turns. Do not force the adjuster
screw post the stopped position or you may damage the ad-
juster.

• Turn the adjuster screw counte rclockwise and the 10th

position is the standard position.
Standard setting : 10th click

Air Pressure Adjustment

• Place a block under the chassis t ube to li ft the front w heel
off the ground.
• Remove the air bleed screw and equalize the air pressure
in the front forks to atmosphe ric pressure .
• Re-fit the air bleed screw.

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 4·9 MACHINE TUNING

Front Fork Oil Level Adjustment

• Remove the front forks. 10" 15-21
• Remove the front fork caps. 10 15-2)

• Fit the special tool on the fork cap and tighten it to the c
outer tube and pour the specified fork oil. ~ Fork cylinder
09940-42810 Fork cylinder holder holder
Fork cylinder -

~
Outer tube
t---

NOTE: Tilt the fork slightly to make it easier to pour oil.

Do not pull the outer tube any more than 250 mm (9.84 in)
from the axle holder of the inner tube.

E
E
o
~
N

Front Fork Oil Air Bleeding

• Lift up the special tool and outer tube press down on the
special tool slowly.
• Repeat this process 2-3 times.

• Repeat the same process untill no more bubbles come

from oil.

• Wait 10 minutes and then measure the oil Jevel.

NOT£: Compress the front fork fullV. Set the fork in a ver-
tical position and measure the 0# level from the top end of
the outer tube.

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 MACHINE TUNING 4·10

NOTE: Cut the hatched area of the special tool to set it

on the front fork.
09943 -74111 Front Fork Oil Level Gauge
25 mm

Oil type: SUZUKI FORK OIL 5505 or equivalent fork oil

Standard oil capacity : 440 ml 114.9/ 15 .5 US/Imp azl
Oil level range : 121 -2 15 rnm 14.76 -8.46 in)
Standard oil level: 170 mm (6.69 in)
09943 -74111 Front Fork Oil Level Gauge
09940-54851 Front Fork Spacer
09940-42810 Fork cylinder holder I
Oil level Oil quantity
121 mm (. 76.,1
215 mm 18.46 in) 405 ml 113.7/ 14.3 US/Imp 0') 130mmI5_121n1
155mm(S.10 1n)
155 mm (6.'0 in) 465 ml 115.6/ 16.4 US/ Imp 0')
o
~ 215mm[B .•S,nl
130 mm (5.12 in) 488 ml 116.5/17.2 USllmp 0') g
121 mm /4 .76 in) 495 ml 116.7/ 17.4 USllmp 0')

NOTE: An oil/eve/lower Dr higher than the above range STROKE

will affect the front fork performance. Be sure to adjust the
front fork oil level within the above range.

NOTE: Front fork body should contain the same type oil
as fork cylinder contains.

NOTE: See page 15-5 for fork cylinder oil replacement

procedure.

Front Fork Mounting Height Adjustment

• Reassemble the front forks. (c:7" 15-7)
• Adjust the front fork mounting height from oute r tube
top surface to upper bracket top surface, t o 5.0 mm (0.20
in ).
• Mount the front forks. (Q"'15- 11 )

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 4·11 MACHINE TUNING

Front Fork Tuning Procedure

Test ride the motorcycle and find out how t he front suspension reacts on va rious t ypes of surface.
According to the sympt om noticed, adju st the front fork to the best setting for rider and race track
conditions. T o adjust, attempt changing fork oi l capacity and compressionirebound damping fol -
lowing the instructions below.

SYMPTOM SECTION ADJUSTMENT PROCEDURE

Feels too hard overall 0 Jump
o Large bumps
,. Adjust both the compression and re-
bound damping to a softer setting.
0 Series of medium 2. Decrease fork oil capacity .
bumps
Feels too soft overall 0 Jump 1 . Adjust the compression damping to a
and bottoms 0 Large bump stiffer setting.
0 W hen braking 2. Increase fork oil capacity.
3. Replace the spring with an optional
stiffer one .
Feels too ha rd near 0 Jump 1. Decrease fork oil capacity.
end of travel
Feels too soft near end 0 Jump 1. Adjust the compression damping to a
of travel and bottoms 0 Large bump stiffer settting.
harshly 2. Inc rease fork oil capacity.
Feels too hard in the 0 Jump 1. Adjust the compression damping to a
beginning of stroke 0 Large bump softer setting.
0 Se ri es of medium
bumps
0 Series of sma ll
bumps
Feels too soft and 0 Series of medium 1. Adjust the rebound damping to a
unstable bumps stiffer setting.
0 Series of sma ll 2. Replace the spring with an optional
bumps stiffer one.
Bounces 0 Jump 1. Adjust the rebound damping to a
0 Large bump stiffer setting .
Bounces 0 Series of small 1. Adjust the rebound damping to a
bumps softer setting.

NOTE: When adjusting the front fork oil capacity, make sure that the oil level is within the speci-
fied range. Also, the capacity should be increased or decreased by 5 mm (Approx. 5ml) at a time.
When adjusting the damping setting, attempt turning the adjuster 1 to 2 click stops at a time for
each adjustment.

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 MACHINE TUNING 4·11

REAR SUSPENSION
The rear suspension compression and rebound damping
force, and spring pre-load is adjustable for rider's preference ,
rider's weight and course condition .

NOTE: Break-in the rear suspension when riding with a new

rear cushion unit. (a 1-4)

Compression Damping Force Adjustment

• Turn the adjuster screw clockwise until it stops that is
full hard .

NOTE: To set the adjuster, you must gently turn the ad-
juster screw clockwise until it stops, then back it out the
recommeded number of turns. Do not force the adjuster
screw past the stopped posWon or you may damage the ad-
juster.

• Turn the adjuster screw counterclockwise and the 10th

position is the standard position.
Standard setting: 10th click

Rebound Damping Force Adjustment

• Turn the adjuster screw clockwise until it stops that is
full hard.

NOTE: To set the adjuster. you must gently turn the ad·
juster screw clockwise until it stops. then back it out the
recommened number of turns. Do not force the adjuster
screw past the stopped position or you may damage the ad·
juster.

• Turn the adjuster screw counterclockwise and the 13th

position is the standard position.
Standard setting: 13th click

Spring Pre -load Adjustment

• Loosen the lock nut. Turning the adjuster without loosen·
ing the lock nut can damage the rear cushion unit.
• Turn the adjuster clockwise or counterclockwise to
change the spring pre-load.
• Tighten the lock nut.

Spring set length Adjustabl e range: 248.5-270 mm

19.8-10.6 inl
Standard spring set length : 255.0 mm (10.0 in)

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 4·13 MACHINE TUNING

Rear Suspension Tuning Procedure

• Select the rear suspension aearding to the rider's weight
and preference by referring to the table below.

Rider's weight Spring Remarks

Below 52kg Soft If you prefer hard setting.
(115Ibs) (Option) use standard spring.
52 - 68 kg Standard If you prefer hard setting.
(115 - 150Ibs) use hard spring . If you prefer
soft setting, use soft spring.
Over 68 kg Hard If you prefer soft setting,
(150Ibs) (Option) use standard spring .

• Measure the distance L 1 from the seat bolt to the chain

adjuster lock nut with the motorcycle on the stand and
the fear wheel lifted off the ground.
• Measure the distance L2 from the seat bolt to the chain
adjuster lock nut with the motorcycle off the stand and
riding the motorcycle normally in full riding gear .
• Find the sag by subtracting L2 from L 1. Standard sag
range is 95 - 105 mm (3 . 7 - 4 . 1 in) .

When the sag Adjustment procedure

measured is:
Less than 95 mm Increase spring pre-set length by
(3 .7 in) turning the spring adjuster nut.

More than 105 Reduce spring pre-set length by

mm (4.1 in) turning the spring adjuster nut.

NOTE: Two turns of spring adjuster ring varies sag bV 8. 5

mm (0.3 in).

Rear Suspension
After th e sag measurement has been set between 95 mm
(3.7 in) t o 105 mm (4 .1 in), test ride the motorcycle and
adjust the sus pensi on for the rider and track conditions
referring to the guide below.

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 MACHINE TUNING 4-14

SYMPTON SECTION ADJUSTMENT PROCEDURE

• Jump 1 . Adjust the compression damping to a hard-
• Large bump er (H) setting. (See note below.)
Bottoms 2. Adjust the sag to a smaller measurement
(closer to 95 mm).
3. Repla ce the spring w ith an optional stiffer
one.
• Medium to large 1. Adjust the rebound damping to a harder (H)
bumps setting. (See note below .)
• Small to medium 2. Adjust the sag to a larger measurement
Kicks up bumps (closer to 105 mm).
• Decelerating or 3. Replace th e spring wi th an optional softer
braking one.
0 Jump 1. Adjust the compression damping to a softer
0 Large bump (S) setting. (See note below .)
Hits bu m ps too • Se ries of medium 2. Adjust the sag to a la rger measu rement
harshly bumps (closer to 105 mm).
3. Replace the spring with an optional softer
one .
• Series of medium 1. Adjust the rebound damping to a soher (S )
Feels harsh and t ends bumps setting. (See note below .)
to sink • Series of small bumps

• Series of medium 1 . Adjust the rebound damping to a harder (H)

Feels too soft and bumps setting.
unstable
• Series of small bumps
• Accele rating 1. Adjust the compression and rebound damp-
• Series of small ing to a softer setting, each at a t ime alter-
bumps natively until the optimum settings are
Provides poor traction obtained .
2. Replace the sp ring with an optional soher
one.

NOTE: When adjusting the damping setting, attempt turning the adjuster 1 to 2 click stops at a
time for each adjustment.

SUSPENSION BALANCE
Balancing th e front to rear suspension properly is the most c riti cal adjustment for sus pension perfor-
mance. If the front forks are adjusted hard er than su spension, such as changing to heavier front
frok oil , stiffer comp ression and rebound setting , air pressure build up in the forks and so on, the
front forks will co ll apse less on bumps. This tran sfers more of the motorcyce and rider weight to
possibly bottom , w here as it felt f ine before the front fork adjustment was mad e.
Balance Test
Stand next to the motorcycle on level ground. Place one f oot on the foot rest closest to you. Sharply
push down . The front and rear suspensions shou ld both collapse equa lly.
Balancing Tips
• Check for air pressure build-up in front forks . Heat and altitude wi ll increase air pressure in the
front forks.
• A lways stay with in sag measurement limits, 95 - 105 mm (3.7- 4 .1 in), when u sing spring pre -
set to st iffen or soften rea r suspension. If this is not possible, th e next stiffer or softer accessory
sp ring is needed.
• The rear shock compression damping can be used to fine tune suspension balance and is easy
to access.

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 5-1 ENGINE DISMOUNTING AND MOUNTING

ENGINE DISMOUNTING AND MOUNTING

DISMOUNT ING
• Remove the seat and frame covers.

• Remove the radiator cover.

• Turn the fuel cock lever to the " OFF " position and dis-
connect the fue l hose.
• Remove the two bolts and band from the fuel tank.
• Remove the fuel tank .
• Drain transmission oil. (t:7" 2-5)
• Drain coolant. (0 11-21

• Remove the exhaust pipe fitting springs with the special

tool .

0 9920·203 10 Sprin g hook

• Remove the muffler fitting bolts.

• Remove the exhaust pipe and muffler.

• Disconnect the radiator hoses .

• Di sco nnect the lead wires.
• Remove the spark plug.
• Remove the carburetor.
• Remove the engine sprocket cover.
• Remove the drive chain.
• Remove the chain buffer fitting upper bolts.
• Shi ft the chain buf fer down and remove the engine
sprocket.

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 ENGINE DISMOUNTING AND MOUNTING 5·2

• Remove the clutch release arm.

• Remove the engine mounting bolts and plates.
• Remove the swing arm pivot shaft.

NOTE: The swing arm will come off when the swing arm
pivot shaft is completely removed,

• Remove the engine from the frame.

ENGINE MOUNTING
• Mount the engine on the frame .
• Tighten the engine mounting nuts.

Tightening torque
N.m kg-m Ib·ft
CD@ 43 4.3 31.0
@ 35 3.5 25.5
@ 65 6.5 47 .0

NOTE: Replace the self-locking nuts with new ones.

Reassemble the parts in the reverse order of removaL

NOTE: Route the cables and lead wires correctly.

l a 19·1)

After mounting the engine , inspect the following items.

• Transmission oil level! c:r 2-5)
• Coolant level ! c:r 2-5)
• Throttle cable play ( c:r 2- 7)
• Clutch lever play ( c:r 2-7)
• Drive chain slack ( c:r 2-8)

, ,.
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 - MEMO -

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 CYliNDER, PISTON AND EXHAUST VALVE 6·1

CYLINDER, PISTON AND EXHAUST VALVE

~ 2.5 kg .m _
'Q
~~ 2.8 kg·m

fJ
~ ®
.,' .,~ ~
~ 4 . 1 kg·m

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J
 6·2 CYLINDER, PISTON AND EXHAUST VALVE

CYLINDER HEAD REMOVAL

• Remove the fuel tank .
• Drain caolant . ( r:::r 11 -2)
• Loosen the ctamp and disconnect the radiator hose .
• Remove the spark plug .
• Remove the engine mounting bracket.

• Remove the cylinder head .

NOTE: Loosen the cylinder head nuts diagonally to prevent

cylinder head distortion.

• Remove the cylinder head O-rings.

CYLINDER REMOVAL
• Remove the exhaust pipe . (c:::r 5- 1)
• Remove the exhaust valve rod cover .
• Unhook the stopper and remove the exhaust valve rod .
• Remove the four cylinder nuts.

NOTE: Loosen the cylinder nuts diagonally.

• Remove the radiator hose connecting right and left

radiators .
• Remove the radiator mounting bolts and move the radi-
ator forward .
• Remove the cylinder.
• Remove the gasket.
• Remove the reed valve . ( r::r 10-3)

•
'"

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 CYLINDER, PISTON AND EXHAUST VALVE 6·3

PISTON REMOVAL
• Remove the piston pin circlip.

NOTE: Place cloth on the crankcase to prevent the piston

pin eirclip from dropping into the crankcase chamber.

• Remove the piston pin.

• Remove the piston .
• Remove the con·rod small end bearing .

EXHAUST VALVE REMOVAL

• Remove two screws and retainer.
• Remove the exhaust valve cap. spring and spacer.
• Remove the exhaust valve shaft stopper bolt.

• Remove the exhaust valve cover.

• Remove the . arm stopper screw . Remove the exhaust
valve shaft.
• Remove the exhaust valve guide stopper screws.
• Remove the exhaust valves.

CYLINDER HEAD INSPECTION

• Remove carbon deposits from the cylinder head .
• Inspect the cylinder head for cracks around the spark plug
hole.
• Inspect for cylinder head distortion .
Service limit : 0 .05 mm (0.002 in)

CYLINDER INSPECTION
• Remove carbon deposits from the exhaust port.
• Inspect the cylinde r for cracks and replace the cylinder
if necessary .
• Inspect the cylinder bore for wear and scratches.

NOTE: Chrome-plated cylinder bore can not be modified

such as boring and honing.

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 6·4 CYLINDER, PISTON AND EXHAUST VALVE

• Inspect for cylinder distortion .

Service limit : 0 .05 mm (0.002 in)

• Measure the cylinder bore for wear w ith a cylinder gauge

20 mm from the t op su rface.

NOTE: The cylinder bore must be measured perpendicular

to the crankshaft axis direction.
Standard : 67.000 - 67 .015 mm 12.6378 -2.6384 inl 20 mm
09900·20508 Cylinder gauge set 140 - 80 mml ~~

• Disconnect the exha ust valve breather hose and fil ter.
• Remove ca rbon deposits from the filter and clean it .

PISTON AND PISTON RING INSPECTION

• Remove the piston ring from t he piston ring groove.
• Remove carbon deposits from the piston.
• Inspect the piston for wear, sc ratches and damage.
• Measure the piston outer diameter 24 mm 10.94 in) from
the skirt end .
24 mm
(0.94 in )
Service limit : 66 .950 mm (2 .6381 in)
09900·20203 Micrometer 150 - 75 mml

• Measure the piston pin bore and piston pin diameter .

Service limit
Pi ston pin bore 18.030 mm 10 .7098 in)
Piston pin 0 .0 . 17 .980 mm 10 .6724 in)

09900 -20605 Dial gauge

09900-20205 Micrometer

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 CYLINDER, PISTON AND EXHAUST VALVE 6·5

• Remove carbon deposits from piston ring and piston ring

groove.
• Fit the piston ring into the ring groove and measure the
clea rance wi t h a thickness gauge .
Standard : 0 .020 - 0 .060 mm 10.0008-0 .0024 in)
09900·20803 Thickness gauge

• Fit the piston ring into the cylinder and measure the piston
ring end gap with a thickness gauge.
Service limit : 0 .85 mm (0.033 in)
09900·20803 Thickness gauge

• Measure the piston ring free end gap.

Service limit : 5.1 mm (0 .20 in)

EXHAUST VALVE INSPECTION

• Remove carbon deposits from the exhaust valve and
valve guide.
• Inspect the exhaust valve and valve guide for wear and
scratches.
• Inspect the return spring for spring tension.

• Inspect the spacer for cracks and wear.

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 6-6 CYLINDER, PISTDN AND EXHAUST VALVE

CON ROD INSPECTION

• Measure the conrad small end bore.
Service limit: 23.040 mm (0 .9071 in)
09900-20605 Dial gauge

• Fit the pist on pin and bearing into the conred small end
and check the play.

PISTON RING AND PISTON REASSEMBLING

• Apply engine oil to the piston ring and piston ring groove.
• Fit the piston ring into the piston ring groove so the piston
ring end comes to the piston ring locating pin.
• Apply engine oil to the piston pin and bearing.
• Fit the bearing to the conrad small end.

• Face the arrow mark on the piston top to the exhaust

port side and fit the piston.
• Fit the piston pin and piston pin circl ip. Piston pin circli p
end should face upside.

NOTE:
• Replace the piston pin circlip with a new one.
• Place cloth on the crankcase tD prevent piston pin cir-
clip from dropping into the crankcase chamber.

EXHAUST VALVE REASSEMBLING

• Apply engine oil to the exhaust valve and valve guide.
• Fit the sha1t to the exhaust va lves.

NOTE: Fit the shaft of long side to the right exhaust valve.

• Fit the exhaust valves into the cylinder.

• Tighten the exhaust valve guide stopper screws.
• Reassemble the exhaust valve shaft and arm stopper.
• Apply thread lock" 1303" and tighten the bolt.
Tightening torque: 5 N'm (0 .5 kg-m. 3 .8 Ib-ftl

• Fit the cover and tighten the screws.

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 CYLINDER, PISTON AND EXHAUST VALVE 6·)

CYLINDER REASSEMBLING
• Fit the new gasket. Fit the dowel pins.
• Fit the exhaust valve breather hose to the cylinder.
• Move t he piston to the top dead center.
• Apply engine oil to the cyl ind er bore .
• Hold the piston and piston ring , and insert the piston into
the cyl inder.

.. CAUTION

o
If the piston pin end is not at the proper position. you can
not insert the piston into the cylinder properly and the
piston ring will be damaged .
Locate the piston ring end to the locating pin and inse rt
the piston into the c ylinder. OK NG

• Tighten the cylinder nuts t o the specified torque accord-

ing to the specified tightening order as shown. ~------'O
Tightening torque : 38 N' m (3 .8 kg -m. 27 .5 Ib -fU 0 , 30

4
Xi 2

° 0

• Fit the exhaust valve rod .

• Install the space r, spring, exhaust valve ca p and retainer .
• Tighten the screws temporarily.
• Turn the exhaust valve cap clockwise one turn .
• Tighten the screws.
• Inspect the exhaust valves for smooth movement.

• Install the new O-rin gs.

• Install the cylinder head .

NOTE: Apply Bond "1207B" to the stud bolt threads when

assembling the removed stud bolts into the cylinder.

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 6·8 CYLINDER, PISTON AND EXHAUST VALVE

• Tighten the cylinder head nuts to the speicfied torque ac-

cording to the specified tightening order as shown .
Tightening torque: 25 N'm (2 .5 kg-m. 18.0 Ib-ftl

• Reassemble the engine mounting bracket. ( r:::r 5-2)

• Reassemble the spark plug and spa rk plug cap .
• Connect the radiator hose and tighten the clamps.
• Pour coolant .( r::7 2-5)
• Inspect coolant leak.

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 CLUTCH ) ·1

CLUTCH

~ 9.0 kg-m

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 ) ·2 CLUTCH

CLUTCH PLATE REMOVAL

• Drain transmission oil. ( a 2-5)
• Remove the cotter pin and rear brake pedal.
( 0 14· 11 )
• Remove t he clutch release arm .
• Remove the clutch cove r bolts.

• Loosen the bolts diagonally and remove them.

• Remove the clutch springs and washers.
• Remove the circrip from the cl utch release rack.
• Remove the pressure plate.
• Remove the rack and bea ring from the pressure plate.
• Remove the drive and driven plates.

CLUTCH PLATE INSPECTION

Drive Plate
• Measure the drive plate thickness and claw w idth .

Service limit
Thickness 2 .4 mm (0.09 in)
Claw width 15 .3 mm (0 .60 in)
• Inspect the drive plates fo r wear, distorti on and disco lo-
ration .
Driven Plate
• Measure the driven pla te distortion .
Service limit : 0 .10 mm (0.004 in)

• Inspect the driven pla tes for wear and discoloration.

Clutch Spring
• Measure the clutch spring free le ng th .
Service limit: 44 .4 mm (1.75 in)

NO TE: Replace five clutch springs together even if only one

spring is beyond the service lim;t. •

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 CLUTCH ) ·3

RACK AND PINION INSPECTION

• Inspect the clutch release rack and pinion for wear and
damage.
• Inspect the clutch release arm for smooth movement and
oil leakage around the oil seal.

CLUTCH PLATE REASSEMBLING

• Apply transmission oil to the drive and driven plates and
fit them .
• Fit the bearing, rac k and pressure plate.
• Fit the clutch spring s, washe rs and bolts.
• Tighten the bolts diag ona lly.

• Align the clutch release rack teeth with the pinion gear.
• Replace the o-ring with a new one.
• Fit the cover .
• Tighten the bolts diagonally.
• Reassemble the rear brake pedal. f CT 14- 11)

• Fit the clu tch release arm. Inspect the clutch cable play.
( c::r 2· 7)
• Fill the transmission w ith speci fied transmission oil to the
correct level. ( r:::T 2 -5)

PRIMARY DRIVEN GEAR ASS 'Y REMOVAL

• Drain transmission oil. ( 0" 2· 5)
• Drain coolant. Disconnect the radiator hose . ( cr 11 · 2)
• Remove the cotter pin and rear brake pivot bolt .
( c::r 14· 11)
• Remove the clutch release arm.
• Remove the kick starter lever.
• Remove the clutch cover bolts. Remove the clutch cover .

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 J.4 CLUTCH

• Remove the bolts and pressure plate . ( a 7· 2)

• Remove the clutch plates. ( r::r 7·2)
• Flatten the lock washer.

• Hold the clutch sleeve hub with the special tool and 1005-
en the nut.
09920 -53740 Clutch sleeve hub holder

• Remove the clutch sleeve hub.

• Remove the primary driven gear ass ' y .
• Remove the bearing .

PRIMARY DRIVEN GEAR ASS ' Y INSPECTION

• Inspect the clutch sleeve hub and primary driven gear
ass'y for w ear and cracks.

• Inspect the needle bearing for damage.

PRIMARY DRIVEN GEAR ASS ' Y REASSEMBLY

• Fit the washer and needle bearing.
• Fit the primary driven gear ass ' y.
• Fit the washer , clutch sleeve hub and tock washe r.
• Tighten the clutch sleeve hub nut with the special tool
to the specified torque .
09920-53740 Clutch sleeve hub holder
Tightening torque : 90 N' m 19 .0 kg-m . 65 .5 Ib -ft)

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 CLUTCH 7-5

• Bend the lock washer to secure the nut.

• Reassemble the clutch plates and pressure plate. ( c::r7 · 3)
• Fit the dowel pins. Repla ce the O-ring with a new one.
• Fit the clutch cover and bolts . Tighten the clutch c over
bolts diagonally.
• Reassem ble the kick starter lever.
• Reassem ble the clutch release arm.
• Reassemble the rear brake pedal. ( r:::r 14- 111
• Reassemble the radiator hose and refill coolant. ( c::r 11 -21
• Refill transmission oil. ( r:::r 2-5)

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 - MEMO -

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 KICK STARTER 8·1

KICK STARTER

~) --

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 8·1 KICK STARTER

KICK STARTER REMOVAL

• Drain transmission oil. ( r:::r 2-5)
• Drain coolant. Disconnect the radiator hose. ( a 11 - 2)
• Remove the cotter pin and rear brake pivot boh.
l er 14- 111
• Remove the clutch release arm.
• Remove the kick starter lever.
• Remove the clutch cover bolts. Remove the ctutch cover.
• Remove the clutch. ( r::r 7-3)
• Remove the kick idle gear circlip with snap ring pliers.
• Remove the kick idle gear.
• Unhook the kick return spring.
• Remove the kick starter shaft.

• Remove the following parts from the kick starter shaft.

Spring guide
Kick return spring
Washer
Spring
Kick starter

• Remove the ci rclip wit h snap ring pliers. Remove the kick
drive gear.

KICK STARTER INSPECTION

• Inspect the oil seal for oil leakage and oil seal lip damage.

• Inspect the return spring for damage.

• Inspect the kick drive gear teeth for damage.
• Inspect the kick drive gear ratchet part for wear and
damage.
• Inspect the kick shaft and drive gear for contact surface
wear.

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 KICK STARTER 8·3

• Inspect the kick idle gear teeth for damage.

• Inspect the kick idle gear and driveshaft contact surface
for wear.

KICK STARTER REASSEMBLY

• Fit the kick drive gear and washer to the kick shaft. Fit
the circlip firm ly with snap ring pliers.
• Fit the return spring into the kick shaft hole.
• Fit the spacer.

• Fit the kick starter to the kick starter shaft.

NOTE: Be sure to align the punch marks on the kick starter

and kick starter shaft when fitting the kick starter,

• Fit the kick starter ass'y to the crankcase. Hook the return
spring.
• Reassemble the kick id le gear.
• Reassemble the clutch. ( a 7 - 5)
• Reassemble the clutch cover. ( a 7-5)
• Reassemble the kick starter lever.
• Reassemble the clutch release arm.
• Reassemble the rear brake pedal. ( c:r 14-11)
• Connect the radiator hose. Refill coolant. ( c:r 11-2)
• Refill transmission oil. ( c:r 2-5)
• Inspect the clutch lever play.
• Inspect for coolant and transmission oil leaks.
• Inspect the kick starter for smooth movement.

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I
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 TRANSMISSION AND CRANKSHAfT 9·'

TRANSMISSION AND CRANKSHAFT

I
IU

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 9·2 TRANSMISSION AND CRANKSHAFT

• Dismount the engine. ( r::r 5- 1)

• Remove the cylinder and piston . ( 0" 6 -21
• Remove the clutch. ( r:::r 7-2)
• Remove the kick starter. ( t::T 8-2)
• Remove the magneto rotor and stator. ( r::r 1 2-4)
• Remove the exhaust valve actuator.

GEARSHIFT LINKAGE REMOVAL

• Remove the gearshifting shaft.
• Remove the t wo screws. Remove the pawl lifter.
• Remove the driven gear. Be careful that the pins and
springs do not fly off.

• Remove the gearshift cam bolt.

PRIMARY DRIVE GEAR

• Remove the primary drive gear with the specia l tool.
09910-20116 Conrad holder

CRANKCASE SEPARATION
• Remove the crankcase fitting screws.

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 TRANSMISSION AND CRANKSHAFT 9·3

• Separate the crankcase with the special tool.

09920· 13120 Crankcase separating tool
-
NOTE:
• Set the crankcase separating tool to the clutch side of
the crankcase.
• Separate the crankcase gradually while hitting the crank-
case boss and countershaft softly with a plastic hammer.

TRANSMISSION REMOVAL
• Remove the gearshift fo rk shafts and forks.
• Remove the gearshift cam.
• Remove the drive shaft ass'y and countershaft ass'y.

CRANKSHAFT REMOVAL
• Remove the crankshaft with the special tool.
09920·13120 Crankcase separating tool

GEARSHIFT LINKAGE INSPECTION

• Inspect the gearshift shaft for bends and damage.
• Inspect the return spring for damage.

• Inspect the pawls, spri ngs and pins for damage.

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 9·4 TRANSMISSION AND CRANKSHAfT

TRANSMISSION INSPECTION
• Inspect the gea r teeth, dogs, and gea rshift grooves for
abnormal wear and damage.
• Inspect the bushes and splines for abnormal wea r and
discoloration.

• Inspect the gearshift cam groove for abnormal wear and

damage.

• Inspect the gearshift forks and shafts for wea r and

damage.

• Measure the gearshi ft fork thickness with a ve rn ier

cal iper.
Stand ard : 4.60 - 4 .70 mm (0 .181 - 0 .185 in)

• Measure the gearshift fork groove w idth w ith a vernier

ca liper.
Standard : 4 .80 - 4 .90 mm (O.189 - 0 .193 in)

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 TRANSMISSION ANO CRANKSHAFT 9·5

• Measure the gearshift fork to groove clea rance with a

thickness gauge.
Service limit : 0 .50 mm 10 .020 in)

CRANKSHAFT INSPECTION
• Measure the crankshaft runout with V -blocks and dial
gauge .
Service limit : 0 .05 mm (0 ,002 in)
09900· 20605 Dial ga uge

• Measure the crankshaft web t o web width with a verni -

er caliper .
Standard : 57 .9 - 58 .1 mm 12.28 - 2 .29 inl

OIL SEAL INSPECTION , REMOVAL AND INSTAL·

LATION
• Inspect the oil sea l lips f or wear and damage .

• Remove the oil seal with the special tool.

09913· 50121 Oil seal remover

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 9-6 TRANSMISSION ANO CRANKSHAFT

• Fit a new oil sea l with the spec ial tool.

09914-79610 Bearing/Oil seal installer

• Apply grease to the oi l seal lip.

NOTE: Be sure to check the direction of the bearing oil seals

before fitting them. left Right
OUT OUT
SIDE SIDE

IIr-~ lCcCJ
""'i\._~
y

I T
BEARING INSPECTION. REMOVAL AND INSTAL-
LATION
• Inspect the bearings for play, discoloration, wear and
seizure.
• Move the inner race by finger and inspect for smooth
movement.

• Remove the bearing retainers .

• Remove the bearing with the special tools .
09923-73210 Bearing puller
09923 -74510 Bearing puller
09930-30102 Rotor remover slide shaft

• Fit the bearing with the specia l tool.

09914-79610 Bearing/Oil seal installer

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 TRANSMISSION ANO CRANKSHAfT 9·)

• Apply thread lock " 1303" to the bearing retainer screw.

CRANKSHAFT INSTALLATION
• Fit the crankshaft into the left crankcase half with the
special tool.

09910 -3281 2 Crankshaft installer

TRANSMISSION REASSEMBLY

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 9-8 TRANSMISSION ANO CRANKSHAFT

NOTE: Sea t the circlip in the groove and locate its end as
shown in the illustration.
---;to Thrust

L1
• Apply transmission oil to the following parts: driveshaft,
countershaft, transmission gears, bearings, gearshift
forks, gearshift shafts. gearshi ft cam.
• Reassemble the driveshaft and countershaft with gears
installed.
• Reassemble the gearshift cam, shift forks and shafts.
NOTE: Tum the gearshift cam to the neutral position and
confirm that the driveshaft and countershaft turn without
resistance.
• Fit the new gasket and dowel pins.
CRANKCASE REASSEMBLY
• Fit the left crankcase half on the right crankcase half.
• Tighten the crankcase bolts.

NOTE: Tighten the bolts graduallv and diagonally to guide

the crankshaft into the bearing. If it is hard to tighten the
bolts, separate the crankcase and confirm that the trans-
mission parts are assembled correctly.

• Inspect the crankshaft for smooth movement.

• Apply grease to O-rings. Fit the O-rings and spacer to the
driveshaft.

PRIMARY DRIVE GEAR

• Tighten the primary drive gear bolt to the specified torque.
Tightening torque : 70 N.m (7 .0 kg-m. 51 .0 Ib-ft)

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 TRANSMISSION AND CRANKSHAFT 9·9

GEARSHIFT LINKAGE REASSEMBLY

• Fit the spring pin and pawl to the driven gear. Wider side
@of pa w l CD shou ld be positioned outside.
®

• Apply thread lock" 1303 " to the gearshift cam bolt and
tighten it.

• Reassemble the driven gear and pawl lifter.

• Apply thread lock "1303" to the screws and tighten
them.
• Fit the gearshift return spring to the gearshift shaft
properly.

• Align the center lines of drive and driven gears.

• Reassemble the exhaust valve actuator.
• Reassemble the stator and magneto rotor. ( 0- 12-4)
• Reassemble the kick starter. ( r:::r 8-3)
• Reassemble the clutch. ( r:::r 7-3)
• Reassemble the piston and cylinder. ( a 6-5)
• Remount the engine. ( c::7 5-2)

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 FUEl SYSTEM 10·1

FUEL SYSTEM

: I

~ I

UI)
1/

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 10·2 fUEL SYSTEM

CARBURETOR
Carburetor Remova l
• Turn the fuelcock to the "OFF" position and disconnect
the fuel hose .
• Loosen the carburetor clamp screws and remove the car·
bureter .
• Remove the carburetor top cap. Remove the throttle
valve.

• Disconnect the throttle cable from the throttle valve ,

• Push the cable holder and turn it 90° . Remove the cable
holder, jet needle, set spring and set collar.

• Remove the screws.

• Remove the carburetor float chamber.

• Remove the buffer plate.

• Remove the float pin and floats.
• Remove the needle valve ass'y .
• Remove the pin and disassemble the needle valve ass'y .
• Remove the main jet, and slow jet.

• Remove the choke/idle adjuster knob .

• Remove the air screw.
• Clean the carburetor body with pressurized air.

u ,
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 FUEl SYSTEM 10·3

Carburetor Inspection
• Inspect the following parts for damage:
Jet needle
Throttle valve
Float
• Inspect the following jets for clogging:
Main jet
Pilot jet
Starter jet
• Inspect the needle valve for wear.
I I :7

• Measure the f loat height with a vernier caliper . To meas-

ure the float height, tilt the carburetor until the float tip
just contacts the float va lve.

Standard float height : , 6.0 mm 10 .63 in)

Carburetor Reassembly
Reverse the sequence of removal.

REED VALVE
Reed valve Removal
• Remove the carburetor . ( a 10-2)
• Remove the six bolts .
• Remove the intake pipe and reed valve .

Reed Valve Inspection

• Inspect the reeds for damage.
• Inspect the reed valve stoppers for damage.
• Inspect the valve seat rubber for damage.

NOTE: Be careful not to damage the removed reed valve

ass 'y.

Reed Valve Reassembly

Reverse the sequence of removal.

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 COOLING SYSTEM " .,

COOLING SYSTEM

ID

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 " ·2 COOLING SYSTEM

ENGINE COOLANT REPLACEMENT

A WARNING
You can be injured by scalding fluid or steam if you open
the radiator cap when the engine is hot.
Do not open the radiator cap when the engine is hot . Wait
until engine cools.

• Place the motorcycle on a block.

• Remove the radiator cap.
• Remove the drain plug and drain engine coolant.
• Tighten the drain plug.
• Pour specified coolant through the radiator inlet hole up
to the bottom of filler hole . ( r::r 2-6)
Engine coolant capacity : 1100 ml 12.3 US pt)
• Tighten the radiator cap firmly.
• Run the engine a few minutes and inspect the coolant
level. f r::r 2-5)

RADIATOR CAP INSPECTION

• In spect the radiator cap for function with a radiator cap
pressure gauge .
Radiator cap valve release pressure:
95 - 125 kPa 10.95-1 .25 kg/em' . 13 .5 - 17 .B psil

NOTE: Apply wa ter to radiator cap seal before fitting the

radiator cap to the pressure gauge.

RADIATOR
Removal
• Remove the seat and fuel tank.
• Drain coolant.
• Disconnect the radiator hoses and overflow tube .
• Remove the radiator fitting bolts . Remove the radiator .

Reassemblv
Reverse the sequence of removal.

WATER PUMP
Removal
• Drain coolant. ( r::7 " · 2)
• Remove the bolts and water pump cover.

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 COOLING SYSTEM 11 ·3

• Remove the gasket and dowel pins.

• Inspect the impeller for damage .

• Remove the clutch cover . ( a 7·2)

• Remove the circlip with snap ring pliers.
• Remove the water pump driven gear and water pump
shaft.
• Inspect the water pump driven gear and shaft for damage.

• Inspect the bearing for smooth inner race movement.

• Inspect the oil seal for damage.
• Remove the oil seal with the special tool.

09913-50121 Oil seal remover

• Remove the bearing.

Reassembly
• Fit the bearing and circlip. Apply transmission oi l to the
Grease
bea ring.
• Apply thread lock" 1303" to the outer surface of the
oil seal. Fit the oil seal.
• Apply grease to the oil seal lip.
• Insert the water pump shaft. Fit the water pump driven
gear and circlip. Thread Lock " 1303"

• Reassemble the clutch cover. ( rJ 7-5)

• Reassemble the water pump impeller.
• Fit the dowel pins and a new gasket.
• Fill the radiator with coolant. ! r J 11 -2)

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 ELECTRICAL SYSTEM 12·1

ELECTRICAL SYSTEM

,
•

:#r
~ 3.5 kg-m

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 12·2 ELECTRICAL SYSTEM

ELECTRICAL CIRCUIT

Engine Sl Op swi tch

Magneto Ignition coil

,.--·--11- -- --. - -- ---

Sperk plag

L __• __________ _

COl unit

Color code:
B Black
BfR : Black with red tracer
8fW : Black with white tracer
B/Y : Black with yellow tracer
G Green
R Red
R/W : Red with white t racer
W181 : White with blue tracer

IGNITION COIL INSPECTION Select " IG .COll "

Checking with Electro Tester
• Set the power switch to " OFF" position . Power 5OUrC'~'~~
• Connect the coil test leads with the yellow tip atta ched Yellow

to the white/blue lead of ignition coil and the bla ck tip ,.d_.N·'-,
to the green lead (ground) . Connect the high tension lead
w ith the red ® lead attached to the spark plug co rd and
the black e lead to the green lead (ground l. ~
8 mm Wh,le/Blue

• Set the test selector kn ob to " IG . COIL" position . Spt,rk n

• Switch on the power.

• Note the spark in the spark plug window . It shou ld be
strong and continuous . not intermittent. across pre-set
8 mm 10 .3 in) gap. Allow the spark to jump the test gap
for at least five minutes continuously . to insure proper
operati on under the temperature conditions of ac tual
riding.
09900·28106 Electro tester

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 ELECTRICAL SYSTEM 12·3

Che cking with Pocket Tester

Measure the ignition coil electrical resistance with the pocket Terminal
tester.
09900-25002 Pocket tester

Primary Terminal - Ground Appro x . 0 - 1 {}

Secondary Plug ca p- Ground Approx . 20-30 KO Ground

COl UNIT INSPECTION

Checking with Pocket Tester
Measu re resista nce between the lead wires with the pock-
et teste r (x 1kO range) .

09900-25002 Pocket tester

.. CAUTION
Using a insulation-resistance meter Iso -called megger) for
this purpose can damage circuit elements in the COl unit .

Use a circuit tester of the type used by radio repairmen .

A High -grade circuit tester or an ohmmeter is preferred .

Unit, Approx kn
Positive + probe pin
B/A A/W A G B/Y W /SI B/w
."•
<>
c
-------
B/A
-------
100 200 50 200 50 200 a OFF 50 - 200
0
ii
CD
A/W
A
B-18
5- 9 ----- -----
5- 10
7 - 17 5- 9
2- 5
8-18
5- 9
OFF
OFF
5- 9
2- 5

•
-•
•••
G
BIY
1- '
0
2- ' 2-5
----
100- 200 50 - 200 50 200
1- '

5-------
OFF
OFF
a
50 - 200
5- 13 5 - 15 - 13
----- -----
0> W /BI 5 - 10 2- ' 2- '
z B/W 2 -5 0 OFF
1- ' 2- ' 1- '

Wire color

G : Green
R : Red
B/R : Black with Red tracer
B/W : Black with White tracer
B/Y : Black with Yellow tracer
R/W : Red with White tracer
W /BI : White with Blue trecer

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J
 12·4 ELECTRICAL SYSTEM

STATOR COIL INSPECTION

Measure the stator coils electrical resistance.

Black/Red - Red /White 20 - 300

Red - Green 50-200 n

MAGNETO ROTOR AND STATOR REMOVAL AND

RESSEMBLY
• Remove the bolts and magneto cover.
• Remove the screws and stator. Disconnect the lead
wires.

• Loosen the nut with a special tool.

09930·40113 Rotor holder

• Remove the magneto rotor with the special tool. Remove

the key.
09930-30113 Flywheel rotor remover

• Loosen the screws and remove the stator.

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 ELECTRICAL SYSTEM 12·5

Magneto Rotor and Stator Reassembly

• Align the line on the stator and triangle mark on the crank-
case to set the ignition timing correctly.

• Fit the key into the crankshaft.

• Fit the magneto rotor.
• Apply Thread l ock Super "'303" to the nut and tight-
en t he nut to the specified torque w ith the special tool.
99000 -32030 THREAD LOCK SUPER " '303 "
09930 -40113 Rotor holder
lightning torque : 35 N' m (3.5 kg-m. 25.5 Ib-ttl

• Reassemble the magneto cover.

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 fRONT ANO REAR WHEELS 13·1

FRONT AND REAR WHEELS

[!J 6.5 kg-m

•
d?
"k1
~

~
[!J 0.9 kg-m

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 13·2 fRONT AND REAR WHEELS

FRONT WHEEL DISASSEMBLY AND REASSEMBLY

Front Wheel Removal
• Place the motorcycle on a block to lift front wheel off
the ground.
• Remove the brake disc cover.
• Loosen t he four ax le sha ft holder nuts.
• Loosen the axle shaft and remove it .
• Remove the front wheel.

Front Wheel Reasembly

• Reassemble the spacer, front wheel and axle shaft.
• Tighten the axle shaft to the specifi ed torque .
Tightening torque: 65 N.m (6 .5 kg· m. 47 .0 Ib·ftl

• Fit the axle holder and tighten the nuts temporarily .

• Remove the block from under the chassis tube and move
the front trok up and down several times .
• Tighten the axle holder nuts to the specified torque .
Tightening torque : 10 N.m (1.0 kg-m . 7 .5Ib·ftl

NOTE: To tighten the axle holder. tighten the upper nuts

first and then tighten the lower nuts so that the lower side
of the holder has clearance.

REAR WHEEL REMOVAL AND REASSEMBLY

Rea r Wheel Removal
• Place the motorcycle on a block to lift the rear wheel off
the ground .
• Remove the cotter pin and axle nut.
• Loosen the chain adjuster lock nuts and chain adjuste rs.
• Remove the rear wheel. Left Right
Rear Wheel Reassembly
• Reassemble the rear wheel and axle shaft .
• Adjust the drive chain slack . ( r::r 2-8)
• Tighten the axle nut to the speci fied torque .
Tightening torque : 100 N.m (10 .0 kg-m . 72.5 Ib -ftJ
• Replace the cotter pin with a new one .
Chain adjuster washer

FRONT AND REAR WHEEL INSPECTION

Axl e Shaft Inspection
Support the axle shaft with V-blocks and measure the axle
shaft runout.
Service limit : 0 .2 5 mm {0 .010 inJ

Wheel Rim Inspection

Measure the wheel rim runout with a dial gauge.
Service limit: 2 .0 mm (o .oa in) ... axial and radial

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 fRONT AND REAR WHEElS 13·3

Rear Wheel Spacer Inspection

• Inspect the right and left rear w heel spacers and the dust
seals for wea r and cracks.
• Replace the spacer together with the dust seal, if you find
excessive wear on the spacer.
Service limit: 1 mm (0.04 in) depth of worn groove

NOTE: Apply grease on the spacer and dust seal before

reassembling.

Wheel Bearing Inspection

• Turn the inner race by finger and inspect it for smooth
movement.
• Inspect the clearance between the outer race and wheel
hub .
• Inspect for bearing damage.

WHEEL BEARING REMOVAL AND REASSEMBLY

Front Wheel Bearing Removal
• Fit the bearing remover into the wheel bearing.
09941 -50110 Bearing remover
• Insert the wedge bar into the slit of the bea ri ng remover
from the opposite side.
• Hit the wedge bar with a hammer and remove the bear-
ing and spacer.

Rear Wheel Bearing Removal

• Remove the dust seal.
• Remove the circlip wi th snap ring pliers.
• Fit the bearing remover into the wheel bearing.
09941 -50110 Bearing remover
• In sert the wedge bar into the sl it of the bearing remover
from the opposite side.
• Hit the wedge bar w ith a hammer and remove the bearing.

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 13-4 FRONT AND REAR WHEELS

Front Wheel Bearing Reassembly

• Apply grease to t he bearings.
• Reassemble the spacer and bearings with the special tool.
09941 · 34513 Bearing installer set

NOTE:
• Reasemble the left side (disc side) bearing first and then
reassemble the right side bearing.
• Position the bearing so sealed side faces out.
• After reassembling the bearings, inspect the bearings for
smooth movement.

Rear Wheel Bearing Reasembly

• Apply grease to the bearings .
• Reassemble the spacer and bearings with the special tool.
-" ) .-:::

09941 · 34513 Bearing installer set

NOTE: After reassembling the bearings, inspect the bear-

ings for smooth movement.
( \ '::::-
• Fit the circlips.

NOTE: Place the manufacturer's code indicated side of

the dust seal outside, when installing the dust seal.

DISC PLATE REPLACEMENT

• Apply thread lock. super" 1303" to the bolts.
• Tighten the bolts to the specified torque .
Tightening torque: 9 N.m (0 .9 kg -m , 6 .5 Ib-ftJ

REAR SPROCKET REPLACEMENT

• Tighten the nuts to the speci fied torque .
Tightening torque: 35 N .m (3 .5 kg-m. 25 .5 Ib -ftl

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 FRONT AND REAR BRAKES 14·1

FRONT AND REAR BRAKES

i ~ 10 kg-m

~~
~
~~
~~.~ 2,3 kg-m

1.0 kg-m

t!] 1.8 kg-m

t!) 1.8 kg-m

(!J
"~ ~
2.0 kg-m

,
'l"> g.,.. i')~" ~~ 2.3 kg-m
/
t!) 0.8 kg-m

. @~

~.~ .'

~ ~}
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 14·2 FRONT ANO REAR BRAKES

BRAKE FLUID AIR BLEEDING

A WARNING
Brake fluid can be hazardous to humans and pets. Brake
fluid is harmful or fatal if swallowed. and harmful if it
comes in contact with your skin or eyes.
Keep both fluid away from children. Call your doctor im-
mediately if brake fluid is swallowed and induce vomit·
ing. Flush eyes or skin with water if brake fluid gets in
eyes or comes in contact with skin.

A WARNING
The use of any fluid except DOT4 brake fluid from a sealed
container can damage the brake system and lead to an
accident.
Use only DOT4 brake fluid from sealed container. Never
use or mix different types of brake fluid.

A CAUTION
Spilled brake fluid can damage painted surface and plas-
tic parts .
Be careful not to spill any brake fluid when servicing brake
fluid. Wipe spilled fluid up immediately.

• Remove the reservoir cap .

• Connect a transparent tube to the bleeder valve and set
the other end into a receptacle.
• Pour brake fluid up to the UPPER line.
• Pump the brake lever/pedal until air bubles stop coming
out from the reservoir.
• Pump the brake lever/pedal in the squeezed position.
• Open the bleeder valve and tighten the bleeder valve .
• Release the brake lever/pedal.
• Repeat this sequence until air bubbles stop coming out
from the bleeder valve.

NOTE: Do not release the brake /ever/pedal while the bleed-

er valve ;s opened.
• Replenish brake fluid to the UPPER line when the brake
fluid level drops below LOWER line.

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 FRONT ANO REAR BRAKES 14·3

• Tighten the air bleeder valve.

Tightening torque: 8 N .m (0 .8 kg -m. 5 .5 Ib-ft)

• Pou r brake fl uid up to the UPPER line .

• Reassemble the reservoi r cap.

BRAKE FLUID REPLACEMENT

• Remove the reservoir cap.
• Connect a transparent tube to the bleeder valve and set
the other end into a receptacle.
• Loosen the bleeder valve and pump the brake lever/pe-
dal untit brake fluid stops coming out from the bleeder
valve.
• Pour brake fluid into the reservoir.
• Bleed air f rom the brake system. ( r:7 14-2)
• Reassemble the reservoir cap.

BRAKE PADS REPLACEMENT

Front Brake Pad s
• Remove the pad mounting bolts.
• Remove t he ca liper mounting bolts and ca liper.
• Remove the brake pads.

NOTE: Replace the two brake pads as a set.

• Fit the new brake pads into the caliper and tighten the
pad mounting bolts temporarily.
• Tighten the ca liper mounting bolts.
Tightening torque : 23 N .m (2 .3 kg-m. 16.5 Ib -ft)

• Tighten the brake pad mounting bolts .

Tightening torque: 20 N .m (2 .0 kg-m. 14. 5 Ib-ftl

NOTE: Pump the brake lever several times to seat the brake
pads after reassembling.

Rear Brake Pad s

• Remove the two bolts and the caliper cover.
• Remove the pad mounting bolts.

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 14·4 FRONT AND REAR BRAKES

• Remove the brake pads.

NOTE: Rep/ace the two pads 8S a set.

• Fit the brake pads into the caliper.

• Tighten the brake pad mounting bolts.
Tightening torque : 18 N.m 'l .a
kg-m . 13 .0 Ib-ftJ

• Reassemble the caliper cover.

NOTE: Pump the brake pedal several ames to seat the brake
pads after reassembling.

BRAKE DISC INSPECTION

• Measure the front and rear brake disc thickness .

Service limit
Front 2 .5 mm 10 .10 inl
Rear 4 .0 mm (0 . '5 in)

• Measure the front and rea r brake disc runout .

Service limit: 0 .3 mm (0 .01 in)

CALIPER

.... WARNING
The use of any brake fluid except DOT4 brake fluid from
8 sealed container can damage the brake system and lead
to an accident.
Use only DOT4 brake fluid from a sealed container . Never
use or mix different types of brake fluid.

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 FRONT AND REAR BRAKES 14·5

A WARNING
Brake fluid can be hazardous to humans and pets. Brake
fluid is harmful or fatal if sw allowed, and harmful if it
comes in contact with your skin or eyes.
Keep brake fluid away from children . Call your doctor im·
mediately if brake fluid is swallowed , and induce vomit-
ing . Flush eyes or skin with water if brake fluid gets in
eyes or comes in contact with skin .

... CAUTION
Spilled brake fluid can damage painted surface and plas-
tic parts .
Be careful not to spill any fluid when servicing the caliper.
Wipe spilled fluid up immediate ly .

Front Caliper Removal and Disassembly

• Place a drain pan under the caliper and remove the
union bolt.
• Remove t he pad mounting bolts.
• Remove the caliper mounting bolts.
• Remove the brake pads and spring from the caliper.
• Remove the ca liper braket from the ca liper.
• Remove the boots from the caliper bracket.
• Wrap the caliper with a rag to prevent brake flu id scat-
ter and piston pop-out.
• Apply low-pressure air into the cali per through the hole
to remove the pistons.

A WARNING
Fingers can get caught between piston and caliper body
when removing the piston.
00 not place your fingers on the piston when removing
the piston .

• Remove the piston seals CD and dust seals @.

(i) ®

660
00 0

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 14·6 FRONT AND REAR BRAKES

Rea r Caliper Removal and Disassembly

• Place a block under the chassis tu bes.
• Place a rag under the brake hose union bolt to catch
spilled brake fluid .
• Disconnect the brake hose.
• Remove the brake pad mounting bolts .
• Remove the cotter pin and axle nut.
• Draw out the axle shaft.
• Slide off the caliper bracket w it h the ca liper .
• Remove the brake pads and spring from the caliper.
• Wrap the caliper with a rag to prevent brake fluid scat-
ter and piston pop-out.
• Apply low-pressure ai r into the ca liper through the hole
to remove the piston.

A WARNING
Fingers can get caught between piston and caliper body
when removing the piston.
Do not place your fingers on the piston when removing
the piston .

• Remove the piston seal and dust seal.

Caliper Inspection
• Measure the caliper cylinder bore with a small bore gauge.
Fron. : 27 .000 - 27 .050 mm 11 .0630-1 .0650 in)
Rear: 30.000 - 30.050 mm 11 .1811 - 1.1831 in)
• Inspect the caliper cylinder for scuffing.

• Measure the caliper piston diameter with a micrometer.

Front: 26.900 - 26.950 mm 11 .0591 - 1 .0610 in)
Rear: 29 .900 -29 .950 mm 11.1772 - 1 .1791 in)

• Inspect the caliper piston for scuffing .

Caliper Cleaning

~
• Flush the Caliper ports with pressurized air .
• Wash the caliper piston and cyl inder with fresh brake
fluid .

NOTE: Do not use gasoline or other cleaning solvents to

« ~
wash the caliper parts.
@ @

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 FRONT AND REAR BRAKES 14·)

Front Caliper Reassembly

• Apply brake fluid to the piston seals and fit the piston CD ®

660
seals CD and dust seals @ .
• Fit the pistons into the ca liper.
• Apply si licone grease to the caliper axles.

00 0
99000-2 5100 Suzuki silicone grease
• Fit the boots and caliper brackets.
• Fit the spring and brake pads. Tighten the brake pad
mounting bolts temporari ly.
• Tighten the caliper mounting bolts to the specified torque .
Tightening torque : 23 N .m (2.3 kg-m. 16.5 Ib-ftJ

• Tighten the brake pad mounting bolts to the specified

torque.
Tightening torque: 20 N.m (2 .0 kg-m. 14.5 Ib-ft)

• Tighten the brake hose union bolt to the specified torque .

Tightening torque : 23 N,m 12.3 kg-m . 16.5 Ib-ft)

• Refill brake fluid and bleed air from the brake system .
( a- 14-21

Rear Caliper Reassembly

• Apply brake fluid to the piston seal and fit the piston seal
CD and dust seal @ .
• Fit the piston into the caliper.
• Fit the spring and pads . Tighten the brake pad mounting
bolts temporarily.
• Apply silicone grease to the caliper axles.
99000-25100 Suzuki silicone grease
• Fit the caliper to t he bracket.
• Slide the bracket into the swing arm.
• Reassemble the axle shaft. ( cr , 3-2)
• Tighten the brake hose union bolt.
Tightening torque : 23 N .m 12 .3 kg-m. 16.5 Ib -tt )

• Refill brake fluid and bleed air from the brake system.
( a- 14-21

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 14·8 FRONT AND REAR BRAKES

MASTER CYLINDER

A WARNING
Brake fluid csn be hazardous to humans and pets. Brake
fluid is harmful or fatal if swallowed , and harmful if it
comes in contact with your skin or eyes .
Keep brake fluid away from children . Call your doctor im-
mediately if brake fluid is swallowed , and induce vomit-
ing . Flush eyes or skin with water if brake fluid gets in
eyes comes in contact with skin .

J. WARNING
The use of any fluid except DOT4 brake fluid from a sealed
container can damage the brake system Bnd lead to an
accident.
Use only DOT4 brake fluid from 8 sealed container. Never
use or mix different types of brake fluid .

A CAUTION
Spilled brake fluid can damage painted surface and plas-
ti c parts.
Be careful not to spill any fluid when filling the brake fluid
reservoir , Wipe spilled fluid up immediately .

Front Master Cylinder Removal and Disassembly

• Drain brake flu id . ( r::r 14-3)
• Loose n t he brake hose adapto r and di sconn ect the
brake hose.

NOTE: Hold the brake hose with a wrench to prevent

the brake hose ' rom twisting when loosening the adaptor.

• Remove t he mast er cylinder holde r bolts.

• Remove the mast er cylinder ca p.
• Remove the bol t and brake lever.
• Remove the brake lever return spring .

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 fRONT AND REAR BRAKES 14·9

• Remove the dust seal boot CD.

• Remove the circl ip @ with snap ri ng pl iers .
• Remove the washer @. piston ® and spring ®.

Rear M aste r Cylinder Removal and Disassembly

• Drain brake f luid.( C7' 14-3)
• Remove t he rea r brake pedal. ( r=:r 14- 11)
• Place a rag under the hose to catch spilled brake fl uid.
• Remove the clamp and discon nect t he hose (reservoir).
• Remove the union bolt.
• Remove the maste r cylinde r clamp bolts.
• Remove the dust seal boot CD.
• Remove the circlip @ with snap ring pliers.
• Remove the push rod @.
• Remove t he piston /cup set (1),

Mast er Cylinder Inspection

• Measure the cylinder bore with a small bore gauge.
Front: 11 .000 - 11.043 mm 10 .4331 - 0 .4348 in)
Rear: 14 .000 - 14 .043 mm 10 .5512 - 0 .5529 in)

• Measure the cylinder piston diameter w ith a micrometer.

Front: 10 .957 - 10 .984 mm (0.4314 - 0 .4324 in)
Rear: 13 .957 - 13 .984 mm 10.5495 - 0.5506 inl
• Inspect t he cyli nde r bore and piston fo r scuffing .
• Inspect the pisto n rod and spri ng for damage.

Rear
Front

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 14·10 FRONT AND REAR BRAKES _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

Mast er Cylinder Cleanin g

• Flush the master cylinder ports with pressurized air.
• Wash the master cylinder bore and piston with fresh
brake fluid.
NOTE: Do not use gasoline or other cleaning solvents to
wash the master cylinder parts.
tJ
Front M aster Cylinder Reassembly
• Fit the spring, piston and washer.
• Fit the circlip with snap ring pliers.
0
-' ~
D
• Fit the dust sea l boot.
• Reassemble the brake lever.
• Tighten the master cylinder clam p bolts to the specified
torque,
Tightening torqu e: 10 N.m 11 .0 kg -m . 7 .S lb-ft)

Tighten the brake hose union bol ts to the specified torque.

Tightenin g torqu e:
Q) la N.m (1 .a kg·m. 13.0 Ib ·lt l
@ la N.m (1 .a kg·m. 13 .0 Ib·ltl

NOTE: Hold the brake hose with a wrench to prevent the

brake hose from twisting when tightening the adaptor.

• Refill brake fluid and bleed air from the brake system .
( 0' 14· 21
• Reassemble the reservoir cap.
Rea r M aster Cylinder Reassembly
• Fit the piston /cup set and push rod.
• Fit the circlip with snap ring pliers.
• Fit the boot .
• Tighten the master cylinder clamp bolts to t he specified
torque.
Tightening to rque: 10 N .m (1.0 kg-m . 7 .5Ib-ft)

• Reassemble the rear brake peda!.( c:7 14-1 1)

• Tighten the brake hose union bolt to the specified torque.
Tightening torque: 23 N .m (2 .3 kg-m . 16.5 Ib-ftl

A CAUTION
1--------
Impro per brake hose routing can damage th e brake hose.
Set the brake hose so it touches the st opper and tighten
the union bolt. En sure th e brake hose has enough cl ear-
ance to th e reBr suspension spring .

• Connect the hose (reservoir) and clamp it.

• Refill brake fluid and bleed air f rom the brake system.
( 0' 14-21

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 FRONT AND REAR BRAKES 14·11

BRAKE PEDAL REMOVAL AND REASSEMBLY

Removal
• Remove the cotter pins behind the frame.
• Loosen and remove the brake peda l pivot bolt.
• Remove the return spring.
• Remove the cotter pins and pin.

Reassembly
• Reassemble the pin, washer and cotter pins.
• Fit the return spring .
• Apply grease to the brake pedal pivot bolt. Tighten the
bolt .
• Fit the washer and cotte r pins.
• Adjust the brake pedal height. ( a 2- 12)

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 - MEMO -

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 fRONT fORK ANO STEERING 15·1

FRONT FORK AND STEERING

I) I ~t!J 3.0 kg-m

t!J 3. 5 kg-m

~ 1.0 kg-m
I
~ 2.0 kg-m

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 15·2 FRONT FORK ANO STEERING

FRONT FORK
Front Fork Dismounting
• Place a block under the chassis tubes.
• Remove the protecter.
• Remove the caliper. ( r:::r 14-5)
• Remove the front wheel. ( c:r 13-2)

• Loosen the upper bracket clamp bolts @ .

• Loosen the front fork cap bolt <D 1 - 2 turns.
• Hold the fork body and loosen the lower bracket clamp
bOlts @ .
• Remove the front fork.

NOTE: To facilitate the front fork disassemblv, loosen the

upper clamp bolts ® before loosening the fork cap bolt CD
then loosen the lower bracket calmp bolts @.

Front Fork Disassembly

NOTE: If the fork has not been disassembled before, you
may find that some threaded components are very tight. Set
rebound and compression damper settings to the minimum
settings before disassembling.

• Thorough ly clean the fork before disassembly.

A CAUTION
Scrat ches or oth er dam age on the inner tube or on the
oil sea l lip will cause oil leak.

Avoid scratching or damaging the inner tube or the oil seal.

Use a mild detergent or ca r w ash soap and sponge out
dirt w ith plenty of wat er.

• Set the spacer on the inner tube.

09940· 5485 1 Front fork spacer

NOTE: The spacer between the outer tube and caliper

bracket (axle holder) can avoid dust seal damage when the
inner tube is fully compressed.

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 fRONT fORK AND STEERING 15·3

• Separate the fork cap bolt @ from the outer tube ® and
slowly slida down the outer tube.
• Place a drain pan under the front fork and drain the fork
Spacer
oil.

• Clamp the axle holder for right fork or caliper bracket for
leh fork in a vise. Protect the axle holder or caliper bracket
with a rag when using a vise.
• Move the inner tube and inspect it for smooth movement .

.. CAUTION
Clamping the axle holder too tight can damage it which
will affect riding stability.

Do not clamp the axle holder too tight .

• Loosen the center bolt ® completely from the bottom

of fork with a 21 mm socket wrench .

• Press the fork cap inward until the center bolt @ and lock
nut ® are exposed on the opposite end.

1\

• Place the stopper plate around the inner rod stem w hile
pressing on the fork cap.
--
09940·94920 Stopper plate

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 15·4 FRONT FORK AND STEERING

• Loosen t he cente r bolt with an open end w rench on the

flat portion of fork cylinder inner rod lock nut @ and sock-
et wrenc h on the center bolt ®.
• Remove the center bolt and sealing washer from the fork
cylinder inner rod ,

.. CAUTION
Removing the lock nut and pushing the inner rod thread
into the fork cylinder will damage the inner rod oil seal.

Do not remove the inner rod lock nut @'

• Remove the stopper plate while pressing the fork cap bolt
inward.
• Remove the fork cylinder and fork spring .

NOTE: The push rod @ ca n come out of the inner rod w hen
the cen ter bolt is rem oved.

- ~. • """""11 I

• Remove the dust seal ® and the stopper ring ®. @ ®

.. CAUTION
Scratches on the inner tube could cause oil leaks.

Avoid scratching when removing .

• Compress the outer t ube fully, then pull it off .

L/-Vise

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 FRONT FORK ANO STEERING 15·5

• Open the slide bushing with a ftat-blade screwdriver and

remove the slide bushing .

A CAUTION
Scratching the teflon coated surface of the slide bushing
or warping the slide bushing can decrease front fork per-
formacne .

Be careul not to scratch the teflon coat. Do not open the

slide bushing any more than necessary.

• Remove the following parts from the inner tube.

Guide bushing CD
Washer @
Oil seal @
Stopper ring @
Dust seal ®

Fork Cylinder Disassembly.

• Loosen the fork cap bolt with a 32 mm socket wrench
on the fork cap bolt and 30 mm open end wrench on the
flat portion of fork cylinder body,
• Place a drain pan under the fork cylinder. Pull off the fork
cap bolt while pressing in the inner rod.
• Push and pull the inner rod to drain the oil.

NOTE; The compression damping adjuster will pop loose

suddenly when removed from fork cyinder. Be careful not
to spray fork oil when removing the adjuster.

NOTE; The fork cylinder and compression damper unit can

not be disassembled any further.

A CAUTION
Lasening the lock nut CD or removing any parts from the
compression damper unit will damage it. '---~y-----'
compression dumper unit
Do not attempt to disassemble or to remove the damper
unit from the fork cap bolt.

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 15·6 FRONT FORK AND STEERING

Front Fork In spection

• Inspect the center bolt for damage. If it is damaged,
replace it with new one.
• Inspect inner tube for scratches or bending. If it has
scratches or bend , replace it with a new one.
• Inspect the outer tube for dent. If it is dented all the way
to the inner side, replcae it with a new one.
• Inspect fork cylinder and fork cyl inder inner rod for
scratches or bending . If they have scratches or bend ,
replace the fork cylinder assembly.
• Inspect guide bushing and slide bushing for wear or
damage. If they are worn or damaged , replace them with
newones.
• Inspect metal particles on the guide bush ing and sl ide
bushing. If they are not clean, clean them with a nylon
brush and fork oil.

• Measure the free length of front fork spring.

Service limit: 478.5 mm 118 .8 in)

Fork Cylind er Reassembly

• Clean the fork cylinder thread .
• Apply front fork oil to the O-rings and slide-bush.
• Extend the inner rod fully and pour the specified amount
of fresh front fork oil into the f ork clinder.

Fork cylinder oil t ype: SUZUKI FORK OIL 55-05

Fork cylind er oil capacity : Approx 145 m l
(0 .2 /0 .1 USlimp qtl

• Slowly move the inner rod several strokes to let out the

!
air bubbles .
• Apply the thread lock 1303 to the fork cylinder thread.

• Place the spring retainer CD on a edge of a desk . Use a

rag to protect the spring retainer.
• Exterd the inner rod fu lly and insert the compression
damper unit into the fork cylinder.
• Depress the fork cap hard and tighten it to the fork
cylinder.
R,g - -c"l!:<:;::::::s,
Tightening torqu e. 80 N 'm 18 .0 kg fcm . 58 .0 Ib -ftl

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 FRONT FORK AND STEERING 15·)

NOTE: Air bubbles and excess oil will be discharged

through the blow-by valve when depressing the fork cap. Fork cap

Too much fork oil may be discharged if the inner rod is com- '11-- Drain hole
pressed when assembling the fork cap.
Blow-by \/al\/e -il:~;1l---FO'k oil

• Hold the fork cylinder vertically and move the inner rod
up and down several strokes to ensure that air bubbles
are discharged. -.
• Drain excess oil that has come through the blow-by valve
t hroug h the drain hole.

t
• Compress the inner rod folly. place the fork cylinder
horizontally, release the inner rod and wait until t he in-
ner rod comes out and stops. The inner rod must come
out to fully exte rded position by itself. Pull the inn er rod
to examine whethe r it has come out fully.

Front Fork Reassembly

NOTE: The fork outer body and fork cylinder must contain
the same type of oil. Replace both fork outer body oil and
fork cylinder together.

• Remove the old oit from the fork parts .

.. CAUTION
Scratches on the oit seal lip can cause oil leaks .

When installing the seal. place a vinyl cover over the bush-
ing attachment groove and edges of the inner tube to
avoid damage to the seal lip.

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 15·8 FRONT FORK AND STEERING

• Apply front fork oil to the oil seal lip.

• Attach the fo llowing pa rts to the inner tube:
Vinyl cover
New dust seal
Stopper ring
New oil seal

NOTE: The side of the oil seal that has a mark should face
the dust seal.

• Remove the vinyl cover and then install the washer, guide
bushing and slide bushing.
• Apply front fo rk oil to t he guide bushing and slide bushing.

NOTE: Inspect the slide bushing for burrs. If there is 8 burr,

remove it with a knife, taking care not tD peel off the teflon
coating. If the slide bushing has a large crack or excessive
play after installing it replace it with a new one.

.. CAUTION
Teflon coating dam age on the slide bushing can decrease
front fork performance.

When in st alling the slide bushing. be careful not to

damage th e teflon coating.

• Apply fork oil on the outer sureface of the oil seal to make
it easy to fit.
• Insert the inner tube in the outer tu be.

• Install the oil sea l wi t h t he special t ool until the st opper

ring groove of the ou ter tube can be seen.

09940-32720 Front fork oil sea l installer

• Attach the stopper ring securely to the stop per ring

groove of the out er tube.
• Attach the dust seal.

NOTE: Afterattaching the dust seal, make sure that there

are no cracks around the circumference of the seal. Cracks
could allow water, mud and alike to enter and cause an oil
leak.

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 fRONT fORK AND STEERING 15·9

.. CAUTION
Use of grease as a substitute for fork oil when Installing
the oil seal can result in oil leak. Applying grease to the
dust seal and oil seal can cause dirt to accumulate and
damaging dust seal lip and oil seal lip .

Use only a thin coat of fork oil on the oil seal.

• Attach the spacer on the inner tube .

NOTE: The spacer between the outer tube and caliper

brakcte (axle holder) can avoid dust seal damage when the
inner tube ;s fully compressed.

• Place the oute r tube on the spacer.

• Clamp the axle holder (for right front fork) or caliper brack-
et (for Jeft front fork) in a vise. Be sure to protect the axle
holder or ca liper bracket with a rag when clamping with
the vise .

.. CAUTION
Clamping the axle holder too tight can damage it and it
will affect riding stability.

Do not clamp the axle holder too tight.

• Insert the fork spring.

• Make sure more than 14 mm (0 . 55 in) of inner rod thread
is exposed on the end.
• Inse rt the fork cyl inder slowly in the inner tube and can·
firm that it is securely inserted in the hole on the bottom
of the axle holder.

• Press in the fork inward cap until the lock nut is exposed.
On the other side place the stopper plate around the in-
ner rod stem while pressing on the fork cap.

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 15·10 fRONT fORK AND STEERING

• Apply the thread lock 1303 to the inner rod thread .

• Make sure the push rod <D is in the inner rod .
• Anach the sealing washer ® to the center bolt and in-
sert the a shaped projection ® of center boh into the
push rod 0 ,
• Turn the cent er bolt clockw ise until the end of inner rod
is fully inserted into the center bolt. Tighten the lock nut
to the center bolt .

Tightning torque 2 .0 kg-m

A WARNING
Inner rod
Front fork will be broken if the inner rod is not correctly
tightend .
lock nut
In sert the inner rod fully into the center bolt before tight- Cefller bolt
ening the lock nut.

NG

• Apply thread lock 1303 to the center bolt thread

• Remove the stopper plate whi le pressing in the fork cap
bolt . Tighten the center bolt to the inner tube.

Tightening torque 6 ,5 kg-m

• Release the front fork from the vise and hold it vertically .
• Fit the fork cylinder holder on the fork cap and tighten
it to the outer tube thread .
09943-74'" Front Fork Oil level Gauge
09940-428'0 Fork Cylinder Holder

NOTE: Cut the hatched 8re8 of the special tool to set it

on the front fork.
25 mm
o

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 FRONT FORK AND STEERING 15·11

• Depress the fork cyl inder holder to compress the front

fork fully. Pour the specified fork oil to the top of the outer 9
tube Move the outer tube up and down to let out the air ~ f-Fork cylinder
babbles. holder
• Hold the fork in the fully compressed position by depress- Fork cylinder - t:
ing the fork cylinder holder. Place the oi l level gauge on )~
the top end of the outer tube, and measure the oil level.
Outer tube
Standard oil lev el 170 mm (6 .69 in) r-
• Remove the fork cylinder holder and tighten the fork cap Fig 2
bolt to the outer tube.
Fork cyllnd,,, --Jl1:: If--r o, ' cylinder
NOTE: When assembling the 'ront fork without the fork holder
cylinder halder, remove the old oil thrroughly by using the
pressured air and pour correctly measuhed fork oil. Use an
~. u'ne, tube
injector to measure the oil.
I+---In"., tube
Standard oil amount 440 ml {14 ,9 / 15 .5 US/Imp ozl

NOTE: Damage to the O-ring on the fork cap can cuase

oil leaks. Replace with a new one in case of damage. Apply
fork oil to the O-ring of the fork cap and attach the fork cap
to the outer tube,

• Raise the outer tube and tighten it to the fork cap bolt,

Front Fork Mounting

• Tighten the lower bracket bolts CD to the specified torque.
• Tighten the friont fork cap bolts ® to the spcified torque.
• Tighten the upper bracket bolts @ to the specified torque.

NOTE: Tighten the fork cap bolt @ before tightening the

upperbracket bolts @ to obtain the correct torque.

Tightening torque

N·m kg -m Ib-It
CD 25 2.5 18.0
0 35 3 .5 25.5
@ 30 3 .0 20.0

• Remount the front w heel. ( r:7 13-2)

• Remount the caliper ( CT' 14-7)
• Remount the proctecter.

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 15·12 FRONT FORK AND STEERING

STEERING
Steering Removal
• Remove the front wheeL( 0'" 13· 2)
• Remove the caliper. ( 0 ' 14-5)
• Remove the front fender .
• Remove the front number plate.
• Remove the handlebar clamp bolts and remove the han-
dlebar.

• Remove the front fork . ( cr15-2)

• Remove the steering stem head nut.
• Remove the upper bracket.

• Remove the steering nut with the specia l tool.

09940- 14960 Steering nut socket wrench

• Remove the lower bracket.

Steering Inspection
• Inspect the bearing races for wear.
• Inspect the needle bearings for wear.
• Inspect the steering stem for distortion.

Steering Bearing Replacement

NOTE: Replac e the outer race and bearing as set.

• Remove the upper and lower oute r races w ith the spe-
cial tools .

09941 -54911 Steering race remover

09941 -74910 Steering bearing installer

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 FRONT FORK ANO STEERING 15·13

• Remove the lower bearing with the special toot.

09941 -84510 Bearing inner race remover

• Fit the lo w er bearing with the special tool.

09925· 18010 Steering bearin g installe r

• Fit the upper and lower outer races with the spacial tool.

09941 -34513 Steering outer race and swing arm

bearing installer

Steering Reassembly
• Apply grease to the bearings.
• Fit the steering stem , upper bearing, dust sea l and steer-
ing stem nut.
• Tighten the stee ring s tem nu t with the special tool.
09940- 14960 Steering nut soc ket wrench
Tightening torque : 45 N 'm (4 .5 kg-m . 32 .5 Ib -ftl

• Move the steering stem right and left severa l times t o

seat the bearings.
• Turn back the stee ring stem nut by IA to Ih t urn.
• Fit the stee ring stem head nu t and tighten it t empora ri ly .
• Remount the f ront fork. ( r:::r 15-8)
• T ighten the steeri ng stem head nut to the specified
torque.
Tightening torque : 90 N 'm (9 .0 kg-m . 65 .5 Ib-ft)

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 15·14 FRONT FORK AND STEERING

• Reassemble the front wheel. ( r:::T 13-2)

• Reassemble the handlebar.

• Rock the front fork forward and backward to ensure that

the steering has no play .
• Inspect the steering for smooth movement so that the
handlebar can move righ t and left under its own weight.

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 REAR SUSPENSION 16·'

REAR SUSPENSION

,~/\
." ~ 6.0 kg · m ,~ ~

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 16·2 REAR SUSPENS10N

REAR SHOCK ABSOBER

Rear Schock A bsorber and A ir Cl eaner Removal
• Place a block under chassis tubes.
• Remove the seat.
• Remove the frame cove rs.

• Remove the side tube.

• Remove the air cleaner

• Remove the rear shock absorber mounting bolts and nuts.

• Remove the rear shock absorber.

• Loosen the lock nut and turn the adjuster with the spe-
cial tool .
09910-60611 Universa l clamp wrench

•
Rea r Shoc k Absorber Inspecion
• Inspect the rear suspension for oil leak.
• Inspect the damper rod for bends and smooth movement.
• Inspect the stopper rubber for deterioration and damage.
• Inspect the bearing for play and smooth movement.

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 REAR SUSPENSION 16·3

Rear Shock Absorber Disposal

High pressure nitrogen gas is sealed in the rear shock ab·
sorber unit. Be sure to release gas before disposing the rear
shock absorber unit.
• Remove the valve cap.
• Press the valve with a screwdriver.

it. WARNING
Releasing high pressure gas from the rea r shock absorb-
er unit can be hazardous .
Place 8 rag over the valve and push the valve with a screw-
driver to release nitrogen gas. Do not use your finger to
push the valve . and direct the valve away from your face
and body .

.
Bearing Replace ment
• Remove the dust seals.
• Remove the circlip.

.
• Set a pipe , washer. bolt (M 10) and nut 1M 10) as shown.
• Tighten the nut and remove the bearing.

• Apply grease to the bearing.

• Set pipes, washers, bolt (M' 0) and nut (M' 0) as show n.
• Tighten the nut and fit the bearing.

..
• Fit the circlip.
• Apply grease to the dust seal and fit it as grooved side
faces outside.

Rear Shock Absorber Reassembly

• Fit the spring. adjuster and lock nut.
• Adjust the spring set length.
Standard : 255 .0 mm (10 .0 in)
Range : 248.5 - 270.0 mm (9 .8 - 10 .6 in)

• Tighten the upper and lower mounting bolts and nuts to

the specified torque.
Tightening torque : 60 N'm (6 .0 kg -m . 43 .5 Ib·ft)

• Reassemble the frame side t ube.

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 16-4 REAR SUSPENSION

Air Cleaner Reassembly

• Place the air cleaner box in the frame so that the right
plate comes between the right and left seat rails.
• Pull up the air cleaner box and move it backward (Step ' 1.
• Place the outlet tube between the flame body tubes (Step
21.

• Set the air cleaner mounting boss at the outside of the

frame boss (Step 3) .

• Fit the both right and left upper flanges to the seat rails
(Step 41.

• Reassemble the cleaner cover (Step 5).

• Reassemble the frame cover and seat.

• Tune the rear suspension ( c:r 4 - 131

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 REAR SUSPENSION 16·5

OIL REPLACEMENT PROCEDURE

Tools an d Equipement
• Following tools and equipment are required to perform
oi l replacement.

CD
r
Screwdriver or small punch
® Vise-
@ Drain Pan
CD @ Oilean
® Beaker
® Specified Shock Oil (5525)
® o Rags
® Nitrogen tank
® Filler Hose and Nozzle
@J Regulator Assembly
OW/<US
SEUICE
MANUAL
® Owner's Service Manual

RM 2W • Not Shown in t he illustration

®

Oil Repla cem ent Procedure

• Remove the rear cushion unit f rom t he f rame. Clean and
dry t he rea r cushion unit.
• Remove t he spring from the rea r cushion unit.

NOTE: Inspect the rear cushion unit for oil leak.

• Remove the valve cap. Push the gas valve core wi t h a

screwdriver to bleed ou t nitrogen gas.

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 16·6 REAR SUSPENSION

A WARNING
Releasing high pressure gas from the rear shock absorb-
er unit can be hazardous .

Never perform any servicing until the nitrogen gas pres-

sure has been released from the feaf cushion unit. When
releasing the gas pressure , place a rag over the gas valve
and the end of the screwdriver etc. to press the valve.
Do not use your finger to depress the gas valve, and direct
valve away from your face and body .

• Remove the compression adjuster ass'y.

• Place a drain pan under the rear cushion unit. Move the
rod and drain the oil.
• Push the valve core again to make the bladder in the reser-
voir at the normal condition .

• Move the rod and pour the oil as shown .

NOTE: Be sure to extend the rod after filling the oil.

• Tilt the rear cushion unit as shown and pour the fresh
rear suspension oil into the reservoir tank.
Oillype : SUZUKI REAR SUSPENSION OIL SS-25 or eQuiva -
lent rear suspension oil.
Oil capacity: 340 ml (11.5/12 .0 US/Imp oz)

• Reassembly the compression adjuster ass ' y. 10 mm

Tightening torque: 18 N 'm '1 .8 kg-m. 14.5 Ib -ft)

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 REAR SUSPENSION 16·)

• Vise th e rear cushion unit as shown and loosen the air

bleed bolt.
• Temporarily charge the reservoi r with 50 kPa (0.5 kg/cm2,
7 psi) of air slowly to inf late the bladder inside.
• Bleed out air in the oil.
• Tightening the air bleed bolt .
Tightening torque : 8 N 'm (0 .8 kg·m. 6 .0 Ib·ft)

• Pressure the rear cushion unit wi th nitrogen gas to

1000 - 1200 kPa (10 - 12 kg/em' . 142 - 171 psil.

" WARNING
Use of inflammable gas for pressuring the rear cushion
unit can be hazardous. Inflammable gas such 8S gas weld-
ing oxygen can create a fire hazard.

Use nitrogen gas . If is nitrogen gas is not available, com-

pressed air free from water can be substituted.

" WARNING
Applying too much pressure to the rear cushion unit may
rupture the rear cushion unit .

Be sure to pressure the rear cushion unit to the specified .

A CAUTION
Riding the motorcycle with the abnormal gas pressure can
damage the rear cushion unit. low gas pressure can result
in oil leakage. Abnormal gas pressure cannot obtain nor-
mal rear cushion unit perfomance .

Be sure to pressure the rear cushion unit to the specified

pressure .

• Tighten the gas valve cap .

• Reinstall the sp ring and mount the shock abso rber .

SWING ARM
Swing Arm Removal
• Remove the rear w heel. ( 0" 13-2)
• Remove the brake pedal. ( CT 14- 11)
• Remove the rear brake hose from the gu ides.
• Remove the rear caliper. ( 0" 14-6)
• Remove the drive chain .

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 16·8 REAR SUSPENSION

• Remove the chain guide.

• Remove the rear cushion rod bolt.

• Remove the swing arm pivot bolt.
• Remove the swing arm.

• Remove the covers and bushings .

C=='IIOO

Swing Arm Inspection

• Measure the pivot shaft runout with a dial gauge and V-
blocks .
Service limit: 0.3 mm (O.01 in)

• Inspect the swing arm for cracks and damage.

• Inspect the bearings, bushings and oil sea ls for damage.
• Insert the bushings into the bearings and inspect them
for play and smooth movement.

Bearing Replacement
• Remove the bearings and oil seals with the special tools .
09923-74510 Bearing pul/er
09930-30102 Rotor remover slide shaft ,-

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 REAR SUSPENSION 16·9

• Apply grease to the bearings.

• Fit the bearings with the special tool and a pipe, 24 mm
(0.9 in) in diameter and 7 . 5 mm (0.3 in) in length.
09941 ·34513 Bearing installer set

• Fit the oil seals with the special tool and the spacer.

Swing Arm Reassembly

• Reassemble the bushings and covers .
• Fit the swing arm to the frame .
• Tighten the swing arm pivot shaft nut to the specified
torque.
Tightening torque: 70 N'm (7 .0 kg-m, 51 .0 Ib-ftJ

• Tighten the rear cushion rod nut to the specified torque.

Tightening torq\.Je: 100 N' m (10.0 kg-m . 72.5 Ib·ft)

• Reassemble the chain guide.

• Reassemble the rear caliper. ( r::r 14-7)
• Fit the rear brake hose guides.
• Reassemble the brake pedal. ( 0" 14- 11)
• Reassemble the rear wheel. ( r:7" 13-2)

REAR SUSPENSION LINKAGE

Rear Suspension linkage Removal
• Remove the swing arm. ( a 16-6)
• Remove the swing arm linkage bolts.

Rear Suspension linkage Inspection

• Inspect the cushion lever rod and cushion.
• Inspect the spacers for damage.
• Inspect the bearings for damage.
• Insert the spacers into the bearings and inspect them for
smooth movement.

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 16-10 REAR SUSPENS10N

Cu shion Lever Bearing Replacement

• Rem ove t he circlips.
• Rem ove the bearings w ith th e special tools.
09923-74510 Bearing puller SPECIAL TOOL
09930-30102 Rater remove siids shaft .

• Apply grease to the bearings.

• Fit the bea rings with t he special tool.
09941 -34513 Bearing inst aller set

• Fit the circlips.

,
NOTE: See page 16-3 for cushion unit lawer bearing ®
replacement.

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 REAR SUSPENSION 16·11

Rea r Suspension Linkage Reassembling

• Reasse mble the rear suspension li nkage.
• Tighten the nuts to the speci fied to rque.
Tightening torque:
A : 60 N 'm 16.0 kg ·m, 43.5 Ib-It)
B : 60 N 'm 16.0 kg ·m . 43 .5 Ib-ftJ
c : 100 N 'm 110.0 kg·m , 72.5 Ib-It)
0 : 80 N' m IB .O kg ·m , 58.0 Ib-It)
E : 100 N 'm 110 .0 kg ·m , 72.5 Ib-It)
F : 70 N' m 17 .0 kg ·m , 51 .0 Ib-It)

• Reassemble the swing arm. ( c:r 16 -8)

'"",
11' .....

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 - MEMO -

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 SERVICE DATA 17·1

SERVICE DATA

CYLINDER + PISTON + PISTON RING Unit: mm (in)

ITEM STANDARD LIMIT
Piston t o cylinder clearance 0.045 - 0 .055 0 . 120
(0.0017 - 0 .0022) (0.0047)
Cylinder bore 67 .000 67.015
(2.6381 - 2 .6384) ~-

Measure 20 (0.8) from the top surface

Piston diam . 66 .950-66.965 66.950
(2.6381-2.6384) (2.6381)
Measure 24 (0.91 from the skirt end
Cylinder distortion ~-
0.05
(0.002)
Cylinder head distort ion ~-
0.05
(0.002)
Piston ring free 1st & A 6.4 5. 1
R
end oap 2nd I pprox . (0.25) (0.20)
Piston ring 1st & 0 . 20 0.40 0.85
end oap 2nd (0.008-0.016) (0.033 )
Piston ring to 1st & 0 .020 0 .060 ~-

groove clearance 2nd (0 .0008 - 0 .0024)

Piston pin bore 18 .000 18.006 18.030
(0 .7087 - 0 .7089) (0 .7 098)
Piston pin 0 .0 . 17.995 - 18.000 17.980
(0.7085 - 0 .7087) (0.6724)

CONROD + CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrad small end 1. 0. 23.003 - 23 .0 11 23.040
(0 .9056 - 0 .9059) (0.907 1)
Crank web to web w idth 58 .0±0.1 ~-

(2.283+ 0 .004)
Crankshaft run out ~-
0.05
(0.002)

CLUTCH Unit: mm (in )

ITEM STANDARD LIMIT
Clutch c able play 2-3 ~-

(0.08-0. I 2)
Drive plate thickness 2.45 2 .7 5 2. 15
(0.096 - 0 .108) (0 .085)
Drive plate claw width 15.9- 16.0 15.3
(0.626 - 0 .630) (0. 602)
Driven plate distortion ~-
0 . 10
(0.004)
Clutch spring f ree length ~-
45.4
(1.79)

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 17-2 SERVICE DATA

RADIATOR
ITEM STANDARD LIMIT
Radiator cap valve release
pressure 11 0 kPa( 1. 1 kg /cm2. 16 psi)

TRANSMISSION Unit: mm (in) Except ratio

ITEM STANDARD LIMIT
Primary reduction ratio 2.652161 / 231
Final reduction ratl o 3.769 149/131
Gear ratios Low 2 .153 128/ 131
2nd 1.705 (29 / 171
3rd 1.411124/ 171
4th 1.157 122/ 191
Top 1.000 (23 /23)
Shift fork to graove clearance 0.10 - 0.30 0.50
10.004 - 0.012) (0 .020)
Shift fork groove w idth 4.80 - 4 .90
10.189 - 0 . 193)
Shift fork thicknes 5 4 .60- 4 .70
(0.181 - 0.185)

DRIVE CHAIN
ITEM STANDARD LIMIT
Drive chain Type DAIDO: 0.1.0 520DS5
Links 112
323.8
20-pitch length (12.75)
Drive chai n slack 45 - 55
11.8 - 2.2)

CARBURETOR
ITEM SPECIFICATION
Carburetor type KEIHIN PJ38
Bore size 38 mm
1.0. No. 28El0
Float height 16.0 mm 10.63 in)
Main jet IM.J.) # 180
Jet needle (J.N.) R 1470NS-3rd
Cut-away (C.A.) # 5
Slow jet (S.J.) #52
By-pass (8.P.) 0.8 mm (0.031 in)
Pilot outlet (P.O.) 0.7 mm (0.028 in)
Air screw (A.S.) ' -1J2 turns out
Throttle cable play 0.5 - 1.0 mm 10.02 - 0.04 in)

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 SERVICE DATA 1)·3

ELECTRICAL Unit ' mm (in)

ITEM SPECIFICATION NOTE
Ignition timi ng 7 ' + 2 ° B.T.D.C. at 9 000 r/min.
Spark plug Type NGK: R4118S-8
0.55 - 0.65
Gap
(0.022-0.026)
Spa rk performance Over 8 (0.3) at 1 atm.
Ignition coil resistance Primary 0 - 1 Il Terminal -G round
Secondary 10 - 17kn Plug cap-G round
Magneto coil resistance 50 - 200 n R- G
20 30 n RfW B/R
BRAKE + WHEEL Unit ' mm (in)
ITEM STANDARD LIMIT
Brake lever play 0.1 - 0.3
--
(0.004 - 0.0 1)
Rear brake pedal height 10 - -
10.4)
Brake disc thickness 3.0±0.2 2.5
Front
(0 . 11 8 ± 0.008) (0.10)
4.5±0.2 4 .0
Rear (0. 177 + 0.008) (0. 15)
Brake disc runDut 0.30
Front&Rear --
(0.0 1)
Master cylinder bore 11.000- 11.043
Front - -
(0.4331 -0.43 48 )
14.000 - 14.043
Rear (0 . 55 12 - 0.5529)
--

Master cylinder piston diam . 10.957 - 10.984

Front --
(0.43 14 - 0 .4324)
13.957- 13.984 --
Rear
(0.5495 - 0.5506)
Brake caliper cylinder bore 27.000 - 27.050 - -
Front (1.0630 - 1.0650)
30.000 - 30 .050 --
Rear 11.1811 - 1. 1831 in)
Brake caliper piston diam. 26.900- 26.950 --
Front (1 .0591 - 1.0610)
29.900 - 29.950 --
Rear (1.1772 - 1.1791 in)
Wheel rim runcut -- 2.0
Axial (0.08)
-- 2.0
Radi al (0.08)
Wheel axle runcut -- 0.25
Front (0.0 10)
0 .25
Rear --
(0.0 10)
Tire size Front 80/ 100 - 21 51M --
Rear 110/ 90 - 1962M --

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 17-4 SERVICE DATA

SUSPENSION Unit: mm (in)

ITEM STANDARD LIMIT NOTE
Front fork stroke 310 --
112.2)
Front fork spring fr ee length 486.0± 2.5 478.5
119.1 ±0.098) 118.8)
Front fork oil level 170 - - See page 4·9 and
16.7) 4-10
Front fork air pressure Atmospheric pressure --
Rear shock absorber gas 1000 1200 kPa
1000 kPa 10 - 12 kg/cm2
pressure 110 kg/em'. 142 psi) 142 - 170 psi
Rear shock absorber spring 255.0 --
pre·set length 110.0)
Rear wheel travel 324 --
112.8)
Swingarm pivot shaft runout 0 .3
-- 10.01)
TIRE PRESSURE

Front 70 - 110kPa
& 0 .7- 1. 1 kg /cm 1
Rear 10- 16 psi

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 SERVICE DATA 11·5

FUEL + OIL + COOLANT

ITEM SPECIFICATION NOTE
Fuel type Unleaded gasoline minumum 90 pump
octane (R + Ml / 2
Fuel tank capacity 7.5 L
(2.0 US gal)
Engine oil type SUZUKI CCI SUPER 2· CYC LE MOTOR
LUBRICANT or equivalent Two Cycle Racing
Lubricant
Transmission oil type SAE 10W/40
Transmission oil capacity 750 ml
Change (0.7 US qt)
850 ml
Overhaul 10.8 US qt)
Front fork oil type SUZUKI fork oil 55-05 or an equivalent fork oil
Front fork oil capacity Outside
(each leg ) Fork 440 ml See page 4- 1 0
Cylinder 114.9/ 15.5 US/Imp oz)
Inside See page 15·6
Fork 145 ml
14.9/5. 1 US/Imp) Filled in the fork
Cylinder cylinder.
Coolant type SUZUKI GOLDEN CRUISER 1200NA.
Use an anti-freeze&summer coolant compat-
ible with aluminum radiator, mixed w ith dis-
tilled water only, at the ratio of 50 : 50.
Coolant capacity 900 ml
11.9 US pt)
Rear shock absorber oil 340 ml
capacity 111.5 US oz)
Brake fluid type DOT4

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 18·1 SPECIAL TOOLS

SPECIAL TOOLS

09900-0040 , 09900-06'07 09900-06'08 09900-09003 09900-20'0'

Hexagon wrench Snap ring pliers Snap ring pliers Impact dirver set Vernier calipers
set 1150 mm)

09900-20203 09900-20205 09900-20508 09900-20602 09900-20605

Micrometer Micrometer Cylinder gauge Dial gauge Dial gauge
150 - 75 mm) (0 - 25 mm) set

09900-20803 09900-25002 09930- 70210 099' 3-50' 2 ' 099'4-796'0

Thickness gauge Pocket tester COl unit test Oil seal remover Bearing/Oil seal
lead installer

09920· '3'20 09920-53740 09930-30'02

Crankcase Clutch steeve hub 09923-732'0 09923-745'0 Rotor remover
separating tool holder Bearing puller Bearing puller slide shaft

09940- 14911
09930-30113 09930-4011 3 09940-14960 09940-94920
Flywheel rotor Rotor holder Steering nut Stopper plate
remover socket wrench ,

09940-32720 0994' -345' 3 09941-50110 09941-54911

Front fork oil Bearing installer Wheel bearing Bearing outer 09941-74910
seal installer set remover race remover Bearing installer

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 SPECIAL TOOLS 18·2

09941 -84510 09943-74111 09910·201 16 09921 -20200 09910-60611

Bearing inner Front fork oil level Con rod holder Bearing remover Universal clamp
race remover gauge wrench

09925· 18010 09910-32812 09920-20310 09940· 42810

09940· 54851 St eering bearing Crankshaft Spring hook Fork cylinder
Front fork spaser installer installer holder

•
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 19·1 WIRE, CABLE AND HDSE RDUTING

WIRE , CABLE AND HOSE ROUTING

Throttle cabel

Front brake hose

ThroUle cable

Clutch cable

1
j
Clutch cable clamp

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 WIRE. CABLE AND HOSE ROUTING 19·1

Carburetor air vent hose (R)

CLAMP

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 19·3 WIRE. CABLE AND HDSE RDUTING

Rear shock absorber spring

mm
± 0.12 in)

Guide

Bolt

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 WIRE. CABLE AND HDSE RDUTING 19·4

Radiator

lead wire

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 19·5 WIRE. CABLE AND HOSE ROUTING

1,

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 SPECifiCATIONS 20·1

SPECIFICAnONS
DIMENSIONS AND DRY MASS
Overall length ............. . .. . .•... 2 165 mm (85.2 in)
Overall width . . . . . . . . . . . . . . . . . . . • ... 835 mm (32 .9 in)
Overall height . . . . . . . . . . . . . . . . ..... . 1 250 mm (49 .2 in)
Wheelbase . ...... . . . . . . .. .. . . . .. . . . 1 465 mm (57 .7 in)
Ground clearance . ..... . . . .. . . . .. . .. . 360 mm 114.2 in)
Seat height ...... ...... . .......... . 960 mm (37 .8 in)
Dry mass . . .... . ........ . ... . ..... . 98 kg (2 16Ibs)

ENGINE
Type ...... . . . . . . . . . . . . . . . ....... . Two -stroke water-cooled
Intake system. .. . . . .... . .... . . . .... Crankcase reed valve
Number of cylinder. . . . . . . . . . . . . . . . .. ,
Bore , .. .. ... .. ....... . .. . .... . ... 67.0 mm (2 .638 in)
Stroke . .... . . . . . . . . . . . . . . . . . . . . . . . 70.8 mm (2 . 787 in)
Piston displacement ......... . ........ 249 em] (15 . 2 cu . in)
Corrected compression ratio ............ 8 . 7 : 1 (EX VALVE OPEN) and 10.4: 1
Carburetor . ... .. . . ....... . .... . .... KEIHIN PJ38 , single
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . Polyurethane foam element
Starter system. . . . . . . . . . • . . . . . . . . . . . Primary kick
Lubrication system . ......•.... • ...... Fuel/oil premixture of 32 : 1

TRAN SMISSION
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . .. Wet multi-plate type
Transmission . . . . . . . . . . . . . . . . . . . . . . . 5-speed constant mesh
Gearshift pattern . . . . . . . . . . . . . . . . . . .. l -down. 4 -up
Primary reduction . . . . . . . . . . . . . . . . . . . 2. 652 (61 / 23)
Final reduction . .. . ........ . ......... 3. 769 (49 / 13)
Gear rati os, Low . . ... . .... . . . .. . .... 2 . 153 (28 / 13)
2nd. . . . . . . . . . . • . • . • . . .. 1.705 (29 / 17)
3rd . . . . . . . • . . . . . . . . . . .. 1.41 1 (24117)
4th . . . . . . . • . . . . • . . . . . .. 1. 157 (22119)
Top .... . ............... 1.000 (23 /23)
Drive cha in ........ . .. . .. . . . . . . .... OAIDO: 0 .1.0. 520055 112 links

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 20·2 SPECIFICATIONS

CHASSIS
Front suspension ... . ...... . ....•.... Telescopic , pneumatic/coil spring, oil damped
compression damping force la-way adjustable re -
bound damping force l a-way adjustable.
Rear suspension .... . ..• . .• .• . . • .. . Linkage suspension system. spring pre-load fully ad -
justable, compression damping force 21-way ad-
justable, rebound damping force 21 -way adjustable.
Steering angle ...... . . . ......•...... 45 0 (right & left)
Caster ............. . .. . . .. • . ...... 62 0 45 '
Trail . . . . . .... .. . .. . ....... . . 108 mm (4.3 in)
Turning radius ........ .... ... • ...... 2.3 m 17.5 II)
Front brake ........... . . • ........ Disc brake, hydraulically operated
Rear brake . . . . . . . .... • ........ Di sc brake , hydraulically operated
Front tire size .. . ...... . •........ . 80/ 100-21 51M
Rear tire size . ......... .. .. . .. . . . 110/ 90- 1962M
Front fork stroke ........ .. . . .. . 310 mm (12.2 in)
Rear w heel trave l ................ ... . 324 mm (12.8 in)

ELECTRICAL
Igniti on type ..... . . ... . . .. .... . ... . Electronic Ignition (COl)
Ignition tim ing .. . . . .... . .... . 7 ° B.T.O.C . at 9 000 rpm
Spark plug .............. • ....•..... NGK R4118S · 8 ... The others
NGK BR8EV ... For Canada and France

CAPACITIES
Fuel tank ...... . 7 . 5 L 12.0/1.6 US/Imp gal)
Front fork oil . .. .. . . . . . . . . . . . . . . . . . . 440 ml 114.9/ 15.5 US/ Imp oz) . .... outside Fork
Cylinder
145 ml (4.9/5.1 US/Imp ozl ..... inside Fork Cylinder
Transm issio n oiL oil change . . ... . . . . .. . 750 ml 11.4/1 . 1 US/Imp pI)
overhaul ............ . 850 ml 11.6/1.3 US/Imp pI)
Coolant ... 900 ml 11.9/1.6 US/ Imp pI)

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 INDEX
ITEM PAGE
AIR CLEANER 2·4
AlA CLEANER REASSEMBLY 16·4
BEARING INSPECTION , REMOVAL AND INSTALLATION 9·6
BRAKE DISC INSPECTION 14-4
BRAKE FLUID AIR BLEEDING 14-2
BRAKE FLUID REPLACEMENT 14-3
BRAKE PADS REPLACEMENT 14-3
BRAKE PEDAL REMOVAL AND REASSEMBLY 14- 1 1
BRAKES 2· 10
BREAK· IN 1·4
CALIPER 14·4
CARBURETOR 10· 2
CDI UNIT INSPECTION 12· 3
CLUTCH 2· 7
CLUTCH PLATE INSPECTION 7· 2
CLUTCH PLATE REASSEMBLING 7·3
CLUTCH PLATE REMOVAL 7·2
CON ROD INSPECTION 6· 5
CRANKCASE REASSEMBLY 9·8
CRANKCASE SEPARATION 9·2
CRANKS HAFT INSPECTION 9· 5
CRANKSHAFT INSTALLATION 9· 7
CRANKSHAFT REMOVAL 9· 3
CYLINDER HEAD INSPECTION 6· 3
CYLINDER HEAD REMOV AL 6· 2
CYLINDER HEAD , CYLINDER AND PISTON 2·8
CYLI NDER INSPECTI ON 6·3
CYLINDER REASSEMBLING 6·6
CYLINDER REMOVAL 6· 2
DISC PLATE REPLACEMENT 13·4
DRI V E CHAIN AND SPROCKETS 2·8
DRI V E CHAIN GUIDE, BUFFER , TENS10NER ROLLER 2· 10
ELECTRICAL CIRCU IT 12-2
ENGINE COOLANT 2· 5
ENGINE COOLANT REPLACEMENT 11 -2
ENGINE DISMOUNTING AND MOUNTING 5· 1
ENGINE MOUNTING 5· 2
EXHAUST VALV E 2· B
EXHAUST VALVE IN SPECTION 6· 5
EXHAUST VALVE REASSEMBLING 6·6
EXHAUST VALVE REMO VAL 6· 3
FRONT AND REAR W HEEL INSPECTION 13· 3
FRONT FORK 2- 12
4 ·8
FRONT FORK DISASSEMBLY 15· 2
FRONT FO RK DISMOUNTING , 5-2
FRONT FORK INSPECTION 15-5
FRONT FORK MOUNTING 15·8
FRONT FORK REASSEMBLIN G 15· 5
FRONT WHEEL DISASSEMBLY AND REASSEMBLY 13· 2
FUEL 1·2
FUEL HOSE 2· 7

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 ITEM PAGE
GEARSHIFT LINKAGE INSPECTION 9-3
GEARSHIFT LINKAGE REASSEMBLY 9-9
GEARSHIFT LINKAGE REMOVAL 9-2
IGNITION COil INSPECTION 12·2
INSPECTION BEFORE PRACTICE 2- 1
INSPECTION BEFORE RACE 2-1
KICK STARTER INSPECTION B-2
KICK STARTER REASSEMBLY B-3
KICK STARTER REMOVAL B-2
LOCATION OF PARTS 1-1
LUBRICATION 2-14
MACHINE TUNING , CARBURETOR 4- 1
MACHINE TUNING , FOR NT FORK 4-9
MACH INE TUN ING , REAR SUSPENS ION 4- ' 2
MAGNETO ROTOR AND STATOR REMOVAL AND REASSEMBLY '2· 4
MASTER CYLINDER 14-B
Oil SEAL INSPECTION . REMO VAL AND INSTALLATION 9-5
OPERATING INSTRUCTIONS 1-3
PERIODIC MAINTE NANCE CHART 2-2
PISTON AND PISTON RING INSPECTION 6-4
PISTON RING AND PISTON REASSEMBLING 6-5
PRIMARY DRIVE GEAR 9-2
PRIMARY DRIVEN GEAR ASSY INSPECTION 7-4
PRIMARY DRIVEN GEAR ASSY REASSEMBLY 7-4
PRIMARY DRIVEN GEAR ASSY REMOVAL 7-3
RACK AND PINION INSPECTION 7-3
RADIATOR 11 -2
RADIATOR CAP INSPECTION 11 -2
REAR SHOCK ABSORBER OIL REPLACEMENT 16-4
REAR SHOCK ABSORBER DISPOSAL 16-3
REAR SHOCK ABSORBER INSPECTION 16-3
REAR SHOCK ABSORBER REASSEMBLY 16-4
REAR SHOCK ABSORBER AND AIR CLEANER REMOVAL 16-2
REAR SUSPENSION 2-12
REAR SUSPENSION LINKAGE 16-9
REAR SUSPENSION LINKAGE REASSEMBLING 16- 10
REAR WHEEL REMOVAL AND REASSEMBLY 13-2
REED VALVE 10-3
SERVICE DATA 17-1
SPARK PLUG 2-3
SPECIAL TOOLS AND MATERIAL 18· 1
STATOR COIL INSPECTION 12·4
STEERING 2· 13
STEERING BEARING REPLACEMENT 15· 9
STEERING REASSEMBLY 15· 10
STEERING REMOVAL 15·9
SWINGARM 16-7
THROTILE CABLE 2-7
TIGHTENING TORQUE 2· 15
TRANSMISSION 1-4
TRANSMISSION INSPECTION 9 -4
TRANSMISSION OI L 2-5

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 ITEM PAGE
TRANSMISSION REASSEMBLY 9-7
TRANSMISSION REMOVAL 9-3
TROUBLESHOOTING , ENGINE 3- 1
TROUBLESHOOTING , CHASSIS 3-4
WATER PUMP 11-3
WHEEL BEARING REMOVAL AND REASSEMBLY 13-3
W HEELS AND TIRES 2- 13
WIRE, CABLE AND HOSE ROUTING 19- 1

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