ari MANUAL TOO EiOOrForeword We sincerely thank you for choosing this fine Suzuki motorcycle from among the many modeis available. Suzuki motoreyeles, with high performance and modern lines resulting from top design and exhausting tests, are world champions. You are assured of satisfactory performance in a Suzuki motorcycle which is manufactured with high engineering techniques such as won the Isle of Man T.T. and many Grand Prix races, is based on the company’s rich experience gained since 1938 when it began making motorcycles and automobiles, and is produced by modern factory equipment. Even an excellent motorcycle, however, cannot maintain peak performance unles it is serviced properly. Read this rider's handbook and follow its instructions carefully. Treat your Suzuki motorcycle properly and ride it correctly. Enjoy the comfort and exhilaration of riding a Suzuki world champion motorcycle. We thank you for your confidence in this Suzuki motorcycle and wish you “happy riding”. $ SUZUKI MOTOR co.LTO.SIDE VIEWS OF SUZUKI 120 MODEL B100 & B100P SUZUKI 120 MODEL B100PCONTENTS Location of Parts Specifications Tips on Operation Operation of Important Parts ‘Tips on Riding Inspection and Maintenance Trouble Shooting Optional Parts + Wiring DiagramLOCATION OF PARTS SUZUKI 120 MODEL B100 Front Fender Head Lamp Front Turn Speedometer Clutch Lever Choke Lever Fuel Tank Cap Puel Tank Fuel Cock Ignition Switeh ignal Lamp Frame Left Cover Tail Brake Lamp Chain Case Side Stand Center Stand Gear Shifting Lever Speedometer Cable Front Brake Cable Rear Fender Rear Shock Absorber Dual Seat i) Kick Starter Lever Frame Right Cover © Swinging Arm Knee Grip ) Rear Footrest Throwle Grip } Muffler Front Brake Lever Front Fork Exkaust Pipe Power Unit Brake Pedal Front FootrestSUZUKI 120 MODEL B100P The model B100P has the “Suzuki Posi-Force Lubrication” whi for 2cycle engines. Except the lubrication devices the specifications of the model BIW0P are common to those of the model B100. is the most advanced lubrication system Oi Tank » Oil Level Inspection Fye ) Oil Control Cable Of Pump2. SPECIFICATIONS Dimensions, Weight Overall length 1.905 mm (74.9 in Overall width a 685 mm (252 Overall height 985 mm (3729 in Wheelbase 1.20 mov (480 in Road clearance esses 150 mm (9 in) Tires front cweapsientsanoantess s+ 2AM? in, 4 PR rear 22517 in, 4 PR Dry weight (Model B100) 83 kg (183 Ib) (Mode! B100P) 88 ike (189 th Performance Maximum speed 10 kph (68 mph Fuel consumption 65 Kpl (154 mpg US, 184 mpg Imp), at 40 kph « mph Climbing ability ; 18 Braking distance soe Tm (28 ft) at 35 kph (22 mph Engine ‘Dype s+ 2eyele, air cooled gasoline engine U8 ce (7.2 eu in 36 mm (205 x 220 in) Piston displacement Bore » strokeCylinder Corrected compression ratio ‘Maximum horsepower Maximum torque « Starter Fuel System Carburetor Air cleaner Fuel tank capacity Lubrication System Engine (Model B100) (Mode! B100?) Gearon Oil tank capacity (Model B100P only) Ignition System Tanase atenetiaing Spark plug Transmission System Ctateh Gearbox Sleeved Aluminum single, inclined forward 72:1 + 10 hp at 7,000 rpm + LI kgm (7.95 Ib-ft) at 5,000 rpm kiek lever Amal VM 20 SH resin-processed filter itr (2.11 US gal; 1.76 Imp gal) including 1 Ite 21 US pt, 18 Imp pt) reserve fuel mixture Suzuki Posi-Force Lubrication cil bath L3 hr 2 3 US pt, 2.31 Imp pt) flywheel magneto 24° before top dead center NCK BT wet multi-dise type ‘speed, constant-meshGear shifting «+--+ Primary reduction ratio Final reduction ratio Overall reduction ratios Suspension Front suspension Rear suspension Ste Steering angle Caster ring Front brake--: Rear brake Electrical Equipment Generator Battery Fuse Headlamp + hydrat left foot, return change type 50-tooth gear/16-tooth pinion ~3.125 29-tooth rear sprocket /13:tooth engine sprocket = 22a 7.87 (in top gear) hydraulically damped telescopic fork ically damped swinging arm 45° (right & left ae 70 mea (276 in) 41,900 mm (74.8 in) right hand, internal expanding. right foot, internal expanding flywheel magneto eV 4AH + 1A eV 15/15WTail,rake lamp ‘Neutral indicator lamp Speedometer lamp Turn signal lamps 6y 3cP/21cP ev aw ev aw evew x 43. TIPS ON OPERATION Follow these tips to keep the motorcycle in peak condition and it will give top performance at all times. © Meximam spaed in broakng-in pariod ‘The life of the motorcycle depends on the breaking.in of the engine and the way the motorcycle is treated. Just as with a newborn baby, it must be given the best care possible. During the breaking-in period, do not ride the motorcycle at high speeds nor allow the engine to run Wide open, Keep to the specified breaking.in speed limit. Gradually raise the top speed after the engine is broken in. for the first 1,600 km (1,000 mi. © lubrication of engine below 55 kph (35 mph) ‘Suauki 129 Mode! B100 ‘The model B100 requires a mixture of gasoline and oil as fuel. Never put gasoline only in the fuel tank. The fuel must be mixed in the proper ratio Suauki distributes a handy oil bottle with the model B100 to simplify ‘ve mixed with gasoline, Always use the oil bottle when maicing « gas oil mixture. ‘The correct gas/0il mixture ratios for model B100 engine are: y measuring oil to for the first 1,600 km (1,000 mi) gasoline 15: oil 1 for 1,600 km (1,000 mi) gasoline 20: oil 1 ‘The gasoline and oil must be mixed well. Be sure to stir the fuel mixture until it is well blended. When mixing the gasoline and oil inside the fuel tank, first close the fuel cock, put gasoline in the motorcycle fully to make the gasoline and oil mixed well. These engine oils are recommended. 10SHELL 21 TWO STROKE O1L SUPER SHELL MOTOR OIL MOBIL SUPER MOTOR OLL SHELL OUTBOARD ENGINE OIL MOBIL MIX TT MOBIL OUTBOARD OLL ESSO 27 MOTOR OIL ESSO OUTBOARD OLL CALTEX 21 PLUS MOTOR OTL STANDARD OUTBOARD OIL UNION 76 OUTBOARD OIL, TEXACO OUTBOARD O1L If low grade oil or less oil than specified is used in an ill-advised attempt to save on fuel expenses, the engine will overheat and wear of engine parts will be hastened, requiring expensive repairs, so that actually it is more costly in the long run. Oy of gas 50 18 00 28 80 275 00 25 80 aSuzuki 120 Mode! B10OP ‘The model B1OP engine requires no gas/oil mixture as fuel unlike the model B100 engine. The engine's moving parts such as crankshaft, crankshaft bearings; con-rod, piston and cylinder wall are positively lubri- cated by fresh oil which is separately pressure-delivered from the variable displacement oil pump. This unique forced oiling system is called “Suzuki Posi-Force Lubrication". Put gasoline only in the fuel tank and lubrication oil in the oil tank. As for lubrication oil, be sure to use one of these prescribed oils * If the temperature is below 10°C (50°F) SHELL 21 TWO STROKE OIL SHELL SUPER MOTOR OIL MOBIL SUPER MOTOR OIL * If the temperature is above 10°C (50°F. SHELL 27 TWO STROKE OIL SHELL OUTBOARD ENGINE OL, SHELL SUPER MOTOR O1L MOBIL MIX TT MOBIL OUTBOARD OIL MOBIL SUPER MOTOR OIL ESSO 2T MOTOR OIL ESSO OUTBOARD OIL CALTEX 27 PLUS MOTOR OIL STANDARD OUTBOARD OIL UNION 76 OUTBOARD OIL TEXACO OUTBOARD OIL ‘Make it @ rule to check the oil level in the oil tank and see if oil is properly fed to the engine, without interruption before riding the motorcycle, lest the engine is damaged. © Gensine ports Do not alcer any original part or fit any part other than a genuine Suzuki Part on the miotoreyle, for this will shorten the life of the motorcycle as well as lowering performance. All original parts are accu. rately designed following repeated research and tests, When replacing parts, always use genuine Suzuki Parts, whieh are precision-made under severe quality control, If imitation parts not genuine parts) are used, good performance cannot be expected from the motorcycle and in the worst ease, they can cause a breakdown, 124, OPERATION OF IMPORTANT PARTS Engine and Frame Numbers The engine and frame numbers of your machine are given on the identification plate on the right hand side of the frame. These numbers are required especially for licensing the machine and or dering spare parts, When writing to the factory or your dealer, never fail to mention them as well as the mileage reading. Fuel Cock Fig. 5. Identitication plote ‘The fuel cock on this motorcycle has three positions, off, on and reserve, Turn the fuel cock lever to the “on” position before starting the engine. If you run low on fuel, turn the lever to the “reserve” position, which opens a tap to the reserve supply. Be sure to replenish the tank with’ fuel ‘at the nearest gasoline station to prevent running out of fuel when the fuel cock lever has been turned to the “reserve” position. Turn the fuel cock lever off when the motorcycle is stopped. 8 ltr (2.11 gal) including 1 ltr (0.26 gal) reserve Fuel tank capacity Fig. 6 Furl cockIgnition Switch The ignition switch turns the engine ignition system and electric equipment on and off. The ignition switch key can be * (off) position, as shown removed from the switch only in the 7. When the key is turned to the “I” (day) and “2" (night) positions, the electrical equipment works as shown in the chart. Fig. 7 lapition switch Neat ‘Speed Key Position Ingit'on Indicator orn Tall Lamp Head Lamp meter: Lamp Lemp 0 Go) 1 (daytime rigieg) 6 ¢ 3 2 _(oighttime citing 9 O 14Carburetor Choke System ‘The carburetor choke system gives easy starts even in cold weather by supplying a rich fuel/air mixture to the engine. The choke system is operated by a lever fitted on the left handlebar. When starting a cold engine, open the choke lever. Be sure to return it to its original position when the engine warms up and motoreycle is run. Do not open the throttle when the choke lever is operated If the throttle grip is opened even a small amount, the carburetor choke system will not wor Engine Starter ‘The engine can be started easily by depressing the kick starter lever installed on the right side of the engine. As a primary kick starter system is used on this motorcycle the engine can be started with the transmission in any gear, if the clutch is disengaged by squeezing the clutch lever. It is good practice to shift the gears into neutral before starting the engine, Fig. 8 Corburator choke lover Fig. 9 Kick starter lover 15Clutch Lever ‘The clutch lever fitted on the left side of the handlebar is for disengaging or engaging the engine with the rear wheel when starting or shifting gears. Squeezing the lever disengages the clut connects the engine with the rear wheel ch and releasing it Fig. 10. Clutch Ie Throttle Grip Engine speed is controlled by the throttle grip on the right end of the handlebar. If the throttle grip is twisted inward toward you, engine speed rises. The racing type throttle grip is very sensitive. Fig. 11 Throttle grip 16Gear Shifting Lever A transmission system is installed as the motorcycle requires more torque than speed when starting and more speed than torque when running. The gear shifting lever operates the transmission system. Depressing front of lever: shifts to higher gear Depressing rear of lever --- shifts to lower gear Fig. 12 Gear shitting lover Neutral Indicator Lamp The green ne on when the gears are in neutral and off when the gears are engaged, al indicator lamp in the speedometer turns Fig. 13. Neviral indicotor Jomp 7Head Lamp Dimmer Switeh The head lamp dimmer switch is located on the left handlebar switch box Pushing knob to left turns on high beam Pushing knob to right ---- turns on low beam Use low beam when running along illuminated roads or meet ing other vehicles Adjusting The head lamp beam can be adjusted up and down by loosen ing the front turn signal lamp stays after removing head lamp assy by loosening two head lamp fitting screws with a cross screw driver. 18 om, titty bee tO Hadiane oN Fig. 1 Headlamp switch Fig. 1S Tue signal lomp staysTurn Signal Lamps The turn signal lamp switch is located on the right switch on the handlebar. @Pushing knob to the right right front and rear cura signal lamps turned on . @ Pushing knob to the left left front and rear tura signal lamps turned on for eight warn signal lamps. Fig: 15° Torn signal lomp switch Oil Tank (Model B100P only) The oil tank located on the right side of the frame holds Iwbri- cant oil for the engine, Be sure to check the cil level in the oil tank before starting the engine, If the oil level is found below the red line marked on the oil level inspection eye, replenish the oil tank with one of the prescribed oils on the page 12, The oil tank eapacity is approx. 1.3 Itr (2.73 US Pt, 34 Imp pt Fig. 17 Oil tonkTool Kit A tool kit which includes all tools needed for daily maintenance is fitted inside the frame left cover. 1 Too! Bag 1417 mm Open End Wrench 1012 mm Open End Wrench 7 9 mm Open End Wrench Pliers 21» 23 mm Box Wrench 7 Md mm Box Wrench 8 10 mm Box Wrench Cross Head Screw Driver i) Combination Screw Driver Screw Driver Handle i Contact Point Wrench Fig. 18 Too! kit 205. TIPS ON RIDING Starting Engine When engine is cold: ‘eTurn the fuel cock lever to the “on” position, @Check to see if there is sufficient oil in the oil tank. (Mode! BIOOP onis) @lasert the key into the ignition switch and turn it clockwise one noteh to the “day” position, and the neutral indicator lamp will turn on if the gears are in neutral. (Tt is good practice to shift the gears into neutral before starting the engine.) ‘Open the carburetor choke lever. Close the throttle completely. @Depress the kick starter lever and the engine will start. eWhen the engine starts. allow it to warm up at idling speed for 1-2 minutes, Do not close the carburetor choke lever until the engine has warmed up. When engine is already warm: Open the throttle 46 to ti and start the engine Operation of the carburetor choke lever is not necessary. Starting Motorcycle @Pull in the clutch lever om the left end of the handlebar to disengage the clutch and depress the gear shifting lever to shift into low gear. eTwist the throttle grip inward toward you and at the same time let out the chuteh lever slowly. 21The motorcycle will start. (If the engine is run at too high speed or the clutch lever is released rapidly, the motorcycle will start with jerky spurts or the engine will stall.) @When the speed of the motorcycle reaches about 20 kph (13 mph), twist the throttle grip outward away from you to reduce the engine speed, at the same time pull in the clutch lever to disengage the clutch, and then depress the gear shifting lever to shift into 2nd gear. @Let out the clutch tever slowly and smoothly and slowly open the throttle again. Follow the same Procedure to shift into 3rd gear at about 30 kph (20 mph) and into top gear at about 40 kpt (27 mph. ‘@After shifting into top gear, the speed of the motorcycle is controlled by the throttle grip. Riding Tips elf the speed of the motorcycle decreases when riding up a hill, shift down into a lower gear. Shift gears rapidly to prevent the motorcycle from losing momentum. When riding down a hill or slope, leave the motoreycle in gear and close the throttle to utilize engine brake. Bear in mind if only engine brake is used when riding down long slopes, an. insufficient amount of lubrication oil is supplied to the engine and the piston can seize. Lightly apply the front and rear brakes and “race” the engine occasionally to supply lubrication oil to the engine, Stopping ‘eTurn the throttle grip outward away from you to close the throttle completely. @Apply the front and rear brakes evenly at the same time. The motorcycle will stop smoothly and safely. Using only the front or rear brake is dangerous and can cause skidding and loss of control, Make it a rule to always apply both brakes at the same time, @Apply the brakes lightly and with great care on wet highway pavement or other slippery surfaces and on 22corners. Abrupt braking on slippery roads or corners is par: ticularly dangerous, @Afier the motorcycle stops, be sure to shift the gears into neutral Turn the ignition key to the “off” position to stop the engine. When parking the motorcycle, take the following steps without fail ‘@Remove the ignition key from the switch. ‘eShut the fuel cock. @Lock the steering. (The ignition switch key can be used for both the ignition switch and the steering lock.) Fig. 19 Steering lock 236. INSPECTION AND MAINTENANCE Daily Inspection Check these things on the motorcycle yourself every day before riding i ‘e Brake pedal travel Brake lever play @Ctuteh lever play Front tire air pressure ‘Rear tire air pressure eFuel @Horn + + 20-30 mm (08 ~ 12 in) 2 mm (0.8 in) between lever and grip when brake applied 4mm (0.16 in) 1.6 keg/sq em (23 Ib/sq in) 1.8 — 28 kg/sq cm (25 - 32 1b/sq in’ check amount in tank Fuel tank capacity; 8 Itr (2.11 US gal, 1.76 Imp gal) including 1 ltr (2.1 US pt, 18 Imp pt) reserve make sure it sounds @Head lamp, tail lamp and brake lamp:++> check to see they turn on properly. Periodical Inspection Odometer Reading Operation First 800 km (500 mi 24 Clean spark plug @ Change transmission oil @ Adjust play of throttle cable @ Adjust engine idling with carburetor throttle valve adjusting screw and pilot air adjusting screw @Checke contact breaker point gap and ignition timing—adjust if necessaryEvery 1.500 km (1,000 mi) Every 6000 km (4,000 mi) ‘Lubricate contact breaker cam oil felt eRetighten cylinder head nuts eCheck battery electrolyte solution—add distilled water if necessary © Clean fuel strainer Adjust clutch @ Adjust and lubricate drive chain @ Adjust play of brakes ‘@Retighten bolts, nuts and spokes @ Adjust fork stem and crown bearings eTest ride Clean spark plug, adjust gap if necessary @Check transmission oil level ‘@ Adjust play of throttle cable @Adjust engine idling with carburetor throttle valve adjusting screw and pilot air adjusting screw ‘eCheck contact breaker point gap and i ‘@Lubricate contact breaker cam oil felt eCheck hattery electrolyte solution ade distilled water if necessary @Clean fuel strainer eClean air cleaner @ Adjust cluich ‘@ Adjust and lubricate drive chain @ Adjust play of brakes ‘@Retighten bolts, muts and spokes ‘eLubricate cables eTest ride jon timing adjust if necessary @Clean spark plug, adjust gap if necessary Change transmission oil Overhaul and clean carburetor 25@Check contact breaker point gap and ignition timing—adjust if necessary @Lubritate contact breaker cam oil felt heck battery electrolyte solution—add distilled water if necessary Clean air cleaner @ Adjust clutch @Remove carbon from exhaust pipe and muffier baffle pipe eWash and lubricate drive chain Adjust play of brakes ‘eRetighten bolts, nuts and spokes ePut grease in throttle grip uubricate cables eTest ride © Adjusting Carburetor The throttle cable, pilot air adjusting screw and throttle valve adjusting screw can get out of adjustment from vibration when the motorcycle is running, so periodical inspection and adjustment are necessary. Inspection interval -- at first 800 km 500 mi), again at 1,500 km (1,009 mi), then every 1,500 km (1,000 mi) When checking the carburetor be sure to retighten the mixing chamber cap to prevent dust and water from finding their way into the carburetor. Adjusting Throttle Cabt A proper play is required in the throttle cable, Adjust the cable before adjusting the carburetor. Adjust the throttle cable play to 5 10 mm (0.02 0.04 in) by turning the throttle cable adjuster on the throttle grip housing. 26Then open the throttle grip to full throttle position and re move the rubber cover on the carburetor mixing chamber cap. Now tug on the throttle cable just above the mixing chamber cap. There should be approximately 05 mm (0.020 in) slack in the cable at full throttle. If this is not the case, adjust as follows @Loosen the locknut on the cable adjuster in the mixing cham: ber cap. Adjust full throttle cable slack with the adjusting collar Thrattte cable S in this manner: ‘Turning adjuster out decreases play Turning adjuster in - increases play Take the air cleaner tube off of the carburetor and check to ‘Fig. 201 Thetite enite odptor see, with your fingers inserted into the air intake of the carbure: tor, if the throttle valve moves up and down smoothly and simultaneously when the throttle grip is turned inward and outward, Hf the movement is not smooth, readjust the play, oF lubricate qm the cable and make sure it is not bent or twisted, After adjustment, tighten the throttle cable adjuster lock nut firmly and reattach the air cleaner tube. 2. Adjusting Pilot Air Adjusting Screw he pilot air adjusting screw regulates the mixing ratio of fuel and ait at low speed Before adjusting the pilot air adjusting screw start the engine and allow it to warm up at idling speed for several minutes. After the engine warms up, screw the pilot air adjusting Fig. 21 Checking throttle valve movement 27Fig. 22. Tursing pilot wie dusting serene Fig. 23° Theale valve adjusting screw serew all the way in and then back it out 1 turns. Adjust the engine idling speed to the lowest rpm possible with the throttle valve adjusting screw. Screw the pilot air adjusting screw in and out within %; turn from the standard setting (11% turns) to find the optimum position where the engine runs most smoothly When the pilot air adjusting screw has been adjusted. obtain the proper engine idling speed with the throttle vatve adjusting screw. But note that turning the pilot air adjusting screw too much from staridard setting affects the engine performance adversely. Turning in too much increases fuel consumption ‘Turning out too much increases fuel consumption and overheats engine 3, Jet Needle Position The jet needle is c jpped in the fouth groove from the top. The jet needle meters the fuel air mixture ratio at medium to high speeds Adjusting of the jet needie is seldom needed, so do not change the 28adjustment unless there is an urgent necessity because incorrect adjustment of the jet needle will adversely affect carburetor performance, Change the position of the jet needle only if the motorcycle is subjected to very hard use such a8 constant climbing of steep hills or running at top speed all the time and the engine overheats. Clip the jet needle in the 5th groove from the top for these severe conditions. rich Jet Ne 1 groove, 2 Needle Clip Throttle Valve Figs 24. Traile vous end it nolo Adjusting Oil Pump Control Cable (Mode! B100P only) ‘The oil pump control cable must be adjusted with the adjuster eo that about 1.0 mm (0.04 in) of clearance is left between the control lever and stop when the throttle valves are fully opened. Fig. 25° Control lever clecronce Fig, 26 Adjusting oil pump contro! cable 29It is to be noted that too much clearance can cause insufficient lubrication, whereas no clearance increases il consumption: To adjust the oil pump control cable, remove the oil pump cover with a cross head screw driver, loosen the control cable adjuster lock nut with a 12 mm wrench and then turn the adjuster in or out until proper clearance is obtained. After adjustment, be sure to secure the adjuster with lock mut Incorrect ignition timing decreases engine performance and shortens the life of the engine. Particularly when the motorcycle is given hard use, overheating, wearing of important parts and damage to other engine components without good enyine performance developing will result if the ignition timing is not correct. Check the ignition timing periodically When adjusting the ignition timing, adjust the contact breaker point gap first and then adjust the ignition timing. If the ignition timing is adjusted first, adjusting the point gap will make the ignition timing incorrect again. @Remove flywheel inspection cover. Turn the flywheel rotor by hand and find the position where the contact breaker point gap is the largest, ‘eCheck the point gap with the feeler gauge (0.35 mm, 0.014 in thick) on the points wrench, The standard gap is 0.35 mm (Q014 in). Ii the gap is too large or too small, adjust it to the siandard as follows: @Loosen screw Adjust the gap to 0.35 mm (0.014 in) by inserting a screw driver in slot “b’ and moving the stationary ‘contact point. 30 Fig. 27° Contact breaker point gap (1)Fig. 28 Contact breaker point gop (2 Fig. 2% lanition timing morks Tighten screw “a” securely after the adjustment is made. After the point wap is adjusted, adjust the ignition timing as follows a Turn the Aywheel rotor by hand to the point at which the Feeler eanse | contact breaker points just begin to open. eCheck to see if pointer “A" on the crankcase left cover aligns with the line “B” on the flywheel rotor. If line “B" is on the 9 right side of the pointer, ignition timing is retarded. ff line 'B" is on the left side of the pointer. ignition timing is advanced. elf ignition timing is slightly retarded, adjust by setting the contact breaker point gap larger than standard but not more Fig. 30. Contact point wrnch than 04 mm (0.016 in). 1F innition timing is slightly advanced, adjust by setting the point gap smaller than standard but not less than 03 mm (0012 in 31@Check again to make sure “A” aligns perfectly with “B”. elf ignition timing cannot be adjusted correctly by changing the point gap within the limits of 0.3 - 04 mm (0.012 - 0.016 in), adjustment inside the magneto is repuired. Take your motorcycle to your Suzuki dealer and have them adjust the ignition timing. © Spark Plug The NGK B-7 spark plug with 14 min (055 in) thread diameter and a 95 mm (037 in) reach ie standard for this motorcycle. Bear in rind that the spark plug must be correct in what is called the “heat range” as well as the size of the threaded part, ‘The wrong heat range spark plus causes overheating, hard starting, ete. When the heat range is correct, the spark plug shows a light brown appearance, sometimes with greyish deposits, Be sure to retighten the spark plug at first the 500 km (300 mi). When carbon accumulates on the spark plug, a hot, strong spark will not be produced. Fig. 31 Mooturing spark plug gop Fig. 32 Clecning spork plug 32Check the spark plug every 1,500 km (1,000 mi). Remove carbon deposits with a wire or pin. Be careful not to damage the porcelain core when removing carbon from inside the spark plug. Gently striking or prying the side electrode, adjust the spark plug aap to 05-0.7 mm(0.020 - 0.028 in). Measure with a feeler gauge Caution: When putting in the spark plug, first clean the seat in the cylinder head. Be careful not to let dirt or dust fall into the cylinder through the spark plug hole. Be sure the spark plug gasket is in good condition, If the spark plug gasket loses flexibility, compression will leak, Use a new gasket. Next screw the spark plug with your fingers, not @ wrench, to prevent stripping the threads, After you set it lightly with your fingers, tighten with a wrench. Cleaning Air Cleaner stance will be increased with a resultant decrease in If the air cleaner is clogged with dust intake re ‘output and increase in fuel consumption. Fig. 33 Al cleaner fitting screw Fig. 24 Cleaning lr cleaner clement 33Check and clean every 3000 km (2,000 mi). ame left cover and take out the battery, @Remove the ‘@Remove the sir cleaner fitting screw. e Loosen the air cleaner tube clamp and take out the air cleaner from inside the frame. ‘eRemove the air cleaner cover by loosening the fitting serews and take out the air cleaner element. ese air pressure or a brush to clean dust and dirt from the air cleaner element. Caution: Washing the air cleaner element with water or gasoline decreases its performatice, so do not wash the air cleater element. If the motorcycle is run without the air cleaner in an ill-advised attempt to get more power from the engine, wear of engine parts will be hastened, so that this must be strictly avoided Cleaning Fuel Strainer eTurn the fuel cock lever off Fig. 95. Removing fuel cock strainer 34 e 3 ; i Fig. 35 Foal strainerLoosen the strainer cup with a 9 mm wrench and remove by turning with your fingers, eWash the strainer cup and screen thoroughly with gasoline. Cleaning Oil Tank Outlet Cup (Medel B100P A piece of magnet is provided in the oil tank outlet cup to attract fron dust and prevent it from getting into the oil pamp. Remaye and clean the oil tank outlet cup every 3,000 km (2,000 mi) To clean the oil tank outlet cup, use compressed. air or tweezers. Fig. 37 Oil tank outlet cup Changing Transmission Oil Oil in the transmission deteriorates and its lubricating performance decreases if it weed too long. ‘Change oil after the first 800 km (500 mi) and every 3,000 km (2,000 mi) after the first oil change. @Remove the oil filler hole cap and the ofl drain plug located on the bottom of the engine and drain all the fe the engine is warm and the oil used oil. To finish the job completely and fast, drain the used oil wi viscosity is low. Replace the oil drain plug. remove the oil level screw and slowly pour oil in through the oil filler hole until it runs out of the oil level screw hole. Use a good brand of SAE 2°" /,o multigrade motor oil. 35The transmission holds 800 cc (17 us pt, 14 Imp pt) of oil. ‘@Repiace the oil level screw and oil filler hole cap. Be sure to refit the gaskets when replacing the oil drain plug and oil level screw Fig. 38 Oil drain plug Fig. 39 Oil filler hole cop Fig, 40\t) Oil laval screm (8100) Fig. 40(2) Oil lovel seraw (1007) 36Caution: ‘Too much oil in transmission increases mechanical loss and clutch becomes hard to disengage Too Little oft in transmission lubrieation becomes incomplete and wear is hastened > Adjusting Clutch The clutch inner wire stretches as the bike’s mileage increases, and the clutch plates also wear more or less, with a consequent increase of the amount of play in the clutch cable It should be adjusted. periodically. Adjust the clutch with both the clutch cable adjuster and release adjusting screw. Note that if you try to adjust the clutch with only one of them, various troubles such as incomplete disengagement, clutch slipping, ete will occur. The play of the clutch shoutd be 4’mm (0.16 in) messured at the clutch lever holder on the left hand grip. If you find the play of the clutch incorrect, adjust it in the following way @Loosen the clutch cable adjuster lock aut and screw the clutch cable adjuster all the way in temporarily. eCheck the play of the cable and loosen the clutch cable adjuster luntil there is no play left ia the cable. Fix the clutch adjuster with the clutch cable adjuster lock nut, @ After the cable has been adjusted, remove the clutch cover. by loosening three cross screws with cross screw driver and adjust the play of the clutch to 4mm (0.16 in) with the relew se adjusting screw. If the release adjusting screw is turned clockwise, the play will decrease (no clutch cable slack). Fig, 41 Clteh lever ployIf the releas adjusting screw is turned counterclockwise, the play will increase (too much cable slack’ ‘eFinally, fix the release adjusting screw with the lock nut. Caution: When the clutch play is too large, the clutch f s pulled in. If the So it must be adjusted to a proper amount (4 mm’ S to be completely disengaged even if the cluteh lever "e is no play, the clutch slips, Fig. 42. Adjusting cluteh cable Fig. 43. Release adjusting serew Removing Carbon from Muffler Baffle Pipe Carbon produced when fuel is burned in the engine accumulates in the baifle pipe of the muifler. This carbon deposit increases re jance to the passage of exhaust gas and causes a loss in engine power and overheating of the engine ‘When a poor quality oi! sed, particularly, carbon accumulates rapii So remove carbon deposits periodically.This job is comparatively easy and cam be done by yourself. Clean carbon deposits from the muffler bafile pipe every 6.000 km (4.00 mi ‘© Pulling an old drive chain back and forth through the exhaust pipe is effective in removing carbon from the curve portion. @Remove the fitting screw and washer at the end of the muffler and pull out the bafle pipe with a pair of pliers. @Remove carbon deposits by gently striking the baifle pipe. @Wash the bafiie pipe with gasoline or cleaning solvent. If the carbon deposit is hard and cannot be removed from the baille pipe by stri with a burner or a welding torch until flames cease to be seen on the baffle pipe and then strike it gently. The carbon can be removed in this manner. ing it gently, heat it Caution: Some riders remove the mufiicer baile pine so that their motorcycle will make more exhaust noise, With a two-cycle engine, however, the muffler baffle pipe not only silences engine exhaust noise but also prevents the blow-by of fuel mixture. Running without the muffler baffle pipe installed reduces engine output, Do not remove the baffle pipe Fig. 44 Extracting bottle pipe 39Battery ‘The battery for this model is 6 V4 AH. The battery is mounted inside the frame. A loose battery wire connection results in insufficient battery charging. When inspecting the battery, always check the battery wire connections to see if they are fastened firmly. Battery electrolyte solution decr from evaporation. The solution must be kept above the lower limit Tine at all times. If the sol ss gradually jon level is found below the lower limit line, add pure distilled water up to the upper limit line. Do not add diluted sulphuric acid. Check the battery every two weeks. Fig. 45 Batery solution Invel ig. 46 Hale For battery axhoust pipe Caution: Be careful not to bend the battery exhaust pipe made of nylon sharply. If it is pinched shut between the frame and the battery or bent sharply, gas generated in the battery during operation cannot be exhausted and sometimes the battery case will crack, Be sure to pass the battery exhaust pipe through the hole made on the hottom frame member. See Fig. 45: 40Servi ing Drive Chain If the drive chain is too tight it results in an increased mechanical loss of power. Acdrive chain which is too tight or loose wears fast. Put the motorcycle on the center stand, @Remove the chain inspection hole cap. @Loosen the rear axle nut shown in Fig. 47 ‘@ Adjust the drive chain by turning the right and left chain adjuster nuts until it has 20.30 mm (08 1.2 in} of play at the inspection hole. ‘Turning adjuster nut in tightens chain ‘Turning adjuster nut out loosens chain Marks on both chain adjusters must indicate the same position to keep the wheel aligned correctly. After the drive chain adjustment is correct, tighten the rear axle nut and fix with a cotter pin. Otherwise it could become loose while you are riding the motorcycle and cause a dangerous situation. Adjust and lubricate the chain at the first 500 km (900 mi) and every 1,500 km (1,000 mi) afterward. Use chain lube oil or motor oil for lubricating the drive chain. Fig. 47 Choin adjuster Fig, 48 Drive chin ploy Fig. 49 Lubricating drive chain alCaution: Dirt on the drive chain hastens wear of the drive chain itself and also the sprockets. Wash a dirty ve chain in cleaning solvent, drain and dry. sd grease for several minutes or soak overnight in lis Install it on the motorcycle after it is drained and dried Then soak the chain in mi motor oil Adjusting Brakes Brakes are most important for safe riding, Always check the brakes before riding the motorcycle Front Brake Adjust the brake cable with the brake cam adjusting nut so that there is 20-30 mm (08-12 in) of elearance between the front brake lever and the throttle grip when the brake engages. Turning adjusting nut in increases clearance Turning adjusting nut out decreases clearance Fig. $0 Brake laver clearance Fig. 81 Adjusting front broke a2Rear Brake Adjust the travel of the brake pedal with the brake rod adjusting aut to 20-30 mm (08-12 in) Turning adjusting nut in + decreases travel Turning adjusting aut out ” increases travel When carrying @ passenger or heavy load, increases brake pedal travel slight! Fig. 52. Brake padel travel Fig, $2. Adjusting reor broke Adjusting Brake Lamp Switch ‘The brake lamp lets traffic behind you know the rear brake has been applied. so be sure that the switch works properly at all times. Loosen the switch lock nuts and move the switch up and down to adjust it until the switch operates and turns on the brake lamp about 5 mm (0.2 in) before the brake pedal is fully depressed, 43feta alow Acts quiekiy Fig. 55 Broke lamp sviteh adjustment Fig. $4 Broke lomp switch Tire Pressure Insufficient air pressure in the tires hastens tire wear and increases road resistance which, in turn, increases fuel consumption and adversely affects the performance of the motorcycle. Soft tives also make smooth corneting difficult. Over-inflated tires decrease the amount of tire in contact with the ground and cause skids when the brakes are applied, as well as subjecting the tire to stress, which is bad for it. Hard Be sure that tire pressure is correct at all tires also tend to throw the motorcycle into slides on corners, times, Front 1.6 kg/sq em (23 th/sq in) Rear solo riding 18 kg seq em (25 Ib/sq. in dual riding 2.8 kg/sq em (32 Tb sq. in Changing Front Fork Oil ‘The front fork is a telescopic type with oil dampers. When changing oil of the front fork. 44eRemove the drain plug at the end of one leg. Pump the fork up and down to drain all) of the oil. Refit the drain plug when the oil inside has been completely drained out @Repeat the same procedure on the other leg. Loosen the two fork fitting bolts and pour in £30 motor oil, about 160 ce (5.4 US o2, 56 Imp oz) for cach leg. ‘The more oil in the fork the stiffer the suspen suspension becomes, Too little oil, llowever, causes an abnormal noise when running on bad roads. becomes, while the less oil in the fork the softer the Fig. 57 Fork fitting Bolte Adjusting Rear Shock Absorbers ‘The tension of the rear shock absorber springs can be adjusted to each of three stages in accordance ‘with load or road conditions. Position i) is for normal use. Position 2 is for running at high speeds or with heavy loads. Position 3) is for running at low speeds. 45The tension can be adjusted by turning the rear shock absorber adjuster ring with the cross head screw driver provided in the tool kit bag. Insert the driver into the hole on the adjuster ring and turn it as shown in Fig. 59, Fig. 58 Rear shock absorber Fig. $9 Adjusting reer shock obsorber Lubrication Rotating and rubbing parts must be lubricated periodically. Insufficient lubrication will cause rapid wear and severe damage can result Lubricate these parts periodically. 46Whot to torieate When to lubricate tubricant Front brake cam shafts very 8,000 han (2,000 mi) crease Rear brake cam shaft very 3,000 km (2,000 mi) ervase huteh, brake and throttie cables very $000 kim (2,000 mi rotor oil Drive chain every 3,000, kan (2,000 mii) chain tube or motor Twrotwe grip ‘very 6,000 km (4,000 mi arvase Caution: Be careful not to apply too much grease to the brake resulting in brake slippage. cam shafts because grease gets on the linings Fig. 61 Throttle grip a7Tightening Bolts & Nuts Bolts and nuts on the engine and frame can become loose from vibrations during riding. Tighten these bolts and nuts periodically Item Qty i Handleber Fitting Bolts 4 2 Steering Stem Head Fitting Bolts 3 ) Steering Stem Lock Nut 1 4 Engine Mounting Bolt Nuts 3 > Exhaust Pipe Clamp 1 & Cylinder Head Nuts 4 > Muffler Fitting Nuts 2 5) Swinging Arm Pivot Shaft Nut 1 5 Rear Shock Absorber Bolts & Nuts 3 i) Brake Cam Lever Bolt Nuts 2 Spoke Nipples 7 Front Axle Nut 1 i Rear Axle Nut 1 ib Chain Adjuster Tap Nuts 487. TROUBLE SHOOTING Regardless of how excellent the design and manufacture may be, all machinery is subject to wear and occasional breakdowns, The following trouble shooting list will help you find the cause of most troubles If Engine does not Start ‘When the engine is hard to start or does not start, there is something wrong with the fuel system or ignition system, 1. Check to see if the spark plug porcelain part and electrodes are wet or dirty with cxirbon. If so, clean the inside of the spark plug completely. In case the spark plug remains dry and the engine does not start even if the engine is turned with the kick starter lever, check to see if there is fuel in the tank and the fuel cock is not clogged 2 Place the spark plug, with the ignition wire attached, on the cylinder head after removing from the spark plug hole. Turn on the ignition switch and check to see that a strong blue spark jumps between the electrodes by turning the engine with the keicle starter lever. In case no spark is produced, take your motoreycle to your Suauki dealer to remedy the trouble. Caution: Do not place the spark plug near the spark plug hole since the fuel mixture inside the cylinder could be ignited, Fig. 63. Check ignition 49If Engine Fails to Develop Power 1, When the engine fails to develop power and the engine gets dirty excessively, there can be loose points which allow com- pression to leak in the engine. Check the following points ‘A loose spark plug causes the portion (1) to get dirty. Loose cylinder head nuts cause the portions (2) and (2) to get dirty. ‘The cylinder head gasket and/or base gasket must be replaced if Compression still leaks after the above-mentioned parts are properly tightened, Holding your palm at about 15 cm ( in) from the muffler end, check to sce if the fumes are exhausted vigorously. If not, carbon may be collected in the muffler baile pipe Remove carbon from it, If Engine Stops Suddenly 1. Check to seo'if there is fuel in the tank and the fuel cock and fuel tank cap air vent are not clogged. 2. Check too see if the spark plug electrodes are not bridged with carbon. 3. When the engine seems to be overheated, take your motorcycle to your Suzuki dealer and have him check it, 50 Fig. 65 Checking exhaus! presureBad Stabilization and Steering 1. Check to see if the front and rear tire pressures are proper. 2. Check to see if there is play in the front fork fitting. 4. Check to see if the rear axle is fitted squarely in the swinging arm and the rear wheel is perfectly aligned. If not, adjust by using the drive chain adjusters If the Transmission Gears Fail to Shift Smoothly L. Check to see if the clutch is disengaged completely when the clutch lever is squeezed 2. In case the gear shifting is not smooth until the engine is warmed up enough, check the viscosity of the transmission oil. ‘The standard transmission oil is SAE 20W /40 multigrade motor oil. Fig. 66 hacking front fork fing Fig 47 Rear whee! oligamen? marks 518, OPTIONAL PARTS ‘These parts are available at your Suzuki dealer as optional parts. Part Name Remarks BIOL-IS1ITOISOS BIOI-1311T1SLO B100-1320K 1805 B100-1320K 181.0 BI00-1121SL.0 SB25LISI2 ‘SB2592512 SBS2L0KIA ‘M15 3210K1T02 $32-4A20K2TO1 BIOOF S611 BIOOR-9751 BIOOF 5752 BIOOF-5753 KUF 9754 1B100 8441828 B100-6441831 100-8100, MIs 8211701 K10-9110K1 TS) ‘M10 9271TOL ‘MLO-280T01 100-8334 ‘SB9S80KIA 52 Oversize Piston Comp. Oversize Piston Comp. Oversize Piston Ring Set Oversize Piston Ring Set Oversize Cylinder Head Gasket Engine Sprocket Engine Sprocket Washer Spark Plug Assy Spark Plug Assy ‘Tank Cap Assy Handlebar Brake Cable Assy Clutch Cable Assy Throttle Cable Assy Starter Cable Comp. Rear Sprocket Rear Sprocket Leg Shield Assy Wind Shiclé Rear View Mirror Assy Tire Levers Inner Tube Repairing Tool Set Carrier Air Inf_ator 05 mm (0.02 in) oversize piston 1.0 mm (0.04 in) oversize piston for BIOL-I311TOISO5 for BIOI-1311TDIS1.0 for BIOI-1311T01805 and BIOL-1311 T01SLO 12tooth, for power for SB2511812 NGK B 6 NGK B77C key lock type flat for BIOOF S811 for BLOOF 3611 for BIOOF-3611 for BIOOF-S611 2B.tooth, for speed B1-tooth, for power for rain, cold weather for rain, cold weatherOUTSTANDING SUZUKI MOTORCYCLES a SUZUK 50 Model M30 ‘SUZUKI 80 Model K10 5354 SUZUKI 150 Model $32-2 Super Sport SUZUKI 250 Model T20$ suzuxi moToR co,LTp. Head Office: P.O. Box 116, Hamamatsu, japan Tokyo Branch: 5-1, Shiba Shimbashi, Minato-ku, Tokyo, Japan Brussels Representative Office; No. 203 Avenue Louise, Brussels, Belgium U.S, SUZUKI MOTOR CORPORATION : 200 West Central Ave., Santa Ana, California, U.S.A.‘Vern Sinn! @) ey si LJ rt | 8y Suzuki 120 Model 8100 & BIOOP Wiring Diagram Diy eae “fired a ls tel icy ‘Sileon Raster ao] { ey 4any Salone Lan Biel Rose wen Siam J Lay (ov aw TAH Y Brake Le sy dgcry ead Lamy Sintch Issition i} seis ) i Late Hee 3] tm Siena =e » (ov BW_ Home of world-champion motorcycles Suz 2 UKI K SUZUKI MOTOR co., ei Head Office —P.O.Box 1 16, Hamamatsu, Japan