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Suzuki FD 110 XC Service Manual

Summary of FD 110 XC

  • Page 1

    Fd110 fd 110

  • Page 2: Group Index

    Group index general information 1 periodical maintenance 2 engine 3 fuel and lubrication system 4 chassis 5 electrical system 6 servicing information 7 cooling and lubrication system 8 chassis 9 electrical system 10 servicing information 11 emission control information 12 vzr1800k7 (’07-model) 13 vz...

  • Page 3: How To Use This Manual

    How to use this manual to locate what you are looking for : 1. The text of this manual is divided into sections. 2. As the title of these sections are listed on the previous page as group index, select the section where what you are looking for belong. 3. Holding the manual as shown as the right wil...

  • Page 4

    Symbol listed in the table below are the symbols indicating instructions and other information necessary for servic- ing and meaning associated with them respectively. Symbol definition symbol definition torque control required. Data beside it indicates specified torque. Apply thread lock super “130...

  • Page 6: General Information

    General information 1-1 general information contents 1 warning/caution/note........................................................................... 1-2 general precautions ............................................................................ 1-2 suzuki fd 110 xc / xcs / xcd / xcsd............

  • Page 7: Warning/caution/note

    1-2 general information warning/caution/note please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words warning, caution and note have special meanings. Pay special attention to the mes- sages highlighted by these signal words. Indicates...

  • Page 8

    General information 1-3 * if parts replacement is necessary, replace the parts with suzuki genuine parts or their equivalent. * when removing arts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation. * be sure to use spec...

  • Page 9: Suzuki Fd 110

    1-4 general information suzuki fd 110 xb517qd/xb517qsc • difference between illustrations and actual motorcycles depends on the markets. Serial number location the frame serial number or v.I.N. (vehicle identification number) is stamped on the left side of the steering head tube. The engine serial n...

  • Page 10: Break-In Procedures

    General information 1-5 engine oil be sure the engine oil you use comes under api classification of sf or sg and that its viscosity rating is sae 40. If an sae 40 motor oil is not available, select an alternate according to the right chart brake fluid specification and classification: dot 4 front fo...

  • Page 11: Specifications

    1-6 general information specifications dimensions and dry mass overall length.............................................................. 1,932 mm overall width .............................................................. 650 mm overall height .......................................................

  • Page 12

    General information 1-7 chassis frame ......................................................................... Ssrf (suzuki single rectangular frame) front suspension ........................................................ Telescopic, coil spring, oil damped rear suspension ..........................

  • Page 13

    1-8 general information.

  • Page 14: Periodical  Maintenance

    Periodical maintenance 2-1 contents 2 periodical maintenance periodical maintenance schedule ................................................. 2-2 periodic maintenance chart....................................................... 2-2 lubrication points ...................................................

  • Page 15

    2-2 periodic maintenance periodical maintenance schedule the chart below lists the recommended intervals for all the required periodic service work necessary t keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilometers and time for your convenience. ...

  • Page 16

    Periodic maintenance 2-3 lubrication points proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. Note: * before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or g...

  • Page 17

    2-4 periodic maintenance maintenance and tune-up procedures this section describes the servicing procedures for each item of the periodic maintenance requirements. Battery • the battery must be removed to check the electrolyte level and specific gravity. • open the seat. • remove battery - and + lea...

  • Page 18

    Periodic maintenance 2-5 • make sure that the breather pipe is tightly secured and undamaged, and is routed as shown in the photograph. Exhaust pipe bolts • tighten the exhaust pipe clamp bolts and muffler mounting bolts to the specified torque with a torque wrench. Exhaust pipe nut: 1.1 kg-m muffle...

  • Page 19

    2-6 periodic maintenance • loosen the four screw and remove the air cleaner cover. • remove the air cleaner element. • carefully use an air hose to blow the dust form the cleaner element inside. • reinstall the cleaned or new cleaner element in the reverse order of removal. Valve clearance excessive...

  • Page 20

    Periodic maintenance 2-7 • remove spark plug, valve inspection caps 1 and valve timing inspection plug 2. • remove the magneto cover cap and rotate the magneto rotor with box wrench to set the piston at (tdc) of the compression stroke. (rotate the rotor until the “t” line on the rotor is aligned wit...

  • Page 21

    2-8 periodic maintenance spark plug • carbon deposits on the spark plug will prevent good sparking and cause misfiring. Clean the deposits off periodically • if the center electrode is fairly worn down, the plug should be replaced and the plug gap set to the specified gap using a thickness gauge. 09...

  • Page 22

    Periodic maintenance 2-9 engine oil after a long period of use, the engine oil will deteriorate and quicken the wear of sliding and interlocking surfaces. Replace the transmission oil periodically following the procedure below. • start the engine to warm up the oil, this will facilitate draining of ...

  • Page 23

    2-10 periodic maintenance necessary amount of engine oil oil change: 800 ml oil filter change: 900 ml over haul: 1,000 ml fuel hose fuel filter carburetor idle rpm (idling adjustment) • adjust the throttle cable play. • warm up the engine note: make this adjustment when the engine is hot. • connect ...

  • Page 24

    Periodic maintenance 2-11 drive chain visually inspect the drive chain for the below listed possible malconditions. • loose pins • damaged rollers • rusted links • twisted or seized links excessive wear if any defects are found, the drive chain must be replaced. Checking • remove the chain case by l...

  • Page 25

    2-12 periodic maintenance note: when replacing the drive chain, replace the drive chain and sprockets as a set. Cleaning and lubricating wash the drive chain in cleaning solvent and lubricate it with chain lube or motor oil. If the motorcycle operates under dusty conditions, frequent rapid accelerat...

  • Page 26

    Periodic maintenance 2-13 brake front brake (disc type) • keep the motorcycle upright and place the handlebars straight. • check the brake fluid level by observing the lower limit line on the front brake fluid reservoir. • when the level is below the lower limit line, remove the front handlebar’s co...

  • Page 27

    2-14 periodic maintenance air bleeding the brake fluid circuit (disc brake) air trapped in the fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylin- der and thus interferes with the full braking performance of the brake caliper. The presence of...

  • Page 28

    Periodic maintenance 2-15 rear brake adjusting adjust the free travel 1 to 15-25 mm. By turning the adjusting nut 2. Rear brake shoe wear this motorcycle is equipped with brake lining wear limit indica- tor. As shown in fig., at the condition of normal lining wear, the extension line of the index ma...

  • Page 29

    2-16 periodic maintenance tire tire tread condition operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous ours situation. It is highly recommended to replace a tire when the remaining depth of tire tread reaches the following specific...

  • Page 30

    Periodic maintenance 2-17 front fork inspect the front forks oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defective parts, if necessary. (refer to page 5-19) rear suspension inspect the rear shock absorber for oil leakage and damage. Replace any defective pa...

  • Page 31

    2-18 periodic maintenance chassis bolts and nuts the nuts and bolts listed below are important safety related parts. They must be retightened when neces- sary to the specified torque with a torque wrench. (refer to page 2-18 for the locations of the following nuts and bolts on the motorcycle.) tight...

  • Page 32

    Periodic maintenance 2-19 1 5 9 13 14 6 11 8 7 10 12 2 3.

  • Page 33

    2-20 periodic maintenance compression pressure check (fd110xc / xcs / xcd / xcsd) the compression of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic maintenance records kept at your dealersh...

  • Page 34: Oil Pressure Check

    Periodic maintenance 2-21 oil pressure check check periodically the oil pressure in the engine to judge roughly the condition of the moving parts. Oil pressure specification if the oil pressure is lower or higher than the specification, the following causes may be considered. Low oil pressure • clog...

  • Page 35

    2-22 periodic maintenance automatic clutch inspection this motorcycle is equipped with an automatic clutch. The engagement of the clutch is gove med by engine rpm and centrifugal mechanism located in the clutch. To insure proper performance and longer lifetime of the clutch assembly it is essential ...

  • Page 36: Engine

    Engine 3-1 engine contents 3 engine components removable with the engine in place....................................................................................................... 3-2 engine removal and reinstallation.............................................. 3-3 engine removal ...............

  • Page 37

    3-2 engine engine components removable with the engine in place the part listed below can be removed and reinstalled without removing the engine from the frame. Refer to the page listed in each section for removal and reinstallation instructions. Engine center exhaust pipe carburetor cam chain tensi...

  • Page 38: Engine Removal And

    Engine 3-3 engine removal and reinstallation engine removal before taking the engine out of the frame, wash the engine with a steam cleaner. The procedure of engine removal is sequen- tially explained in the following steps. • support the motorcycle with the center stand. • remove the oil drain plug...

  • Page 39

    3-4 engine • remove the engine sprocket by loosen the bolt 1 and sprocket lock plate 2. • remove the sprocket. • disconnect the several lead wires. • magneto lead wire coupler 3. • gearshift indicator lead wire coupler 4. • engine ground coupler • disconnect the engine breather pipe. • disconnect th...

  • Page 40

    Engine 3-5 engine reinstallation reinstall the engine in the reverse of engine removal. • install the engine mounting bolts and tighten the nuts to the specification. Engine mounting nut: 55 n-m (5.5 kg-m) • install the drive chain. • tighten the exhaust pipe clamp bolts and muffler mounting bolts t...

  • Page 41: Engine Disassembly

    3-6 engine engine disassembly the procedure for engine disassembly is sequentially explained in the following steps. • remove the gearshift lever and kick starter lever. • remove the cam pocket cover. • remove the cap and insert the screwdriver into the slotted end of the cam chain tension adjuster ...

  • Page 42

    Engine 3-7 • remove the chain guide and gasket. • loosen the cylinder nut and remove the cylinder. • place a clean rag over the cylinder base to prevent piston pin circlip from dropping into the crankcase and then, remove the piston pin circlip with a long-nose pliers. • remove the piston pin and pi...

  • Page 43

    3-8 engine • loosen the nut by using the special tool. 09910-20115: con-rod stopper • remove the first clutch assembly, circlip and primary drive gear. • remove the clutch bearing. • loosen the nut by using the special tool. 09930-40113: rotor holder • loosen the spring mousing bolt by using the spe...

  • Page 44

    Engine 3-9 • remove the oil washer and oil pump drive gear. • remove the shift cam stopper bolt 1. • remove the shift cam pin bolt 2. • remove the shift cam stopper plate, shift cam pin guide and pins. • remove the outer bearing, clutch bearing, and gearshift shaft and plate shift cam. • remove the ...

  • Page 45

    3-10 engine • loosen the rotor nut by using the special tool. 09930-44550: rotor holder • loosen the rotor by using the special tool. 09930-34951: rotor remover • loosen the screw and remove the starter clutch plate • remove the starter driven gear. • remove the starter driven idle gear by removing ...

  • Page 46

    Engine 3-11 • remove the crankcase screws. • separate the right and left crankcase by using the special tool. 09920-13120: crankcase/crank shaft separator • remove the kick starter shaft by turning it. • remove the gearshift fork shaft, gearshift fork and gearshift cam. • remove the transmission ass...

  • Page 47

    3-12 engine • remove the crankshaft by using a plastic mallet. • remove the oil seals and bearings by using the special tools. 09914-79610: bearing installer 09921-20210: bearing puller 09930-30102: sliding shaft 09913-76010: bearing installer 09925-98221: bearing installer 09913-75520: bearing inst...

  • Page 48

    Engine 3-13 • remove the rocker arm shafts by using an 8 mm thread bolt. Note: intake and exhaust rocker arm shafts differ in the length. • remove the rocker arms • remove the wave washer • remove the spring valve by compress the valve springs with the special tools. 09916-14510: valve spring compre...

  • Page 49

    3-14 engine • remove the stem seal 1 with a long nose pliers. • take out the spring seat 2. For installing the valve spring seat and valve stem seal, refer to pages 3-21 and 22. • remove the valve guide by using the special tool. 09916-44310: valve guide remover for servicing the valve guide, refer ...

  • Page 50: And Service

    Engine 3-15 clutch cover and clutch adjustments • loosen the lock nut and remove clutch release arm. Clutch adjustment • loosen the lock nut 1. • first, turn the adjusting bolt clockwise by a one turn and turn it counterclockwise until resistance is felt, then turn it clockwise by a 1/8 turn. • tigh...

  • Page 51

    3-16 engine • clutch wheel-inspect visually the condition of the inner clutch wheel surface for scoring, cracks, or uneven wear. Clutch housing inspection inspect the inner surface of clutch housing for deep scratches or discoloration caused by burning. If any defects are found, replace the clutch h...

  • Page 52

    Engine 3-17 drive plate distortion gear shift fork using a thickness gauge, check the shifting fork clearance in the groove of its gear. This clearance for each of the two shifting forks plays an important role in the smoothness and positive ness of shifting action. Each fork has its prongs fitted i...

  • Page 53

    3-18 engine crankcase bearing and oil seal bearing inspection rotate the bearing inner race by finger to inspect for abnormal play, noise and smooth rotation while the bearings are in the crankcase. Replace the bearing in the following procedure if there is anything unusual. Left crankcase oil seal ...

  • Page 54

    Engine 3-19 right crankcase bearing disassembly • remove the right crankcase bearing by using the special tool. 09913-75821: bearing installer 09921-20210: bearing puller 09930-30102: sliding shaft right crankcase bearing reassembly • install the right crankcase bearing into the crankcase by using t...

  • Page 55

    3-20 engine measure the diameter of rocker arm shaft with a micrometer standard: 9.981 - 9.990 mm 09900-20205: micrometer (0-25 mm) when checking the valve rocker arm, the inside diameter of the valve rocker arm and wear of the camshaft contacting surface should be checked. Standard: 10.003-10.018 m...

  • Page 56

    Engine 3-21 valve valve face wear measure the thickness “t” and, if the thickness is found to have been reduced to the limit, replace the valve. Note: visually in sport each valve for wear of its seating face, replace any valve with an abnormally worm face. Service limit : 0.05 mm valve stem runout ...

  • Page 57

    3-22 engine valve guide service • remove the valve guide with the valve guide remover. 09916-44310: valve guide remover • re-finish the valve guide holes in cylinder head with a reamer 1 and handle 2. 09916-34580: valve guide remover (10.8 mm) 09916-34542: handle • fit a ring to each valve guide. • ...

  • Page 58

    Engine 3-23 • lubricate valve stem seal with oil, and press-fit the seal into position with a finger tip. Valve seat width • coat the valve seat uniformly with prussian blue. Fit the valve and tap the coated seat with the valve face in a rotating man- ner, in order to obtain a clear impression of th...

  • Page 59

    3-24 engine • insert the solid pilot with a slight rotation. Seat the pilot snugly. Install the 45° cutter, attachment and t-handle. • using the 45° cutter, rescale and clean up the seat with one or row turns. • inspect the seat by the previously described seat width mea- surement procedure. If the ...

  • Page 60

    Engine 3-25 valve stem end condition inspect the valve stem end face for pitting and wear. If pitting or wear of the stem end face are present, the valve stem end may be resurfaced, providing that the length 1 will not be reduced to less than 2 mm. If this length becomes less than 2.4 mm, the valve ...

  • Page 61

    3-26 engine • fit a valve spring retainer, compress the springs with a valve spring compressor and fit the cotter halves to the stem end. 09916-14510: valve spring compressor 09916-14521: attachment 09916-84511: tweezers camshaft cam wear worn-down cams are often the cause of mistimed valve opera- t...

  • Page 62

    Engine 3-27 note: * before reassembling the cam sprocket flange onto the camshaft, apply the internal face of the cam sprocket flange with thread lock super “1303”. * this procedure may be performed only once before camshaft replacement is required. * installation of the cam sprocket flange requires...

  • Page 63

    3-28 engine piston cylinder clearance as a result of the above measurement, if the piston to cylinder clearance exceeds the following limit, overhaul the cylinder and use an oversize piston, or replace both cylinder and piston. Service limit: 0.120 mm piston ring-groove clearance using a thickness g...

  • Page 64

    Engine 3-29 oversize rings • oversize piston ring the following two types of oversize pis- ton ring are used. They bear the following identification num- bers. Piston ring 1 st. And 2nd 0.5 mm: 50 1.0 mm: 100 • oversize oil ring the following two types of oversize oil ring are used. They bear the fo...

  • Page 65

    3-30 engine conrod deflection and conrod big end side clearance wear on the big end of the con rod can be estimated by check- ing the movement of the small end of the rod. This method can also check the extent of wear on the parts of the con rod’s big end. Service limit: 3.0 mm 09900-20701: magnetic...

  • Page 66: Engine Reassembly

    Engine 3-31 engine reassembly the engine is reassembled by carrying out the steps of disassembly in the reversed order, but there are a number of steps which demand special description or precautionary measures. Note: apply engine oil to each running and sliding part before reassembling. Crankshaft ...

  • Page 67

    3-32 engine crankshaft shim selection • degrease the right crankshaft web, shim and inner race of the right crankshaft bearing. • place the removed shim 1 on the right crankshaft. • put the plastic-gauges (special tool) cut out about 10 mm. On the shim, as shown in the photograph at right. 09900-223...

  • Page 68

    Engine 3-33 kick starter • align the punch mark 1 of kick starter shaft with punch mark 2 of kick starter • turn the kick starter shaft counter-clockwise and then lock the kick starter with kick starter guide. *(a) : thread lock super “1322”.

  • Page 69

    3-34 engine transmission • seat the circlip in the groove and its ends a should be located as shown in the photo. • when mounting circlip, pay attention to the direc- tion of the circlip. Fit it to the rounded side against the gear surface circilp shaft gear.

  • Page 70

    Engine 3-35 gearshift fork • no.1 gearshift fork drive and no.2 driven • install the transmission assembly and gearshift forks • install the gearshift cam. • install the gearshift fork shafts. Crankcase • wipe the crankcase mating surfaces (both surfaces) with a cleaning solvent. • fit the dowel pin...

  • Page 71

    3-36 engine shift cam retainer • install the shift cam retainer after applying thread lock super “1322” to the screws. 99000-32110: thread lock super “1322” rotor and stator • install the stator magneto cover. Starter clutch • apply a small quantity of thread lock super “1303” to the starter clutch ...

  • Page 72

    Engine 3-37 • wipe the tapered portion of the crankshaft and also the generator rotor with a cleaning solvent. • install the key to the crankshaft. • install the rotor assembly after resembling the rotor and starter gear. • apply thread lock super “1303” to the thread and tighten the nut by using th...

  • Page 73

    3-38 engine • when installing the gearshift lever, align the stopper bolt with gearshift lever relating part. Note: install the bearing as shown in the photograph. • when install the shift cam pin bolt, apply thread lock super “1322” to thread. 99000-32110: thread lock super “1322” • when install th...

  • Page 74

    Engine 3-39 oil pump • when installing the oil pump, use dowel pin and new o-rings. • apply thread lock “1342” to the oil pump securing screws. 99000-32050: thread lock super “1342” gear shifting clutch • install the gear shifting clutch by using the circlip. • apply engine oil to push piece and dri...

  • Page 75

    3-40 engine first clutch • when installing the clutch shoe in the clutch housing align the boss 1 of one way clutch inner with slit 2 of clutch shoes. • fix the primary drive gear to clutch housing, circlip by using a special tool. 99000-06107: snap ring pliers.

  • Page 76

    Engine 3-41 • installing the first clutch to the crankshaft. • tighten the first clutch shoe nut to specified torque by using the special tool. First clutch shoe nut: 5 n-m (5.0 kg-m) 9915-20115: conrod holder note: clean the oil filter when reassembling it. Clutch adjustment refer to page 3-14. Pis...

  • Page 77

    3-42 engine • 1st and 2nd rings have the letter “rn” marked on the top. Be sure to bring the marked side to the top when fitting them to the piston. • position the gaps of the three rings as shown. Before inserting piston into the cylinder, check that the gaps are so located. The following are remin...

  • Page 78

    Engine 3-43 cylinder before mounting the cylinder block, oil the big end and small end of the conrod and the sliding surface of the piston. • inspect the oil orifice for cragged. • fit dowel pins to crankcase and then fit gasket. • hold each piston ring with the piston ring section properly and inse...

  • Page 79

    3-44 engine • tighten the cylinder head nut to the specified torque. Cylinder head nut: 20 n.M (2.0 kg-m) cylinder head nut: 10 n.M (1.0 kg-m) cylinder base nut: 10 n.M (1.0 kg-m) ignition timing • position “t” mark 1 on the magneto rotor with the center of magneto cover hole 2 keeping the camshaft ...

  • Page 80

    Engine 3-45 cam chain tension adjuster • install a new gasket and the cam chain tension adjuster to the cylinder with the two bolts and tighten them to the specified torque. Chain tension adjuster bolt : 1.2 kg-m note: * before installing the cam chain tension adjuster, lock the tension spring with ...

  • Page 81

    3-46 engine.

  • Page 82: Driveline/axle

    Shaft drive 4-1 contents 4 fuel and lubrication system driveline/axle fuel system ................................................................................................. 4-2 fuel tank, fuel valve, fuel filter and fuel level gauge ....... 4-3 fuel tank and fuel valve removal ..................

  • Page 83: Fuel System

    4-2 fuel and lubrication system fuel system when tuning the starter motor, a negative pressure is generated in the combustion chamber. This negative pressure draws on the fuel tap diaphragm, (through a passage way in the carburetor intake pipe) and vac- uum hose. Due to this, the negative pressure i...

  • Page 84: And Fuel Level Gauge

    Fuel and lubrication system 4-3 fuel tank, fuel valve, fuel filter and fuel level gauge fuel tank and fuel valve removal • remove the leg side shields/frame covers, left and right. (see page 5-1.) • remove the seat by removing its mounting nuts 1. • remove the fuel tank mounting bolts 2. • remove th...

  • Page 85

    4-4 fuel and lubrication system fuel level gauge removal • remove the right leg side shield/right frame cover. (see page 5-1.) • disconnect the fuel level gauge lead wire coupler 1. • remove the fuel level gauge 2 by removing the mounting screws. For inspecting the fuel level gauge, refer to page 6-...

  • Page 86: Carburetor

    Fuel and lubrication system 4-5 carburetor specifications i.D. No. Location the carburetor has i.D. Number a stamped on the carburetor body according to its specifications. Item service limit carburetor type mikuni vm 17 bore size 17 mm i.D. No. 09gf idle r/min 1,500 100 r/min float height 16 1.0 mm...

  • Page 87

    4-6 fuel and lubrication system carburetor 1) jet needle 2) throttle valve 3) needle jet 4) main jet 5) pilot jet 6) float 7) needle valve 8) float pin 9) throttle valve adjuster screw 10) plunger 11) overflow pipe 12) pilot air screw 13) jet needle locker.

  • Page 88

    Fuel and lubrication system 4-7 slow system this system supplies fuel to the engine operation with the piston valve 5 close or slightly opened. The fuel from the float chamber 6 is metered by the pilot jet 8. Where it mixes with air coming in the pilot air jet #1 and pilot air passage 9. This mixtur...

  • Page 89

    4-8 fuel and lubrication system starter system when the starter plunger 1 is lifted, the fuel metered by the starter jet 2 is mixed with the air coming from the float chamber 3. The mixture, rich in fuel content, reaches plunger area and mixes again with air com- ing from the starter air passage 4. ...

  • Page 90

    Fuel and lubrication system 4-9 transient enrichment system the transient enrichment system is a device which keeps fuel/air mixture ratio constant in order not to gen- erate unstable combustion when the throttle grip is returned suddenly during high speed driving. When the throttle valve is closed ...

  • Page 91

    4-10 fuel and lubrication system carburetor removal • remove the center leg shield. (see page 5-1.) • remove the leg shields, left and right. (see page 5-1.) • remove the carburetor intake pipe 1. • disconnect the fuel hose 2 and 3 vacuum hose. • remove the starter plunger 4 from the carburetor body...

  • Page 92

    Fuel and lubrication system 4-11 • remove the float assembly 1 by removing the pin 2. • remove the main jet 3. • remove the pilot jet 4. • remove the pilot air jet 5. Note: before removing the pilot air screw, determine the setting by slowing turning it clockwise and count the number of turns requir...

  • Page 93

    4-12 fuel and lubrication system float height adjustment to check the float height, invert the carburetor body, with the float arm kept free, measure the height a while float arm is just in contact with needle valve by using calipers. Bend the tongue 1 as necessary to bring the height a to this valu...

  • Page 94: Lubrication System

    Fuel and lubrication system 4-13 lubrication system oil pressure refer to page 2-18 oil filter refer to page 2-8. Oil sump filter when you replace the engine oil, check to be sure that the oil sump filter is free from any sign of rupture, also wash the oil sump filter clean periodically. Replace the...

  • Page 95

    4-14 fuel and lubrication system engine lubrication system chart camshaft in.Rocker arm and shaft cam faces ex.Rocker arm and shaft cam sprocket adn cam drive chain piston and piston pin by pass oil sump filter oil pan oil pump oil filter oil orifice cylinder oil cooler cylinder head conrod small en...

  • Page 96

    Fuel and lubrication system 4-15 lubrication system.

  • Page 97: Chassis

    Chassis 5-1 contents 5 chassis exterior parts ........................................................................................ 5-3 removal ............................................................................................... 5-5 reinstallation..........................................

  • Page 98

    Fi system diagnosis 5-2.

  • Page 99: Exterior Parts

    5-3 chassis exterior parts c e n t e r l e g shield rear fr ame c o ver upper cover left frame c o ver rear fen der batte ry b o x l e f t l e g s h ie l d front fende r frame hea d c o ver r ig h t l e g s h ie l d.

  • Page 100

    Chassis 5-4 front handlebar’s cover rear handlebar’s cover.

  • Page 101

    5-5 chassis removal cover, frame head • remove the plate, front license by removing the bolts 1 and 2. • remove the frame head cover. Rear - view mirror • remove the rear-view mirrors, left and right, by loosening the lock nuts. Handlebar’s cover • remove the handlebar’s cover screws. • remove the s...

  • Page 102

    Chassis 5-6 • remove the handlebar’s cover screws. • remove the rear-side of the handlebar’s cover along with the speedometer by disconnecting the speedometer cable and speedometer lead wire couplers. Reinstallation • reinstall the removed parts in the reverse order of removal. Front wheel and front...

  • Page 103

    5-7 chassis removal and disassembly front wheel raise the front wheel of the ground with a jack or wooden block. • remove the axle nut 1. • disconnect the speedometer cable 2. • disconnect the front brake cable 3. • remove the axle and front wheel. Front brake • remove the front brake panel from the...

  • Page 104

    Chassis 5-8 • remove the brake cam lever bolt/nut 1. • remove the brake cam lever, brake lining wear indicator, washer, spring, o-ring and brake cam. (see page 5-4) inspection and disassembly speedometer gearbox turn the speedometer gear 3 and check to see that gear turns smoothly together with the ...

  • Page 105

    5-9 chassis axle: shaft using a dial gauge, check the axle shaft for run out and replace it if run out exceeds the limit. 09900-20606: dial gauge (1/100 mm) 09900-20701: magnetic stand 09900-21304: v-block set (100 mm) service limit: 0.25 mm wheel inspect the wheel run out. Excessive run out is usua...

  • Page 106

    Chassis 5-10 reassembly and remounting reassemble and remount the front wheel and front brake in the reverse order of removal and disassembly. Pay attention to the following points: wheel bearing • apply suzuki super grease "a" to the bearings before installing. 99000-25010: suzuki super grease "a” ...

  • Page 107

    5-11 chassis brake cam/shaft • apply suzuki super grease "a" to the brake cam/shaft and pin before installing the brake shoes. 99000-25010 suzuki super grease "a" brake cam lever • when installing the brake cam lever and brake lining wear indicator, align the groove 1 on the cam/shaft with the punch...

  • Page 108

    Chassis 5-12 front wheel and front brake (disc brake) removal and disassembly front wheel remove the front wheel in the same manner of the drum brake type. (see page 5-5.) front brake • flatten the lock portions of the lock washers. • remove the brake disc from the wheel by removing its bolts. Inspe...

  • Page 109

    5-13 chassis measure the run out with a dial gauge. Replace the disc if the run out exceeds the service limit. Service limit brake disc run out: 0.3 mm 09900-20606: dial gauge (1/100 mm) 09900-20701: magnetic stand reassembly and remounting wheel bearing …………………….. Refer to page 5-8. Brake disc make...

  • Page 110

    Chassis 5-14 speedometer gearbox and front wheel refer to page 5-9. Brake pad replacement • loosen the brake pad pins 1. Remove the brake caliper by removing the caliper mounting bolts 2. • remove the brake pads by removing the brake pad pins. Caliper removal and disassembly • disconnect the brake h...

  • Page 111

    5-15 chassis • remove the caliper bracket 6. • place a rag over the piston to prevent its popping out and push out the piston with an air gun. • remove the dust seal 7 and piston seal 8. Caliper inspection • inspect the piston surface and caliper cylinder wall for nicks, scratches or other damage. •...

  • Page 112

    Chassis 5-16 • install the pistons seal 2 and dust seals 1. • install the pistons 3. • apply suzuki silicone grease to the caliper axles. 99000:25100: suzuki silicone grease • install the break pads. • tighten the caliper mounting bolts 4 to the specified torque. • after touching the break hose unio...

  • Page 113

    5-17 chassis • break lever 4. • break light switch 5. • remove the reservoir cap 6 and diaphragm 7. • drain break fluid. • remove the dust seal 8. • remove the circlip 9 by using the special too. 09900-06108: snap ring pliers • remove the piston / cup 0 and return spring a. Master cylinder inspectio...

  • Page 114

    Chassis 5-18 note: when fitting the circlip, make sure that the sharp edge of the circlip faces outside. • when remounting the master cylinder on the handlebar, align the master cylinder holder's mating surface “a” with punched mark “b” on the handlebar and tighten the upper clamp bolt first as show...

  • Page 115: Handlebar

    5-19 chassis handlebar removal • remove the rear-view mirrors. (see page 5-3.) • remove the front and rear handlebar's covers. (see pages 5-3 and 5-4.) • disconnect the speedometer cable and speedometer lead wire couplers. • disconnect the brake light switch lead. • remove the left handlebar parts. ...

  • Page 116

    Chassis 5-20 reassembly reassembly the handlebar in the reverse order of removal. Pay attention to the following points: • install the handlebar clamp bolt 1. • tighten the handlebar clamp bolt 1 to the specified torque. Handlebar clamp bolt 1: 55 n-m (5.5kg-m) note: before installing the front brak...

  • Page 117: Front Fork And Steering

    5-21 chassis • connect each lead wire. • connect the speedometer cable. • install the front and rear handlebar's covers. Front fork and steering.

  • Page 118

    Chassis 5-22 removal and disassembly • remove the rear-view mirror. (see page 5-3.) • remove the left and right leg shields. (see page 5-1.) • remove the handle bar • remove the front fender 1. • remove the front fender by remove the screw 2. • remove the front fork, left and right by loosen the bol...

  • Page 119

    5-23 chassis • loosen the speedometer cable/front brake cable 1 (for drum brake clamp bolt.) • remove the steering stem lock nut 2 by using universal clamp wrench. 09910-60611: universal clamp wrench • remove the washer. • remove the steering stem nut 3. 9910-60611: universal clamp wrench • remove t...

  • Page 120

    Chassis 5-24 • remove the outer lower race with a thin chisel or screw driver. • remove the spring 1. • invert the fork and stroke it several times to drain out fork oil. • hold the fork inverted for a few-minutes to drain oil. • remove the dust seal 2 and stopper ring 3. • remove the damper rod bol...

  • Page 121

    5-25 chassis • remove the damper rod 1 from the inner tube. • remove the oil seal 2. Inspection steering race and ball • inspect the upper race, lower race and balls for corrosion, dents or damage. Damper rod ring inspect the damper rod ring 1 for wear or damage. Front fork spring measure the fork s...

  • Page 122

    Chassis 5-26 inner and outer tube inspect the inner tube sliding surface and outer tube sliding surface for any scuffing reassembly and remounting reassemble and remount the front fork/steering in the reverse order of removal and disassembly. Pay attention to the following points: • apply thread loc...

  • Page 123

    5-27 chassis • pour specified fork oil into the inner tube. Fork oil type : fork oil # 10 9000-99044-10 g: suzuki fork oil # 10 capacity (each leg): 70 ml • hold the front fork vertical and adjust the fork oil level with the special tool. 09943-74111 : fork oil level gauge oil level: 116 mm note: wh...

  • Page 124

    Chassis 5-28 • apply suzuki super grease “a” to the upper and lower races sufficiently and place the balls to the specified quantity. (upper): 22 pcs number of balls (lower): 28 pcs 99000-25010: suzuki super grease “a” • install the steering stem bracket 2. • install the dust seal 3. • tighten the s...

  • Page 125

    5-29 chassis rear wheel and rear brake removal and disassembly rear wheel • support the motorcycle with the center stand. • remove the rear brake adjusting nut 1. • remove the cotter pin and torque link nut 2. • remove the chain case 1 by removing the bolts and screw..

  • Page 126

    Chassis 5-30 • remove the rear axle nut 1. • loosen the drive chain adjusting nuts 2, left and right. • draw out the axle shaft. • disengage the drive chain from the rear sprocket. • remove the rear wheel. Rear sprocket • remove the rear sprocket along with its mounting drum out of the wheel hub. • ...

  • Page 127

    5-31 chassis • flatten the lock portions of the lock washers. • remove the rear sprocket by removing the nuts. • remove the spacer out of the sprocket 1 mounting drum. • remove the oil seal with the special tool. 09913-50121: oil seal remover • remove the rear sprocket drum bearing in the same manne...

  • Page 128

    Chassis 5-32 • remove the brake cam lever bolt/nut 1. • remove the brake cam lever, brake lining wear indicator, washer, o-ring and brake cam. (see page 5-27.) inspection and disassembly. Wheel bearing ................................. Refer to page 5-6. Axle shaft .....................................

  • Page 129

    5-33 chassis reassembly and remounting reassemble and remount the rear wheel and rear brake in the reverse order of removal and disassembly. Pay attention to the following points: wheel bearing • apply suzuki super grease "a" to the bearings before installing. 99000-25010 : suzuki super grease "a" •...

  • Page 130

    Chassis 5-34 rear sprocket drum bearing • install the bearing by using the bearing installer. 09913-84510: bearing installer note: apply grease to the bearing and oil seal lip before assembling rear wheel. Rear sprocket • tighten the sprocket mounting nuts to the specified torque and bend up the loc...

  • Page 131: Rear Suspension

    5-35 chassis rear suspension swing arm and shock absorber removal • remove the rear wheel.(see page 5-27) • remove the shock absorber mounting lower bolts 1, left and right.

  • Page 132

    Chassis 5-36 • remove the swing arm pivot nut 1. • remove the swing arm by removing its pivot shaft. Inspection and disassembly swingarm bushing/swingarm inspect the swing arm bushing for wear or damage. Inspect the swinger for distortion. If any defects are found, replace the swing arm bushings and...

  • Page 133

    5-37 chassis • remove the bushing from the swing arm by using a suitable hand-press. Reassembly and remounting reassemble and remount the swing arm and shock absorber in the reverse order of removal and disassembly, and also carry out the following steps: swingarm bushing • press the bushing into sw...

  • Page 134: Electrical  System

    Electrical system 6-1 contents 6 electrical system cautions in servicing............................................................................ 6-2 location of electrical components ............................................ 6-4 charging and lighting system ......................................

  • Page 135: Cautions In Servicing

    6-2 electrical system cautions in servicing connector • when connecting a connector, be sure to push it in until a click is felt. • inspect the connector for corrosion, contamination and break- age in its cover. Coupler • with a lock type coupler, be sure to release the lock before disconnecting it ...

  • Page 136

    Electrical system 6-3 connecting battery • when disconnecting terminals from the battery for disassembly or servicing, be sure to disconnect the negative - terminal first, • when connecting terminals to the battery, be sureto connect the positive + terminal first. • if the terminal is found corroded...

  • Page 137

    6-4 electrical system location of electrical components 1) battery 7) ignition coil 2) fuse 8) generator 3) fuel level gauge 9) starter motor 4) turn signal relay 10) horn 5) regulator / rectifier 11) cdi unit 6) starter relay.

  • Page 138

    Electrical system 6-5 charging and lighting system description the circuit of the charging and lighting system is indicated in the figure, which is composed of an ac gener- ator, regulator / rectifier unit and battery. The ac current generated from ac generator is converted by rectifier and is turne...

  • Page 139

    6-6 electrical system troubleshooting battery runs down quickly. Check accessories which excessively waste electric power. Not installed inspect battery leak current. (refer to page 6-6.) no leak inspect charging voltage between battery terminals. (refer to page 6-6.) inspect continuity generator co...

  • Page 140

    Electrical system 6-7 inspection battery leak current inspection • open the seat. • turn the ignition switch to the off position. • disconnect the battery - lead wire. Note that leakage is indicated if the needle swings even a little when the milliampare meter of the pocket tester is connected betwe...

  • Page 141

    6-8 electrical system generator (charging/lighting) coil inspection • remove the center leg shield, leg shields and leg side shields/frame covers. (see page 5-1) • disconnect the generator lead wire coupler. Using the pocket tester, measure the resistance between the lead wires and ground. If the re...

  • Page 142: Starter System

    Electrical system 6-9 regulator/rectifier inspection • remove the right leg side shield/right frame cover. (see page 5-1). • disconnect the regulator/rectifier coupler. Using a pocket tester (x1 kΩ range), measure the resistance between the terminals in the following table. 09900-25002: pocket teste...

  • Page 143

    6-10 electrical system troubleshooting , n o i t i s o p n o s i h c t i w s n o i t i n g i : k c e h c * . D e g r a h c s i d t o n s i y r e t t a b : e h t e r o f e b n w o l b t o n s i e s u f : . S i s o n g a i d starter motor will not clicks no click run not run not voltage voltage measur...

  • Page 144

    Electrical system 6-11 starter motor removal and disassemble • remove the center leg shield and leg shields. • disconnect the starter motor lead wire and remove the starter motor by removing the mounting screws. (refer to page 3-15) • disassemble the starter motor as shown in the illustration. Start...

  • Page 145

    6-12 electrical system armature coil inspection check for continuity between each segment. Check for continuity between each segment and the armature shaft. If there is no continuity between the segments or there is conti- nuity between the segments and shaft, replace the armature with a new one. Oi...

  • Page 146

    Electrical system 6-13 • apply a small quantity of thread lock super “1322” to the starter motor housing screws. 9000-32110: thread lock super “1322” starter relay inspection • remove the right leg side shield/right frame cover. (see page 5-1.) • disconnect the lead wire coupler from the starter rel...

  • Page 147: Ignition System

    6-14 electrical system ignition system description the fd110 xc / xcs / xcd / xcsd engine is equipped with a new type ignition system. This new system minimizes timing fluctuations. It has an “ignition timing control circuit” which accurately controls ignition tim- ing depending on the engine r/min....

  • Page 148

    Electrical system 6-15 troubleshooting no spark at plug *check : ignition switch is on position. : fuse is not blown before the diagnosis. Check the cdi unit coupler for poor contact. Looseness correct inspect the resistance of charging coil (w/r and ground). (refer to page 6-7.) incorrect correct i...

  • Page 149

    6-16 electrical system inspection ignition coil primary peak voltage • remove the spark plug cap. • connect a new spark plug to the spark plug and ground it to the cylinder head. Note: make sure that the spark plug cap and spark plug are connected properly. Measure ignition coil primary voltage usin...

  • Page 150

    Electrical system 6-17 ignition coil resistance • disconnect the ignition coil lead wires and spark plug cap. Measure the ignition coil resistance in both the primary and sec- ondary windings using the multi circuit tester. If the resistance in both the primary and secondary windings is close to the...

  • Page 151

    6-18 electrical system if the peak voltage measured on the cdi unit coupler is lower then the standard value, measure the peak voltage on the pickup coil coupler as follows. • disconnect the pickup coil coupler • connect the multi circuit tester (dm 200) with the peak volt adaptor as follows. + prob...

  • Page 152

    Electrical system 6-19 cdi unit • remove the left leg side shield/left frame cover. (see page 5-1.) • disconnect the cdi unit coupler. Measure the resistance between the terminals. If the resistance is infinity or less than the specifications, the cdi unit must be replaced. Note: as capacitor, thyri...

  • Page 153

    6-20 electrical system spark plug • remove the spark plug. 09930-10121: spark plug socket wrench set carbon deposit check to see the carbon deposit on the plug. If the carbon is deposited, remove it with a spark plug cleaner machine or carefully using a tool with a pointed end. Spark plug gap measur...

  • Page 154: Fuel Meter

    Electrical system 6-21 fuel meter fuel meter circuit inspection fuel level gauge • remove the fuel level gauge. (see page 4-3). Check the resistance of each float position with a pocket tester. If the resistance measured is incorrect, replace the fuel gauge assembly with new one. The relation betwee...

  • Page 155: Combination Meter

    6-22 electrical system fuel meter • disconnect the fuel level gauge lead wire coupler. (see page 4-3). To test the fuel meter two different checks may be used. The first connect a jumper wire between b/w and y/b wires coming from the main wiring harness. With the ignition switch turned on, the fuel ...

  • Page 156

    Electrical system 6-23 inspection using the pocket tester, check the continuity between lead wires. If the continuity measured is incorrect, replace the respective parts. 09900-25002: pocket tester tester knob indication: x 1Ω range note: when making this test, it is not necessary to remove the comb...

  • Page 157: Lamps

    6-24 electrical system lamps headlight and turn signal light headlight bulb replacement • remove the front handlebar’s cover. • push in on the bulb socket, turn it to the left, and pull it out • remove the headlight bulb. Turn signal light bulb replacement • remove the turn signal light lenses. • pu...

  • Page 158

    Electrical system 6-25 tail/brake light and turn signal light tail / brake light bulb and turn signal light bulb replacement • remove the tail/brake light lens and turn signal lens. • push in on the bulb, turn it to the left, and pull it out. Turn signal relay the turn signal relay 1 is located the ...

  • Page 159: Switches

    6-26 electrical system switches inspect each switch for continuity with the pocket tester. If any abnormality is found, replace the respective switch assemblies with new ones. 09900-25002: pocket tester tester knob indication: x 1Ω range horn button front brake switch rear brake switch gear position...

  • Page 160: Battery

    Electrical system 6-27 battery specifications in fitting the battery to the motorcycle, connect the breather pipe to the battery vent. Intial charging filling electrolyte remove the short sealed tube “a” before filling electrolyte. Fill the battery with electrolyte (dilute sulfuric acid solution wit...

  • Page 161

    6-28 electrical system check the electrolyte level and add distilled water, as necessary to raise the electrolyte to each cell’s upper level. Check the battery for proper charge by taking an electrolyte s.G. Reading. If the reading is 1.22 (yb5l-b) or less/1.20 (gm3-3b) or less, as corrected to 20 °...

  • Page 162

    Electrical system 6-29 service life lead oxide is applied to the pole plates of the battery which will come off gradually during the service. When will come off gradually during the sediment, the battery can not be used any more. If the battery is not charged for a long time, lead sulfate is generat...

  • Page 163

    6-30 electrical system.

  • Page 164: Servicing Information

    Servicing information 7-1 contents 7 servicing information troubleshooting .................................................................................... 7-2 engine .................................................................................................... 7-2 carburetor ................

  • Page 165: Troubleshooting

    7-2 servicing information troubleshooting engine complaint symptom and possible causes remedy engine will not start, or is hard to start. Compression too low 1. Out of adjustment valve clearance. 2. Worn valve guides or poor seating of valves. 3. Mistiming valves. 4. Excessively worn piston rings. 5...

  • Page 166

    Servicing information 7-3 noise seems to come from clutch 1. Worn or slipping clutch shoe. 2. Worn or slipping clutch drive plate. Replace. Replace. Noise seems to come from crankshaft 1. Due to wear ratting bearings. 2. Worn and burnt big-end bearing. 3. Worn and burnt journal bearings. 4. Too larg...

  • Page 167

    7-4 servicing information 9. Spark plug too cold. 10. Clogged jets in carburetor. 11. Deflective magneto. Replace by hot type plug. Clean. Replace. Engine runs poorly in high speed rage. 1. Weakened valve springs. 2. Worn camshaft or rocker arms. 3. Valve timing out of adjustment. 4. Too narrow spar...

  • Page 168

    Servicing information 7-5 clutch slips or drags hard gearshifting carburetor complaint symptom and possible causes remedy engine overheats. 1. Heavy carbon deposit on piston crown. 2. Not enough oil in the engine. 3. Defective oil pump or clogged oil circuit. 4. Too low in float chambers fuel level....

  • Page 169

    7-6 servicing information chassis complaint symptom and possible causes remedy medium-or high speed trouble. 1. Clogged main jet or main air jet. 2. Clogged needle jet. 3. Not operating properly throttle valve. 4. Clogged fuel filter. 5. Clogged fuel tank air vent hose. Check and clean. Check and cl...

  • Page 170

    Servicing information 7-7 brakes complaint symptom and possible causes remedy rear suspension too soft. 1. Weakened shock absorber spring. 2. Leakage oil of shock absorber. Replace. Replace. Noisy rear suspension 1. Loose bolts on shock absorber. 2. Worn swing arm bushing. Retighten. Replace. Compla...

  • Page 171

    7-8 servicing information electrical complaint symptom and possible causes remedy 4. Loose connection of lead wire. Connect/tighten. Spark plug soon become fouled with carbon. 1. Mixture too rich. 2. Idling speed set too high. 3. Incorrect gasoline. 4. Dirty element in air cleaner. 5. Too cold spark...

  • Page 172

    Servicing information 7-9 battery complaint symptom and possible causes remedy “sulfation”, acidic white powdery substance or spots on surfaces of cell plates. 1. Not enough electrolyte. 2. Battery case is cracked. 3. Battery has been left in a run down condi- tion for a long time. 4. Contaminated e...

  • Page 173

    7-10 servicing information wiring diagram fd 110 (xb517qsc/xb517qd) rear turn signal light (r) brake light / t ailli ght rear turn signal light (l ) ground battery fuse regulator / recti fier ma gne t gear po sition s w itc h ignition switch front turn signal light (l) head light front turn signal l...

  • Page 174

    Servicing information 7-11 wire harness, cable and hose routing wire harness routing c lamp ig nit io n s w it c h t he f ue l ho s e c lamp r e ar b r ak e l ig ht s w it c h f ue l g aug e f us e b o x b at t e r y ( + ) t e r minal c o v e r b at t e r y ( + ) t e r minal s t ar t e r r e l ay b ...

  • Page 175

    7-12 servicing information magneto lead wire routing pick-up coil magneto lead wire magneto stator grommet engine ground wire gear position indicator grommet 8.0 kg-m clamp.

  • Page 176

    Servicing information 7-13 cable routing s t ar t e r c ab l e s t ar t e r l e v e r s t ar t e r c ab l e c l amp c l amp f r o nt b r ak e c ab l e f r o nt b r ak e c ab l e s p e e do me t e r c ab l e s p e e do me t e r c ab l e view b view a a.

  • Page 177

    7-14 servicing information front brake hose routing s t ar t e r c ab l e t h r o t t l e c ab l e s t ar t e r c ab l e c l amp s p e e do me t e r c ab l e c l amp f r o nt b r ak e c ab l e s t ar t e r c ab l e c l amp c ar b u r e t o r.

  • Page 178

    Servicing information 7-15 fuel hose routing fuel tank clamp.

  • Page 179

    7-16 servicing information battery battery breather hose fuel tank.

  • Page 180

    Servicing information 7-17 front wheel set up (drum type) 4 .0 k 0 .8 k g -m mm . 7.86 14 o.

  • Page 181

    7-18 servicing information front wheel set up (disk type) 2 .3 k g -m 2 .6 k g -m 2 .3 k g -m 4 .0 k g -m.

  • Page 182

    Servicing information 7-19 rear wheel set up 5 .4 k g -m 0 .8 k g -m 114.8 mm..

  • Page 183

    7-20 servicing information special tools 09900-00401 “l” type haxagon wrench set 09900-00410 hexagon wrench set 09900-06107 snap ring pliers 09900-06108 snap ring pliers 09900-09003 impact driver set 09900-20101 vernier calipers (1/20 mm, 150 mm) 09900-20605 dial calipers (1/100 mm, 10-34 mm) 09900-...

  • Page 184

    Servicing information 7-21 09913-84510 bearing installer 09913-76010 09914-79610 bearinginstaller 09915-64510 compression gauge 09915-63310 (adaptor) 09915-74510 oil pressure gauge 09915-44531 oil pressure gauge adaptor 09916-14510 valve spring compressor 09916-14521 valve lifter attach- ment 09916-...

  • Page 185

    7-22 servicing information note: when ordering the special tool please confirm whether it is available of not. 09941-50111 bearing remover 09941-74910 steering bearing installer 09943-74111 front fork oil level gauge 09951-16080 bearing installer 09940-14920 steering stem nut wrench 09940-52860 fron...

  • Page 186: Tightening Torque

    Servicing information 7-23 tightening torque engine item n-m kg-m cylinder head nut 18.0-22.0 1.8-2.2 cylinder head bolt 8.0-12.0 0.8-1.2 cam sprocket bolt 9.0-11.0 0.9-1.1 cam chain tensioner bolt 8.0-12.0 0.8-1.2 starter clutch bolt 14.0-16.0 1.4-1.6 spark plug 10.0-12.0 1.0-1.2 valve clearance in...

  • Page 187

    7-24 servicing information chassis item n-m kg-m front axle/nut 30.0-47.0 3.0-4.7 steering stem lock nut 25.0-35.0 2.5-3.5 handlebar clamp bolt 50.0-60.0 5.0-6.0 handlebar mounting nut 13 1.3 front fork cap bolt 45 4.5 front fork clamp bolt 25.0-40.0 2.5-4.0 front brake master cylinder bolt 8.0-12.0...

  • Page 188

    Servicing information 7-25 tightening torque chart bolt diameter a (mm) conventional or w4w marked bolt “7” marked bolt n-m kg-m n-m kg-m 4 1.5 0.15 2 0.2 5 3 0.3 5 0.5 6 6 0.6 10 1.0 8 13 1.3 23 2.3 10 29 2.9 50 5.0 12 45 4.5 85 8.5 14 65 6.5 135 13.5 16 105 10.5 210 21.0 18 160 16.0 240 24.0 conve...

  • Page 189: Service Data

    7-26 servicing information service data valve + guide unit: mm camshaft + cylinder head unit: mm cylinder + piston + piston ring unit: mm item standard limit valve diam. In. 25 -------------- ex. 22 -------------- valve clearance (when cold) in. 0.04-0.07 -------------- ex. 0.04-0.07 -------------- ...

  • Page 190

    Servicing information 7-27 unit: mm conrod + crankshaft unit: mm oil pump first clutch unit: mm gear shift clutch unit: mm item standard limit piston ring end gap 1 st 0.10 – 0.25 0.500 2 nd 0.10 – 0.25 0.500 piston ring to groove clearance 1 st ------------- 0.180 2 nd ------------- 0.150 piston ri...

  • Page 191

    7-28 servicing information transmission + drive chain unit: mm carburetor unit: mm electrical item standard limit primary reduction ratio 3.666 (77/21) -------------- final reduction ratio 2.428 (34/14) -------------- gear ratios low 3.000 (33/11) -------------- 2 nd 1.875 (30/16) -------------- 3 r...

  • Page 192

    Servicing information 7-29 wattage brake + wheel item standard limit primary peak voltage morn then 130 v (+)ground , (-)white/blue pickup coil peak voltage morn then 4 v (+)green/white , (-)blue/yellow magneto coil resistance lighting y/w – b/w 0.3 - 1.5 Ω charging w/r – b/w 0.5 – 2.0 Ω pick-up g/w...

  • Page 193

    7-30 servicing information brake + wheel suspension tire pressure fuel + oil item standard limit master cylinder bore 12.700-12.743 --------------- master cylinder piston diam. 12.657-12.684 --------------- brake caliper cylinder bore 27.00-27.050 --------------- brake caliper piston diam. 2.930-26....