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Suzuki JR50 Owner's Manual

Summary of JR50

  • Page 1

    99011-04493-03a jr50 part no. 99011-04493-03a june, 2005 en tk k6 jr50 printed in taiwan 300 takatsuka, hamamatsu, japan owner’s manual this owner’s manual contains important safety information. Please read it carefully. Warning failure to follow these safety precautions may increase your risk of in...

  • Page 2: Warning

    This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator. The manual contains important safety information and instructions which should be read carefully before operating the motorcycle....

  • Page 3: Warning/caution/note

    Important warning/caution/note please read this manual and fol- low its instructions carefully. To emphasize special information, the symbol and the words warning, caution and note have special meanings. Pay spe- cial attention to the messages highlighted by these signal words: note: indicates speci...

  • Page 4

    Foreword motorcycling is one of the most exhilarating sports and to ensure your youngster’s riding enjoy- ment. You and your youngster should become thoroughly famil- iar with the information presented in this owner’s manual before your youngster rides the motorcy- cle. The proper care and maintenan...

  • Page 5: •

    Important advice to parents this motorcycle is designed for use only as follows: • read this owner’s manual carefully. • off-road use only – not for use on public roads. • single rider only – weight limit 30 kg (65 pounds). • not recommended for children under age 7. • parental supervision required ...

  • Page 6: Rider.

    Tips for supervising the young rider. Your child’s safety depends on your commitment to take the time necessary to fully educate him or her on the proper operation of the jr50. Remember that proper instruction before your child begins to ride is as important as proper instruction and supervision dur...

  • Page 7: Getting to Know The Jr50.

    Outfit your child in proper clothing when he or she rides. Avoid loose clothes or scarves, which could get caught in moving parts. Abra- sion injuries can be minimized by wearing protective clothing includ- ing gloves, strong boots that fit over the ankle, long pants, and long sleeve shirt or jacket...

  • Page 8: Inspect The Machine Before

    Practice this exercise until your child can start off, accelerate, and stop correctly and with confi- dence. Slowly introduce new maneuvers into this routine as the child becomes more comfortable with the motorcycle, such as turn- ing and stopping quickly on your signal. Inspect the machine before r...

  • Page 9: Table of Contents

    Table of contents 1 2 3 4 5 6 7 8 9 10 instructing the young rider fuel and oil recommendation controls, equipment and adjustments break-in and inspection before riding riding tips accessory use and motorcycle loading inspection and maintenance troubleshooting storage procedure and appearance care c...

  • Page 10

    Jr50_03a.Book page 2 tuesday, april 12, 2005 5:06 pm.

  • Page 11: Instructing The Young Rider

    1-1 1 instructing the young rider operating skill ............................................................................................. 1-2 clothing ........................................................................................................... 1-4 jr50_03a.Book page 1 tuesday, a...

  • Page 12: Operating Skill

    1-2 instructing the young rider children are impatient; the sight of a new motorcycle excites their imagination; and in their excite- ment they may forget the impor- tance of safety precautions. Please go through this manual with your youngster, page by page, and help him or her under- stand not onl...

  • Page 13: The First Time.

    1-3 rehearse before riding out for the first time. Let the young rider mount the machine and do a dry rehearsal with the engine off. The rider should be fully outfitted with hel- met, eye protection (goggles or face shield), and protective cloth- ing (gloves, leather or heavy cloth pants, long sleev...

  • Page 14: Clothing

    1-4 clothing as stated before, the minimum acceptable riding outfit includes helmet, eye protection, and pro- tective clothing. Some guidelines for protective clothing are: wear simple clothes. Dangling belts and scarves, rib- bon-like trimmings, etc., are haz- ardous since they can get caught in mo...

  • Page 15: Fuel and Oil

    2-1 2 fuel and oil recommendation fuel .................................................................................................................... 2-2 engine oil ......................................................................................................... 2-3 transmission oil .....

  • Page 16: Fuel

    2-2 fuel and oil recommendation fuel your motorcycle requires regular unleaded gasoline with a mini- mum pump octane rating of 87 ((r+m)/2 method). In some areas, the only fuels that are available are oxygenated fuels. Oxygenated fuels which meet the minimum octane requirement and the requirements d...

  • Page 17: Engine Oil

    2-3 note: • to help clean the air, suzuki recommends you to use the oxygenated fuels. • be sure that any oxygenated fuel you use has octane rat- ings of at least 87 pump octane ((r+m)/2 method). • if you are not satisfied with the driveability of your motorcycle when you are using an oxy- genated fu...

  • Page 18

    Jr50_03a.Book page 4 tuesday, april 12, 2005 5:06 pm.

  • Page 19: Controls, Equipment and

    3-1 3 controls, equipment and adjustments location of parts ....................................................................................... 3-2 left handlebar ............................................................................................. 3-5 right handlebar ......................

  • Page 20: Location of Parts

    3-2 controls, equipment and adjustments location of parts 1 engine stop switch 2 front brake lever 3 throttle grip 4 fuel tank cap jr50_03a.Book page 2 tuesday, april 12, 2005 5:06 pm.

  • Page 21

    3-3 5 fuel valve 6 spark plug 7 gearshift lever 8 footrest 9 side stand 0 drive chain jr50_03a.Book page 3 tuesday, april 12, 2005 5:06 pm.

  • Page 22

    3-4 a kick starter lever b engine oil inspection window c transmission oil filler cap d air cleaner e choke lever f carburetor g rear brake pedal h transmission oil level screw jr50_03a.Book page 4 tuesday, april 12, 2005 5:06 pm.

  • Page 23: Left Handlebar

    3-5 left handlebar engine stop switch 1 to stop the engine, push the engine stop switch. Right handlebar throttle grip 1 engine speed is controlled by the position of the throttle grip. Turn it toward you to increase engine speed. Turn it away from you to decrease engine speed. Front brake lever 2 a...

  • Page 24: Fuel Tank Cap

    3-6 fuel tank cap to open the fuel tank cap, remove the end of vent tube from the han- dlebar cover and turn the cap counterclockwise. To close the cap, turn it clockwise and tighten it securely. Be sure that the vent tube is connected securely and routed properly. warning overfilling the fuel tank...

  • Page 25: Fuel Valve

    3-7 fuel valve this motorcycle has a manually operated fuel valve. There are two positions: “on” and “off.” “on” position the normal operating position for the fuel valve is in the “on” posi- tion. In this position, fuel will flow from the fuel valve to the carbure- tor whenever the fuel level in th...

  • Page 26: Engine Oil Level

    3-8 engine oil level the engine oil tank is located behind the right frame cover. Check the oil level through the oil level inspection window 1 each time before starting the engine. If the oil level is below the inspec- tion window, replenish the oil tank with the specified oil. To replenish the oil...

  • Page 27: Choke Lever

    3-9 choke lever this motorcycle has a choke sys- tem to provide easy starting when the engine is cold. The choke works by pushing the choke lever down. The choke works best when the throttle is in the closed position. When the engine is warm, you do not need to use the choke for starting. Note: refe...

  • Page 28: Gearshift Lever

    3-10 gearshift lever this motorcycle has a single- speed transmission which oper- ates as shown. To shift properly, close the throttle before you oper- ate the gearshift lever. Lift the gearshift lever to shift to the neu- tral position or depress the lever to shift to the drive position. Rear brake...

  • Page 29: Power Reduction Plate

    3-11 power reduction plate the power reduction plate reduce the power output of the engine. This enables the young rider to develop his riding skills gradually with reduced power output. Removal of these plate allows the engine to deliver full power. Power reduction plate removal instructions 1. Loo...

  • Page 30

    3-12 4. Remove the bolt securing the muffler at the center of the machine. This bolt needs a 12- mm t type wrench. 5. Using a 12-mm t type wrench and a 12-mm wrench, remove the bolt securing second muf- fler. 6. Remove the muffler. Remove the power reduction plate from exhaust pipe flange. This plat...

  • Page 31: Seat Height Adjustment

    3-13 seat height adjustment the seat height of this motorcycle is adjustable for the rider’s physi- cal size. If higher seat height is required, carry out the following proce- dures. 1. Remove the fastener and take off the front number plate. Note: to remove the fastener, push in the center pin as b...

  • Page 32: Warning

    3-14 note: the spacers and longer bolts are provided in the tool bag. 5. Tighten the upper and lower bolts securely in that order. 6. Reinstall the number plate. 7. Remove the frame cover and loosen the upper rear shock absorber bolt. Do this on right and left sides. 8. Remove the lower rear shock a...

  • Page 33: Tightening Torque:

    3-15 10.Adjust the side stand in order to maintain the correct parking lean angle. Remove screw 2 and extend inner stand 1 so that the higher clearance hole is visible through the outer stand screw hole. Reinstall and securely tighten screw 2. Tightening torque: warning failure to adjust the seat h...

  • Page 34

    Jr50_03a.Book page 16 tuesday, april 12, 2005 5:06 pm.

  • Page 35: Break-In and Inspection

    4-1 4 break-in and inspection before riding break-in ............................................................................................................ 4-2 inspection before riding .......................................................................... 4-3 jr50_03a.Book page 1 tuesday, ...

  • Page 36: Break-In

    4-2 break-in and inspection before riding break-in the first 20 hours is the most important in the life of your motor- cycle. Proper operation during this break-in period will help assure maximum life and perfor- mance from your new motorcycle. The following guidelines explain proper break-in proced...

  • Page 37: Inspection Before Riding

    4-3 inspection before riding check the condition of the motor- cycle to help make sure that you do not have mechanical problems when your youngster rides. Before your youngster rides the motorcycle, be sure to check the following items. Be sure your motorcycle is in good condition for the personal s...

  • Page 38

    4-4 what to check check for steering • smoothness • no restriction of movement • no play or looseness brakes • proper pedal and lever play • no dragging • brake shoe wear tires • proper pressure • enough tread depth • no cracks, rips or other damage fuel tank • enough fuel for the planned run • tank...

  • Page 39: Riding Tips

    5 5-1 riding tips starting the engine .................................................................................... 5-2 starting a cold engine ............................................................................. 5-2 starting a warm engine ................................................

  • Page 40: Starting The Engine

    5-2 riding tips starting the engine before attempting to start the engine, make sure: 1. Turn the fuel valve lever from off to on. 2. Shift to neutral. Starting a cold engine 3. Push the choke lever down as far as it will go. 4. Close the throttle grip com- pletely. Jr50_03a.Book page 2 tuesday, apr...

  • Page 41: Starting A Warm Engine

    5-3 5. Kick the kick starter lever to start the engine and, if this fails to fire up, kick again. If 3rd or 4th kick fails, then pull back choke lever to original position, open throttle wide (by turning the grip all the way), and kick again. 6. Upon firing up, run the engine for 30 to 60 seconds. 7...

  • Page 42: Warning

    5-4 warning an improperly retracted kick starter lever can interfere with rider control. Be sure the kick starter lever is returned to its home position after starting the engine. warning running the engine indoors or in a garage can be hazardous. Exhaust gas contains carbon monoxide, a gas that i...

  • Page 43: Starting Off and Shifting

    5-5 starting off and shifting 1. Kick up side stand. 2. Apply the front brake. warning carrying a passenger can greatly reduce your ability to balance and steer this motor- cycle. If you carry a passenger, you can lose control and both you and the passenger can be severely injured. Never carry a pa...

  • Page 44: Stopping and Parking

    5-6 3. Push down to shift from neu- tral to drive position. 4. Release the front brake and open throttle gently. Stopping and parking 1. Turn the throttle grip away from yourself to close the throttle completely. 2. Apply the front and rear brakes evenly and at the same time. warning riding the mot...

  • Page 45: Warning

    5-7 3. Attempting to slow down by using one brake alone is haz- ardous, particularly braking the front wheel alone. The front wheel may slide out (front wheel braking) or the rear wheel might skid sidewise (rear wheel braking). 4. Shift into neutral just before the motorcycle stops. warning inexper...

  • Page 46: Advice To The Parent:

    5-8 5. Park the motorcycle on a firm, flat surface where it will not fall over by using the side stand. 6. Press and hold the engine stop switch until the engine stops. 7. Turn the fuel valve lever to the “off” position. Advice to the parent: it takes some time for engine and muffler to cool off aft...

  • Page 47: Accessory Use and

    6-1 6 accessory use and motorcycle loading modification ................................................................................................... 6-3 jr50_03a.Book page 1 tuesday, april 12, 2005 5:06 pm.

  • Page 48: Warning

    6-2 accessory use and motorcycle loading there are a great variety of accessories available to suzuki owners. Suzuki can not have direct control over the quality or suitability of accessories you may wish to purchase. The addition of unsuitable accessories can lead to unsafe operating conditions. It...

  • Page 49: Modification

    6-3 • inspect for proper ground clearance and bank angle. Improperly mounted load could critically reduce these two safety factors. Also deter- mine that the load does not interfere with the operation of the suspension, steering or other control operations. • accessories fitted to the han- dlebars o...

  • Page 50

    Jr50_03a.Book page 4 tuesday, april 12, 2005 5:06 pm.

  • Page 51: Inspection and Maintenance

    7-1 7 inspection and maintenance maintenance schedule .............................................................................. 7-2 general lubrication .................................................................................. 7-4 air cleaner ...............................................

  • Page 52: Maintenance Schedule

    7-2 inspection and maintenance maintenance schedule it is very important to inspect and maintain your motorcycle regu- larly. Follow the guidelines in the chart. The intervals between peri- odic services in months are shown. At the end of each inter- val, be sure to perform the main- tenance listed....

  • Page 53

    7-3 maintenance chart note: i= inspect and clean, adjust, replace or lubricate if necessary, c= clean, r= replace, t= tighten interval initial 1 month every 3 months every 6 months item * cylinder head and cylinder – – c * cylinder head nuts t – t spark plug – i r air cleaner element c c c carbureto...

  • Page 54: General Lubrication

    7-4 general lubrication proper lubrication is important for safe, smooth operation and a long life for your motorcycle. Be sure that all lubrication is performed during periodic maintenance on the motorcycle. Increase fre- quency when your motorcycle is used in severe conditions. 1 throttle grip 2 f...

  • Page 55: Air Cleaner

    7-5 air cleaner the air cleaner element must be kept clean to provide good engine power and gas mileage. If your youngster uses the motorcycle under normal low-stress condi- tions, you should service the air cleaner at the intervals specified. If your youngster rides in dusty, wet, or muddy conditio...

  • Page 56: Air Cleaner Element Removal

    7-6 air cleaner element removal 1. Remove the cleaner cap. 2. Take out the element. Washing the element wash the element as follows: 1. Fill a wash pan larger than the element with a non-flammable cleaning solvent a. Dip the element in the solvent and wash it. 2. Squeeze the element by pressing it b...

  • Page 57: Warning

    7-7 6. Clean any dirt or debris from inside the air cleaner case. Be sure no dirt enters the carbure- tor. 7. Reinstall the cleaner element in reverse order of removal. Be sure that the element is securely in position and is properly sealed. Note: recycle or properly dis- pose of used oil and solven...

  • Page 58: Spark Plug

    7-8 spark plug 1. Extract the spark plug cap. 2. Remove the spark plug with the spark plug wrench pro- vided in the tool kit. To maintain a hot, strong spark, keep the plug free from carbon. Remove carbon deposits from the plug, and adjust the gap to 0.6 – 0.7 mm (0.024 – 0.028 in) for good ignition...

  • Page 59: Plug Replacement Guide

    7-9 plug replacement guide installation to install a spark plug, turn it in as far as possible with your fingers, then tighten it with a wrench. Carefully turn the spark plug by hand into the threads until it is fin- ger tight. If the spark plug is new, tighten it with a wrench about 1/2 turn past f...

  • Page 60: Carburetor

    7-10 carburetor the carburetor is factoryset for the best performance. Do not attempt to alter its setting. There are two items of adjustment, how- ever, under your care: idle speed and throttle cable play. Idle speed adjustment the engine idle speed may be adjusted by turning the throttle valve adj...

  • Page 61: Throttle Cable Adjustment

    7-11 throttle cable adjustment measure the throttle cable play by turning the throttle grip. The throt- tle grip should have 2.0 – 4.0 mm (0.08 – 0.16 in) play. To adjust the throttle cable play: 1. Loosen the lock nut 1. 2. Turn the adjuster 2 in or out to obtain the proper amount of throttle grip ...

  • Page 62: Transmission Oil

    7-12 transmission oil the transmission oil should always be changed when the engine is warm so the oil will drain easily. To change transmission oil: 1. Place the motorcycle on level ground on its side stand. 2. Remove the oil filler cap 1. 3. Remove the drain plug 3 from the bottom of the engine. D...

  • Page 63: Drive Chain

    7-13 drive chain the condition and adjustment of the drive chain should be checked before each use of the motorcy- cle. Always follow the guidelines below for inspecting and servicing the chain. Inspecting the drive chain when inspecting the chain, look for the following: • loose pins • damaged roll...

  • Page 64: Drive Chain Cleaning and

    7-14 drive chain cleaning and oiling clean and oil the chain as follows: 1. Wash the chain with kerosene. Kerosene will lubricate and clean the chain. 2. Allow the chain to dry, then lubricate the links with suzuki chain lube or an equivalent. Drive chain adjustment inspect the drive chain slack bef...

  • Page 65

    7-15 to adjust the drive chain, follow the procedure below: 1. Remove the cotter pin 1 and loosen the axle nut 2. 2. Turn the right and left adjuster nuts 3 until the chain has 20 – 25 mm (0.8 – 1.0 in) of slack halfway between the engine sprocket and rear sprocket. 3. At the same time that the chai...

  • Page 66: Brakes

    7-16 brakes this motorcycle is equipped with front and rear drum brakes. Note: operating in mud, water, sand, or other extreme conditions can cause accelerated brake wear. If your youngster operates the motorcycle under these condi- tions, the brake must be inspected more often than recom- mend in t...

  • Page 67: Rear Brake Pedal Adjustment

    7-17 1. Turn the front brake adjuster 1 clockwise or counterclock- wise to obtain the specified play. Turning the adjuster clockwise will decrease the play. 2. After adjusting the play, check that there is no dragging when turning the front wheel with the wheel off the ground and that there is enoug...

  • Page 68: Tires

    7-18 tires tire pressure and loading tire pressure and tire loading are important factors. Overloading your tires can lead to tire failure and loss of motorcycle control. Check tire pressure each time before you ride, according to the table below. Tire pressure should only be checked and adjusted be...

  • Page 69: Tire Condition and Type

    7-19 tire condition and type tire condition and tire type affect motorcycle performance. Cuts or cracks in the tires can lead to tire failure and loss of motorcycle con- trol. Worn tires are susceptible to puncture failures and subsequent loss of motorcycle control. Tire wear also affects the tire p...

  • Page 70: Spark Arrester

    7-20 spark arrester the muffler has a spark arrester which must be periodically cleaned to maintain good effi- ciency. At the intervals shown in the maintenance chart, clean the spark arrester as follows. 1. Remove the bolts 1. 2. Remove the spark arrester. 3. Use a brush to remove carbon deposits f...

  • Page 71: Troubleshooting

    8-1 8 troubleshooting fuel system check ...................................................................................... 8-2 ignition system check ................................................................................ 8-3 jr50_03a.Book page 1 tuesday, april 12, 2005 5:06 pm.

  • Page 72: Fuel System Check

    8-2 troubleshooting this troubleshooting guide is pro- vided to help you find the cause of some common complaints. Complaint: engine is hard to start or does not start at all. Something is probably wrong with the fuel system or ignition system. Fuel system check 1. Make sure there is enough fuel in ...

  • Page 73: Ignition System Check

    8-3 ignition system check 1. Remove the spark plug and reattach it to the spark plug lead. 2. While holding a spark plug with its base firmly against the engine, depress the kick starter lever. If the ignition sys- tem is operating properly, a blue spark should jump across the spark plug gap. If the...

  • Page 74

    Jr50_03a.Book page 4 tuesday, april 12, 2005 5:06 pm.

  • Page 75: Storage Procedure and

    9-1 9 storage procedure and appearance care procedure for returning to service ................................................. 9-3 corrosion prevention ............................................................................... 9-3 motorcycle cleaning .............................................

  • Page 76: Motorcycle

    9-2 storage procedure and appearance care if your motorcycle is to be left unused for an extended period of time, it needs special servicing requiring appropriate materials, equipment and skill. For this rea- son, suzuki recommends that you trust this maintenance work to your suzuki dealer. If you w...

  • Page 77: External

    9-3 external 1. Spray all vinyl and rubber parts with rubber protectant. 2. Spray unpainted surface with rust preventative. 3. Coat painted surfaces with car wax. Procedure for returning to service 1. Clean the entire motorcycle. 2. Remove the oily rags from the air cleaner intake and muffler outlet...

  • Page 78: Motorcycle Cleaning

    9-4 3. Repair finish damage as soon as possible carefully examine your motor- cycle for damage to the painted surfaces. Should you find any chips or scratches in the paint, touch them up immediately to prevent corro- sion from starting. If the chips or scratches have gone through to the bare metal, ...

  • Page 79: Waxing The Motorcycle

    9-5 waxing the motorcycle after washing the motorcycle, waxing is recommended to further protect and beautify the paint. Observe the precautions speci- fied by the wax manufacturer. Inspection after cleaning for extended life of your motorcy- cle, lubricate according to “gen- eral lubrication” secti...

  • Page 80

    Jr50_03a.Book page 6 tuesday, april 12, 2005 5:06 pm.

  • Page 81: Consumer Information

    10 10-1 consumer information tampering with noise control system prohibited ...................... 10-2 serial number location .......................................................................... 10-3 location of labels .............................................................................

  • Page 82: Tampering With Noise

    10-2 consumer information tampering with noise control system prohibited federal law prohibits the following acts or the causing thereof; 1. The removal or rendering in- operative by any person other than for purposes of mainte- nance, repair, or replacement, of any device or element of design incor...

  • Page 83: Serial Number Location

    10-3 serial number location you need to know the frame and engine serial numbers to get title documents for your motorcycle. You also need these numbers to help your dealer when you order parts. The frame number 1 is stamped on the steering head tube. The engine serial number 2 is stamped on the lef...

  • Page 84: Warning

    10-4 1 2 3 warning failure to follow these safety precautions may increase your risk of injury: • wear a helmet, eye protec- tion, and bright protective clothing. • off-road use only – do not use on public roads or high- ways. • slow down on slippery sur- faces, unfamiliar terrain, or when visibili...

  • Page 85

    Jr50_03a.Book page 5 tuesday, april 12, 2005 5:06 pm.

  • Page 86: Specifications

    Specifications dimensions and dry mass overall length ..................................................1245 mm (49.0 in) overall width.................................................... 595 mm (23.4 in) overall height .................................................. 730 mm (28.7 in) wheelbase .....

  • Page 87

    Jr50_03a.Book page 2 tuesday, april 12, 2005 5:06 pm.

  • Page 88: Index

    Index a air cleaner ....................... 7-5 b brakes............................... 7-16 break-in .............................. 4-2 c carburetor .................... 7-10 choke lever...................... 3-9 clothing............................. 1-4 corrosion prevention ..........................

  • Page 89

    R rear brake pedal ......... 3-10 right handlebar ............. 3-5 s seat height adjustment ..................... 3-13 serial number location ........................... 10-3 side stand........................ 3-10 spark arrester............. 7-20 spark plug ........................ 7-8 starting a ...

  • Page 90

    Jr50_03a.Book page 3 tuesday, april 12, 2005 5:06 pm.

  • Page 91: Warning

    This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator. The manual contains important safety information and instructions which should be read carefully before operating the motorcycle....

  • Page 92: 99011-04493-03A

    99011-04493-03a jr50 part no. 99011-04493-03a june, 2005 en tk k6 jr50 printed in taiwan 300 takatsuka, hamamatsu, japan owner’s manual this owner’s manual contains important safety information. Please read it carefully. Warning failure to follow these safety precautions may increase your risk of in...