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Suzuki LT-Z50 Service Manual

Summary of LT-Z50

  • Page 1

    Group index general information 1 periodic maintenance 2 engine 3 fuel system 4 chassis 5 electrical system 6 servicing information 7 foreword this manual contains an introductory description on the suzuki lt-z50 and procedures for its inspec- tion/service and overhaul of its main components. Other ...

  • Page 2: Partshark.Com

    Partshark.Com 877-999-5686.

  • Page 3: Supplements

    03 engine.Book page 105 tuesday, february 28, 2006 3:03 pm supplements lt-z50k9 ( 09-model) 8 11 partshark.Com 877-999-5686.

  • Page 4: 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. The section titles are listed in the group index. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily. 4. The contents are listed on ...

  • Page 5: Partshark.Com

    Symbol listed in the table below are the symbols indicating instructions and other information necessary for servic- ing. The meaning of each symbol is also included in the table. Symbol definition symbol definition torque control required. Data beside it indicates specified torque. Measure in volta...

  • Page 6: General Information

    General information 1-1 1 general information contents country and area codes the following codes stand for the applicable country (-ies) and area (-s). Model code country or area effective frame no. Lt-z50k6 p-03 u.S.A. Lm4az413 61100001- p-19 e.U. P-28 canada warning/caution/note ....................

  • 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: Partshark.Com

    General information 1-3 * if parts replacement is necessary, replace the parts with suzuki genuine parts or their equiva- lent. * when removing parts 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 s...

  • Page 9: Serial Number Location

    1-4 general information suzuki lt-z50k6 (’06-model) • difference between photograph and actual vehicle may exist depending on the markets. Serial number location the frame serial number or v.I.N. (vehicle identification number) 1 is stamped on the left side of the rear frame pipe. The engine serial ...

  • Page 10: Fuel and Oil Recommendation

    General information 1-5 fuel and oil recommendation fuel (for usa and canada) use only unleaded gasoline of at least 87 pump octane (r/2 + m/2) or 91 octane or higher rated by the research method. Gasoline containing mtbe (methyl tertiary butyl ether), less than 10 % ethanol, or less than 5 % methan...

  • Page 11: Break-In Procedures

    1-6 general information break-in procedures during manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “break-in” before subjecting the engine to maximum stresses. The future performa...

  • Page 12: Information Labels

    General information 1-7 information labels a: attached information marks d label is attached on the left side of frame. 1 certification plate a (for p-03, 19) 2 compliance label a (for p-28) 3 manual notice label a (for p-03) 4 parking brake label (english) a (for p-03, 19, 28) 5 parking brake label...

  • Page 13: Specifications

    1-8 general information specifications dimensions and dry mass overall length.......................................................................... 1 270 mm (50.0 in) overall width ........................................................................... 760 mm (29.9 in) overall height...........

  • Page 14: Partshark.Com

    General information 1-9 chassis front suspension..................................................................... Independent, swing axle, coil spring, oil damped rear suspension ..................................................................... Swingarm, coil spring, oil damped front wheel t...

  • Page 15: Partshark.Com

    Partshark.Com 877-999-5686.

  • Page 16: Periodic Maintenance

    2 6 periodic maintenance 2-1 contents periodic maintenance periodic maintenance schedule .....................................................2- 2 periodic maintenance chart .....................................................2- 2 maintenance and tune-up procedures ....................................

  • Page 17: Partshark.Com

    2-2 periodic maintenance periodic maintenance schedule the chart below lists the recommended intervals for all the required periodic service work necessary to keep the vehicle operating at peak performance and economy. Note: more frequent servicing may be required on vehicles that are used under sev...

  • Page 18: Partshark.Com

    Periodic maintenance 2-3 maintenance and tune-up procedures this section describes the servicing procedures for each item of the periodic maintenance requirements. Before performing the servicing procedures mentioned in the periodic maintenance chart, remove following parts to ease ser- vicing work;...

  • Page 19: Partshark.Com

    2-4 periodic maintenance • fill a container with a non-flammable cleaning solvent. • immerse the air cleaner element in the cleaning solvent and wash it. • squeeze the cleaning solvent out of the washed element by pressing it between the palms of both hands: do not twist or wring the element or it w...

  • Page 20: Partshark.Com

    Periodic maintenance 2-5 exhaust pipe nuts and muffler mounting bolt • tighten the exhaust pipe nuts 1 and muffler mounting bolt 2 to the specified torque.  exhaust pipe nut: 10 n·m (1.0 kgf-m, 7.0 lb-ft) muffler mounting bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft) valve clearance excessive valve clearanc...

  • Page 21: Partshark.Com

    2-6 periodic maintenance • turn the crankshaft counterclockwise, to bring the line a on the generator rotor to the index mark b of the generator case. • press intake and exhaust rocker arm to the inside and mea- sure the valve clearance.  09900-20806: thickness gauge  valve clearance (when cold): ...

  • Page 22: Partshark.Com

    Periodic maintenance 2-7 spark plug • disconnect the spark plug cap 1 and remove the spark plug 2. Carbon deposits check carbon deposits on the spark plug. • if carbon is deposited, remove it using a spark plug cleaner machine or carefully use a tool with a pointed end. Spark plug gap measure the sp...

  • Page 23: Partshark.Com

    2-8 periodic maintenance spark plug installation • tighten the spark plug to the specified torque.  spark plug: 11 n·m (1.1 kgf-m, 8.0 lb-ft) spark arrester • extract the spark arrester 1 from the muffler. • clean the spark arrester 1 by brush. • reinstall the spark arrester 1. Fuel line inspect th...

  • Page 24: Partshark.Com

    Periodic maintenance 2-9 engine oil engine oil level check follow the procedure below to inspect the engine oil level. • place the vehicle on level ground. • remove the maintenance lid. ( 5-6) • start the engine and run it for a few minutes. • stop the engine and wait three minutes. • check the eng...

  • Page 25: Partshark.Com

    2-10 periodic maintenance final reduction gear box oil final reduction gear box oil lever check • place the vehicle on level ground. • remove the right frame cover. ( 5-4) • remove the generator cover 1. • remove the oil filler cap 2. • inspect the oil level. If the oil level is below the edge of t...

  • Page 26: Partshark.Com

    Periodic maintenance 2-11 • loosen the lock-nut 1 of the throttle cable. • turn the adjuster 2 in or out to obtain the correct play. • after adjusting the throttle cable play, tighten the locknut 1.  throttle cable play: 3 – 5 mm (0.12 – 0.20 in) \ engine idle speed • adjust the throttle cable play...

  • Page 27: Partshark.Com

    2-12 periodic maintenance • remove the fixed drive face nut 3 and starter cup 4 with the special tool.  09930-40113: rotor holder • remove the fixed drive face 5. • remove the clutch housing 6 with the special tool.  09930-40113: rotor holder • remove the movable driven face 7 with drive belt 8. I...

  • Page 28: Partshark.Com

    Periodic maintenance 2-13 remounting remount the drive belt in the reverse order of removal. Pay attention to the following points: • insert the drive belt, as low as possible, between the movable driven face to provide the maximum drive belt clearance before installing. • install the movable driven...

  • Page 29: Partshark.Com

    2-14 periodic maintenance • turn the fixed drive face until the drive belt is properly seated and both the drive and driven face rotate together smoothly and without slipping. Drive chain visually check the drive chain for the possible defects listed below. (support the vehicle by a jack and a woode...

  • Page 30: Partshark.Com

    Periodic maintenance 2-15 • count out 21 pins (20-pitch) on the chain and measure the distance between the two points. If the distance exceeds the service limit, the chain must be replaced.  drive chain 20-pitch length: service limit: 259.0 mm (10.20 in) adjusting • place the vehicle on level groun...

  • Page 31: Partshark.Com

    2-16 periodic maintenance • after cleaning and drying the chain, oil it with a heavy-weight engine oil. The drive chain joint clip should be attached in the way that the slit end will face opposite to the direction of travel. Direction of travel partshark.Com 877-999-5686.

  • Page 32: Partshark.Com

    Periodic maintenance 2-17 brakes front brake lever play • adjust the right and left cable end length a to become equal by adjusting nuts 1. • turn the adjusters 2 so that the brake lever play b is within specification after loosening the locknut.  front brake lever play b: 4 – 6 mm (0.16 – 0.24 in)...

  • Page 33: Partshark.Com

    2-18 periodic maintenance tires tire tread condition operating the vehicle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of the tire tread reaches the following specificati...

  • Page 34: Partshark.Com

    Periodic maintenance 2-19 steering steering system should be adjusted properly for smooth manip- ulation of the handlebar and safe running. Toe-in • place the vehicle on level ground. • make sure the tire pressure for both tire is the same and set to the proper specification. • set the front wheels ...

  • Page 35: Partshark.Com

    2-20 periodic maintenance chassis nuts and bolts check that all chassis nuts and bolts are tightened to their specified torque. (refer to page 2-21 for the loca- tions of the following nuts and bolts.) tighten initially at 1 month and every 3 months there- after. Item n·m kgf-m lb-ft 1 front suspens...

  • Page 36: Partshark.Com

    Periodic maintenance 2-21 partshark.Com 877-999-5686.

  • Page 37: Partshark.Com

    2-22 periodic maintenance general lubrications proper lubrication is important for smooth operation and long life of each working part of the vehicle. Major lubrication points are indicated below. 1 steering shaft holder 2 brake lever holder 3 brake cable 4 throttle cable 5 drive chain 6 throttle le...

  • Page 38: Compression Pressure Check

    Periodic maintenance 2-23 compression pressure check the compression pressure reading 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 mainte- nance records kept at your dealership should ...

  • Page 39: Partshark.Com

    2-24 periodic maintenance initial engagement and clutch lock-up inspection the lt-z50 is equipped with a centrifugal type automatic clutch. To insure proper performance and longevity of the clutch assemblies it is essential that the clutches engage smoothly and gradually. Before checking the initial...

  • Page 40: Partshark.Com

    Periodic maintenance 2-25 clutch lock-up inspection perform this inspection to determine if the clutch is engaging fully and not slipping. • connect a multi-circuit tester onto the spark plug high-tension code. • start the engine. • apply the front and rear brakes as firmly as possible. • fully open...

  • Page 41: Partshark.Com

    Partshark.Com 877-999-5686.

  • Page 42: Engine

    3 6 engine 3-1 contents engine engine components removable with engine in place ...........3- 2 engine center ..................................................................................3- 2 engine left side ...............................................................................3- 2 en...

  • Page 43: Partshark.Com

    3-2 engine engine components removable with engine in place the parts listed below can be removed and installed without removing the engine from the frame. Refer to the page listed in each section for removal and installation instructions. Engine center engine left side engine right side parts remov...

  • Page 44: Partshark.Com

    Engine 3-3 engine removal and installation engine removal before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. • drain engine oil. ( 2-9) • remove the frame center cover. ( 5-5) muffler • remove the exhau...

  • Page 45: Partshark.Com

    3-4 engine • remove the vacuum hose 5. • remove the carburetor assembly 6. Drive chain • remove the clip 1. • remove the drive chain 2. Electrical parts and hoses • disconnect the starter motor lead wire coupler 1. • disconnect the generator lead wire coupler 2. • remove the ground wire 3. • remove ...

  • Page 46: Partshark.Com

    Engine 3-5 engine mounting bracket and bolts • remove the engine mounting bracket 1. • remove the engine mounting bolts and nuts. • remove the engine from the left side. Partshark.Com 877-999-5686.

  • Page 47: Partshark.Com

    3-6 engine engine installation install the engine in the reverse order of engine removal. Pay attention to the following points: • tighten the engine mounting nuts to the specified torque.  engine mounting nut: 31 n·m (3.1 kgf-m, 22.5 lb-ft) lh rh rh lh 1 engine mounting bolt (25 mm) 4 engine mount...

  • Page 48: Partshark.Com

    Engine 3-7 • install the drive chain 1. • install the clip 2. • apply suzuki super grease “a”to the o-ring.  99000-25010: suzuki super grease “a” or equivalent • tighten the carburetor mounting bolts 3 to the specified torque.  carburetor mounting bolt: 6 n·m (0.6 kgf-m, 4.5 lb-ft) • install the e...

  • Page 49: Partshark.Com

    3-8 engine • tighten the exhaust pipe nuts to the specified torque.  exhaust pipe nut: 10 n·m (1.0 kgf-m, 7.0 lb-ft) • tighten the muffler mounting bolt to the specified torque.  muffler mounting bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft) • after remounting the engine, inspect the lead wires and hoses r...

  • Page 50: Engine Disassembly

    Engine 3-9 engine disassembly spark plug • remove the spark plug with a spark plug wrench. Cylinder head cover • remove the cylinder head cover 1 and its gasket. Generator cover • remove the generator cover 1. A: hooked part cylinder head • turn the crankshaft counterclockwise to bring the line a on...

  • Page 51: Partshark.Com

    3-10 engine • remove the push rods 2. • remove the gasket 3 and dowel pins 4. Starter motor • remove the starter motor 1. Generator • remove the generator rotor nut with the special tool.  09930-40113: rotor holder • remove the generator rotor 1 with the special tool and removed nut 2.  09920-1312...

  • Page 52: Partshark.Com

    Engine 3-11 recoil starter • remove the recoil starter 1. Movable drive • remove the cvt case cover 1. • remove the dowel pins 2 and gasket 3. • remove the starter pinion 4. • remove the fixed drive face nut 5 with the special tool.  09930-40113: rotor holder • remove the starter cup assembly. • re...

  • Page 53: Partshark.Com

    3-12 engine • remove the movable drive spacer 7 together with the power reduction spacer 8 and movable drive face assembly 9. Note: movable drive face disassembly. ( 3-36) • remove the washer 0. Movable driven • remove the clutch housing 1 with the special tool.  09930-40113: rotor holder • remove...

  • Page 54: Partshark.Com

    Engine 3-13 • remove the dowel pins 2 and gasket 3. Generator case • remove the generator case 1. • remove the dowel pins 2 and gasket 3. Cam rocker arm • remove the washer 1 and camshaft assembly 2. • remove the washer 3, spring 4 and cam rocker arms 5. Partshark.Com 877-999-5686.

  • Page 55: Partshark.Com

    3-14 engine upper crankcase/cylinder and lower crank- case • remove the crankcase bolts. • remove the dowel pins 1. Crankshaft • remove the crankshaft 1 together with piston. • remove the crankshaft bearing retainer 2. Piston • remove the piston pin circlip 1. • remove the piston pin 2 and piston 3....

  • Page 56: Engine Components Inspection

    Engine 3-15 engine components inspection and servicing cylinder head disassembly • remove the intake pipe 1 and insulator 2. • pull out the rocker arm shaft 3. • remove the intake rocker arm 4 and exhaust rocker arm 5. • push the spring retainer 6 by the finger and move it side- ways. • remove the s...

  • Page 57: Partshark.Com

    3-16 engine • remove the intake valve stem seal 0 with an acute angle bar. Rocker arm shaft inspection inspect the rocker arm shaft for abnormal wear or damage. If it is worn or damaged, replace it with a new one. Rocker arm inspection inspect the rocker arm for abnormal wear or damage. If they are ...

  • Page 58: Partshark.Com

    Engine 3-17 valve face wear visually inspect each valve for wear or damage of its seating face. If anything unusual is found, replace the valve with a new one. Measure the valve head thickness t. If the thickness is less than the service limit, replace the valve with a new one.  valve head thicknes...

  • Page 59: Partshark.Com

    3-18 engine valve stem wear if the valve stem is worn down to the limit, as measured with a micrometer, replace the valve. If the stem is within the limit, replace the cylinder head. After replacing the valve, be sure to recheck the deflection.  valve stem o.D.: standard (in): 3.975 – 3.990 mm (0.1...

  • Page 60: Partshark.Com

    Engine 3-19 valve spring the force of the coil spring keeps the valve seat tight. Weak- ened spring results in reduced engine power output, and often account for the chattering noise coming from the valve mecha- nism. • check the valve springs for proper strength by measuring their free length and a...

  • Page 61: Partshark.Com

    3-20 engine • assemble the valve spring 1 and spring retainer 2. • push the spring retainer by the finger with the valve prevented from falling. • incline the spring retainer 2 and set it into the valve stem groove. • apply engine oil to the rocker arm shaft 3. • install the rocker arm shaft 3. • in...

  • Page 62: Partshark.Com

    Engine 3-21 camshaft assembly inspection check the camshaft for abnormal wear or damage. Measure the cam height h with a micrometer. If the cam height h is less than the service limit, replace the camshaft assembly with a new one.  cam height h (in & ex): service limit: 28.13 mm (1.1075 in)  09900...

  • Page 63: Partshark.Com

    3-22 engine cylinder bore inspect the cylinder wall for any scratches, nicks or other dam- age. If anything unusual is found, replace the upper crankcase/cylin- der. Measure the cylinder bore diameter at six places.  cylinder bore: standard: 36.005 – 36.015 mm (1.4175 – 1.4179 in) piston and piston...

  • Page 64: Partshark.Com

    Engine 3-23 piston ring free end gap and piston ring end gap measure the piston ring free end gap with a vernier calipers. Next, fit the piston ring squarely into the cylinder and measure the piston ring end gap with a thickness gauge. If any of the measurements exceeds the service limit, replace th...

  • Page 65: Partshark.Com

    3-24 engine conrod and crankshaft conrod small end i.D. Measure the conrod small end inside diameter with a caliper gauge. If the conrod small end inside diameter exceeds the service limit, replace the conrod.  conrod small end i.D.: service limit: 10.040 mm (0.3952 in)  09900-20605: dial calipers...

  • Page 66: Partshark.Com

    Engine 3-25 crankshaft bearing inspection inspect the outer race play and smooth rotation of the bearing by hand while it is on the crankshaft. If any abnormality is found, replace the bearing with a new one. Note: if there is no abnormal noise, the bearing removal is not neces- sary. Crankshaft bea...

  • Page 67: Partshark.Com

    3-26 engine crankshaft bearing installation • press-fit the bearing with the bearing installer and suitable plate as shown in the illustration. • press-fit the cam drive gear 1 with the suitable tool.  phase angle between the crank pin center a and the cam drive gear engraved line b: 0° ± 30’ suita...

  • Page 68: Partshark.Com

    Engine 3-27 conrod big end side clearance inspection push the big end of the conrod to one side and measure the side clearance with a thickness gauge. If the clearance exceeds the limit, replace the crankshaft assem- bly with a new one or bring the deflection and the side clearance within the servic...

  • Page 69: Partshark.Com

    Partshark.Com 877-999-5686.

  • Page 70: Engine

    3 6 engine 3-1 contents engine engine components removable with engine in place ...........3- 2 engine center ..................................................................................3- 2 engine left side ...............................................................................3- 2 en...

  • Page 71: Partshark.Com

    3-28 engine final reduction gear box and cvt case disassembly • remove the snap ring 1 and engine sprocket 2. • remove the drain plug 3 and gasket. • drain final reduction gear box oil. • remove the final reduction gear box cover 4. Note: loosen the final reduction gear box cover bolts little by lit...

  • Page 72: Partshark.Com

    Engine 3-29 drive shaft inspection inspect the drive shaft for wear or damage. If it is worn or damaged, replace it with a new one. Bearing inspection rotate the bearing inner race by finger to inspect for abnormal play, noise and smooth rotation while the bearings are in the those cases. Replace th...

  • Page 73: Partshark.Com

    3-30 engine • remove the snap ring 3. • remove the bearing 4 with the special tool.  09913-70210: bearing installer set bearing installation • install the bearings with the special tool.  09913-70210: bearing installer set • apply suzuki super grease “a” to the bearing 1.  99000-25010: suzuki sup...

  • Page 74: Partshark.Com

    Engine 3-31 • install the bearing 3 with the special tool.  09913-70210: bearing installer set • install the snap ring 4 securely. • install the oil seal 5 with the special tool.  09913-70210: bearing installer set • apply suzuki super grease “a”to the oil seal lip.  99000-25010: suzuki super gre...

  • Page 75: Partshark.Com

    3-32 engine • apply molybdenum oil solution to the inside of the drive shaft journal.  molybdenum oil solution • install the washer 2 to the drive shaft. • install the drive shaft 3 to the cvt case. • install the washer 4 and 5. • install the dowel pins 6. • apply suzuki bond “1215” to the final re...

  • Page 76: Partshark.Com

    Engine 3-33 • install the engine sprocket 8. • install the snap ring 9. Cvt case cover bushing inspection inspect the cvt case cover bushing for wear or damage. If anything unusual is found, replace the bushing or cvt case cover. Generator case bushing inspection inspect the bushing 1 for wear or da...

  • Page 77: Partshark.Com

    3-34 engine • remove the oil seal 1 with the special tool.  09913-70210: bearing installer set • install the oil seal 2 with the special tool.  09913-70210: bearing installer set • apply suzuki super grease “a”to the oil seal lip.  99000-25010: suzuki super grease “a” or equivalent starter pinion...

  • Page 78: Partshark.Com

    Engine 3-35 movable and fixed drive and driven face 1 concaved washer c movable driven face spring 2 fixed drive face d movable driven face spring seat 3 drive belt e roller 4 movable drive spacer f pin 5 power reduction spacer g movable driven face 6 movable drive face h fixed driven face 7 roller ...

  • Page 79: Partshark.Com

    3-36 engine movable drive disassembly • remove the movable drive face plate 1 and dampers 2. • remove the rollers 3. Spacer inspection inspect the movable drive spacer 1 and power reduction spacer 2 for any wear or damage. If they are worn or damaged, replace them with new ones. Movable and fixed dr...

  • Page 80: Partshark.Com

    Engine 3-37 damper inspection inspect the dampers for wear or damage. If any defects are found, replace the dampers with new ones. Reassembly • position the rollers 1 on the movable drive face 2. • mount the dampers 3 on the movable drive face plate 4. • check that the rollers 1 are in normal positi...

  • Page 81: Partshark.Com

    3-38 engine • loosen the special tool handle slowly and remove the clutch shoe assembly 4 and spring 5. • remove the movable driven face spring seat 6. • remove the pins 7 together with rollers 8. • remove the movable driven face 9. Inspection inspect the movable driven face metal a for wear or dama...

  • Page 82: Partshark.Com

    Engine 3-39 bearing inspection rotate the bearing inner race by finger to inspect for abnormal play, noise and smooth rotation while the bearing is in the fixed driven face. Replace the bearing in the following procedure if there is any- thing unusual. • remove the needle bearing 1 with the special ...

  • Page 83: Partshark.Com

    3-40 engine measure the thickness of clutch shoe at the center position. If the thickness is less than the service limit, replace the clutch shoe assembly with a new one.  clutch shoe thickness: service limit: 3.0 mm (0.12 in)  09900-20102: vernier calipers clutch housing inspection inspect the cl...

  • Page 84: Partshark.Com

    Engine 3-41 reassembly • install the bearing 1 to the fixed driven face 2 with a suitable spacer. • install the snap ring 3. • install the needle bearing 4 with a suitable spacer. • apply suzuki super grease “a” to the needle bearing.  99000-25010: suzuki super grease “a” or equivalent • install th...

  • Page 85: Partshark.Com

    3-42 engine • install the pins 6 to the pin hole with the rollers 7 fitted. • install the movable driven face spring seat 8 to the movable driven face 5 securely. • install the spring 9 and clutch shoe assembly 0 onto the movable driven face 5. • compress the spring 9 with the special tool.  09922-...

  • Page 86: Partshark.Com

    Engine 3-43 recoil starter 1 starter cup spacer 8 reel 2 starter cup 9 spiral spring 3 starter cup bolt 0 starter case 4 friction plate a rope 5 friction spring b knob 6 ratchet c cap item n·m kgf-m lb-ft 7 return spring a recoil starter friction plate bolt a 5.4 0.54 4.0 partshark.Com 877-999-5686.

  • Page 87: Partshark.Com

    3-44 engine disassembly • remove the bolt 1 and friction plate 2. • remove the ratchet 3 and return spring 4. • remove the cap 5 from the knob 6. • untie a knot at the rope. • hook the rope to the groove a of the reel 7. • turn the rope on the reel 7 properly. • remove the reel 7. • remove the spira...

  • Page 88: Partshark.Com

    Engine 3-45 reassembly reassemble the recoil starter in the reverse order of disassem- bly. Pay attention to the following points: • when installing the spiral spring, hook the spiral spring end 1 with the recoil starter case. • apply suzuki super grease “a”to the spiral spring.  99000-25010: suzuk...

  • Page 89: Partshark.Com

    3-46 engine • apply suzuki super grease “a”to the return spring 5.  99000-25010: suzuki super grease “a” or equivalent • install the return spring 5. • apply suzuki super grease “a”to the sliding part of the friction spring 6 and ratchet.  99000-25010: suzuki super grease “a” or equivalent • align...

  • Page 90: Engine Reassembly

    Engine 3-47 engine reassembly reassemble the engine in the reverse order of disassembly. Pay special attention to the following points: note: apply engine oil to each running and sliding surface before reas- sembling. Piston ring and piston • install the piston rings in the order of oil ring, 2nd ri...

  • Page 91: Partshark.Com

    3-48 engine note: end gap of the circlip should not be aligned with the cutaway f in the piston pin bore. Note: when installing the piston 4, the punched mark g on the piston head is located to the exhaust side. Crankshaft • apply engine oil to the crankshaft bearing 1. • apply suzuki super grease “...

  • Page 92: Partshark.Com

    Engine 3-49 • install the crankshaft 4 and dowel pins 5 to the upper crank- case/cylinder. Note: apply engine oil to the bearing 6 balls and conrod big end 7. Crankcase • apply suzuki bond “1215” to the lower crankcase matching surface.  99000-31110: suzuki bond “1215” or equivalent note: use of su...

  • Page 93: Partshark.Com

    3-50 engine cam rocker arm • assemble the cam rocker arms 1, shaft 2 and washer 3. Note: align the hollows a of the cam rocker arm. • apply engine oil to the cam rocker arm shaft 4. • install the cam rocker arms 5, spring 6 and washer 7 to the upper crankcase/cylinder. • keep the rocker arms 5 open....

  • Page 94: Partshark.Com

    Engine 3-51 • tighten the generator case bolts to the specified torque.  generator case bolt: 11 n·m (1.1 kgf-m, 8.0 lb-ft) cvt case • install the dowel pins 1 and gasket 2. • tighten the cvt case bolts to the specified torque.  cvt case bolt: 11 n·m (1.1 kgf-m, 8.0 lb-ft) movable driven face • in...

  • Page 95: Partshark.Com

    3-52 engine • tighten the clutch housing nut 3 to the specified torque with the special tool.  09930-40113: rotor holder  clutch housing nut: 50 n·m (5.0 kgf-m, 36.0 lb-ft) note: degrease the inside of the clutch housing and clutch shoe. Movable drive face • install the washer 1. • install the mov...

  • Page 96: Partshark.Com

    Engine 3-53 note: turn the fixed drive face 3 until the drive belt is seated in and both the drive and driven faces will move together smoothly without slip. Cvt case cover • install the dowel pins 1 and gasket 2. • install the starter pinion 3. • install the cvt case cover 4. • tighten the cvt case...

  • Page 97: Partshark.Com

    3-54 engine • tighten the generator rotor nut 4 to the specified torque with the special tool.  09930-40113: rotor holder  generator rotor nut: 35 n·m (3.5 kgf-m, 25.5 lb-ft) starter motor • install the starter motor 1. Cylinder head • apply molybdenum oil solution to both ends of the push rods 1....

  • Page 98: Partshark.Com

    Engine 3-55 • install the gasket 2 and dowel pins 3. • install the cylinder head. • position the push rods 1 to the rocker arm adjust bolt hollows d. • tighten the cylinder head bolts to the specified torque.  cylinder head bolt: 14 n·m (1.4 kgf-m, 10.0 lb-ft) note: tighten the bolts little by litt...

  • Page 99: Partshark.Com

    3-56 engine b: hooked part cylinder head cover • assemble the cylinder head cover gasket 1. • tighten the cylinder head cover bolts to the specified torque.  cylinder head cover bolt: 11 n·m (1.1 kgf-m, 8.0 lb-ft) • tighten the spark plug to the specified torque with a spark plug wrench.  spark pl...

  • Page 100: Fuel System

    Fuel system 4-1 4 fuel system contents fuel tank and fuel valve ...................................................................4- 2 removal ...............................................................................................4- 3 fuel filter inspection and cleaning .......................

  • Page 101: Fuel Tank and Fuel Valve

    4-2 fuel system fuel tank and fuel valve 1 fuel tank breather hose 6 fuel hose 2 fuel tank cap 7 o-ring 3 fuel tank inlet rubber 8 vacuum hose 4 fuel tank 9 gasket item n·m kgf-m lb-ft 5 fuel valve a fuel valve bolt a 4.5 0.45 3.3 partshark.Com 877-999-5686.

  • Page 102: Partshark.Com

    Fuel system 4-3 removal • remove the frame center cover. ( 5-5) • turn the fuel valve to “on” position. • disconnect the fuel hose 1. • disconnect the vacuum hose 2. • remove the fuel tank 3. • remove the fuel valve assembly 4. Fuel filter inspection and cleaning if the fuel filter is dirty with se...

  • Page 103: Partshark.Com

    4-4 fuel system remounting remount the fuel tank and fuel valve in the reverse order of removal. Pay attention to the following points: • tighten the fuel valve bolts to the specified torque.  fuel valve bolt: 4.5 n·m (0.45 kgf-m, 3.3 lb-ft) note: install the rounded side a of fuel hose to the fuel...

  • Page 104: Carburetor

    Fuel system 4-5 carburetor 1 choke lever 0 spring i needle jet 2 carburetor top cap a throttle stop screw j main jet 3 spring b air vent hose k float pin 4 spring seat c o-ring l float 5 jet needle d needle valve seat m gasket 6 piston valve e needle valve n float chamber 7 starter plunger f needle ...

  • Page 105: Partshark.Com

    4-6 fuel system specifications i.D. No. Location • the carburetor has i.D. Number a stamped on its body according to its specifications. Item specification carburetor type mikuni vm13 bore size 13 mm i.D. No 43g0 idle r/min. 2 000 ± 150 r/min. Float height 23.4 ± 1.0 mm (0.92 ± 0.04 in) main jet (m....

  • Page 106: Partshark.Com

    Fuel system 4-7 removal • remove the left frame cover. ( 5-4) • remove the right frame cover. ( 5-4) • remove the fuel hose 1. • remove the air vent hose 2. • remove the vacuum hose 3. • loosen the drain plug 4. • drain the fuel from the carburetor. • remove the drain hose 5 from the clamp. • remo...

  • Page 107: Partshark.Com

    4-8 fuel system disassembly • remove the spring 1 and piston valve 2 from the throttle cable. • remove the spring seat 3. • remove the jet needle 4 from the piston valve 2. • remove the drain hose 5. • remove the float chamber 6. The removed o-rings and gasket must be replaced with new ones. Partsha...

  • Page 108: Partshark.Com

    Fuel system 4-9 • remove the gasket 7. • remove the float pin 8. • remove the float 9. • remove the needle valve 0. • remove the main jet a and needle jet b. • remove the pilot jet c. • remove the screw d. • remove the needle valve retainer e and needle valve seat f. • remove the throttle stop screw...

  • Page 109: Partshark.Com

    4-10 fuel system • remove the spring h, washer i and o-ring j. • remove the choke lever k. • remove the starter plunger l. Partshark.Com 877-999-5686.

  • Page 110: Partshark.Com

    Fuel system 4-11 cleaning • clean all jets with a spray-type carburetor cleaner and dry them with compressed air. • clean all circuits of the carburetor thoroughly - not just the perceived problem area. Clean the circuits in the carburetor body with a spray-type cleaner and allow each circuit to soa...

  • Page 111: Partshark.Com

    4-12 fuel system if the needle valve is worn, as shown in the illustration, replace the needle valve assembly with a new one. Clean the fuel pas- sage of the mixing chamber with compressed air. Float height adjustment to check the float height, turn the carburetor upside down. Mea- sure the float he...

  • Page 112: Partshark.Com

    Fuel system 4-13 gasket • install the gasket 1. Piston valve and spring • install the piston valve 1 and spring 2 to the throttle cable. Carburetor • apply suzuki super grease “a” to the o-ring 1.  99000-25010: suzuki super grease “a” or equivalent • install the piston valve 2 to the carburetor. • ...

  • Page 113: Partshark.Com

    4-14 fuel system • after remounting the carburetor, perform the following: * inspect fuel leakage. * engine idle r/min adjustment..................... 2-11 * throttle cable play adjustment .................. 2-10 partshark.Com 877-999-5686.

  • Page 114: Chassis

    5 chassis 5-1 chassis contents exterior parts ...................................................................................... 5- 2 construction .................................................................................. 5- 2 fastener removal and installation ..............................

  • Page 115: Exterior Parts

    5-2 chassis exterior parts construction 1 seat 5 maintenance lid 9 fuel tank cap 2 battery holder 6 front frame cover 0 fuel tank inlet rubber 3 frame center cover 7 left frame cover a fuel tank 4 right frame cover 8 front grip partshark.Com 877-999-5686.

  • Page 116: Partshark.Com

    Chassis 5-3 fastener removal and installation fastener removal • depress the head of fastener center piece 1. • pull out the fastener a. Installation • let the center piece stick out toward the head so that the pawls 2 close. • insert the fastener into the installation hole. Note: to prevent the paw...

  • Page 117: Partshark.Com

    5-4 chassis removal seat • remove the seat. Front frame cover • remove the fasteners. • remove the ignition switch ring nut 1. • remove the front frame cover 2. Note: “ ✩” indicates hook location. Left frame cover • remove the screws 1 and fasteners. • remove the bolts 2. • remove the left frame cov...

  • Page 118: Partshark.Com

    Chassis 5-5 frame center cover • remove the seat. ( 5-4) • remove the front frame cover. ( 5-4) • remove the left frame cover. ( 5-4) • remove the right frame cover. ( 5-4) • disconnect the - battery cable first, and then + battery cable. • remove the battery 1. • remove the fuse box 2 from the ...

  • Page 119: Partshark.Com

    5-6 chassis maintenance lid • remove the fastener. • remove the maintenance lid 1. Front grip • remove the front grip. Remounting remount the exterior parts in the reverse order of removal. Pay attention to the following points: fuel tank inlet rubber • align the fuel tank inlet rubber hollow a with...

  • Page 120: Front and Rear Wheels

    Chassis 5-7 front and rear wheels construction removal • place the vehicle on level ground. • support the vehicle with a jack or wooden block and remove the front and rear wheel set nuts. • remove the front and rear wheels. Remounting remount the wheels in the reverse order of removal. Pay atten- ti...

  • Page 121: Tires

    5-8 chassis tires tire replacement • remove the front and rear wheels. ( 5-8) • after removing the air valve caps, release the tire pressure by depressing the valves. • dismount the bead from the rim completely as shown. • separate the tire from the rim using a set of tire levers and rim protectors...

  • Page 122: Partshark.Com

    Chassis 5-9 • when installing each tire, make sure the arrow a on the tire points in the direction of rotation. Also, make sure the outer side of the wheel rim is facing outward. Note: for inspecting the tires, refer to page 2-18. Inspect the valve cores, before installing. • inflate the tire to sea...

  • Page 123: Front Brake

    5-10 chassis front brake construction 1 wheel center cap 0 front brake camshaft 2 axle spacer a o-ring 3 outer dust seal b front brake dust seal 4 wheel hub outer bearing c brake plate 5 front wheel hub d brake cam lever 6 spacer e front brake cam lever bolt 7 wheel hub inner bearing f spring item n...

  • Page 124: Partshark.Com

    Chassis 5-11 removal • remove the front wheel. ( 5-8) • remove the wheel center cap. • remove the cotter pin and front hub nut 1. • remove the front wheel hub 2. • remove the front brake shoe assembly 3. • remove the spring 4. • remove the front brake adjusting nut 5. • remove the front brake cam l...

  • Page 125: Partshark.Com

    5-12 chassis • remove the brake plate 0. • remove the axle spacer a. Inspection and disassembly brake drum/wheel hub inspect the brake drum and measure the brake drum i.D. To determine the extent of wear. Replace the brake drum if the measurement exceeds the service limit. The value of this limit is...

  • Page 126: Partshark.Com

    Chassis 5-13 dust seal • remove the each dust seal with the special tool.  09913-50121: oil seal remover bearing inspect the play a of the wheel hub bearings by finger while they are in the wheel hub. Rotate the inner race by finger to inspect it for abnormal noise and smooth rotation. If there is ...

  • Page 127: Partshark.Com

    5-14 chassis reassembly and remounting bearing • apply suzuki super grease “a” to the bearing before installing.  99000-25010: suzuki super grease “a” or equivalent • install the wheel hub inner bearing with the special tool.  09913-70210: bearing installer set • install the wheel hub outer bearin...

  • Page 128: Partshark.Com

    Chassis 5-15 • apply suzuki super grease “a” to the camshaft.  99000-25010: suzuki super grease “a” or equivalent • align the punched mark a of the brake cam lever with the slit b of the front brake camshaft. • apply suzuki super grease “a” to the front brake cam- shaft and pin, and install the bra...

  • Page 129: Partshark.Com

    5-16 chassis steering and front suspension construction 1 front shock absorber 0 knuckle arm bushing 2 front suspension arm a knuckle arm 3 bushing b spacer item n·m kgf-m lb-ft 4 front suspension arm nut a front shock absorber upper bolt a 29 2.9 21.0 5 tie-rod b front shock absorber lower bolt b 2...

  • Page 130: Partshark.Com

    Chassis 5-17 1 handlebar upper holder 7 steering shaft lower dust seal 2 handlebars 8 steering shaft bushing 3 handlebar lower holder 9 o-ring item n·m kgf-m lb-ft 4 steering shaft a handlebar clamp bolt a 26 2.6 19.0 5 steering shaft holder b steering shaft holder bolt b 23 2.3 16.5 6 dust seal c s...

  • Page 131: Partshark.Com

    5-18 chassis removal and disassembly front suspension • remove the front wheel. ( 5-8) • remove the front grip. ( 5-6) • remove the front brake. ( 5-12 to -13) • remove the front brake cable 1. • remove the cotter pin and knuckle arm nut 2. • remove the cotter pin and tie-rod end nut 3. • remove ...

  • Page 132: Partshark.Com

    Chassis 5-19 • remove the dust seals and spacer. • remove the knuckle arm bushings with the special tools.  09923-73210: bearing remover 09930-30104: sliding shaft steering • remove the front frame cover. ( 5-4) • remove the front suspension. ( 5-19) • remove the front and rear brake cables. • re...

  • Page 133: Partshark.Com

    5-20 chassis • remove the cotter pin and steering shaft lower nut 1 and o- ring. • remove the cotter pins and tie-rod end nuts 2. • remove the tie-rods. • remove the handlebar clamp bolts. • remove the cotter pins. • remove the steering shaft holder and steering shaft. * the removed cotter pins must...

  • Page 134: Partshark.Com

    Chassis 5-21 • remove the steering shaft bushing. • remove the dust seals 3 and steering shaft lower dust seal 4. • separate the tie-rod ends 5, locknuts (6, 7) and tie-rods 8. Inspection inspect the removed parts for the following abnormalities. * handlebar distortion. * handlebar clamp wear. Dust ...

  • Page 135: Partshark.Com

    5-22 chassis suspension arm inspect the suspension arm and suspension arm bushing for wear or damage. If any defects are found, replace it with a new one. Front shock absorber inspect the shock absorber body and bushing for damage and oil leakage. If any defects are found, replace it with a new one....

  • Page 136: Partshark.Com

    Chassis 5-23 reassembly and remounting reassemble and remount the steering in the reverse order of removal and disassembly. Pay attention to the following points: • install the steering shaft bushing with the special tool.  09924-84521: bearing installer set steering shaft • apply grease to the ste...

  • Page 137: Partshark.Com

    5-24 chassis • tighten the steering shaft holder bolts to the specified torque and install the new cotter pins.  steering shaft holder bolt: 23 n·m (2.3 kgf·m, 16.5 ib-ft) tie-rod • tighten the tie-rod end nuts to the specified torque.  tie-rod end nut: 29 n·m (2.9 kgf-m, 21.0 lb-ft) note: after i...

  • Page 138: Partshark.Com

    Chassis 5-25 • install the handlebar upper holders as shown. • first, tighten the bolts 1 to the specified torque and then tighten the bolts 2 to the specified torque.  handlebar clamp bolt: 26 n·m (2.6 kgf-m, 19.0 lb-ft) • make sure the cable, harness are routing properly. Handlebar switch • align...

  • Page 139: Partshark.Com

    5-26 chassis • tighten the front suspension arm bolts to the specified torque.  front suspension arm bolt: 50 n·m (5.0 kgf·m, 36.0 lb-ft) • tighten the front shock absorber bolts to the specified torque.  front shock absorber lower bolt: 29 n·m (2.9 kgf·m, 21.0 ib-ft) front shock absorber upper bo...

  • Page 140: Partshark.Com

    Chassis 5-27 toe-in adjustment adjust the toe-in as follows: • place the vehicle on level ground and set the handlebar straight. • make sure all the tires are inflated to the standard pressure. ( 2-18) • place 30 kg (66 lbs) weight on the seat. • loosen the locknuts (1, 2) on each tie-rod. • measur...

  • Page 141: Partshark.Com

    5-28 chassis rear brake and rear axle housing construction 1 center cap h rear axle housing bearing (l) 2 rear axle washer i spacer 3 rear wheel j chain adjuster 4 rear wheel hub k rear axle housing 5 spacer (l) l rear axle housing bearing (r) 6 rear brake drum cover m dust seal (r) 7 rear brake dru...

  • Page 142: Partshark.Com

    Chassis 5-29 removal • remove the cotter pin 1. • remove the rear hub nut by applying the rear brake. • remove the rear wheels. • remove the center cap holder 2, rear axle washer 3 and rear wheel hub 4. • remove the spacers left 5 and right 6. • remove the chain case cover. • loosen the drive chain....

  • Page 143: Partshark.Com

    5-30 chassis • remove the rear brake drum cover. • remove the rear axle. • remove the rear brake drum. • remove the rear brake shoes 7. • disconnect the rear brake cable 8. • remove the rear brake panel 9. Partshark.Com 877-999-5686.

  • Page 144: Partshark.Com

    Chassis 5-31 • remove the rear brake cam lever bolt and cam lever. • remove the rear brake camshaft 0, brake lining indicator plate a, spring b and o-rings c. • remove the rear axle housing. Inspection and disassembly brake drum inspect the brake drum and measure the brake drum i.D. To determine the...

  • Page 145: Partshark.Com

    5-32 chassis brake shoe inspect the brake shoes for wear or damage. If any wear or defects are found, replace the brake shoes as a set. Rear axle support the rear axle with the v-blocks and measure the rear axle runout with the dial gauge as shown. If the runout exceeds the service limit, replace th...

  • Page 146: Partshark.Com

    Chassis 5-33 dust seal • remove the dust seals with the special tool.  09913-50121: oil seal remover bearing inspect the play a of the rear axle housing bearings by finger while they are in the rear axle housing. Rotate the inner race by finger to inspect it for abnormal noise and smooth rotation. ...

  • Page 147: Partshark.Com

    5-34 chassis • install the rear axle housing bearing with the special tool. • install the dust seals with the special tool.  09924-84510: bearing installer set • tighten the rear axle housing bolts to the specified torque.  rear axle housing bolt: 50 n·m (5.0 kgf-m, 36.0 lb-ft) rear brake • apply ...

  • Page 148: Partshark.Com

    Chassis 5-35 note: face the groove on the camshaft to the inside. • install the brake lining indicator plate 1, spring 2 and rear brake cam lever 3. • align the punched mark a on the cam lever with the slit b on the camshaft. Note: align the groove c on the camshaft with the tongue d of the indicato...

  • Page 149: Partshark.Com

    5-36 chassis • apply suzuki super grease “a” to the brake camshaft and pin.  99000-25010: suzuki super grease “a” or equivalent • install the brake shoes. Rear sprocket and rear axle • the stamped mark on the rear sprocket 1 should face out- side. • tighten the rear sprocket bolt to the specified t...

  • Page 150: Partshark.Com

    Chassis 5-37 • install the spacers left 4 and right 5. • tighten the rear hub nut to the specified torque.  rear hub nut: 75 n·m (7.5 kgf·m, 54.0 ib-ft) • install the new cotter pin. Note: bend the cotter pin to outside. • after installing the rear brake and rear axle housing, adjust the following ...

  • Page 151: Rear Suspension

    5-38 chassis rear suspension construction 1 rear shock absorber 7 spacer 2 chain case 8 swingarm pivot shaft 3 chain case cover a rear shock absorber bolt item n·m kgf-m lb-ft 4 rear shock absorber lower bolt b rear shock absorber nut a 29 2.9 21.0 5 swingarm pivot bushing c swingarm pivot nut b 29 ...

  • Page 152: Partshark.Com

    Chassis 5-39 removal and disassembly • remove the rear brake and rear axle housing. ( 5-31 and 5-32) • remove the chain case 1. • remove the rear shock absorber lower bolt 2. • remove the rear shock absorber bolt 3. • remove the rear shock absorber 4. • remove the swingarm pivot nut 5 and shaft. • ...

  • Page 153: Partshark.Com

    5-40 chassis inspection rear shock absorber inspect the shock absorber body and bushing for damage and oil leakage. If any defects are found, replace it with a new one. Swingarm pivot shaft check the pivot shaft for runout with a dial gauge and replace it if the runout exceeds the limit.  09900-206...

  • Page 154: Partshark.Com

    Chassis 5-41 • install the swingarm pivot bushings with the special tool.  09941-34513: steering race installer note: when installing the swingarm bushings 1 to the swingarm 2, and confirm the distance between the end of the swingarm 2 and bushing edge a is 1.5 mm (0.059 in). • tighten the swingarm...

  • Page 155: Partshark.Com

    5-42 chassis • install the rear axle housing and rear brake. ( 5-35 to -37) • after installing the rear suspension, adjust the following items. * rear brake lever play .................................. 2-17 * drive chain slack ......................................... 2-15 partshark.Com 877-999-...

  • Page 156: Electrical System

    Electrical system 6-1 6 electrical system contents cautions in servicing ..........................................................................6- 2 connector..........................................................................................6- 2 coupler .......................................

  • Page 157: Cautions In Servicing

    6-2 electrical system cautions in servicing connector • when disconnecting a connector, be sure to hold the termi- nals and do not pull the lead wires. • 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 i...

  • Page 158: Partshark.Com

    Electrical system 6-3 semi-conductor equipped part • be careful not to drop the part with a semi-conductor built in such as a cdi unit and regulator/rectifier. • when inspecting this part, follow inspection instruction strictly. Neglecting proper procedure may cause damage to this part. Battery • th...

  • Page 159: Partshark.Com

    6-4 electrical system using the multi-circuit tester • properly use the multi-circuit tester + and - probes. Improper use can cause damage to the vehicle and tester. • if the voltage and current values are not known, begin mea- suring in the highest range. • when measuring the resistance, make sure ...

  • Page 160: Partshark.Com

    Electrical system 6-5 location of electrical components 1 battery 2 starter relay 3 fuse box 4 cdi unit 5 ignition coil 6 starter motor 7 generator 8 pick-up coil partshark.Com 877-999-5686.

  • Page 161: Partshark.Com

    6-6 electrical system 1 ignition switch 2 parking brake switch 3 engine stop switch 4 starter button 5 regulator/rectifier 6 remote engine stop switch partshark.Com 877-999-5686.

  • Page 162: Charging System

    Electrical system 6-7 charging system troubleshooting battery runs down quickly step 1 1) check accessories which use excessive amounts of electricity. Are accessories being installed? Step 2 1) check the battery for current leaks. ( 6-8) is the battery current leaks ok? Step 3 1) measure the regul...

  • Page 163: Partshark.Com

    6-8 electrical system step 5 1) measure the generator no-load performance. ( 6-10) is the generator no-load performance ok? Step 6 1) inspect the regulator/rectifier. ( 6-10) is the regulator/rectifier ok? Step 7 1) inspect wiring harness. Is the wiring harness ok? Battery overcharges • faulty reg...

  • Page 164: Partshark.Com

    Electrical system 6-9 regulated voltage • remove the seat. ( 5-4) • start the engine and keep it running at 2 800 r/min. Measure the dc voltage between the + and - battery termi- nals with the multi-circuit tester. If the voltage is not within the standard range, inspect the generator and regulator...

  • Page 165: Partshark.Com

    6-10 electrical system generator no-load performance • remove the left frame cover. ( 5-4) • disconnect the regulator/rectifier coupler 1. • start the engine and keep it running at 2 800 r/min. Measure the voltage between w/r wire and ground with the multi-circuit tester. If the tester reads under ...

  • Page 166: Starter System

    Electrical system 6-11 starter system troubleshooting make sure that the fuse is not blown and the battery is fully-charged before diagnosing. Starter motor will not run step 1 1) turn on the ignition switch with the engine stop switch, parking brake switch and remote engine stop switch in the “run”...

  • Page 167: Partshark.Com

    6-12 electrical system step 3 1) measure the starter relay voltage at the starter relay connectors (between y/g + and b/w -) when the starter button is pushed. Is a voltage ok? Step 4 1) check the starter relay. ( 6-16 to -17) is the starter relay ok? Engine does not turn though the starter motor r...

  • Page 168: Partshark.Com

    Electrical system 6-13 starter motor disassembly • disassemble the starter motor as shown in the illustration. 1 starter motor case 4 housing end assembly 2 armature 5 o-ring 3 starter motor lead wire partshark.Com 877-999-5686.

  • Page 169: Partshark.Com

    6-14 electrical system starter motor inspection carbon brush inspect the brushes for abnormal wear, cracks or smoothness in the brush holder. If any defects are found, replace the housing end assembly with a new one. Measure the brush length with a vernier calipers. If brush length is less than the ...

  • Page 170: Partshark.Com

    Electrical system 6-15 oil seal inspection check the oil seal lip for damage or leakage. If any defects are found, replace the housing end assembly. Bushing inspect the bushing for wear or damage. If any wear or damage is found, replace the starter motor with a new one. Starter motor reassembly reas...

  • Page 171: Partshark.Com

    6-16 electrical system starter motor installation • tighten the starter motor lead wire screw 1 and starter motor mounting bolts 2. Starter relay inspection • remove the seat. ( 5-4) • remove the starter relay 1 from the frame center cover. • disconnect the starter relay coupler 2. First check the ...

  • Page 172: Partshark.Com

    Electrical system 6-17 measure the relay coil resistance between the terminals with the multi-circuit tester. If the resistance is not within the standard range, replace the starter relay with a new one.  09900-25008: multi-circuit tester set  tester knob indication: resistance (Ω)  starter relay...

  • Page 173: Ignition System

    6-18 electrical system ignition system troubleshooting no spark or poor spark note: check that the engine stop switch, parking brake switch and remote engine stop switch are in the “run”, “on” and “set” positions. Check that the fuse is not blown and the battery is fully-charged before diagnos- ing....

  • Page 174: Partshark.Com

    Electrical system 6-19 step 2 1) measure the battery voltage between input lead wires (o/w and b/w) at the cdi unit with the ignition switch in the “on” position. Is the voltage ok? Step 3 1) measure the ignition coil primary peak voltage. ( 6-20) note: this inspection method is applicable only wit...

  • Page 175: Partshark.Com

    6-20 electrical system inspection ignition coil primary peak voltage • disconnect the spark plug cap. • connect a new spark plug 1 to spark plug cap and ground it to the cylinder head. Note: make sure that the spark plug cap and spark plug are connected properly and the battery is fully-charged. Mea...

  • Page 176: Partshark.Com

    Electrical system 6-21 ignition coil resistance • disconnect the ignition coil lead wires and spark plug cap, and remove the ignition coil. Measure the ignition coil resistance in both the primary and sec- ondary windings with the multi-circuit tester. If the resistance is not within the standard ra...

  • Page 177: Partshark.Com

    6-22 electrical system • repeat the above procedure a few times and measure the highest pick-up coil peak voltage.  tester knob indication: voltage ()  pick-up coil peak voltage: 1.5 v and more if the peak voltage measured on the cdi unit coupler is lower than the standard value, measure the peak...

  • Page 178: Switches

    Electrical system 6-23 switches measure each switch for continuity using a multi-circuit tester. If any abnormality is found, replace the respective switch assemblies with new ones.  09900-25008: multi-circuit tester set  tester knob indication: continuity test () ignition switch engine stop swit...

  • Page 179: Battery

    6-24 electrical system battery specifications 1 upper cover breather 5 terminal 2 cathode plates 6 safety valve 3 stopper 7 anode plates 4 filter 8 separator (fiberglass plate) initial charging filling electrolyte • remove the aluminum tape 1 sealing the battery electrolyte filler holes a. Note: whe...

  • Page 180: Partshark.Com

    Electrical system 6-25 note: if no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the container from the battery. • after confirming that the electrolyte has entered the battery completely, remove the electrolyte containers ...

  • Page 181: Partshark.Com

    6-26 electrical system servicing visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powder...

  • Page 182: Servicing Information

    Servicing information 7-1 7 9 servicing information contents troubleshooting ...................................................................................7- 2 engine ...................................................................................................7- 2 carburetor ................

  • Page 183: Troubleshooting

    7-2 servicing information troubleshooting engine engine will not start or is hard to start engine stalls often symptom, possible causes and remedy 1) compression too low • valve clearance out of adjustment. • worn valve guides or poor seating of valves. • mistimed valves. • excessively worn piston r...

  • Page 184: Partshark.Com

    Servicing information 7-3 noisy engine clutch slips engine idles poorly symptom, possible causes and remedy 1) excessive valve chatter • too large valve clearance. • weakened or broken valve springs. • worn rocker arm or cam surface. 2) noise seems to come from piston • worn down piston or cylinder....

  • Page 185: Partshark.Com

    7-4 servicing information engine runs poorly in high speed range symptom, possible causes and remedy • weakened valve springs. • worn camshaft. • valve timing out of adjustment. • too narrow spark plug gap. • ignition not advanced sufficiently due to poorly working timing advance circuit. • defectiv...

  • Page 186: Partshark.Com

    Servicing information 7-5 engine lacks power engine overheats dirty or heavy exhaust smoke symptom, possible causes and remedy • loss of valve clearance. • weakened valve springs. • valve timing out of adjustment. • worn piston rings or cylinder. • poor seating of valves. • fouled spark plug. • inco...

  • Page 187: Partshark.Com

    7-6 servicing information carburetor starting difficulty idling or low-speed trouble medium or high-speed trouble overflow and fuel level fluctuations symptom, possible causes and remedy • clogged fuel pipe. • air leaking from joint between intake port and car- buretor. • air leaking from carburetor...

  • Page 188: Partshark.Com

    Servicing information 7-7 chassis heavy steering wobbly handlebar steering pulls to one side shocks felt in the steering tires rapidly or unevenly wear steering too noisy symptom, possible causes and remedy • distorted steering shaft. • not enough pressure in tires. • improper front wheel alignment....

  • Page 189: Partshark.Com

    7-8 servicing information front suspension too soft front suspension too stiff noisy front suspension wobbly rear wheel rear suspension too soft rear suspension too stiff noisy rear suspension symptom, possible causes and remedy • weakened spring of shock absorber. • shock absorber leaks oil. Replac...

  • Page 190: Partshark.Com

    Servicing information 7-9 brakes insufficient brake power brake squeaking excessive brake lever stroke brake drags symptom, possible causes and remedy • worn brake drum. • oil adhesion on friction surface of shoes. • worn shoe linings. • too much play on brake lever. Replace. Clean drum and shoes. R...

  • Page 191: Partshark.Com

    7-10 servicing information electrical no sparking or poor sparking spark plug soon becomes fouled with carbon spark plug becomes fouled too soon spark plug electrodes overheat or burn generator does not charge generator does charge, but charging rate is below the specification generator overcharges ...

  • Page 192: Partshark.Com

    Servicing information 7-11 unstable charging start button is not effective symptom, possible causes and remedy • lead wire insulation frayed due to vibration, resulting in intermittent short-circuiting. • internally short-circuited generator. • defective regulator/rectifier. Repair or replace. Repla...

  • Page 193: Partshark.Com

    7-12 servicing information battery “sulfation”, acidic white powdery substance or spots on surface of cell plates battery runs down quickly battery “sulfation” symptom, possible causes and remedy • cracked battery case. • battery has been left in a run-down condition for a long time. Replace the bat...

  • Page 194: Partshark.Com

    Servicing information 7-13 wiring diagram off on off on secede set off ru n push • br b/w b r/b w/b o/b r r/b b/w y/g r r/w b/w b w/b o/w y/g w/b o/w o/g o r/w w/b o y/g b/w o/w o/g o r b/w b/y cdi unit b a tter y st ar ter m oto r genera t or regula t or/ rectifier remo te engine st op switch fuse ...

  • Page 195: Partshark.Com

    7-14 servicing information wiring harness, cable and hose routing wiring harness routing cdi unit starter relay fuse box battery minus terminal battery plus terminal engine ground remote engine stop switch case wiring harness to the rear fender regulator/rectifier clamp clamp starter motor generator...

  • Page 196: Partshark.Com

    Servicing information 7-15 clamp clamp generator lead wire starter motor lead wire pick-up coil generator rotor handleber switch leadwire 20 ± 5 partshark.Com 877-999-5686.

  • Page 197: Partshark.Com

    7-16 servicing information cable routing 3 – 5 mm (0.12 – 0.20 in) w2 4 – 6 mm (0.16 – 0.24 in) throttle cable front brake cable (r) front brake cable (r) front brake cable (r) front brake cable front brake cable (l) bracket bracket bolt bolt rear brake cable fix the boot to the rear brake cable. Ca...

  • Page 198: Partshark.Com

    Servicing information 7-17 fuel hose piping front brake cable (r) rear brake cable front brake cable (l) wiring harness fuel tank breather hose handlebars fuel hose clip vacuum hose clip air vent hose fuel valve clip fuel hose install the rounded side of fuel hose to the fuel valve. Throttle cable c...

  • Page 199: Partshark.Com

    7-18 servicing information carburetor and cvt case hose routing clamp clamp clamp cvt case breather hose clamp clamp clamp clamp drain hose screw screw left right lower upper air vent hose partshark.Com 877-999-5686.

  • Page 200: Partshark.Com

    Servicing information 7-19 handlebars and handlebar pad installation handlebar upper holder handlebar lower holder align the center of knurling on handlebars with the center of handlbar holders. Handlebar clamp bolt handlebars clamp clamp clamp handlebar pad handlebar pad handlebars handlebars punch...

  • Page 201: Partshark.Com

    7-20 servicing information heat shield installation right frame cover heat shield 0 – 4 mm (0 – 0.16 in) 13 – 17 mm (0.51 – 0.67 in) partshark.Com 877-999-5686.

  • Page 202: Partshark.Com

    Servicing information 7-21 special tools 09900-20101 09900-20102 vernier calipers 09900-20202 micrometer (25 – 50 mm) 09900-20205 micrometer (0 – 25 mm) 09900-20602 dial gauge (1/1000 mm, 1 mm) 09900-20605 dial calipers (1/100 mm, 10 – 34 mm) 09900-20607 dial gauge (1/100 mm, 10 mm) 09900-20701 magn...

  • Page 203: Partshark.Com

    7-22 servicing information note: when order the special tool, please confirm whether it is available or not. 09923-73210 bearing remover 09924-84510 bearing installer set 09924-84521 bearing installer set 09930-30104 sliding shaft 09930-40113 rotor holder 09941-34513 steering race installer 09941-50...

  • Page 204: Tightening Torque

    Servicing information 7-23 tightening torque engine fuel item n·m kgf-m lb-ft cylinder head cover bolt 11 1.1 8.0 cylinder head bolt 14 1.4 10.0 valve clearance adjuster locknut 7 0.7 5.0 generator rotor nut 35 3.5 25.5 clutch housing nut 50 5.0 36.0 clutch shoe nut 60 6.0 43.5 fixed drive face nut ...

  • Page 205: Partshark.Com

    7-24 servicing information chassis item n·m kgf-m lb-ft front suspension arm bolt 50 5.0 36.0 knuckle arm nut 50 5.0 36.0 tie-rod end nut 29 2.9 21.0 tie-rod locknut 29 2.9 21.0 steering shaft lower nut 29 2.9 21.0 steering shaft holder bolt 23 2.3 16.5 handlebar clamp bolt 26 2.6 19.0 front shock a...

  • Page 206: Partshark.Com

    Servicing information 7-25 tightening torque chart for other nuts and bolts not listed in the preceding page, refer to this chart: bolt diameter a (mm) conventional or “4” marked bolt “7” marked bolt n·m kgf-m lb-ft n·m kgf-m lb-ft 4 1.5 0.15 1.0 2.3 0.23 1.5 5 3 0.3 2.0 4.5 0.45 3.0 6 5.5 0.55 4.0 ...

  • Page 207: Service Data

    7-26 servicing information service data valve + valve guide unit: mm (in) item standard limit valve diam. In. 14.5 (0.57) ---- ex. 12.5 (0.49) ---- valve clearance (when cold) in. 0.05 – 0.10 (0.002 – 0.004) ---- ex. 0.10 – 0.15 (0.004 – 0.006) ---- valve guide to valve stem clearance in. 0.010 – 0....

  • Page 208: Partshark.Com

    Servicing information 7-27 camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit cam height in. & ex. 28.43 – 28.63 (1.119 – 1.127) 28.13 (1.107) rocker arm i.D. In. & ex. 4.015 – 4.027 (0.1581 – 0.1585) ---- rocker arm shaft o.D. In. & ex. 3.990 – ...

  • Page 209: Partshark.Com

    7-28 servicing information conrod + crankshaft unit: mm (in) clutch unit: mm (in) item standard limit piston ring groove width 1st 1.01 – 1.03 (0.0398 – 0.0405) ---- 2nd 1.21 – 1.23 (0.0476 – 0.0484) ---- oil 1.51 – 1.53 (0.0594 – 0.0602) ---- piston ring thickness 1st 0.97 – 0.99 (0.0382 – 0.0390) ...

  • Page 210: Partshark.Com

    Servicing information 7-29 reduction gear + drive belt + drive chain unit: mm (in) except raito carburetor item standard limit reduction ratio variable change (2.091 – 1.879) — reduction gear ratio 4.272 (47/11) — final reduction ratio 3.700 (37/10) — drive belt width 15.9 (0.63) 14.9 (0.59) movable...

  • Page 211: Partshark.Com

    7-30 servicing information electrical unit: mm (in) item standard/specification limit note spark plug type ngk: cr6hsa denso: u20fsr-u — gap 0.6 – 0.7 (0.024 – 0.028) — spark performance over 8 (0.3) at 1 atm. — ignition coil resistance primary 0.1 – 0.7 Ω — terminal – terminal secondary 14 – 20 k Ω...

  • Page 212: Partshark.Com

    Servicing information 7-31 brake + wheel unit: mm (in) tire unit: mm (in) item standard limit front brake lever play 4 – 6 (0.16 – 0.23) — rear brake lever play 4 – 6 (0.16 – 0.23) — brake drum i.D. Front — 80.7 (3.18) rear — 110.7 (4.36) rear axle runout rear — 3.0 (0.12) wheel rim size front & rea...

  • Page 213: Partshark.Com

    7-32 servicing information suspension unit: mm (in) fuel + oil item standard limit front wheel travel 52 (2.0) ---- rear wheel travel 51 (2.0) ---- swingarm pivot shaft runout ---- 0.6 (0.02) item specification note fuel type use only unleaded gasoline of at least 87 pump octane (r/2 + m/2) or 91 oc...

  • Page 214: Lt-Z50K9   ('09-Model)

    Contents page specifications..................................................................................... 8-2 note: * asterisk mark (*) indicates the new k9-model specifications. * the service data is the same as the k8-model. Lt-z50k9 ('09-model) 8-1 lt-z50k9 ('09-model) 8 partshark.Com 877...

  • Page 215: Specifications

    Specifications dimensions and curb mass overall length ...................................................................................... 1 270 mm (50.0 in) overall width........................................................................................ 760 mm (29.9 in) overall height ........