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Suzuki LT-Z90K7 2007 Service Manual

Manual is about: SUZUKI LT-Z90K7 (’07-MODEL)

Summary of LT-Z90K7 2007

  • Page 1

    Printed in japan k7 99500-40020-01e lt-z90k7_01e service manual 2006. 8. 30 for ps printing top bottom 9 9 5 0 0 - 4 0 0 2 0 - 0 1 e.

  • Page 2: Group Index

    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-z90 and procedures for its inspec- tion/service and overhaul of its main components. Other ...

  • Page 3: How To Use This Manual

    How to use this manual to locate what you are looking for: 1. The text of this manual is divided into sections. 2. 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 4

    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. Apply thread loc...

  • Page 5: 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-z90k7 p-19 e.U. Lm4ad41a71100001- p-28 canada p-33 california (u.S.A.) warning/caution/note ........

  • Page 6: 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. ! Indicat...

  • Page 7

    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...

  • Page 8: Serial Number Location

    1-4 general information suzuki lt-z90k7 (’07-model) • difference between illustration 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 seria...

  • Page 9: 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 10: 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 11: Information Labels

    General information 1-7 information labels e: english f: french no label or plate name applied specification p19 p28 p33 1 certification plate ! ! 2 compliance label ! 3 manual notice label ! 4 tire information label (warning no-passenger) e ! ! ! 5 tire information label (warning no-passenger) f ! ...

  • Page 12: Specifications

    1-8 general information specifications dimensions and dry mass overall length.......................................................................... 1 505 mm (59.2 in) overall width ........................................................................... 875 mm (34.4 in) overall height...........

  • Page 13

    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 14: 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 15

    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 16

    Periodic maintenance 2-3 maintenance and tune-up procedures this section describes the servicing procedures for each item of the periodic maintenance requirements. Air cleaner if the air cleaner is clogged with dust, intake resistance will be increased, with a resultant decrease in power output and ...

  • Page 17

    2-4 periodic maintenance • fill a wash pan a proper size with a non-flammable cleaning solvent. Immerse the air cleaner element in the cleaning solvent and wash it. • press the air cleaner element between the palms of both hands to remove the excess solvent: do not twist or wring the element or it t...

  • Page 18

    Periodic maintenance 2-5 exhaust pipe nuts and muffler mounting bolt • remove the footrest lid. ( 5-4) • tighten the exhaust pipe nuts 1, muffler connection bolt 2, and muffler mounting bolts 3 to the specified torque. " exhaust pipe nut: 23 n·m (2.3 kgf-m, 16.5 lb-ft) muffler connection bolt: 12 n·...

  • Page 19

    2-6 periodic maintenance valve clearance excessive valve clearance results in valve noise and insufficient valve clearance results in valve damage and reduced power. Check the intake and exhaust valve clearances at the interval indicated above and adjust the valve clearances to specification, if nec...

  • Page 20

    Periodic maintenance 2-7 • insert a thickness gauge between the valve end the adjusting screw on the rocker arm. • if the clearance is out of specification, adjust it to the specified range. \ 09900-20806: thickness gauge 09917-14910: tappet adjust drive valve clearance (when cold): in: 0.05 – 0.10 ...

  • Page 21

    2-8 periodic maintenance spark plug • disconnect the spark plug cap 1 and remove the spark plug 2. Carbon deposits check to see if there are 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 ...

  • Page 22

    Periodic maintenance 2-9 spark arrester • remove the spark arrester mounting bolt 1. • extract the spark arrester pipe 2 from the muffler. • clean the spark arrester pipe 2 by brush. • reinstall the spark arrester pipe 2. Fuel line inspect the fuel hose for damage and fuel leakage. If any defects ar...

  • Page 23

    2-10 periodic maintenance engine oil and oil filter the oil should be changed while the engine is warm oil filter replacement at the above intervals, should be done together with the engine oil change. Engine oil replacement the oil should be changed while the engine is warm. • place the vehicle on ...

  • Page 24

    Periodic maintenance 2-11 oil filter replacement • drain the engine oil as described in the engine oil replace- ment procedure. • remove the oil filter cap 1 and oil filter 2. • replace the oil filter with a new one. • install the o-ring 3. • install the spring 4 and o-ring 5. • install the oil filt...

  • Page 25

    2-12 periodic maintenance oil strainer inspection and cleaning • drain the engine oil as descried in the engine oil replacement procedure. • remove the oil strainer cap 1 and oil strainer 2. • clean the oil strainer with compressed air also check the oil strainer for wear and damage. If any defects ...

  • Page 26

    Periodic maintenance 2-13 throttle cable play adjust the throttle cable play a as follows. • loosen the lock-nut 1 of the throttle cable. • turn the adjuster 2 in or out to obtain the correct play. Throttle cable play: 3 – 5 mm (0.1 – 0.2 in) • after adjusting the throttle cable play, tighten the lo...

  • Page 27

    2-14 periodic maintenance drive belt removal • remove the left footrest mudguard. ( 5-5) • remove the left footrest bar 1. • remove the front cooling duct connector 2 and rear cooling duct connector 3. • remove the crankcase cover 4. • remove the crankcase cover gasket 5 and dowel pin. • remove the ...

  • Page 28

    Periodic maintenance 2-15 • remove the fixed drive face 8. • remove the limit clutch housing nut 9 with the special tool. \ 09930-40113: rotor holder • remove the limit clutch stopper 0 and limit clutch spring a. • remove the limit clutch pressure plate b. • remove the limit clutch friction plate c ...

  • Page 29

    2-16 periodic maintenance • remove the limit clutch friction plate e and limit clutch f. • remove the movable driven face g and drive belt h. Inspection inspect the drive belt for wear and damage. If any defects are found, replace it with a new one. Installation install the drive belt in the reverse...

  • Page 30

    Periodic maintenance 2-17 note: degrease the movable drive face assembly. Use non-flammable cleaning solvent to wipe off oily or greasy matter and make its surfaces completely dry. • tighten the clutch housing nut to the specified torque with the special tool. \ 09930-40113: rotor holder " limit clu...

  • Page 31

    2-18 periodic maintenance drive chain visually inspect the drive chain for the possible defects listed below. (support the vehicle by a jack and a wooden block, rotate the rear wheel slowly by hand.) * loose pins * twisted or seized links * damaged rollers * excessive wear * rusted links * kinked or...

  • Page 32

    Periodic maintenance 2-19 adjusting • place the vehicle on level ground. • loosen or tighten both chain adjusters 1 equally until the chain has 15 – 25 mm (0.6 – 1.0 in) of slack at the middle of the chain between the engine and rear sprockets as shown. Drive chain slack: standard: 15 – 25 mm (0.6 –...

  • Page 33

    2-20 periodic maintenance • clean the drive chain with kerosene. If the drive chain tends to rust quickly, the intervals must be shortened. • after cleaning and drying the chain, oil it with a heavy-weight engine oil. Brakes front brake lever play • adjust the right and left cable end length a to be...

  • Page 34

    Periodic maintenance 2-21 front and rear brake shoe wear this vehicle is equipped with brake wear limit indicators for the front and rear brake. Check brake lining wear as follows: • make sure the brake lever play is properly adjusted. • while fully applying the brake, check to see that the extensio...

  • Page 35

    2-22 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 36

    Periodic maintenance 2-23 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 37

    2-24 periodic maintenance chassis nuts and bolts check that all chassis nuts and bolts are tightened to their specified torque. (refer to page 2-25 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 handlebar cla...

  • Page 38

    Periodic maintenance 2-25.

  • Page 39

    2-26 periodic maintenance.

  • Page 40

    Periodic maintenance 2-27 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 41: Compression Pressure Check

    2-28 periodic maintenance 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 42

    Periodic maintenance 2-29 initial engagement and clutch lock-up inspection the lt-z90 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 43

    2-30 periodic maintenance 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 44: Oil Pressure Check

    Periodic maintenance 2-31 oil pressure check check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. Oil pressure: 10 – 40 kpa (0.1 – 0.4 kgf/cm², 1.4 – 5.7 psi) at 3 000 r/min, oil temp. At 60 °c (140 °f) if the oil pressure is lower or hig...

  • Page 45: Engine

    3 6 engine 3-1 contents engine engine components removable with engine in place ...........3- 2 engine left side ...............................................................................3- 2 engine right side .............................................................................3- 2 eng...

  • Page 46

    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 left side engine right side engine center parts remov...

  • Page 47

    Engine 3-3 engine removal and remounting 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. ( 2-10) • remove the fuel tank cover. ( 5-4) • remove the footrest mudguard (...

  • Page 48

    3-4 engine • remove the carburetor assembly 5. ( 4-7) • disconnect the generator coupler 6. • loosen the muffler clamp bolt. • remove the exhaust pipe 7. • remove the gasket 8. • remove the muffler 9..

  • Page 49

    Engine 3-5 • remove the starter motor lead wire 0 and ground lead wire a. • remove the chain case cover b. • loosen the rear shock absorber lower bolt c. • loosen the rear axle housing bolt d. • loosen the chain adjusters e. • remove the snap ring f and engine sprocket g with drive chain..

  • Page 50

    3-6 engine • remove the engine mounting upper brackets h. • remove the engine mounting bolts and nuts. • remove the engine from the right side..

  • Page 51

    Engine 3-7 engine remounting remounting the engine in the reverse order of engine removal. Pay attention to the following points: note: * the engine mounting nuts are self-locking. * once the nut has been removed, it is no longer of any use. Be sure to use new nuts, and then tighten them to the spec...

  • Page 52

    3-8 engine • install the muffler 3 and exhaust pipe 4. • tighten the muffler mounting bolt and exhaust pipe bolt to the specified torque. " muffler mounting bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft) exhaust pipe bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft) • tighten the muffler clamp bolt to the specified torque...

  • Page 53: Engine Disassembly

    Engine 3-9 engine disassembly starter motor • remove the starter motor. Spark plug • remove the spark plug. \ 09930-10121: spark plug wrench set cylinder head cover • remove the cylinder head cover bolts, and then remove the cylinder head cover 1. Cylinder head • remove the valve timing inspection p...

  • Page 54

    3-10 engine • align the engraved line 3 on the camshaft so it is parallel with the mating surface of the cylinder head. • remove the cam chain tension adjuster plug cap 4. • insert the - screwdriver into the slotted end of cam chain ten- sion adjuster and turn the adjusting screw clockwise with the ...

  • Page 55

    Engine 3-11 • remove the cylinder head nut 9 in diagonal stages, and then remove the cylinder head 0. Note: if the cylinder head does not come off easily, lightly tap it using a plastic mallet. Cylinder • remove the cylinder head gasket 1 and dowel pins. • remove the cam chain guide 2. • remove the ...

  • Page 56

    3-12 engine • draw out the piston pin 2 and remove the piston 3. Generator rotor cover • remove the generator rotor cover 1. • remove the gasket 2 and dowel pins. • remove the starter idle gear 3 and starter idle shaft 4. Generator rotor • hold the generator rotor using the special tool, and then re...

  • Page 57

    Engine 3-13 • remove the generator rotor 2 using the special tool. \ 09930-34980: rotor remover note: temporarily install the generator rotor nut to the crankshaft, and then remove the generator rotor using the special tool. • remove the generator rotor key 3. • remove the starter driven gear 4. Oil...

  • Page 58

    3-14 engine oil filter • remove the oil filter cap 1. • remove the oil filter 2 and o-ring 3. Oil strainer • remove the oil strainer cap 1. • remove the oil strainer 2. Recoil starter • remove the recoil starter 1..

  • Page 59

    Engine 3-15 movable drive face • remove the crankcase cover 1. • remove the gasket 2 and dowel pins. • remove the fixed drive face nut 3 with the special tool. \ 09930-40113: rotor holder • remove the fixed drive face fan 4. • remove the fixed drive face 5. Movable driven face • remove the limit clu...

  • Page 60

    3-16 engine • remove the limit clutch stopper 2 and limit clutch spring 3. • remove the limit clutch pressure plate 4. • remove the limit clutch friction plate 5 and clutch housing 6. • remove the limit clutch friction plate 7 and limit clutch 8. • remove the clutch shoe/movable driven face assembly...

  • Page 61

    Engine 3-17 • remove the movable drive spacer a and movable drive face assembly b. Note: movable drive face disassembly. ( 3-51) crankcase • remove the left crankcase bolts. • separate the crankcase with the special tool. \ 09920-13120: crankcase separating tool note: fit the crankcase separating to...

  • Page 62

    3-18 engine engine components inspection and service cylinder head cover disassembly • remove the breather plate 1. • remove the gasket 2. Inspection inspect the cylinder head cover for carbon deposit. If the clogged are found, clean the cylinder head cover. Reassembly • install the breather gasket ...

  • Page 63

    Engine 3-19 • install the breather plate 2. • apply a small quantity of thread lock super “1322” to the breather plate bolts and tighten then securely. H 99000-32080: thread lock super “1322” cylinder head disassembly • remove the intake pipe 1 and insulator 2. • remove the cam chain guide 3. • remo...

  • Page 64

    3-20 engine • remove the rocker arms 6 and wave washer 7. • remove the cam shaft 8. • using the special tools, compress the valve spring and remove the two cotter halves 9 from the valve stem. \ 09916-14510: valve lifter 09916-14521: valve lifter attachment 09916-84511: tweezers • remove the valve s...

  • Page 65

    Engine 3-21 • remove the oil seal d. • remove the other valves in the same manner as described previously. Cylinder head distortion decarbonize the combustion chambers. Check the gasket sur- face of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading ...

  • Page 66

    3-22 engine valve head radial runout place the dial gauge at a right angle to the valve head face and measure the valve head radial runout. If it measures more than the service limit, replace the valve. Valve head radial runout: service limit: 0.03 mm (0.001 in) \ 09900-20607: dial gauge (1/100 mm) ...

  • Page 67

    Engine 3-23 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, then replace the guide. After replacing valve or guide, be sure to recheck the deflection. Valve stem o.D.: standard (in) : 4.975 – 4.990 mm (0....

  • Page 68

    3-24 engine • cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 – 150 °c (212 – 302 °f) with a hot plate. • apply engine oil to the valve guide hole. • drive the valve guide into the hole using the valve guide remover. \ 09916-44310: valve guide remover...

  • Page 69

    Engine 3-25 • if the seat width w measured exceeds the standard value or seat width is not uniform, refuse the seat using the seat cutter. Valve seat width w: standard: 0.9 – 1.1 mm (0.09 – 0.11 in) if the valve seat is out of specification, correct the seat by servic- ing it as follows: valve seat ...

  • Page 70

    3-26 engine valve spring the force of the coil spring keeps the valve seat tight. Weak- ened spring results in reduced engine power output, and often accounts for the chattering noise coming from the valve mecha- nism. Check the valve spring for proper strength by measuring its free length and also ...

  • Page 71

    Engine 3-27 • put on the valve spring retainer 2, and using the valve lifter, press down the spring, fit the valve cotter halves to the stem end, and release the lifter to allow the valve cotter 3 to wedge in between retainer and stem. \ 09916-14510: valve lifter 09916-14521: valve lifter attachment...

  • Page 72

    3-28 engine camshaft cam sprocket inspection inspect the sprocket teeth for wear. If any worn and defects are found, replace the cam sprocket, crankshaft and cam chain as a set. Camshaft bearing inspection inspect the bearings for play, discoloration, wear and seizure. Move the outer race by finger ...

  • Page 73

    Engine 3-29 rocker shaft inspection inspect the rocker arm shaft for abnormal wear or damage. If any defects are found, replace it with a new one. Measure the diameter of rocker arm shaft with a micrometer. Rocker arm shaft o.D. Standard: 9.990 – 9.981 mm (0.3933 – 0.3929 in) \ 09900-20205: micromet...

  • Page 74

    3-30 engine • install the camshaft retainer screw to the specified torque. " camshaft retainer screw: 5.5 n·m (0.55 kgf-m, 4.0 lb-ft) • install the cam chain guide mounting bolt to the specified torque. " cam chain guide mounting bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft).

  • Page 75

    Engine 3-31 cam chain tension adjuster and tensioner/guide inspection check that the push rod slides smoothly when unlocking the spring mechanism. If push rod does not slide smoothly, replace the cam chain ten- sion adjuster with a new one. Check the contacting surface of the cam chain tensioner and...

  • Page 76

    3-32 engine cylinder bore inspect the cylinder wall for any scratches, nicks or other dam- age. Measure the cylinder bore diameter at six places. If any one of the measurements exceed the limit, replace the cyl- inder. Cylinder bore standard: 45.500 – 45.515 mm (1.7913 – 1.7919 in) \ 09900-20530: cy...

  • Page 77

    Engine 3-33 piston pin and pin bore measure the piston pin bore diameter using the small bore gauge. If the measurement is out of specifications replace the piston. Piston pin bore i.D.: service limit: 14.030 mm (0.5523 in) \ 09900-20605: dial caliper gauge (10 – 34 mm) measure the piston pin outsid...

  • Page 78

    3-34 engine piston ring thickness standard: 1st: 0.97 – 0.99 mm (0.0382 – 0.0390 in) 2nd: 0.97 – 0.99 mm (0.0382 – 0.0390 in) piston ring end gap fit the piston ring squarely into the cylinder and measure the piston ring end gap using the thickness gauge. If any of the measurements exceeds the servi...

  • Page 79

    Engine 3-35 push the big end of the conrod to one side and measure the side clearance using a thickness gauge. If the clearance exceeds the service limit, replace the crankshaft assembly with a new one or bring the deflection and the side clearance within the service limit by replacing the worn part...

  • Page 80

    3-36 engine inspection • install the starter clutch in the proper direction as shown. Note: when installing the starter clutch onto the rotor, make sure that the arrow mark a in the bearing faces to the rotor. • apply engine oil to the starter clutch. • apply a small quantity of thread lock super “1...

  • Page 81

    Engine 3-37 starter driven gear bearing installation • install the bearing with the special tool. \ 09913-70210: bearing installer set (¬30) note: the stamped mark on the bearing must face crankcase side. Generator inspection ( 6-9) disassembly • remove the generator coil 1, ckp sensor 2, grommet 3....

  • Page 82

    3-38 engine oil pump disassembly • remove the circrip 1. • remove the oil pump sprocket 2. • remove the oil pump case cover 3. Inspection inspect the outer rotor 1 and inner rotor 2 for any scratches or other damage. If any defects are found, replace them with new ones. Rotate the oil pump by hand a...

  • Page 83

    Engine 3-39 • install the oil pump sprocket 2. • install the circrip 3. Crankcase oil seal installation • remove the left crankcase oil seal the special tool. \ 09913-50121: oil seal remover • install the left crankcase oil seal with the special tool. \ 09913-70210: bearing installer set • apply suz...

  • Page 84

    3-40 engine diassembly • remove the bearings with the special tool. \ 09921-20240: bearing remover set bearing: ¬ 25 reassembly • press the bearings with the special tool. \ 09913-70210: bearing installer set bearing: ¬ 32 note: the stamped mark side of the bearing faces inside. The removed bearings...

  • Page 85

    Engine 3-41 engine mounting bush disassembly • using an appropriate size steel tubes 1 and vise, remove the engine mounting bush 2. (lh, rh and rear) installation using an appropriate side steel tube and vise, press in the bush into the crankcase. (lh, rh and rear) bush end a must be flush the crank...

  • Page 86

    3-42 engine final reduction gear box disassembly • remove the drain plug 1 and gasket. • drain final reduction gear box oil. • remove the final reduction gear box cover bolts and gasket. • remove the final reduction gear box cover 2. • remove the gasket 3 and dowel pins. • remove the snap ring 4 and...

  • Page 87

    Engine 3-43 • remove the snap ring 8. • remove the chain guide 9. P • remove the dust seal 0 and bearing retainer a. • remove the counter shaft b with a plastic mallet. Counter shaft inspection inspect the counter shaft wear or damage. If any defects are found, replace it with a new one..

  • Page 88

    3-44 engine drive shaft inspection inspect the drive shaft for wear or damage. If any defects are found, replace it with a new one. Final driven gear and idle gear inspection inspect the final driven gear 1 and idle gear 2 for wear or dam- age. If any defects are found, replace the drive shaft gear ...

  • Page 89

    Engine 3-45 • remove the snap ring 4. • remove the rear axle shaft washer 5. • remove the bearing 6 with the special tool. \ 9913-20240: bearing remover set (¬20) • remove the rear axle shaft housing 7. • remove the oil seal 8 with the special tool. \ 09913-50121: oil seal remover.

  • Page 90

    3-46 engine • remove the bearings with the special tool. \ 09913-20240: bearing remover set 9: ¬12 0: ¬17 a: ¬20 installation • apply suzuki bond “1215” to the rear axle housing. E 99000-31110: suzuki bond “1215” (or equivalent bond) • tighten the rear axle housing bolts to the specified torque. " r...

  • Page 91

    Engine 3-47 \ 09913-70210: bearing installer set 4, 5: ¬25 6: ¬20 • install the rear axle housing washer 7. • install the snap ring 8. • install the oil seals with the special tool. \ 09913-70210: bearing installer set (¬47) \ 09913-70210: bearing installer set (¬30) the removed bearings must be rep...

  • Page 92

    3-48 engine • install the drive shaft 9. • install the counter shaft 0. • install the idle gear a. • apply final reduction gear box oil to the gears. • install the final driven gear b to the counter shaft. • install the snap ring c. • install the gasket d and dowel pins. The removed gasket must be r...

  • Page 93

    Engine 3-49 • tighten the final reduction gear box cover bolts and drain plug e to the specified torque. " final reduction gear box cover bolts: 10 n·m (1.0 kgf-m, 7.0 lb-ft) final reduction gear box drain plug bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) the removed drain plug bolt gasket and final reduc- t...

  • Page 94

    3-50 engine movable and fixed drive and driven face 1 concaved washer g limit clutch 2 fixed drive face fan h clutch shoe 3 fixed drive face i movable driven face spring 4 drive belt j movable driven face spring seat 5 power reduction spacer k o-ring 6 movable drive face l movable driven face 7 roll...

  • Page 95

    Engine 3-51 movable drive face 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 wear or damage. If they are worn or damaged, replace them with new ones. Movable and fixed d...

  • Page 96

    3-52 engine damper inspection inspect the dampers for wear or damage. If any defects are found, replace the dampers with new ones. Movable drive face installation • mount the dampers 1 on the movable drive face plate 2. • position the rollers 3 on the movable drive face 4. • check that the rollers 1...

  • Page 97

    Engine 3-53 • loosen the special tool handle slowly and remove the clutch shoe assembly 5 and spring 6. • remove the movable driven face spring seat 7. • remove the o-rings 8. • remove the oil seals 9. • install the oil seal with the special tool. \ 09913-70210: bearing installer set (¬35) do not at...

  • Page 98

    3-54 engine clutch shoe inspection inspect the boss and centrifugal weight fulcrum sections for looseness, damage and operation. Inspect the clutch shoe for damage and fouling with oil on the surface. If any abnormality is found, replace the clutch shoe assembly with a new one. Measure the thickness...

  • Page 99

    Engine 3-55 drive belt inspection inspect that the drive belt is free from any greasy substance. Inspect the contact surface of the drive belt for cracks or dam- age and measure the width of the drive belt with a vernier cali- pers. If any defects are found or the measurement exceeds the ser- vice l...

  • Page 100

    3-56 engine • apply suzuki super grease “a” to the o-rings and pin grooves. X 99000-25030: suzuki super grease “a” (or equivalent) • install the rollers and pins 2. • install the spring seat by aligning the hole. • install the spring and spring plate by aligning the spring ends with the holes. • com...

  • Page 101

    Engine 3-57 • tighten the clutch shoe nut temporarily. • remove the special tool from the clutch shoe assembly. • tighten the clutch shoe nut to the specified torque with the special tool. \ 09930-40113: rotor holder " clutch shoe nut: 60 n·m (6.0 kgf-m, 43.5 lb-ft) align the flats a of the fixed dr...

  • Page 102

    3-58 engine recoil starter 1 friction plate 6 reel 2 spring 7 spiral spring 3 friction plate 8 knob 4 friction spring 9 rope 5 starter cap 0 starter case.

  • Page 103

    Engine 3-59 disassembly • remove the nut 1 and friction plate 2. • remove the spring 3 and washer 4. • remove the cap 5 from the knob 6. • untie a knot at the rope. • remove the starter cup 7. • hook the rope to the groove a of the reel 8. • remove the reel 8. # wear hand and eye protection when rem...

  • Page 104

    3-60 engine • remove the spiral spring 9 from the recoil starter case 0. 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 su...

  • Page 105

    Engine 3-61 • apply thread lock “1303” to the bolt 7. • tighten the bolt 7 to the specified torque. J 99000-32050: thread lock “1303” (or equivalent) " recoil starter friction plate bolt: 5.0 n·m (0.5 kgf-m, 3.5 lb-ft) • pull the rope and check that the ratchet is pushed out..

  • Page 106: Engine Reassembly

    3-62 engine engine reassembly reassemble the engine in the reverse order of disassembly. The following steps require special attention or precautionary measures should be taken. Note: apply engine oil to each running and sliding part before reassembling. Crankshaft • determine the width between the ...

  • Page 107

    Engine 3-63 crankcase • thoroughly remove the sealant material and oil stains on the mating surface of the right and left crankcases. • install the dowel pins to the left crankcase. • apply engine oil to the conrod big end. Never fit the crankshaft into the crankcase by striking it with a plastic ha...

  • Page 108

    3-64 engine crankshaft shim selection • degrease the right crankshaft web, shim and inner race of the right crankshaft bearing. • place the removed shim 1 on the right crankshaft. • put the plasti-gauge (special tool) cut out about 10 mm on the shim as shown. \ 09900-22302: plasti-gauge • install th...

  • Page 109

    Engine 3-65 • apply suzuki bond “1215” to the mating surface of the right crankcase as shown. E 99000-31080: suzuki bond “1215” (or equivalent bond) note: use of suzuki bond "1215" is as follows: * make surfaces free from moisture, oil, dust and other foreign materials. * spread on surfaces thinly t...

  • Page 110

    3-66 engine • tighten the crankcase bolts to the specified torque. " crankcase bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) • after the crankcase bolts have been tightened, check if the crankshaft, rotate smoothly. Cam chain • install the cam chain 1 onto the sprocket. Oil pump • apply engine oil to the oil ...

  • Page 111

    Engine 3-67 • install the oil pump cover 4. Starter clutch and generator rotor • apply engine oil to the starter driven gear bearing and crank- shaft. • install the starter driven gear 1. • degrease the tapered portion of generator rotor and also the crankshaft. Use nonflammable cleaning solvent to ...

  • Page 112

    3-68 engine generator rotor cover • before installing the starter idle gear, apply molybdenum oil solution to the hole of starter idle gear shaft. P molybdenum oil solution • install the starter idle gear 1, shaft 2, dowel pins and gasket 3. • tighten the generator rotor cover bolts to the specified...

  • Page 113

    Engine 3-69 • install the clutch shoe/movable driven face assembly 5 with the drive belt 6. • install the limit clutch friction plate 7 and limit clutch 8. • install the limit clutch friction plate 9 and clutch housing 0. • install the limit clutch pressure plate a. • install the limit clutch stoppe...

  • Page 114

    3-70 engine • install the limit clutch nut d with the special tool. \ 09930-40113: rotor holder " limit clutch nut: 75 n·m (7.5 kgf-m, 54.0 lb-ft) movable drive • install the fixed drive face 1. • install the fixed drive face fan 2. • install the fixed drive face nut 3 with the special tool. \ 09930...

  • Page 115

    Engine 3-71 recoil starter • install the recoil starter 1. Oil filter • apply engine oil to the o-ring 1. • install the o-ring 1 and oil filter 2. • apply engine oil to the o-ring 3. • install the o-ring 3 and spring 4. • install the oil filter cap and tighten the bolts securely. Note: face the tria...

  • Page 116

    3-72 engine piston ring • install the piston rings in the order of oil ring, 2nd ring and 1st ring. • the first member to go into the oil ring groove is a spacer 1. • after placing the spacer, fit the two side rails 2. Note: side designations, top and bottom, are not applied to the spacer and side r...

  • Page 117

    Engine 3-73 piston and cylinder • apply molybdenum oil solution onto the piston pin and small end of the conrod. Note: install the piston with the punch mark a on the piston head fac- ing toward the exhaust side. P molybdenum oil solution • place a clean rag over the cylinder base to prevent the pis...

  • Page 118

    3-74 engine • install the cam chain guide 2. Note: make sure that the guide 2 is inserted properly or binding of the cam chain and guide may result. • install the dowel pins and gasket 3. Cylinder head note: apply engine oil to the threaded parts of the cylinder head nuts 1 and both sides of the its...

  • Page 119

    Engine 3-75 cam chain tension adjuster • apply engine oil to the push rod. • turn the adjusting screw clockwise with a - screwdriver until the rod locked. • install the cam sprocket 3. • apply a small quantity of thread lock super “1322” to the cam sprocket bolt 4. H 99000-3208: thread lock super “1...

  • Page 120

    3-76 engine note: make sure that the "up mark" a comes to the upper side. • after installing the cam chain tension adjuster, rotate the crankshaft, and recheck the positions of the camshafts. ( 3-9) • apply suzuki super grease “a” to the o-ring 4. • tighten the generator cover cap 5 and valve timing...

  • Page 121

    Engine 3-77 • apply engine oil to both sides of the washers 1. • install the cylinder head cover 2. • lightly tighten the cylinder head cover bolts and then tighten them to the specified torque. " cylinder head cover bolt initial: 10 n·m (1.0 kgf-m, 7 lb-ft) final: 14 n·m (1.4 kgf-m, 10.0 lb-ft) • i...

  • Page 122: 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 123: Fuel Tank and Fuel Valve

    4-2 fuel system fuel tank and fuel valve 1 fuel tank breather hose 5 fuel valve 2 fuel tank cap 6 fuel hose " 3 fuel tank a fuel valve bolt item n·m kgf-m lb-ft 4 o-ring a 4.6 0.46 3.5.

  • Page 124

    Fuel system 4-3 removal # • remove the fuel tank cover. ( 5-4) • turn the fuel valve to “on” position. • disconnect the fuel hose 1. • disconnect the vacuum hose 2. • remove the breather hose 3. • remove the fuel tank 4. • remove the fuel valve assembly 5. Fuel filter inspection and cleaning if the ...

  • Page 125

    4-4 fuel system installation install 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, 3.0 lb-ft) # • install the fuel tank and tighten the bolts securel...

  • Page 126: Carburetor

    Fuel system 4-5 carburetor 1 choke lever 9 starter plunger g needle jet 2 carburetor top cap 0 washer h main jet 3 gasket a o-ring i float pin 4 spring b spring j float 5 spring seat c throttle stop screw k gasket 6 o-ring d o-ring l float chamber 7 jet needle e needle valve m drain hose 8 piston va...

  • Page 127

    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 vm16sh bore size ¬16 i.D.N. 08h0 idle r/min 1 900 ± 100 r/min float height 16 mm main jet (m.J) #80 jet needle (j.N) 4la4...

  • Page 128

    Fuel system 4-7 removal • remove the fuel tank cover. ( 5-4) • remove the front cooling duct. ( 3-3) • 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 from the clamp 5. • loosen...

  • Page 129

    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, washer 5 and spring 6 from the piston valve 2. • remove the float chamber 7. • remove the gasket 9..

  • Page 130

    Fuel system 4-9 • remove the float pin 0. • remove the float a. • remove the needle valve b. • remove the main jet c and needle jet d. • remove the pilot jet e. • remove the throttle stop screw f. • remove the spring g, washer h and o-ring i from the throttle stop screw f..

  • Page 131

    4-10 fuel system • remove the choke lever j. • remove the starter plunger k..

  • Page 132

    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 s...

  • Page 133

    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 134

    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. • apply suzuki super grease “a” to the o-ring 1. " 99000-25010: suzuki super grease “a” (or equivalent) # • install the gasket 2. # • install the piston valve 3 ...

  • Page 135

    4-14 fuel system • install the carburetor top cap 4. • install the intake pipe clamp 5. • tighten the carburetor mounting bolts 6 to the specified torque. " carburetor mounting bolt: 6 n·m (0.6 kgf-m, 4.5 lb-ft) • install the fuel hose 7. • install the air vent hose 8. • install the vacuum hose 9. N...

  • Page 136: Chassis

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

  • Page 137: Exterior Parts

    5-2 chassis exterior parts construction 1 seat 7 footrest lid 2 front fender 8 right footrest mudguard 3 rear fender 9 left footrest mudguard 4 rear lower fender 0 front grip " 5 right fuel tank cover a right footrest bar item n·m kgf-m lb-ft 6 left fuel tank cover b left footrest bar a 55 5.5 40.0

  • Page 138

    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 139

    5-4 chassis removal seat • remove the seat. Footrest lid • remove the footrest lid. Fuel tank cover • remove the seat. ( above) • remove the footrest lid. ( above) • remove the screw 1 and fastener..

  • Page 140

    Chassis 5-5 left footrest mudguard • remove the fuel tank cover. ( 5-4) • remove the screws 1 and fasteners. • remove the bolts 2. • remove the left footrest mudguard 3. Right footrest mudguard • remove the fuel tank cover. ( 5-4) • remove the footrest lid. ( 5-4) • remove the screws 1 and fasteners...

  • Page 141

    5-6 chassis • remove the front fender 2. Rear fender • remove the seat. ( 5-4) • remove the footrest lid. ( 5-4) • remove the fuel tank cover. ( 5-4) • remove the footrest mudguard, left and right ( 5-5) • disconnect the - battery cable first, and then + battery cable. • remove the battery band 1. •...

  • Page 142

    Chassis 5-7 • remove the rear lower fender fastener 6. • remove the rear fender 7. Front grip • remove the front grip. Installation install the exterior parts in the reverse order of removal. Pay attention to the following points: footrest bar • apply thread lock “1342” to the footrest mounting bolt...

  • Page 143: Front and Rear Wheels

    5-8 chassis front and rear wheels construction removal • place the vehicle on level ground. • support the vehicle with a jack or block and remove the front and rear wheel set nuts. • remove the front and rear wheels. 1 front tire 4 rear wheel " 2 front wheel a wheel set nut (front & rear) item n·m k...

  • Page 144

    Chassis 5-9 installation install the wheels in the reverse order of removal. Pay attention to the following points: • installing each wheel, make sure the arrow a on the tire points in the direction of rotation. • tighten the wheel set nuts to the specified torque. " front and rear wheel set nut: 55...

  • Page 145: Tires

    5-10 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 146

    Chassis 5-11 note: * for inspecting the tires, refer to page 2-22. * inspect the valve cores, before installation. * when installing each tire, make sure that the arrow a on the side wall of the tire points in the direction of rotation. Also, make sure the outer side of the wheel rim is facing outwa...

  • Page 147: Front Brake

    5-12 chassis front brake construction 1 wheel center cap a o-ring 2 axle spacer b front brake dust seal 3 outer dust seal c brake plate 4 wheel hub outer bearing d limit indicator 5 front wheel hub e brake cam lever 6 spacer f front brake cam lever bolt 7 wheel hub inner bearing g spring " 8 inner d...

  • Page 148

    Chassis 5-13 removal • remove the front wheel. ( 5-8) • remove the wheel center cap. • remove the cotter pin and front hub nut 1. • remove the front washer 2 and wheel hub 3. • remove the front brake shoe assembly 4. • remove the spring 5. • remove the front brake adjusting nut 6. • remove the front...

  • Page 149

    5-14 chassis 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. \ 09900-20101: vernier calipers brake drum i.D.: service limit: 110.7 mm (4.35 in)...

  • Page 150

    Chassis 5-15 • remove the dust seals with the special tool. \ 09913-50121: oil seal remover wheel hub bearing inspect the inner race play of the wheel hub bearing by hand while it is in the wheel hub. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. If there is anythi...

  • Page 151

    5-16 chassis • remove the wheel hub inner bearing with the special tool. \ 09941-50111: bearing remover reassembly and installation bearing • apply suzuki super grease “a” to the wheel hub bear- ings. X 99000-25010: suzuki super grease “a” or equivalent • install the wheel hub inner bearing with the...

  • Page 152

    Chassis 5-17 • install the dust seals with the special tool. \ 09913-70210: bearing installer set • install the front brake drum dust seal 1 to the groove of the front brake drum 2. • align the front brake drum a with the groove of front brake drum dust seal b. • apply water resistance grease to the...

  • Page 153

    5-18 chassis • install the o-rings. • apply suzuki super grease “a” to the o-rings and cam- shaft. X 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 ...

  • Page 154

    Chassis 5-19 • tighten the front hub nut to the specified torque. " front hub nut: 65 n·m (6.5 kgf·m, 47.0 ib-ft) • install the cotter pin. • install the front wheel. ( 5-8) • after installing the front brake, adjust the front brake lever play. ( 2-20) the removed cotter pin must be replaced with a ...

  • Page 155

    5-20 chassis steering and front suspension construction 1 front shock absorber 9 tie-lod " 2 front suspension arm a front shock absorber upper nut item n·m kgf-m lb-ft 3 bush b front shock absorber lower nut a 50 5.0 36.0 4 steering knuckle arm c front suspension arm bolt b 50 5.0 36.0 5 knuckle arm...

  • Page 156

    Chassis 5-21 1 handlebar upper holder 7 steering shaft lower dust seal 2 handlebars 8 steering shaft bush " 3 handlebar lower holder 9 o-ring item n·m kgf-m lb-ft 4 steering shaft a handlebar clamp bolt a 25 2.5 18.0 5 steering shaft holder b steering shaft holder bolt b 23 2.3 17.0 6 dust seal c st...

  • Page 157

    5-22 chassis removal and disassembly front suspension • remove the front wheel. ( 5-8) • remove the front grip. ( 5-7) • remove the front brake. ( 5-13) • remove the front brake cable 1. • remove the cotter pin and tie-rod end nut 2. • remove the cotter pin and knuckle arm nut 3. • remove the knuckl...

  • Page 158

    Chassis 5-23 inspection knuckle arm bush insert the spacer into the bush and inspect for abnormal noise and smooth rotation while rotating the spacer. If any defects are found, replace it with a new one. • remove the knuckle arm bushes with the special tools. \ 09923-73210: bearing remover 09930-301...

  • Page 159

    5-24 chassis reassembly and installation steering knuckle arm • install the knuckle arm bush with the special tool. \ 09924-84510: bearing installer set • apply suzuki resistance grease to the knuckle arm bushes, dust seals and spacer. • install the spacer and dust seals. 99000-25160: suzuki resista...

  • Page 160

    Chassis 5-25 • tighten the tie rod end nut to the specified torque and install the cotter pin. " tie rod end nut: 50 n·m (5.0 kgf·m, 36.0 ib-ft) note: make sure that the steering turns smoothly in both directions. • install the front brake. ( 5-16) • install the front grip. ( 5-7) • install the fron...

  • Page 161

    5-26 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 3. • remove the steering shaft holder 4 and steering shaft 5. • remove the steering shaft bush with the special tools ...

  • Page 162

    Chassis 5-27 • remove the dust seals 6 and steering shaft lower dust seal 7. • separate the tie-rod ends 8, lock-nuts (9, 0) and tie rods a. Tie rod/tie rod end inspect the tie-rod for distortion and the boot for wear and tie rod end for smooth movement. If any defects are found, replace it with a n...

  • Page 163

    5-28 chassis reassembly and installation reassemble and install the steering in the reverse order of removal and disassembly. Pay attention to the following points: • install the steering shaft bush with the special tool and suit- able size socket wrench. \ 09924-84521: bearing installer set steerin...

  • Page 164

    Chassis 5-29 • tighten the steering shaft holder bolts to the specified torque. " steering shaft holder bolt: 23 n·m (2.3 kgf·m, 17.0 ib-ft) tie rod • tighten the tie-rod end nuts to the specified torque and install the cotter pins. " tie rod end nut: 50 n·m (5.0 kgf-m, 36.0 lb-ft) note: the lock-nu...

  • Page 165

    5-30 chassis installation install the handlebars in the reverse order of removal. Pay atten- tion to the following points: • apply adhesive agent to the handlebar right and left end and right and left grip inner wall. Handle grip bond (commercial available) • align the punched mark a on the handleba...

  • Page 166

    Chassis 5-31 • install the left handle switch 4 and left grip 5. • align the punched mark f on the handlebars with the mating surface g of throttle lever 6. • install the right grip 7..

  • Page 167

    5-32 chassis 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. ( 2-22) • place 63 kg (139 lbs) weight on the seat. • loosen the locknuts (1, 2) on each tie-rod. • measur...

  • Page 168

    Chassis 5-33 rear brake and rear axle housing construction 1 rear wheel hub d rear sprocket 2 rear brake drum outer seal e rear brake cam shaft 3 rear brake drum cover f o-ring 4 rear brake drum inner seal g spacer 5 rear brake drum h spring 6 rear brake shoe i limit indicator 7 rear axle j rear bra...

  • Page 169

    5-34 chassis removal rear brake • remove the cotter pin and rear axle nut 1. • remove the rear wheel 2. • remove the rear axle washer 3 and rear wheel hub 4. • remove the rear axle lock-nut 5 and axle nut 6 with the spe- cial tool. \ 09940-92430: rear axle nut wrench set • remove the rear brake drum...

  • Page 170

    Chassis 5-35 • remove the rear brake drum cover 8. • loosen the rear brake cable 9. • remove the rear brake drum 0. • remove the rear brake shoes a. • remove the rear brake cable b, rear brake cam lever c, limit indicator d spring e and spacer f..

  • Page 171

    5-36 chassis • remove the breather hose g. • remove the o-rings h. • disengage the drive chain i from the rear sprocket. • remove the rear axle shaft j and sprocket k. • draw out the rear axle shaft j to the right side. • remove the chain guide l, chain case m and rear axle n..

  • Page 172

    Chassis 5-37 inspection and disassembly brake drum 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 indicated inside the brake drum. \ 09900-20101:vernier calipers b...

  • Page 173

    5-38 chassis 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 the rear axle with a new one. Rear axle runout: service limit: 6 mm (0.23 in) \ 09900-20607: dial gauge (1/100 mm) 09900-2070...

  • Page 174

    Chassis 5-39 • remove the rear brake anchor nut 1. • extract the anchor pin 2. • remove the rear axle spacers 3. • remove the dust seals with the special tool. \ 09913-50121: oil seal remover rear axle housing bearing inspect the inner race play of the rear axle housing bearing by hand while it is i...

  • Page 175

    5-40 chassis • remove the rear axle housing bearings with the special tool. \ 09930-30104: sliding shaft 09923-74511: bearing remover ( ¬20) 09923-73210: bearing remover ( ¬17) • remove the spacer 1. Reassembly and installation reassemble and install the rear brake and rear axle housing in the rever...

  • Page 176

    Chassis 5-41 • the stamped mark a on the rear sprocket should face out- side. • tighten the rear sprocket nut to the specified torque. " rear sprocket nut: 28 n·m (2.8 kgf·m, 20.0 ib-ft) • install the rear sprocket flange 1 to the rear axle shaft 2..

  • Page 177

    5-42 chassis bearing and rear axle housing • apply suzuki super grease “a” to the rear axle housing bearings and lip of the dust seals, before installing them. X 99000-25010: suzuki super grese “a” (or equivalent) • install the rear axle housing bearing with the special tool. • install the dust seal...

  • Page 178

    Chassis 5-43 • install the rear axle housing seals with the special tool. \ 09913-70210: bearing installer • when installing the rear brake anchor pin, apply thread lock “1322” to the mating surface of the pin and the axle housing. • apply a small quantity of thread lock super “1322” to the anchor p...

  • Page 179

    5-44 chassis • install the spring 1, limit indicator 2 and rear brake cam lever 3. • tighten the rear brake cam lever nut to the specified torque. " rear brake cam lever nut: 8 n·m (0.8 kgf·m, 6.0 ib-ft) note: align the punched mark a on the cam lever with the slit b on the camshaft. Rear brake drum...

  • Page 180

    Chassis 5-45 • apply suzuki super grease “a” to the brake camshaft and pin. X 99000-25010: suzuki super grease “a” (or equivalent grease) • install the brake shoes. # • apply suzuki super grease “a” to the rear brake drum. X 99000-25010: suzuki super grease “a” (or equivalent grease) • apply a small...

  • Page 181

    5-46 chassis • apply a small quantity of thread lock super “1303” to the thread portion of the axle nut. • tighten the axle nut to the specified torque with the special tool. " rear axle nut: 180 n·m (18.0 kgf·m, 130.0 ib-ft) h 99000-32110: thrad lock super “1322” (or equivalent thread lock) \ 09940...

  • Page 182: Rear Suspension

    Chassis 5-47 rear suspension construction 1 rear shock absorber 9 out spacer 2 chain case cover 0 swingarm pivot bush 3 chain case a swingarm 4 chain guide b spacer " 5 swingarm pivot shaft a rear shock absorber upper bolt item n·m kgf-m lb-ft 6 dust seal b rear shock absorber lower bolt a 29 2.9 21...

  • Page 183

    5-48 chassis removal • remove the rear wheel. ( 5-8) • remove the rear brake and rear axle housing. ( 5-34) • remove the chain guide 1, chain case 2 and rear axle housing 3. • remove the rear shock absorber 4. • remove the breather hose 5. • remove the swingarm pivot nut 6 and shaft. • remove the sw...

  • Page 184

    Chassis 5-49 inspection and disassembly rear shock absorber inspect the shock absorber body for oil leakage or damage. If any defects are found, replace the shock absorber with a new one. Rear shock absorber dust seal • remove the collars. Inspect the dust seal lips and collars for wear or damage. I...

  • Page 185

    5-50 chassis • remove the bearing with the special tool. \ 09921-20240: bearing remover set swingarm pivot shaft check the pivot shaft for runout with a dial gauge and replace it if the runout exceeds the limit. \ 09900-20607: dial gauge (1/100 mm) 09900-20701: magnetic stand 09900-21304: v-block se...

  • Page 186

    Chassis 5-51 • remove the outer spacers 3. • remove the swingarm pivot bushes with the special tool. \ 09923-73210: bearing remover 09930-30104: sliding shaft • remove the swingarm spacer 4. Swingarm bush inspect the swingarm bush for wear or damage. If any defects are found, replace awingarm bushes...

  • Page 187

    5-52 chassis chain buffer inspect the chain buffer for wear and damage. If any defects are found, replace the chain buffer with a new one. Reassembly and installation reassemble and install the rear suspension in the reverse order of removal and disassembly. Pay attention to the following points: • ...

  • Page 188

    Chassis 5-53 • press the swingarm pivot bush into the swingarm to the depth of 4 mm (0.157 in) with the special tool and suitable socket wrench. \ 09941-94513: steering race installer • install the swingarm spacer 1. • install the swingarm pivot bushes with the special tool. \ 09941-34513: steering ...

  • Page 189

    5-54 chassis note: align the oil seal surface a with the swingarm end b. • apply suzuki resistance grease to the dust seals. 99000-25160: suzuki resistance grease • install the dust seals 3 and chain buffer 4. • tighten the swingarm pivot nut to the specified torque. " swingarm pivot nut: 102 n·m (1...

  • Page 190

    Chassis 5-55 • tighten the rear shock absorber lower/bolt to the specified torque. " rear shock absorber lower bolt: 94 n·m (9.4 kgf·m, 68.0 ib-ft) • install the rear axle housing and rear brake. ( 5-40) • install the rear wheel. ( 5-9) • after installing the rear suspension, adjust the following it...

  • Page 191: Electrical System

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

  • Page 192: 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 193

    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 194

    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 195

    Electrical system 6-5 location of electrical components 1 battery 2 starter relay 3 fuse (10 a) 4 cdi unit 5 generator 6 ckp sensor 7 ignition coil.

  • Page 196

    6-6 electrical system 1 ignition switch 2 parking brake switch 3 engine stop switch 4 starter button 5 starter motor 6 regulator/rectifier.

  • Page 197: 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 regula...

  • Page 198

    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 regul...

  • Page 199

    Electrical system 6-9 regulated voltage • remove the seat. ( 5-4) • start the engine to 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/r...

  • Page 200

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

  • Page 201: 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 in the “run”, “on” and “set” positions and...

  • Page 202

    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) is the starter relay ok? Starter motor removal • disconnect the battery - lead w...

  • Page 203

    Electrical system 6-13 starter motor disassembly • disassemble the starter motor as shown in the illustration. 1 o-ring 4 starter motor case 2 housing end (inside) 5 housing end (outside) 3 armature 6 starter motor lead wire mounting bolt.

  • Page 204

    6-14 electrical system starter motor inspection carbon brush • inspect the brushes for abnormal wear, cracks, or smooth- ness in the brush holder. If any defects are found, replace the housing end assembly with a new one. • measure the brush length a of the brushes using a vernier calipers. If measu...

  • Page 205

    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. Starter motor reassembly reassemble the starter motor in the reverse order of disassem- bly. Pay attention to the following points: • apply suzuki supe...

  • Page 206

    6-16 electrical system starter motor installation • tighten the starter motor lead wire mounting bolt 1 and starter motor mounting bolts 2. • tighten the starter motor lead wire mounting bolt to the speci- fied torque. " starter motor lead wire mounting bolt: 4 n·m (0.4 kgf-m, 3.0 lb-ft) starter rel...

  • Page 207

    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 v tester knob indication: resistance ( w) starter relay ...

  • Page 208: Ignition System

    6-18 electrical system ignition system troubleshooting no spark or poor spark note: check that the engine stop switch, parking brake switch is in the “run”, “on” and “set” positions. Check that the fuse is not blown and the battery is fully-charged before diagnosing. Step 1 1) check the ignition sys...

  • Page 209

    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 with...

  • Page 210

    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 211

    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 212

    6-22 electrical system • repeat the above procedure a few times and measure the highest ckp sensor peak voltage. W tester knob indication: voltage () ckp sensor 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 voltag...

  • Page 213: 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 214: 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 215

    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 216

    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 217: Servicing Information

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

  • Page 218: 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 219

    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 220

    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 221

    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 222

    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 223

    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 224

    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 225

    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 226

    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 227

    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 228

    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 229: Lubrication System

    Servicing information 7-13 lubrication system oil pressure 2-31 oil filter 2-11 oil strainer 2-12 oil pump 3-38 engine lubrication system chart oil strainer oil pump oil filter crankshaft bearing (l) oil nozzle crank pin cylinder wall conrod small end cylinder rocker arm rock arm shaft cam chain pis...

  • Page 230

    7-14 servicing information wiring diagram off on off ru n push • st ar ter m oto r genera t o r regula t or/ rectifier ignition coil cdi unit off ro on ignition switch p arking brake switch st ar ter b utt on engine st op switch st ar ter rela y 1 1:main 10a br b/w w/b o/w b/w b/w y/g b/w b/w b/w w/...

  • Page 231

    Servicing information 7-15 wiring harness, cable and hose routing wiring harness routing cdi unit handle ber handle switch (l) starter relay rear brake cable starter motor forward starter motor lead wire frame ignition coil wiring harness *2 brake switch generator lead wire handle switch (l) battery...

  • Page 232

    7-16 servicing information passthe wiring harness down side of the ckp sensor 10 n·m (1.0 kgf-m, 7.0 lb-ft) 6.0 n·m (0.6 kgf-m, 4.0 lb-ft).

  • Page 233

    Servicing information 7-17 cable routing front brake cable (r) front brake cable (l) front brake cable (l) front brake cable (r) front brake cable (r) front brake cable (r) bracket w2 w1 *6 *3 *9 *8 front brake cable (l) front brake cable (l) front brake cable (r) wiring harness wiring harness throt...

  • Page 234

    7-18 servicing information fuel hose piping fuel tank breather hose handlbers v acum hose clip clip fuel hose fuel v alv e.

  • Page 235

    Servicing information 7-19 rear brake breather hose routing clamp clamp rear swingarm *2 *1 rear brake breather hose *1 pass the rear brake breather hose through downside of the rear shock absorber. *2 insert the rear brake breather hose into the joint to the root..

  • Page 236

    7-20 servicing information cooling duct routing setting position setting position attach the “e/g sid” mar k of an engine side 45˚ setting position.

  • Page 237

    Servicing information 7-21 exhaust pipe cover 8.5˚ 8.5˚ 8.5˚ 5.6˚ 45˚.

  • Page 238

    7-22 servicing information special tools 09900-22301 09900-22302 plastigauge 09900-20101 09900-20102 vernier calipers 09900-20202 micrometer (25 – 50 mm) 09900-20205 micrometer (0 – 25 mm) 09900-20530 cylinder gauge set 09900-20602 dial gauge (1/1000 mm, 1 mm) 09900-20605 dial calipers (1/100 mm, 10...

  • Page 239

    Servicing information 7-23 09915-70651 compression gauge set 09915-63311 compression gauge nose 09915-74511 oil pressure gauge set 09915-74521 oil pressure gauge hose 09915-74531 attachment 09916-10911 valve lapper set 09916-14510 valve lifter 09916-14521 attachment 09916-34542 reamer handle 09916-3...

  • Page 240

    7-24 servicing information note: when order the special tool, please confirm whether it is available or not. 09924-84521 bearing installer set 09930-10121 spark plug wrench set 09930-30104 sliding shaft 09930-40113 rotor holder 09930-30721 rotor remover 09930-31920 09930-34980 rotor remover 09930-44...

  • Page 241: Tightening Torque

    Servicing information 7-25 tightening torque engine fuel item n·m kgf-m lb-ft cylinder head cover bolt initial 10 1.0 7.0 final 14 1.4 10.0 cylinder head nut m12 25 2.5 18.0 m10 10 1.0 7.0 valve clearance adjuster locknut 10 1.0 7.0 cam sprocket bolt 11 1.1 8 cam chain guide mounting bolt 10 1.0 7.0...

  • Page 242

    7-26 servicing information chassis item n·m kgf-m lb-ft front suspension arm pivot nut 65 6.5 47.0 steering knuckle arm nut 60 6.0 43.5 tie-rod end nut 50 5.0 36.0 tie-rod locknut 29 2.9 21.0 steering shaft lower nut 35 3.5 25.5 steering shaft holder bolt 23 2.3 17.0 handlebar clamp bolt 25 2.5 18.0...

  • Page 243

    Servicing information 7-27 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 1...

  • Page 244: Service Data

    7-28 servicing information service data valve + valve guide unit: mm (in) item standard limit valve diam. In. 22.5 (0.89) ---- ex. 19 (0.75) ---- 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 – 0.03...

  • Page 245

    Servicing information 7-29 camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit cam height in. 27.92 – 27.97 (1.099 – 1.101) 27.62 (1.087) ex. 27.80 – 27.85 (1.094 – 1.096) 27.50 (1.082) rocker arm i.D. In. & ex. 10.003 – 10.018 (0.393 – 0.394) ---...

  • Page 246

    7-30 servicing information conrod + crankshaft unit: mm (in) clutch unit: mm (in) item standard limit piston ring groove width 1st 1.01 – 1.03 (0.0397 – 0.0405) ---- 2nd 1.04 – 1.03 (0.0397 – 0.0405) ---- oil 2.01 – 2.03 (0.0791 – 0.0799) ---- piston ring thickness 1st 0.97 – 0.99 (0.0382 – 0.0390) ...

  • Page 247

    Servicing information 7-31 reduction gear + drive belt + drive chain unit: mm (in) except ratio carburetor item standard limit reduction ratio variable change (2.645 – 1.621) — reduction gear ratio 8.294 (47/17 × 47/15) — final reduction ratio 2.181 (24/11) — drive belt width 19.9 (0.78) 18.9 (0.74)...

  • Page 248

    7-32 servicing information electrical unit: mm (in) item standard/specification limit note spark plug type ngk: cr7hsa denso: u20fsr-u — gap 0.7 – 0.8 (0.028 – 0.031) — spark performance over 8 (0.3) at 1 atm. — ignition coil resistance primary 0.1 – 0.7 w — terminal – terminal secondary 14 – 20 k w...

  • Page 249

    Servicing information 7-33 brake + wheel unit: mm (in) tire unit: mm (in) item standard limit front brake lever play 4 – 6 (0.16 – 0.24) — rear brake lever play 3 – 5 (0.12 – 0.26) — brake drum i.D. Front — 110.7 (4.35) rear — 130.7 (5.14) rear axle runout rear — 6.0 (0.23) wheel rim size front & re...

  • Page 250

    7-34 servicing information suspension unit: mm (in) fuel + oil item standard limit front wheel travel 62 (2.4) ---- rear wheel travel 61 (2.4) ---- 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 251

    Prepared by september, 2006 part no.99500-40020-01e printed in japan 254.

  • Page 252

    Printed in japan k7 99500-40020-01e lt-z90k7_01e service manual 2006. 8. 30 for ps printing top bottom 9 9 5 0 0 - 4 0 0 2 0 - 0 1 e.