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Suzuki RM125 Owner's Service Manual

Other manuals for RM125: Owner's Service Manual

Summary of RM125

  • Page 1

    Part no. 99011-36f56-01a april, 2006 en tk rm125 owner’s service manual.

  • Page 2

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

  • Page 3: Foreword

    Foreword this manual is presented as a means whereby you can maintain your rm125 in top working condition at all times. Your riding skill and the maintenance steps outlined in this manual will assure you of top performance from your machine under any type of competition. We sincerely wish you and yo...

  • Page 4: General Considerations

    General considerations • wear a helmet and goggles a helmet is the most important piece of gear to wear. Helmets do not reduce essential vision or hearing. Generally, helmets do not cause or intensify injury if you crash. Helmets simply help your skull protect your intelligence, your memory, your pe...

  • Page 5: Serial Number Location

    Serial number location the frame number 1 is stamped on the steering head as shown in the photograph. The engine serial num- ber 2 is stamped on the right side of the crankcase assembly. Write down the serial numbers here for your future reference. Frame no. Engine no..

  • Page 6: Warnings For Servicing

    Warnings for servicing  warning never run the engine indoors or in a garage. Exhaust gas contains carbon mon- oxide, a gas that is colorless and odorless and can cause death or severe injury. Only run the engine outdoors where there is fresh air.  warning hot engine and muffler can burn you. Wait ...

  • Page 7: Precautions For Servic-

    Precautions for servic- ing • replace gaskets, snap rings, circlips, o-rings and cotter pins with new ones. • take care not to expand the end gap larger than required to slip the circlip over the shaft when installing a circlip. • use special tools where specified. • use genuine suzuki parts and rec...

  • Page 8: Symbol Marks and Materials

    Symbol marks and materials listed in the table below are the symbols indicating instructions and other information. The meaning of each symbol is also included in the table. Symbol definition symbol definition torque control required. Data beside it indicates specified torque. Use suzuki fork oil ss...

  • Page 9: Group Index

    Group index general information 1 periodic maintenance 2 troubleshooting 3 machine tuning 4 engine removal and installation 5 cylinder, piston and exhaust valve 6 clutch 7 kick starter 8 gearshifting 9 transmission and crankshaft 10 fuel system 11 cooling system 12 electrical system 13 front and rea...

  • Page 10: General Information

    1 general information 1-1 contents general information country and area codes the following codes stand for the applicable country(-ies) and area(-s). Code country or area effective frame no. 000 e-03 e-19 e-28 japan u. S. A. E. U. Canada js1rf16a000 500001 – js1rf16c 72 100001 – js1rf16a000 500001 ...

  • Page 11: Location of Parts

    1-2 general information location of parts 1 clutch lever 2 engine stop switch 3 front brake fluid reservoir 4 throttle grip 5 front brake lever 6 fuel tank cap 7 fuel valve 8 carburetor starter knob 9 gearshift lever 0 rear brake fluid reservoir a rear brake pedal b kick starter lever c front suspen...

  • Page 12: Fuel and Oil Recommendation

    General information 1-3 fuel and oil recommendation this motorcycle is of the two-stroke design, which requires a premixture of gasoline and oil. Gasoline: use only unleaded gasoline of at least 90 pump octane (r/2 + m/2 method). .....For usa and canada use only unleaded gasoline of at least 95 octa...

  • Page 13: Operating Instructions

    1-4 general information operating instructions starting the engine inspect the transmission oil level, coolant level and air cleaner condition before starting the engine. When the engine is cold: 1) turn the fuel valve lever to the “on” position. 2) shift the transmission into neutral. 3) pull the s...

  • Page 14: Transmission

    General information 1-5 transmission this motorcycle has a 6-speed transmission. Neutral is located between low and 2nd. Engage first gear by pressing the lever down from the neutral position. You can shift into higher gears by lifting on the shift lever once for each gear. When neutral is desired, ...

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  • Page 16: Periodic Maintenance

    2 periodic maintenance 2-1 contents periodic maintenance periodic maintenance ........................................................................ 2- 3 inspection before practice ...................................................... 2- 3 inspection before race (all items of inspection before pr...

  • Page 17: Periodic Maintenance

    2-2 periodic maintenance contents periodic maintenance sprocket inspection ................................................................... 2-17 drive chain guide, buffer, tensioner roller .......................... 2-17 drive chain guide .............................................................

  • Page 18: Periodic Maintenance

    Periodic maintenance 2-3 periodic maintenance inspection before practice inspection before race (all items of inspection before practice above plus) what to check check for spark plug • heat range, fouled electrode, tightness • loose high-tension cord air cleaner element lubrication transmission oil...

  • Page 19

    2-4 periodic maintenance periodic maintenance chart it is very important to inspect and maintain the machine regularly. Follow the guideline in the chart. The life of parts varies depending on the riding conditions. Perform more often than shown in the chart if you use the motorcycle under severe co...

  • Page 20

    Periodic maintenance 2-5 . Note: r = replace, c = clean, t = tighten, i = inspect and clean, adjust lubricate or replace if necessary, l = lubricate interval races every race every 3 races every 5 races remarks service item hours every 2 hours every 6 hours every 10 hours tire i — — spoke nipple i —...

  • Page 21: Spark Plug

    2-6 periodic maintenance spark plug • inspect the spark plug condition, electrode color, carbon deposits, spark plug gap, and washer damage, after removing the spark plug. Note: remove the dirt around the spark plug before removing the spark plug to prevent dirt from entering the combustion cham- be...

  • Page 22: Air Cleaner

    Periodic maintenance 2-7 air cleaner air cleaner element removal • remove the seat. ( 5-3) • remove the air cleaner box lid. ( 2-8) • remove the wing nut 1. • remove the element 2 from the element holder. Washing • fill a washing pan large enough to hold the element with a non-flammable cleaning s...

  • Page 23: Transmission Oil

    2-8 periodic maintenance • install the air cleaner box lid properly as shown. Note: running the engine without the air cleaner box lid can vary the carburetion. Do not run the engine without the air cleaner box lid. Note: follow the instructions below to keep the air cleaner element dry when cleanin...

  • Page 24

    Periodic maintenance 2-9 note: recycle or properly dispose of used oil and solvent. Transmission oil level inspection and replenishment • place the motorcycle on level ground and hold the motorcycle vertically. • run the engine for a few minutes and stop it. Wait 3 minutes. • remove the oil level bo...

  • Page 25: Engine Coolant

    2-10 periodic maintenance engine coolant engine coolant level check • remove the radiator cap 1. • check that the engine coolant level is at the bottom of the inlet hole. If not, replenish the radiator with specified engine cool- ant. • tighten the radiator cap securely. Note: * this motorcycle does...

  • Page 26

    Periodic maintenance 2-11 engine coolant replenishment • use an anti-freeze and summer engine coolant which is com- patible with aluminum radiator, mixed with distilled water at the ratio of 50:50. Note: the radiator, cylinder and cylinder head are made of aluminum alloy. Using non-recommended engin...

  • Page 27: Clutch Cable

    2-12 periodic maintenance clutch cable adjust the clutch cable play as follows: major adjustment • loosen lock-nut 1. • turn adjuster 2 so the clutch lever has 10 – 15 mm (0.4 – 0.6 in) play at the clutch lever end before pressure is felt. • tighten lock-nut 1.  clutch lever play: 10 – 15 mm (0.4 –...

  • Page 28: Fuel Hose

    Periodic maintenance 2-13 • apply oil to the throttle cable. • apply grease to the throttle cable spool.  99000-25010: suzuki super grease “a” (or equivalent grease) fuel hose • inspect the fuel hose for damage and fuel leakage. If any defects are found, the fuel hose must be replaced. • replace th...

  • Page 29: Cylinder Head, Cylinder and

    2-14 periodic maintenance cylinder head, cylinder and piston cylinder head • remove the cylinder head. ( 6-3) • remove carbon deposits from the combustion chamber sur- face. • inspect for pinholes, cracks and other damage. Cylinder • remove the cylinder. ( 6-4) • remove carbon deposits from the ex...

  • Page 30: Exhaust Valve

    Periodic maintenance 2-15 exhaust valve • remove the exhaust valve assembly. ( 6-5) • remove carbon deposits from the main exhaust valve, side valve, spacer and exhaust valve guide. • check for wear and damage. Note: if tar drops from the exhaust valve breather hose when the motorcycle is parked, c...

  • Page 31: Drive Chain and Sprockets

    2-16 periodic maintenance drive chain and sprockets drive chain slack • place the motorcycle on the side stand. • inspect the drive chain slack at the middle point between the drive chain buffer and rear sprocket.  drive chain slack: 40 – 50 mm (1.6 – 2.0 in) drive chain adjustment • loosen the axl...

  • Page 32: Drive Chain Guide, Buffer,

    Periodic maintenance 2-17 • clean the drive chain with non-flammable cleaning solvent. • do not use gasoline to clean the drive chain. • dry the drive chain. • apply suzuki chain lube or equivalent to the link plates and rollers. • reassemble the drive chain. Note: reassemble the drive chain clip so...

  • Page 33: Brakes

    2-18 periodic maintenance drive chain guide buffer • inspect the drive chain guide buffer 1 for wear and cracks. Note: the drive chain can touch the swingarm directly if the chain guide buffer is worn out. This will cause drive chain and swing- arm damage. Drive chain tensioner roller • inspect the ...

  • Page 34

    Periodic maintenance 2-19 brake pad • inspect the brake pads for wear. If the brake pads are worn, replace them with new ones. ( 15-5) note: * pump the brake lever/pedal several times to restore the brake pads after replacing the brake pads. * replace both right and left pads together when replacin...

  • Page 35: Front Fork

    2-20 periodic maintenance front fork • move the front fork up and down several times and inspect for smooth movement. • inspect for damage and oil leaks. • inspect the bolts and nuts for tightness. • place a stand under the chassis tube to lift the front wheel off the ground. • remove the air bleed ...

  • Page 36

    Periodic maintenance 2-21 spoke nipple and rim lock • inspect the spokes for tension by squeezing the spoke nip- ples. • retighten the spoke nipples with a spoke nipple wrench so as all spokes have same tension.  spoke nipple: 4 n·m (0.4 kgf-m, 3.0 lb-ft) • inspect the rim lock 1 for tightness, dam...

  • Page 37: Steering

    2-22 periodic maintenance steering • inspect the steering by moving the front fork up and down, and right and left. If the steering has play or binds, inspect steering stem head nut tightness and steering bearings. ( 16-20).

  • Page 38: Lubrication

    Periodic maintenance 2-23 lubrication apply grease or oil to the moving parts to increase durability and prevent wear. The following materials are necessary: a. Lightweight oil such as wd-40 or penetrating oil. B. Aerosol type chain lube. C. Suzuki super grease “a” or water-proof wheel bearing greas...

  • Page 39

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  • Page 40: Troubleshooting

    3 troubleshooting 3-1 contents troubleshooting troubleshooting ................................................................................. 3- 2 engine ................................................................................................. 3- 2 chassis ...................................

  • Page 41: Troubleshooting

    3-2 troubleshooting troubleshooting engine complaint possible cause remedy engine does not start or hard to start fuel deterioration no fuel flow to the carburetor • fuel valve clogged • fuel hose clogged • fuel tank cap breather hose clogged • carburetor float valve malfunction too rich air/fuel mi...

  • Page 42

    Troubleshooting 3-3 complaint possible cause remedy engine runs poorly in low speed range exhaust valve maladjustment wide spark plug gap carburetor air screw maladjustment incorrect carburetor fuel level improper jet needle size incorrect ignition timing cdi unit malfunction ignition coil damage ma...

  • Page 43

    3-4 troubleshooting complaint possible cause remedy overheating low engine coolant level engine coolant leak too lean air/fuel mixture incorrect ignition timing water pump malfunction cylinder head carbon deposits exhaust pipe carbon deposits improper spark plug heat range fuel deterioration clutch ...

  • Page 44

    Troubleshooting 3-5 chassis * optional stiffer and softer springs are available. Complaint possible cause remedy heavy handling steering stem nut overtightened steering head bearings damaged or rusted steering stem distortion adjust replace replace front wheel wobbling loose spoke nipples wheel dist...

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  • Page 46: Machine Tuning

    4 machine tuning 4-1 contents machine tuning carburetor tuning ............................................................................. 4- 2 principles of carburetor tuning .......................................... 4- 2 carburetor tuning in practice ...............................................

  • Page 47: Carburetor Tuning

    4-2 machine tuning carburetor tuning the carburetion of your motorcycle was carefully selected after extensive testing. You will find that the carburetion will function smoothly under many varied operating conditions. For best results we rec- ommend that the adjustments and carburetion jet- ting be ...

  • Page 48

    Machine tuning 4-3 as shown below, each tuning part is located between the air/fuel passage and has its own air/fuel mixture adjustable range in terms of the throttle valve opening. The chart indicates that the carburetor can supply correct air/fuel mixture to the engine in any range because of the ...

  • Page 49

    4-4 machine tuning needle clip position the jet needle is linked to the throttle valve by means of the needle clip. Its lower part is tapered and it has five grooves cut in the upper part where the needle clip fits. To adjust the air/fuel mixture with the jet needle, change position of the needle cl...

  • Page 50

    Machine tuning 4-5 throttle stop screw the throttle stop screw determines the full close position of the throttle valve and should be adjusted in the following proce- dures. • loosen the throttle stop screw lock-nut. • adjust the throttle stop screw as follows: * turn in (to raise the throttle valve...

  • Page 51

    4-6 machine tuning carburetor tuning in practice in the previous section, basic principles of carburetor tuning have been discussed. Described in this section are the bases for carburetor tuning required when coping with variations in air (oxygen) concentration. Variation in air (oxygen) concentrati...

  • Page 52

    Machine tuning 4-7 judging air/fuel mixture for proper carburetor tuning, it is necessary to know how to judge the air/fuel mixture made in the carburetor; whether too rich, too lean or properly mixed. Given below are the symptoms observed when the engine is not supplied with the proper air/fuel mix...

  • Page 53

    4-8 machine tuning cable holder and washer the cable holder and washer must be used as a set. Jet needle note: shaded: standard *: included alternate parts none: optional parts 1 adjustment of pilot system 1) set the air screw as specified. 2) see if the selected pilot jet is correct or not by judgi...

  • Page 54: Front Fork Tuning

    Machine tuning 4-9 front fork tuning the front fork compression and rebound damping force, and oil level are adjustable for rider’s preference, rider’s weight and course condition. Note: * break-in new front forks before attempting adjustment. * be sure to adjust both right and left front forks equa...

  • Page 55

    4-10 machine tuning oil quantity minor adjustment adding the fork oil • remove the air bleed screw 1. • add the fork oil with a injector from the air bleed hole. Reducing the fork oil • remove the front forks. ( 16-4) • remove the air bleed screw. • leaning the front fork, reduce the fork oil from ...

  • Page 56

    Machine tuning 4-11 oil change (only for outer tube oil chamber) • remove the front forks. ( 16-4) • thoroughly clean the fork before disassembly. • clamp the outer tube with a vise. Protect the outer tube with a rag when using a vise. ( 16-5) • loosen and remove the fork cap bolt (sub-tank) from ...

  • Page 57

    4-12 machine tuning • slide down the outer tube. • pour the specified amount of fork oil into the outer tube.  99000-99001-ss5: suzuki fork oil ss-05 (or equivalent fork oil) note: be sure to adjust the fork oil quantity within the above-men- tioned range. • raise the outer tube and temporarily tig...

  • Page 58

    Machine tuning 4-13 spring change • remove the front forks. ( 16-4) • thoroughly clean the fork before disassembly. • remove the fork cap bolt and drain fork oil. ( 16-5) • loosen the center bolt completely. ( 16-6) • compress the outer tube by hands and install the conrod holder (special tool) b...

  • Page 59

    4-14 machine tuning • make sure approx. 10 mm (0.39 in) of inner rod thread is exposed on the end. ( 16-14) • install the damper rod assembly. ( 16-14) • insert the push rod into the inner rod. • insert the shaped projection of center bolt into the push rod. ( 16-15) • check or adjust the clearan...

  • Page 60

    Machine tuning 4-15 front fork tuning procedure test ride the motorcycle and find out how the front suspension reacts on various types of surface. According to the symptom noticed, adjust the front fork to the best setting for rider and race track conditions. To adjust, attempt changing fork oil cap...

  • Page 61: Rear Suspension Tuning

    4-16 machine tuning rear suspension tuning the rear suspension compression and rebound damping force, and spring pre-load are adjustable for rider’s preference, rider’s weight and course condition. Note: * break-in the rear suspension when riding with a new rear cushion unit. ( 1-5) * inspect the f...

  • Page 62

    Machine tuning 4-17 spring pre-load adjustment • place a block under the chassis tube. • remove the silencer and rear frame assembly. ( 17-3) • loosen the lock-nut 1 with the special tool.  09910-60611: universal clamp wrench • turn the adjuster 2 clockwise or counterclockwise to change the spring...

  • Page 63

    4-18 machine tuning rear suspension tuning procedure • adjust the rear suspension according to the rider’s weight and preference by referring to the table below. • measure the distance l1 from the seat bolt to the chain adjuster lock-nut with the motorcycle on the stand and the rear wheel lifted off...

  • Page 64

    Machine tuning 4-19 after the sag measurement has been set between 95 mm (3.74 in) to 105 mm (4.13 in), test ride the motor- cycle and adjust the suspension for the rider and track conditions referring to the guide below. Note: when adjusting the damping setting, attempt turning the adjuster 1 to 2 ...

  • Page 65: Suspension Balance

    4-20 machine tuning suspension balance balancing the front to rear suspension properly is the most critical adjustment for suspension performance. If the front forks are adjusted harder than the rear suspension, such as changing to heavier front fork oil, stiffer compression and rebound setting, air...

  • Page 66

    5 engine removal and installation 5-1 contents engine removal and installation exterior parts ...................................................................................... 5- 2 engine removal and installation ................................................. 5- 3 removal ......................

  • Page 67: Exterior Parts

    5-2 engine removal and installation exterior parts 5 n·m (0.5 kgf-m, 3.5 lb-ft) 10 n.M 1.0 kgf-m 7.0 lb-ft 10 n.M 1.0 kgf-m 7.0 lb-ft 10 n.M 1.0 kgf-m 7.0 lb-ft 10 n.M 1.0 kgf-m 7.0 lb-ft 10 n·m (1.0 kgf-m, 7.0 lb-ft) 10 n·m (1.0 kgf-m, 7.0 lb-ft) 10 n·m (1.0 kgf-m, 7.0 lb-ft) 10 n.M 1.0 kgf-m 7.0 l...

  • Page 68

    Engine removal and installation 5-3 engine removal and installation removal • drain transmission oil. ( 2-9) • drain engine coolant. ( 12-3) • remove the seat. • turn the fuel valve lever to the “off” position. • disconnect the fuel hose 1. • remove the fuel tank mounting bolts (lh and rh). • remove...

  • Page 69

    5-4 engine removal and installation • remove the exhaust pipe. • remove the exhaust pipe gasket 3. • remove the radiator covers 4 and mounting bolts (lh and rh). • disconnect the radiator hoses 5 6 7. • disconnect the spark plug cap 8. • loosen the carburetor clamp screws and remove the carbure- tor...

  • Page 70

    Engine removal and installation 5-5 • disconnect the magneto lead wire coupler 9 and clamp. • unclamp the magneto lead wire and breathers hoses from the frame. • remove the drive chain by removing the clip 0. • remove the cotter pins a. • remove the brake pedal. • remove the sprocket cover b. • remo...

  • Page 71

    5-6 engine removal and installation • unhook and extract the clutch cable d. Note: loosen the clutch cable adjuster when disconnecting. ( 2-12) • remove the engine mounting bolts and plates. • remove the swingarm pivot nut e and washer. • extract three quarters of the swingarm pivot shaft so as to k...

  • Page 72

    Engine removal and installation 5-7 installation reassemble the removed parts in the reverse order of removal. • fit the swingarm in its position and hold it with the swingarm pivot shaft. • mount the engine on the frame. • tighten the engine mounting nuts.  tightening torque note: * replace the se...

  • Page 73

    5-8 engine removal and installation • reassemble the drive chain clip so the slit end faces opposit the direction of rotation. • fit the projection of carburetor to the depression of intake pipe. • install a new o-ring 6 and connector rubber 7 to the exhaust pipe. • apply a small quantity of transmi...

  • Page 74

    6 cylinder, piston and exhaust valve 6-1 contents cylinder, piston and exhaust valve construction ........................................................................................ 6- 2 engine top end ....................................................................................... 6- 3 ...

  • Page 75: Construction

    6-2 cylinder, piston and exhaust valve construction 25 n.M (2.5 kgf-m, 18.0 lb-ft) 17.5 n.M (1.75 kgf-m, 12.5 lb-ft) 45 n.M (4.5 kgf-m, 32.5 lb-ft) 4.5 n.M (0.45 kgf-m, 3.0 lb-ft) 25 n.M (2.5 kgf-m, 18.0 lb-ft) 1216 1216.

  • Page 76: Engine Top End

    Cylinder, piston and exhaust valve 6-3 engine top end cylinder head removal • remove the seat. ( 5-3) • remove the fuel tank. ( 5-3) • drain engine coolant. ( 12-3) • disconnect the radiator hose 1. • disconnect the spark plug cap 2 and remove the spark plug 3.  09930-10121: spark plug wrench se...

  • Page 77

    6-4 cylinder, piston and exhaust valve • remove the exhaust valve rod bolt 7 using the pin a as a stopper. Note: the pin a is one of the included parts. • remove the cylinder nuts diagonally. • remove the cylinder 8. • remove the gasket 9 and dowel pins. Piston removal • remove the cylinder head and...

  • Page 78

    Cylinder, piston and exhaust valve 6-5 • remove the conrod small end bearing 4. Exhaust valve removal • remove the cylinder head and cylinder. ( 6-3, -4) • remove the exhaust valve shaft stop retainer 1. • remove the breather hoses 2. • remove the exhaust valve cover 3. • remove the exhaust valve s...

  • Page 79

    6-6 cylinder, piston and exhaust valve • remove the side valves and spacers. Cylinder head inspection • remove carbon deposits from the cylinder head. • inspect the cylinder head for cracks around the spark plug hole. • inspect for cylinder head distortion.  cylinder head distortion service limit: ...

  • Page 80

    Cylinder, piston and exhaust valve 6-7 • measure the cylinder bore for wear with a cylinder gauge 20 mm (0.8 in) from the top surface. Note: the cylinder bore must be measured perpendicular to the crank- shaft axis direction.  cylinder bore standard: 54.000 – 54.015 mm (2.1260 – 2.1266 in)  09900-...

  • Page 81

    6-8 cylinder, piston and exhaust valve • measure the piston ring free end gap.  piston ring free end gap service limit: 3.4 mm (0.13 in)  09900-20101: vernier calipers piston-to-cylinder clearance as a result of the previous measurement, if the piston to cylinder clearance exceeds the following li...

  • Page 82

    Cylinder, piston and exhaust valve 6-9 • fit the piston pin and bearing into the conrod small end and inspect the play. • inspect the bearing for smooth movement. Piston ring and piston reassembly • apply engine oil to the piston ring and piston ring groove. • fit the piston ring into the piston rin...

  • Page 83

    6-10 cylinder, piston and exhaust valve • install the exhaust valve assembly to the cylinder. • inspect the main and side valves for smooth movement. • inspect if the side valves are closed when the main valve is lowered and, at the same time, see if the side valvs are open when the main valve is li...

  • Page 84

    Cylinder, piston and exhaust valve 6-11 • tighten the cylinder nuts to the specified torque according to the specified tightening order as shown.  cylinder nut: 25 n·m (2.5 kgf-m, 18.0 lb-ft) • install the exhaust valve rod 2 to the exhaust valve shaft. • tighten the exhaust valve rod bolt using th...

  • Page 85

    6-12 cylinder, piston and exhaust valve exhaust valve governor removal and disassembly • drain transmission oil. ( 2-9) • drain engine coolant. ( 12-3) • remove the exhaust pipe. ( 5-3, -4) • remove the exhaust valve rod bolt. ( 6-4) • remove the right crankcase cover. ( 8-3) • remove the exhau...

  • Page 86

    Cylinder, piston and exhaust valve 6-13 exhaust valve governor inspection • inspect hte bearings for abnormal noise, wear and damage. • replace the bearing if there is anything unusual. • inspect the governer for wear and damage. • replace the governer if there is anything unusual. • inspect the exh...

  • Page 87

    6-14 cylinder, piston and exhaust valve • tighten the exhaust valve rod bolt. ( 6-11)  exhaust valve rod bolt: 4.5 n·m (0.45 kgf-m, 3.0 lb-ft) • reassemble the exhaust pipe. ( 5-8) • transmission oil level ( 2-9) • engine coolant level ( 2-10) • brake pedal heignt. ( 2-19).

  • Page 88: Clutch

    7 clutch 7-1 contents clutch construction ........................................................................................ 7- 2 clutch plate .......................................................................................... 7- 3 removal ..................................................

  • Page 89: Construction

    7-2 clutch construction 70 n.M (7.0 kgf-m, 50.5 lb-ft) 4.5 n.M (0.45 kgf-m, 3.0 lb-ft) fw d fwd no. 1 drive plate (black paint) no. 2 drive plate (purple paint).

  • Page 90: Clutch Plate

    Clutch 7-3 clutch plate removal • drain transmission oil. ( 2-9) • remove the rear brake pedal. ( 5-5) • remove the clutch cover 1. • loosen the bolts diagonally and remove them. • remove the clutch springs. • remove the pressure plate 2. • remove the bearing 3, push piece 4 and push rod 5. • remo...

  • Page 91

    7-4 clutch inspection drive plate • measure the drive plate thickness.  drive plate thickness service limit: 2.42 mm (0.095 in)  09900-20101: vernier calipers • inspect the drive plates for wear, distortion and discoloration. • measure the drive plate claw width.  driven plate claw width service ...

  • Page 92

    Clutch 7-5 reassembly • apply transmission oil to each plates. • install the clutch drive plates and driven plates one by one into the clutch sleeve hub in the prescribed order as show in illustration. • apply transmission oil to the bearing. • insert the clutch push rod. • install the clutch push p...

  • Page 93: Primary Driven Gear and

    7-6 clutch primary driven gear and clutch sleeve hub removal • remove the clutch outer cover. • remove the pressure plate and clutch plates. ( 7-3) • flatten the lock washer 1. • hold the clutch sleeve hub with the special tool and loosen the nut 2.  09920-53740: clutch sleeve hub holder • remove ...

  • Page 94

    Clutch 7-7 inspection • inspect the clutch sleeve hub and primary driven gear assem- bly for wear and cracks. • inspect the kick starer idle gear, needle bearing and spacer for damage and wear. Reassembly • apply transmission oil to the spacer 1 and needle bearing 2. • install the kick starter idle ...

  • Page 95

    7-8 clutch • tighten the clutch sleeve hub nut with the special tool to the specified torque.  09920-53740: clutch sleeve hub holder  clutch sleeve hub nut: 70 n·m (7.0 kgf-m, 50.5 lb-ft) • bend the lock washer to secure the nut 0. • reassemble the clutch plates and pressure plate. ( 7-5) • repla...

  • Page 96: Clutch Release Camshaft

    Clutch 7-9 clutch release camshaft removal • remove the magneto rotor and stator. ( 13-8) • loosen the clutch cable adjuster and unhook the clutch cable. ( 5-6) • remove the clutch release camshaft 1. Inspection clutch release camshaft • inspect the clutch release camshaft for abnormal deflection ...

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  • Page 98: Kick Starter

    8 kick starter 8-1 contents kick starter construction ........................................................................................ 8- 2 removal ................................................................................................... 8- 3 inspection ...............................

  • Page 99: Construction

    8-2 kick starter construction 23 n.M (2.3 kgf-m, 16.5 lb-ft) 10 n.M (1.0 kgf-m, 7.0 lb-ft).

  • Page 100: Removal

    Kick starter 8-3 removal • drain transmission oil. ( 2-9) • drain engine coolant. ( 12-3) • remove the brake pedal. ( 5-5) • remove the kick starter lever. • disconnect the radiator hose 1. • remove the crankcase cover. • remove the clutch and primary driven gear assembly. ( 7-3, -6) • remove th...

  • Page 101: Inspection

    8-4 kick starter inspection oil seal • inspect the oil seal for oil leakage and damage. • remove the oil seal using the special tool.  09913-50121: oil seal remover • install the oil seal using the special tool.  09913-70210: bearing installer set kick starter • inspect the return spring for damag...

  • Page 102: Reassembly

    Kick starter 8-5 reassembly reassemble the kick starter assembly in the reverse order of disassembly. Pay attention to the following points: • apply transmission oil to the kick starter shaft. • install the kick starter drive gear 1 and washer to the kick starter shaft. • install new snap ring.  09...

  • Page 103

    8-6 kick starter • install the kick starter assembly to the crankcase. Hook the return spring 2. • reassemble the kick idle gear 5. • reassemble the primary driven gear assembly and clutch. ( 7-5, -7) • install the crankcase cover.  crankcase cover bolt: 11 n·m (1.1 kgf-m, 8.0 lb-ft) • install the...

  • Page 104: Gearshifting

    9 gearshifting 9-1 contents gearshifting construction ........................................................................................ 9- 2 removal ................................................................................................... 9- 3 inspection ...............................

  • Page 105: Construction

    9-2 gearshifting construction 23 n.M (2.3 kgf-m, 16.5 lb-ft) 24 n.M (2.4 kgf-m, 17.5 lb-ft) 10 n.M (1.0 kgf-m, 7.0 lb-ft).

  • Page 106: Removal

    Gearshifting 9-3 removal • drain transmission oil. ( 2-9) • drain engine coolant. ( 12-3) • remove the gearshift lever 1. Note: mark the gearshift shaft head at which the gearshift lever slit set for correct reinstallation. • remove the right crankcase cover. ( 8-3) • remove the clutch assembly. ...

  • Page 107

    9-4 gearshifting • remove the gearshift cam bolt 9 and stopper plate 0. • remove the gearshift arm stopper bolt a and washer. • remove the gearshift cam stopper b and spring c. • remove the gearshift return spring d by removing the snap ring. 09900-06107: snap ring pliers.

  • Page 108: Inspection

    Gearshifting 9-5 inspection • inspect the gearshift shaft 1 for bends and damage. • inspect the return spring 2 for damage. • inspect the pawls 3, pins 4 and springs 5 for damage..

  • Page 109: Reassembly

    9-6 gearshifting reassembly • temporarily install the spring 1, washer 2 and gearshift cam stopper 3. • hook the spring 1 to the projection a. • tighten the gearshift cam stopper bolt.  gearshift cam stopper bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) • align the pin groove b with the pin c when installing...

  • Page 110

    Gearshifting 9-7 • fit the springs 6, pins 7 and pawls 8 to the gearshift cam driven gear 9. Wider side d of pawls should be positioned outside. • with the pawls held in pushed position, install the pawl lifter 0. • reassemble the gearshift cam driven gear and pawl lifter. • apply thread lock super ...

  • Page 111

    9-8 gearshifting • align the center teeth on the gearshift shaft with the center teeth on the gearshift cam shifter. • reassemble the clutch and crankcase cover. ( 7-5, -7, 8-6) • install the gearshift lever.  gearshift lever bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) • refill transmission oil. ( 2-9) •...

  • Page 112: Transmission and Crankshaft

    10 transmission and crankshaft 10-1 contents transmission and crankshaft construction ...................................................................................... 10- 2 engine bottom end ............................................................................ 10- 3 primary drive gear r...

  • Page 113: Construction

    10-2 transmission and crankshaft construction 70 n.M (7.0 kgf-m, 50.5 lb-ft) fwd fwd.

  • Page 114: Engine Bottom End

    Transmission and crankshaft 10-3 engine bottom end • dismount the engine. ( 5-3) note: the following parts must be removed before disassembling the engine bottom side (crankcase). • remove the gearshift lever. ( 9-3) • remove the kick starter lever. ( 8-3) • remove the cylinder head, cylinder and...

  • Page 115

    10-4 transmission and crankshaft crankcase separation • remove the engine sprocket spacer 1 and two o-rings 2. • remove the crankcase bolts. • separate the crankcase with the special tool.  09920-13120: crankcase separating tool note: * set the crankcase separating tool to the clutch side of the cr...

  • Page 116

    Transmission and crankshaft 10-5 • remove the driveshaft assembly 6 and countershaft assem- bly 7. Crankshaft removal • remove the crankshaft with the special tool.  09920-13120: crankcase separating tool transmission inspection • inspect the gear teeth, dogs, and gearshift grooves for abnor- mal w...

  • Page 117

    10-6 transmission and crankshaft • measure the gearshift fork thickness with a vernier calipers.  gearshift fork thickness standard: 4.80 – 4.90 mm (0.189 – 0.193 in)  09900-20101: vernier calipers • measure the gearshift fork groove width with a vernier cali- pers.  gearshift fork groove width s...

  • Page 118

    Transmission and crankshaft 10-7 • measure the crankshaft runout with v-blocks and dial gauge.  crankshaft runout service limit: 0.05 mm (0.002 in)  09900-20607: dial gauge (1/100 mm) 09900-20701: magnetic stand 09900-21304: v-block note: * place the crankshaft on to the v-blocks so that it become...

  • Page 119

    10-8 transmission and crankshaft • remove the oil seal.  09913-50121: oil seal remover • install new oil seal using the special tool. • apply grease to each oil seal lip.  09913-70210: bearing installer set  99000-25010: suzuki super grease “a” (or equivalent grease) note: be sure to check the di...

  • Page 120

    Transmission and crankshaft 10-9 bearing inspection, removal and installation • inspect the bearings for play, discoloration, wear and seizure. • move the inner race by finger and inspect for smooth move- ment. • remove the bearing retainers. • remove the bearings 1 to 4 by hitting out from the othe...

  • Page 121

    10-10 transmission and crankshaft • remove the bearings 9 and 0 using the special tool.  09917-50410: bearing remover • remove the bearing a using the special tools.  09921-20200: bearing remover 09930-30104: sliding shaft • install the bearings with the special tool.  09913-70210: bearing instal...

  • Page 122

    Transmission and crankshaft 10-11 transmission reassembly note: seat the circlip in the groove and locate its end as shown in the illustration. • apply transmission oil to the following parts: driveshaft, countershaft, transmission gears, bearings. • reassemble the driveshaft 1 and countershaft 2 wi...

  • Page 123

    10-12 transmission and crankshaft • apply transmission oil to the following parts: gearshift forks, gearshift shafts, gearshift cam. • install the gearshift forks 3, 4, 5. Note: each fork differs in shape. • install the gearshift cam 6 and gearshift shafts 7, 8. Note: turn the gearshift cam to the n...

  • Page 124

    Transmission and crankshaft 10-13 primary drive gear installation • reassemble the clutch release camshaft. ( 7-9) • reassemble the stator and magneto rotor. ( 13-9) • install the washer and primary drive gear. Note: the washer is directional. Assemble the washer 1 as shown in the illustration. • ...

  • Page 125

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  • Page 126: Fuel System

    11 fuel system 11-1 contents fuel system carburetor .......................................................................................... 11- 2 construction ................................................................................ 11- 2 removal and disassembly ..............................

  • Page 127: Carburetor

    11-2 fuel system carburetor construction 10 n.M (1.0 kgf-m, 7.0 lb-ft).

  • Page 128

    Fuel system 11-3 removal and disassembly • disconnect the throttle position sensor coupler and solenoid coupler. • open the clamp. • disconnect the fuel hose. ( 5-3) • loosen the carburetor clamp screws and remove the carbure- tor. • drain fuel by removing the drain plug. • remove the carburetor to...

  • Page 129

    11-4 fuel system • remove the cable holder 5 and jet needle 6. • remove the fuel hose 7, air vent hoses 8 and overflow hoses 9. • remove the float chamber. • remove the holder 0. • remove the floats a and needle valve b. • remove the needle valve seat c. • remove the main jet d and needle jet holder...

  • Page 130

    Fuel system 11-5 • remove the power jet g. • remove the starter knob h. • remove the lock-nut and throttle stop screw i. • remove the air screw j and spring. • remove the filter k. • remove the solenoid l. Note: prior to disassembly, mark the sensor’s original position with a paint or scribe for acc...

  • Page 131

    11-6 fuel system • flatten the plate m. • remove the throttle lever shaft bolt. • remove the dust seal n. • remove the throttle lever shaft o. • remove the throttle lever p, spacer q and return spring r..

  • Page 132

    Fuel system 11-7 cleaning • clean all jets with a spray-type carburetor cleaner and dry them using compressed air. • clean all circuits of the carburetor thoroughly, not just the per- ceived problem area. Clean the circuits in the carburetor body with a spray-type cleaner and allow each circuit to s...

  • Page 133

    11-8 fuel system needle valve inspection if foreign matter is caught between the valve seat and the nee- dle valve, the fuel will continue flowing and overflow. If the valve seat and needle valve are worn beyond the permissible limits, similar trouble will occur. Conversely, if the needle valve stic...

  • Page 134

    Fuel system 11-9 • fit the projection on the carburetor body to the depression of the intake pipe. After reinstalling the carburetor body assembly, inspect the fol- lowings. • throttle position sensor adjustment ( 11-11) • idle adjustment ( 4-5) • throttle cable play ( 2-12) • wire, cable and hos...

  • Page 135: Carburetor Solenoid

    11-10 fuel system carburetor solenoid removal and inspection • remove the carburetor solenoid 1. Make sure the coupler 2 is connected. • connect the tachometer sensor. • shift the transmission into neutral. • start the engine. • inspect if the solenoid valve switches according to the follow- ing eng...

  • Page 136: Throttle Position Sensor

    Fuel system 11-11 throttle position sensor inspection throttle position sensor input voltage • disconnect the throttle position sensor coupler 1. • shift the transmission into neutral. • start the engine. • measure the throttle position sensor input voltage with the multi circuit tester.  b/g (+ pr...

  • Page 137: Reed Valve

    11-12 fuel system reed valve removal • remove the carburetor. ( 11-3) • remove the intake pipe and reed valve. Inspection • inspect the reeds for damage. • inspect the reed valve stoppers for damage. • inspect the valve seat rubber for damage. Note: be careful not to damage the removed reed valve a...

  • Page 138: Cooling System

    12 cooling system 12-1 contents cooling system construction ...................................................................................... 12- 2 cooling circuit ................................................................................... 12- 3 inspection .................................

  • Page 139: Construction

    12-2 cooling system construction 5.5 n.M (0.55 kgf-m, 4.0 lb-ft) 10 n.M (1.0 kgf-m, 7.0 lb-ft).

  • Page 140: Cooling Circuit

    Cooling system 12-3 cooling circuit inspection • remove the radiator cap. • connect the tester 1 to the filler. • give a pressure of about 120 kpa (1.2 kgf/cm 2 , 17.1 psi) and see if the system holds this pressure for 10 seconds. • if the pressure should fall during this 10-second interval, it mean...

  • Page 141: Radiator

    12-4 cooling system radiator removal • remove the seat and fuel tank. ( 5-3) • drain engine coolant. ( 12-3) • remove the radiator covers 1. (lh & rh) • remove the hoses. • remove the radiators. Inspection radiator • visually inspect the radiator for damage. • fins bent down or dented can be repai...

  • Page 142: Water Pump

    Cooling system 12-5 water pump removal • drain the engine coolant. ( 12-3) • drain the transmission oil. ( 2-9) • remove the kick starter lever. ( 8-3) • remove the brake pedal. ( 5-5) • disconnect the radiator hose 1. • remove the water pump cover 2. • remove the right crankcase cover and clutc...

  • Page 143

    12-6 cooling system • remove the bearing with the special tool.  09921-20240: bearing remover set oil seal • inspect the oil seal for damage. • remove the oil seal with the suitable size socket wrench. Reassembly • apply thread lock super to the outer surface of the oil seal.  99000-32110: thread ...

  • Page 144

    Cooling system 12-7 • press the bearing with the special tool.  09913-70210: bearing installer set note: when installing the bearing the stamped mark on the bearing must face outside. • hold the water pump shaft with a wrench and tighten the impeller to the specified torque.  impeller: 10 n·m (1.0...

  • Page 145

    12-8 cooling system • reassemble the clutch cover and water pump cover. After reinstalling the water pump, check the followings. • kick starter lever ( 8-6) • brake pedal ( 2-19, 5-7) • transmission oil level ( 2-9) • engine coolant level ( 2-10).

  • Page 146: Electrical System

    13 electrical system 13-1 contents electrical system cautions in servicing ....................................................................... 13- 2 connector ...................................................................................... 13- 2 coupler .......................................

  • Page 147: Cautions In Servicing

    13-2 electrical system cautions in servicing connector • when connecting a connector, be sure to push it in until a click is felt. • inspect the connector for corrosion, contamination and break- age in its cover. Coupler • with a lock type coupler, be sure to release the lock when dis- connecting, a...

  • Page 148

    Electrical system 13-3 location of electrical components 1 engine stop switch 3 cdi unit 2 ignition coil 4 magneto, pick-up coil.

  • Page 149: Construction

    13-4 electrical system construction electrical circuit wire color: b: black b/bl: black with blue b/r: black with red tracer g: green b/br: black with brown b/w: black with white tracer r: red b/g: black with green tracer b/y: black with yellow tracer y: yellow b/o: black with orange tracer r/w: red...

  • Page 150

    Electrical system 13-5 troubleshooting (no spark or poor spark) step 1 1) check the ignition system couplers for poor connections. Is there connection in the ignition system couplers? Step 2 1) measure the peak voltage of ignition coil. ( 13-6) is the peak voltage ok? Step 3 1) inspect the spark pl...

  • Page 151: Ignition System

    13-6 electrical system step 8 1) measure the exciter coil and charge coil resistance. ( 13-7) is the exciter coil and charge coil ok? Ignition system ignition system peak voltage inspection • remove the seat and fuel tank. ( 5-3) • remove the spark plug. • disconnect the magneto lead wire coupler ...

  • Page 152

    Electrical system 13-7 ignition coil inspection • remove the seat and fuel tank. ( 5-3) • disconnect the ignition coil lead wire coupler 1. Measure the ignition coil electrical resistance.  09900-25008: multi circuit tester set  tester knob indication: resistance (Ω) stator coil inspection • remo...

  • Page 153

    13-8 electrical system magneto rotor and stator removal • remove the seat and fuel tank. ( 5-3) • disconnect the magneto lead wire coupler and clamp. • remove the bolts and magneto cover 1. • remove the nut with a special tool.  09930-40113: rotor holder • remove the magneto rotor with the special...

  • Page 154

    Electrical system 13-9 magneto rotor and stator reassembly • fit the key 1 into the crankshaft. • align the line on the stator with the line on the crankcase to set the ignition timing correctly. • install the magneto rotor. • tighten the nut to the specified torque with the special tool.  magneto ...

  • Page 155

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  • Page 156: Front and Rear Wheels

    14 front and rear wheels 14-1 contents front and rear wheels construction ...................................................................................... 14- 2 front wheel ......................................................................................... 14- 3 removal ....................

  • Page 157: Construction

    14-2 front and rear wheels construction 100 n.M (10.0 kgf-m, 72.5 lb-ft) 35 n.M (3.5 kgf-m, 25.5 lb-ft) 10 n.M (1.0 kgf-m, 7.0 lb-ft) 30 n.M (3.0 kgf-m, 21.5 lb-ft) 10 n.M (1.0 kgf-m, 7.0 lb-ft) fwd fwd.

  • Page 158: Front Wheel

    Front and rear wheels 14-3 front wheel removal • place the motorcycle on a block to lift front wheel off the ground. • remove the front axle nut 1. • loosen the left axle holder bolts 2. • loosen the right axle holder bolts 3. • remove the front axle shaft 4. • remove the front wheel. Inspection spa...

  • Page 159

    14-4 front and rear wheels wheel rim • measure the wheel rim runout with the dial gauge.  service limit: 2.0 mm (0.08 in) ... Axial and radial  09900-20607: dial gauge (1/100 mm) 09900-20701: magnetic stand wheel bearing • turn the inner race by finger and inspect it for smooth move- ment. • inspe...

  • Page 160

    Front and rear wheels 14-5 • reassemble the bearings with the special tools. • fit the dust seals and apply grease to their lips.  09941-34513: steering race installer 09924-84521: bearing installer set  99000-25010: suzuki super grease “a” (or equivalent grease) note: * install the left side (dis...

  • Page 161: Rear Wheel

    14-6 front and rear wheels rear wheel removal • place the motorcycle on a block to lift the rear wheel off the ground. • remove rear axle nut 1 and washer 2. • remove the rear axle shaft 3 and chain adjuster washers 4. • disengage the drive chain. • remove the rear wheel. Inspection wheel spacer • i...

  • Page 162

    Front and rear wheels 14-7 bearing replacement • remove the dust seals with the special tool.  09913-50121: oil seal remover • remove the bearings with the special tools.  09921-20240: bearing remover set • remove the spacer. • reassemble the bearings with the special tools. • fit the dust seals a...

  • Page 163

    14-8 front and rear wheels rear sprocket replacement • remove the rear sprocket. Note: install the rear sprocket as the letter on the sprocket surface faces outside. • tighten the bolts/nuts to the specified torque.  rear sprocket bolt/nut: 30 n·m (3.0 kgf-m, 21.5 lb-ft) installation • install the ...

  • Page 164: Front and Rear Brakes

    15 front and rear brakes 15-1 contents front and rear brakes construction ...................................................................................... 15- 2 brake fluid air bleeding ................................................................ 15- 3 brake fluid replacement ................

  • Page 165: Construction

    15-2 front and rear brakes construction fw d fwd fw d fwd 23 n·m (2.3 kgf-m, 16.5 lb-ft) 26 n·m (2.6 kgf-m, 19.0 lb-ft) 29 n·m (2.9 kgf-m, 21.0 lb-ft) 28 n·m (2.8 kgf-m, 20.0 lb-ft) 18 n·m (1.8 kgf-m, 13.0 lb-ft) 10 n·m (1.0 kgf-m, 7.0 lb-ft) 23 n·m (2.3 kgf-m, 16.5 lb-ft) 18 n·m (1.8 kgf-m, 13.0 lb...

  • Page 166: Brake Fluid Air Bleeding

    Front and rear brakes 15-3 brake fluid air bleeding • remove the reservoir cap. • connect a transparent tube to the bleeder valve and set the other end into a receptacle. • pour brake fluid up to the upper line. • pump the brake lever/pedal until air bubbles stop coming out from the reservoir. • hol...

  • Page 167: Brake Fluid Replacement

    15-4 front and rear brakes note: do not release the brake lever/pedal while the bleeder valve is opened. • replenish brake fluid to the upper line when the brake fluid level drops below lower line. • tighten the air bleeder valve.  air bleeder valve: 6 n·m (0.6 kgf-m, 4.4 lb-ft) • pour brake fluid ...

  • Page 168: Brake Pads Replacement

    Front and rear brakes 15-5 brake pads replacement front brake pads • remove the cap 1 and pad mounting pin 2. • remove the brake pads. Note: replace the two brake pads as a set. • fit the new brake pads into the caliper. • tighten the pad mounting pin to the specified torque.  brake pad mounting pi...

  • Page 169

    15-6 front and rear brakes • apply suzuki silicone grease to the o-ring.  99000-25100: suzuki silicone grease • fit the new brake pads into the caliper. • tighten the brake pad mounting pin to the specified torque.  brake pad mounting pin: 18 n·m (1.8 kgf-m, 13.0 lb-ft) note: * inspect not to pinc...

  • Page 170: Brake Disc Inspection

    Front and rear brakes 15-7 brake disc inspection • inspect the brake disc for damage. • measure the front and rear brake disc thickness.  brake disc thickness service limit (front): 2.5 mm (0.10 in) (rear): 3.5 mm (0.14 in)  09900-20205: micrometer (0 – 25 mm) • measure the front and rear brake di...

  • Page 171

    15-8 front and rear brakes front caliper removal and disassembly • drain brake fluid. ( 15-4) • place a rag under the brake hose union bolt to catch spilled brake fluid. • disconnect the brake hose. • remove the caliper mounting bolts 1. • remone the caliper. • remove the brake pads ( 15-5) • remo...

  • Page 172

    Front and rear brakes 15-9 • remove the dust seals 6 and piston seals 7. Rear caliper removal and disassembly • remove the rear wheel. ( 14-6) • remove the disc cover 1 and caliper protector 2. • drain brake fluid. ( 15-4) • place a rag under the brake hose union bolt to catch spilled brake fluid....

  • Page 173

    15-10 front and rear brakes • wrap the caliper with a rag to prevent brake fluid scatter and piston pop-out. • apply low-pressure air into the caliper through the hole to remove the piston. • remove the dust seal 7 and piston seal 8. Caliper inspection • inspect the caliper cylinder for scuffing, we...

  • Page 174

    Front and rear brakes 15-11 caliper cleaning • flush the caliper ports with pressurized air. • wash the caliper piston and cylinder with fresh brake fluid. Note: do not use gasoline or other cleaning solvents to wash the cali- per parts. Front caliper reassembly reassemble and remount the brake cali...

  • Page 175

    15-12 front and rear brakes rear caliper reassembly reassemble and remount the brake caliper in the reverse order of removal. Pay attention to the following points: • apply brake fluid to the new piston seal, new dust seal and- piston fit the piston seal, dust seal and piston.  specification and cl...

  • Page 176: Master Cylinder

    Front and rear brakes 15-13 master cylinder front master cylinder removal and disassembly • drain brake fluid. ( 15-4) • place a rag under the brake hose union bolt to catch spilled brake fluid. • disconnect the brake hose. • remove the master cylinder holder bolts. • remove the master cylinder. No...

  • Page 177

    15-14 front and rear brakes • remove the master cylinder cap. • remove the diaphragm. • remove the dust boot 1. • remove the snap ring 2 with snap ring pliers. • remove the washer 3 and piston/cup set 4.  09900-06108: snap ring pliers rear master cylinder removal and disassembly • drain brake fluid...

  • Page 178

    Front and rear brakes 15-15 master cylinder inspection • inspect the cylinder bore and piston for scuffing, wear and damage. • inspect the piston rod and spring for damage. Master cylinder cleaning • flush the master cylinder ports with pressurized air. • wash the master cylinder bore and piston wit...

  • Page 179

    15-16 front and rear brakes • set the brake hose end between the hose stopper, then tighten the brake hose union bolt 2 to the specified torque.  brake hose union bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft) • refill brake fluid and bleed air from the brake system. ( 15-3) rear master cylinder reassembly ...

  • Page 180: Brake Lever

    Front and rear brakes 15-17 brake lever removal • remove the brake lever. • remove the brake lever adjuster return spring 1.  09930-11960: torx wrench, t20 installation • apply grease to the brake lever adjuster return spring, pivot bolt and contact point between piston and brake lever.  99000-250...

  • Page 181: Brake Pedal

    15-18 front and rear brakes brake pedal removal • remove the cotter pin 1. • remove the cotter pin 2. • remove the washer and master cylinder rod pin 3. • remove the brake pedal pivot bolt 4. Reassembly • apply suzuki super grease to the oil seal and brake pedal pivot bolt.  99000-25010: suzuki sup...

  • Page 182: Front Fork and Steering

    16 front fork and steering 16-1 contents front fork and steering construction ...................................................................................... 16- 2 front fork, steering ................................................................. 16- 2 handlebar controls ....................

  • Page 183: Construction

    16-2 front fork and steering construction front fork, steering 30 n.M (3.0 kgf-m, 21.5 lb-ft) 35 n.M (3.5 kgf-m, 25.5 lb-ft) 70 n.M (7.0 kgf-m, 50.5 lb-ft) 18 n.M (1.8 kgf-m, 13.0 lb-ft) 18 n.M (1.8 kgf-m, 13.0 lb-ft) 22 n.M (2.2 kgf-m, 16.0 lb-ft) 100 n.M (10.0 kgf-m, 72.5 lb-ft) 25 n.M (2.5 kgf-m,...

  • Page 184

    Front fork and steering 16-3 handlebar controls 6 n·m (0.6 kgf-m, 4.4 lb-ft) 6 n·m (0.6 kgf-m, 4.4 lb-ft) adhesive agent adhesive agent 25 n·m (2.5 kgf-m, 18.0 lb-ft).

  • Page 185

    16-4 front fork and steering removal • place the motorcycle on a block to lift front wheel off the ground. • remove the front wheel. ( 14-3) • remove the protector 1. • remove the front number plate band. • remove the handlebars. ( 16-18) • remove the brake hose guide 2 and fork protectors 3. • re...

  • Page 186

    Front fork and steering 16-5 disassembly • set rebound and compression damper settings to the mini- mum settings (softest) before disassembling. Record the set- ting before turning the adjuster. • thoroughly clean the fork before disassembly. • clamp the outer tube with a vise. Protect the outer tub...

  • Page 187

    16-6 front fork and steering • clamp the axle holder 2 with a vise. Protect the axle holder with a rag when using a vise. • loosen the center bolt 3 completely with a 21 mm socket wrench. • compress the outer tube by hands and install the conrod holder (special tool) between the axle holder bottom 2...

  • Page 188

    Front fork and steering 16-7 • with the outer tube compressed by hands, remove the special tool. • loosen the fork cap bolt 1 (sub-tank) and remove the sub- tank 5 along with the damper rod assembly 6. • remove the fork spring 7. • remove the dust seal 8 and the stopper ring 9. Caution removing the ...

  • Page 189

    16-8 front fork and steering inner tube • separate the inner tube out of the outer tube. • remove the slide bushing from the inner tube. • remove the following parts from the inner tube. Guide bushing 1 seal retainer 2 oil seal 3 stopper ring 4 dust seal 5 • clamp the bottom (flat part) of the sub-t...

  • Page 190

    Front fork and steering 16-9 • remove the compression damper unit from the sub-tank. Note: slowly compress the inner rod until it stops so that the compres- sion damper unit can be removed easily. • drain the fork oil from the damper rod assembly by moving the inner rod several strokes. Inspection c...

  • Page 191

    16-10 front fork and steering inner tube and outer tube • inspect the inner tube for scratches. If it has scratches, replace it with a new one. • inspect the outer tube for dent. If it is dented all the way to the inner side, replace it with a new one. • measure the inner tube runout using the v-blo...

  • Page 192

    Front fork and steering 16-11 slide bushing and guide bushing inspect the “teflon coating metals” (slide bushing and guide bushing) for wear or damage. If they are worn or damaged, replace them with new ones. Inspect the metal particles on the “teflon coating metals”. If they are not clean, clean th...

  • Page 193

    16-12 front fork and steering • install the new oil seal 3 with the special tool until the stopper ring groove of the outer tube can be seen.  09940-52861: front fork oil seal installer set • attach the stopper ring securely to the stopper ring groove of the outer tube. • attach the dust seal 1. No...

  • Page 194

    Front fork and steering 16-13 • apply fork oil to the o-rings and bushing on the compression damper unit. • with the damper rod held immovable in fully extended posi- tion, gently install the compression damper unit to the sub- tank. • clamp the bottom (flat part) of the sub-tank with a monkey wrenc...

  • Page 195

    16-14 front fork and steering • force out the remaining oil (discharged oil) using compressed air completely. • with the damper rod in horizontal position, move the inner rod by hand to inspect it if operating smoothly. • if the inner rod is not extend, repeat the “compression damper unit” procedure...

  • Page 196

    Front fork and steering 16-15 • clamp the axle holder with a vise. Protect the axle holder with a rag when using a vise. • compress the outer tube by hands and install the conrod holder (special tool) between the axle holder bottom and lock- nut.  09910-20115: conrod holder • insert the push rod in...

  • Page 197

    16-16 front fork and steering • tighten the center bolt to the specified torque.  center bolt: 70 n·m (7.0 kgf-m, 50.5 lb-ft) • loosen and remove the fork cap bolt (sub-tank) from the outer tube and slowly slide down the outer tube.  09941-53630: front fork top cap wrench • pour the specified amou...

  • Page 198

    Front fork and steering 16-17 installation • install the front fork with the line t aligned with the upper sur- face of the upper bracket. • check that the air valve a is positioned at the front. • tighten the fork lower clamp bolts to the specified torque.  fork lower clamp bolt: 23 n·m (2.3 kgf-m...

  • Page 199: Steering

    16-18 front fork and steering steering removal handlebars • place the motorcycle on a block to lift front wheel off the ground. • remove the front number plate and protector. ( 5-2, 16-4) • remove the clamps. • remove the clutch lever 1. • remove the engine stop switch 2. • remove the left handle g...

  • Page 200

    Front fork and steering 16-19 steering stem • remove the front wheel. ( 14-3) • remove the front forks. ( 16-4) • remove the front fender. • remove the steering stem head nut. • remove the steering stem upper bracket. • remove the steering stem nut with the special tools.  09940-14911: steering n...

  • Page 201

    16-20 front fork and steering inspection steering stem • inspect the needle bearings for wear. • inspect the steering stem for distortion. • inspect the bearing outer races for wear. Bearing replacement note: replace the outer race and bearing as a set. • remove the upper and lower outer races with ...

  • Page 202

    Front fork and steering 16-21 • fit the upper and lower outer races with the special tools.  09941-34513: steering race installer 09924-84510: bearing installer set installation steering stem • apply grease to the bearings.  99000-25010: suzuki super grease “a” (or equivalent grease) • fit the ste...

  • Page 203

    16-22 front fork and steering handlebars • apply adhesive agent to the left handlebar end and inside of the left grip. Handle grip bond (commercial available) • align the “ ” mark on the left grip with the paint mark a on the left handlebar end. • set the “ ” mark b on the handlebar holder forward. ...

  • Page 204

    Front fork and steering 16-23 • apply grease to the throttle cable and their hole.  99000-25010: suzuki super grease “a” (or equivalent grease) • align the “ ” mark on the throttle grip with the hole on the throttle rotor. • align the paint mark d on the handlebars with the throttle holder matching...

  • Page 205

    16-24 front fork and steering inspect the following items. • front fork ( 2-20) • steering ( 2-22) • wire, cable and hose routing ( 18-12, -13, -17).

  • Page 206: Rear Suspension

    17 rear suspension 17-1 contents rear suspension construction ...................................................................................... 17- 2 rear suspension .......................................................................... 17- 2 rear shock absorber ...............................

  • Page 207: Construction

    17-2 rear suspension construction rear suspension 55 n.M (5.5 kgf-m, 40.0 lb-ft) 80 n.M (8.0 kgf-m, 58.0 lb-ft) 80 n.M (8.0 kgf-m, 58.0 lb-ft) 80 n.M (8.0 kgf-m, 58.0 lb-ft) 55 n.M (5.5 kgf-m, 40.0 lb-ft) 70 n.M (7.0 kgf-m, 50.5 lb-ft).

  • Page 208: Rear Shock Absorber

    Rear suspension 17-3 rear shock absorber removal • place a block under chassis tube. • remove the seat. ( 5-3) • loosen the air cleaner clamp screw. • remove the right frame cover. ( 5-2) • remove the silencer and rear frame assembly. • remove the rear shock absorber upper mounting bolt and nut. (...

  • Page 209

    17-4 rear suspension • remove the rear shock absorber lower mounting bolt and nut. • remove the rear shock absorber. Note: if necessary, move the swingarm up or down to facilitate this mounting bolt/nut removal. Spring replacement • loosen the lock-nut 1 with the special tool and turn it fully to th...

  • Page 210

    Rear suspension 17-5 inspection • inspect the rear shock absorber for oil leakage. • inspect the damper rod for bends and smooth movement. • inspect the bump rubber for deterioration and damage. • inspect the damper rod hidden by the bump rubber by moving the bump rubber. • inspect the spacers and d...

  • Page 211

    17-6 rear suspension • install the dust seals. Note: when installing the dust seal, the stamped mark a on the dust seal must face inside. • apply grease to the needle roller bearings and install them. • apply grease to the dust seals and spacers. • install the spacers a and b. A for right side b for...

  • Page 212

    Rear suspension 17-7 oil replacement procedure • remove the rear shock absorber unit from the frame ( 17-4), clean and dry it. • remove the spring from the rear shock absorber unit. ( 17-4) note: inspect the rear shock absorber unit for oil leak. Turn the rebound damping force adjuster screw count...

  • Page 213

    17-8 rear suspension • pour the fresh specified rear suspension oil as shown while moving the rod. Note: be sure to extend the rod after filling the oil. • tilt the shock absorber unit as shown and pour the fresh rear suspension oil fully into the reservoir tank. 99000-99001-s25: suzuki rear suspens...

  • Page 214

    Rear suspension 17-9 • reinstall the compression adjuster assembly 1.  compression adjuster assembly: 30 n·m (3.0 kgf-m, 21.5 lb-ft) • fill the rear shock absorber unit with nitrogen gas to 981 kpa (9.8 kgf/cm 2 , 139.5 psi). • tighten the gas valve cap. • reinstall the spring. ( 17-4) disassembly...

  • Page 215

    17-10 rear suspension • vise the rear shock absorber unit in inverted position. • depress the bump rubber fully to protect the damper rod. • evenly hammer the stopper 1 with a screwdriver or equiva- lent and remove it from the rear shock absorber body. • depress the seal case 2 with a screwdriver un...

  • Page 216

    Rear suspension 17-11 reassembly • apply the rear suspension oil to the o-rings and the “teflon coating metal”. • insert the damper rod assembly 1 and fit a new circlip 2. • pull up the damper rod assembly 1 until it is stopped by the circlip 2. • fit the stopper to the shock absorber body. • fill t...

  • Page 217

    17-12 rear suspension disposal high pressure nitrogen gas is sealed in the rear shock absorber unit. Be sure to release gas before disposing the rear shock absorber unit. • remove the valve cap. • press the valve with a screwdriver. warning releasing high pressure gas from the rear shock absorber ...

  • Page 218: Swingarm

    Rear suspension 17-13 swingarm removal • place the motorcycle on a block to lift rear wheel off the ground. • remove the rear wheel. ( 14-6) • remove the chain guide. • remove the rear brake hose guide. • remove the rear brake caliper from the swingarm. • remove the rear cushion rod bolt and nut. •...

  • Page 219

    17-14 rear suspension • remove the chain buffer. • remove the plates. • remove the following parts from the swingarm. Spacer 1 oil seal 2 washer 3 thrust bearing 4 dust seal 5 spacer 6 inspection pivot shaft • measure the pivot shaft runout with the dial gauge and v-blocks.  swingarm pivot shaft ru...

  • Page 220

    Rear suspension 17-15 swingarm • inspect the swingarm for cracks and damage. Bearing, spacer, dust seal, oil seal • inspect the bearings, spacers, dust seals and oil seals for damage. • insert the spacer into the bearings and inspect them for play and smooth movement. Bearing replacement • remove th...

  • Page 221

    17-16 rear suspension • apply grease to the bearings.  99000-25010: suzuki super grease “a” (or equivalent grease) installation • reassemble the following parts into the swingarm. 1 oil seal 5 washer 2 spacer 6 dust seal 3 washer 7 spacer 4 thrust bearing • apply grease to the dust seals, bearings,...

  • Page 222: Rear Suspension Linkage

    Rear suspension 17-17 rear suspension linkage removal • place a block under the chassis tubes. • remove the lower drive chain control roller 1. • remove the rear cushion rod bolt and nut. • remove the cushion lever bolt and nut. • remove the shock absorber lower bolt and nut. • remove the cushion ro...

  • Page 223

    17-18 rear suspension inspection • inspect the cushion rod and cushion lever for damage. • inspect the dust seals and spacers for damage. • insert the spacers into the bearings and inspect them for excessive play and smooth movement. Bearing replacement • remove the spacers and dust seals. • remove ...

  • Page 224

    Rear suspension 17-19 • press fit the needle roller bearing cages with the special tool.  09913-70210: bearing installer set note: when installing the needle roller bearing cages, the stamped mark on the bearing must face outside. • apply grease to the needle roller bearings and install them.  990...

  • Page 225

    17-20 rear suspension • tighten the cushion lever, cushion rod and swingarm nuts to the specified torque.  tightening torque: a: 55 n·m (5.5 kgf-m, 40.0 lb-ft) b: 55 n·m (5.5 kgf-m, 40.0 lb-ft) c: 80 n·m (8.0 kgf-m, 58.0 lb-ft) d: 80 n·m (8.0 kgf-m, 58.0 lb-ft) e: 80 n·m (8.0 kgf-m, 58.0 lb-ft) f: ...

  • Page 226

    Rear suspension 17-21 • tighten the lower drive chain control roller bolt to the specified torque.  drive chain control roller bolt: 31 n·m (3.1 kgf-m, 22.5 lb-ft) caution improperly reassembled rear suspension linkage bolts can interfere with suspension move- ment and damage the rear suspension li...

  • Page 227

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  • Page 228: Servicing Information

    18 servicing information 18-1 contents servicing information service data ......................................................................................... 18- 2 cylinder + piston + piston ring............................................... 18- 2 conrod + crankshaft ............................

  • Page 229: Service Data

    18-2 servicing information service data cylinder + piston + piston ring unit: mm (in) conrod + crankshaft unit: mm (in) clutch unit: mm (in) item standard limit piston to cylinder clearance 0.030 – 0.040 (0.0012 – 0.0016) 0.120 (0.0047) cylinder bore 54.000 – 54.015 (2.1260 – 2.1266) measure 20 (0.7...

  • Page 230

    Servicing information 18-3 radiator transmission unit: mm (in) except ratio drive chain unit: mm (in) carburetor item standard limit radiator cap valve release pressure 95 – 125 kpa (0.95 – 1.25 kgf/cm 2 , 13.5 – 17.8 psi) — item standard limit primary reduction ratio 3.368 (64/19) — final reduction...

  • Page 231

    18-4 servicing information electrical unit: mm (in) brake + wheel unit: mm (in) item specification note ignition timing 5° b.T.D.C. At 1 000 r/min. Spark plug type ngk: r6918b-8 gap 0.55 – 0.65 (0.022 – 0.026) spark performance over 8 (0.3) at 1 atm. Pick-up coil resistance (reference data) 72 – 127...

  • Page 232

    Servicing information 18-5 suspension unit: mm (in) item standard limit wheel rim size front 1.60 × 21 rear 1.85 × 19 wheel axle runout front — 0.25 (0.010) rear — 0.25 (0.010) item standard limit note front fork stroke 310 (12.2) — front fork inner tube o.D. 47 mm (1.85 in) — front fork spring free...

  • Page 233

    18-6 servicing information tire fuel + oil + coolant item std/spec. Limit cold inflation tire pressure front&rear 70 – 110 kpa (0.7 – 1.1 kgf/cm 2 , 10 – 16 psi) — tire size front 80/100-21 51m — rear 100/90-19 57m — tire type front (e-03) dunlop: sports d742f — front (the others) dunlop: sports d75...

  • Page 234: Tightening Torque

    Servicing information 18-7 tightening torque part n·m kgf-m lb-ft cylinder head nut 25 2.5 18.0 magneto rotor nut 35 3.5 25.5 cylinder nut 25 2.5 18.0 crankcase bolt 10 1.0 7.0 clutch sleeve hub nut 70 7.0 50.5 primary drive gear bolt 70 7.0 50.5 spark plug 17.5 1.75 12.5 transmission oil drain plug...

  • Page 235

    18-8 servicing information for other bolts and nuts not listed in the table, refer to this chart. Part n·m kgf-m lb-ft handlebar holder set nut 15 1.5 11.0 seat rail nut (upper) 23 2.3 16.5 seat rail bolt (lower) 23 2.3 16.5 brake lever pivot bolt 6 0.6 4.4 brake lever pivot nut 6 0.6 4.4 bolt diame...

  • Page 236: Special Tools

    Servicing information 18-9 special tools 09900-00410 hexagon wrench set 09900-06107 snap ring pliers 09900-06108 snap ring pliers 09900-09003 impact driver set 09900-20101 vernier calipers (150 mm) 09900-20203 micrometer (50 – 75 mm) 09900-20205 micrometer (0 – 25 mm) 09900-20508 cylinder gauge set ...

  • Page 237

    18-10 servicing information 09921-20200 bearing remover 09921-20240 bearing remover set 09924-84510 bearing installer set 09924-84521 bearing installer set 09925-18011 steering bearing installer 09930-10121 spark pulg wrench set 09930-11960 torx wernch (t20) 09930-30104 rotor remover slide shaft 099...

  • Page 238: Wiring Diagram

    Servicing information 18-11 wiring diagram wire color b: black bl: blue g: green r: red w: white y: yellow b/bl: black with blue tracer b/br: black with brown tracer b/g: black with green tracer b/o: black with orange tracer b/r: black with red tracer b/w: black with white tracer b/y: black with yel...

  • Page 239: Wire, Cable and Hose Routing

    18-12 servicing information wire, cable and hose routing clutch cable clutch cable throttle cable clutch cable throttle cable throttle cable clamp pass through the clutch cable under the radiator breather hose. Pass through the clutch cable between the engine mounting plates..

  • Page 240

    Servicing information 18-13 throttle position sensor lead wire engine stop switch lead wire engine stop switch lead wire throttle cable clamp clamp clamp clamp clamp clamp clamp frame cdi unit wiring harness engine stop switch lead wire wiring harness clamp engine stop switch lead wire wiring harnes...

  • Page 241

    18-14 servicing information clamp the end of hose securely . Inser t the hose securely . Upper side bac k side matching mar k is left side . Right side 25 mm 25 mm matching mar k is r ight side right side p ass through the w ater hose behind the fr ame . : the clamp bolt head f aces ... Bac k side c...

  • Page 242

    Servicing information 18-15 clamp note: face each clamp end to the downward. Clamp clamp fuel tank cushion rubber fuel tank cushion rubber 10 mm (0.4 in) a a sect aa protector.

  • Page 243

    18-16 servicing information adjustable range do not apply grease to the rubber covers. Fit the cover positively. Adjuster quick adjuster turn to loosen the clutch cable tension. Turn to loosen the clutch cable tension. Turn to tighten the clutch cable tension. Turn to tighten the clutch cable tensio...

  • Page 244

    Servicing information 18-17 front brake master cylinder washer hose guide front brake hose front brake hose clamp front fork protector clamp the upper difference portion in brake hose diameter. Washer after touching the brake hose union to the stopper, tighten the union bolt to the specified torque....

  • Page 245

    18-18 servicing information stopper rear br ak e caliper stopper rear br ak e fluid reser v o ir guide master cylinder set the br ak e hose end betw een the hose stopper , then tighten the br ak e hose union bolt to the specified torque . Outside set the br ak e hose end betw een the hose stopper , ...

  • Page 246

    Servicing information 18-19 10 n . M (1.0 kgf . M, 7.3 lb-ft) 10 n·m (1.0 kgf-m, 7.0 lb-ft) cushion f rame silencer 10 n . M (1.0 kgf . M, 7.3 lb-ft) 10 n·m (1.0 kgf-m, 7.0 lb-ft) cushion 1st m uffler f rame muffler mounting plate 10 n . M (1.0 kgf-m, 7.3 lb-ft) 10 n . M (1.0 kgf . M, 7.3 lb-ft) 10 ...

  • Page 247: Specifications

    18-20 servicing information specifications dimensions and dry mass overall length ....................................................... 2 145 mm (84.4 in) overall width ........................................................ 830 mm (32.7 in) overall height ...........................................

  • Page 248

    Servicing information 18-21 chassis front suspension................................................. Telescopic, pneumatic/coil spring, oil damped rear suspension ................................................. Link type steering angle ..................................................... 45° (ri...

  • Page 249: Spare Parts List

    18-22 servicing information spare parts list optional parts carburetor: 4-2 front fork spring: 4-13 rear suspension spring: 4-18 item part name part number q’ty 1 parts set, spare 19900-36f70 1 1 o-ring, cylinder head no. 1 11147-27c11 2 2 o-ring, cylinder head no. 2 11148-27c11 2 3 gasket, cyl c...

  • Page 250: Setting Data

    Servicing information 18-23 setting data *make copies. Date / / / / / / race/course / / / temp./humidity / / / whether course coudition main jet jet needle / / / pilot jet air screw float level spark plug oil level mm mm mm comp. Adj. Position re-bound adj. Position spring spring spring set length m...

  • Page 251

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  • Page 252

    Printed in japan 300 takatsuka, hamamatsu, japan k7 failure to follow these safety precautions may increase your risk of injury: ! Wear a helmet, eye protection, and bright protective clothing. ! Don’t ride after consuming alcohol or other drugs. ! This owner’s service manual contains important safe...