Summary of RV50
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Foreword the suzuki r v50 is a completely new fun motorcycle designed and built for on and off road use, the suzuki r v50 has outstanding features such as reed valve type intake system and cci lubrication system. In order to obtain good performance, many precise mechanisms are built into the machine...
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Left & right si de views 2.
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1. Specifications index { i', , , i _'t 4: a • a a • a a a a r a a a a a a a a a a a a a a a a a a a s a a a a a a s a 11 a g s a 11 a a s s s a a 2. Performance curves .......................................... . 3. General instructions . .......................................... . Breaking-in .....
Page 5: 1. Specifications
1. Specifications dimensions overall length overall width overall height wheelbase ................................ . Ground clearance tire, front rear dry weight 1 ,625 mm (6 3.9 in) 775 mm (3 0.5 in) 985 mm ( 3 8.8 in) 1,095 mm (43.1 in) 125 mm ( 4.9 in) 5.4- 1 0, 4pr 5.4 - 1 0, 4pr 75 kg (1 6 5 l...
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Transmission system clutch type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multi-plate, wet disc number of speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 speed, constant mesh gear shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left foo...
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0:: w 0 0.. W u) 0:: 0 i 6 2. Performance curves (hp) 4 max. 4hp at 6,000rpm 3 m at 5,00brpm 2 0 ....__ __ ...._ __ __._ __ __._ ___ ,..._ __ _,__ __ -1.-__ ---1 2 3 4 5 6 7 engine revolution(r p m ) b x 10 3 m) 0.5 0.4 0.3 0.2 ( gr/h 500 400 300 w ::) cj 0 1-- z 0 h) fi= ::> u) z 0 u .J w :j ll.
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3. General instructions to keep the motorcycle in peak condition, please advise your customers to follow these tips which will give top performance at all times. Breaking-in the life of the motorcycle depends on the breaking-in of the engine and the way in which the motorcycle is treated. Therefore,...
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4. Special tools special tools listed below are used to disassemble, assemble and for maintenance and service. These special tools make certain jobs easier which can not be done with ordinary tools and prevent the parts from damage. It is recommended that these special tools are purchased as shop eq...
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Piston holder cqmkcase separating tool oil seal remover bearing and oil seal snap ring opener (small) spark plug wrench installing tool @ ® rotor remover engine sprocket & flywheel holder impact driver set loosening . (09900-09101) tightening (09900-09102) bit (09900-09202) hydrometer @ @ pocket...
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5. Necessary materials rv50 requires the following material in addition to the general service equipment, tools, lubricants, cleaning solvent, every doth and so forth. For further details, refer to the pertiment items in this manual. Thread lock cement this cement is applied to the front fork upper ...
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6. Troubleshooting when trouble occurs with a motorcycle, it is important to find the source of the trouble as rapidly as possible. Lt is also necessary to perform only the work required to repair the machine without bothering with parts which are functioning correctly. The list of possible troubles...
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3. Check to see that engine compression is correct (turn engine with kick starter). * if engine compression is low 1. Cylinder and piston rings worn 2. Piston rings stick on piston 3. Cylinder head gasket damaged· 4. Cylinder base gasket damaged 5. Piston damaged 6. Spark plug improperly tightened 7...
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2. Check to see if engine compression is higher than standard 3. Check carbon deposit 4. Check to see that piston rings move smoothly in grooves 5. Check to see that the clutch works properly 6. Check to see that the ignition timing is correct 7. Drive chain too tight - -- 8. Incorrect spark plug he...
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1. Gear shifting shaft return spring damaged replace 2. Friction between gear shifting shaft repair bent shaft and crankcase or replace : 3. Jumping out of gear * if the gears disengage while running 1. Gear shifting fork worn or bent replace 2. Gear dog teeth worn replace gear 3. Gear shifting cam ...
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7. Tune-up in order to maintain the full performance originally built in the motorcycle, a periodic motorcycle tune-up is essential. If any deficiency is encountered during operation of the motorcycle, it must be diagnosed immediately, and rectified. Oil pump by turning the throttle grip, align the ...
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Transmission oil oil in the transmission deteriorates and its lubrica tion performance decreases if it is used too long. It should therefore be changed periodically. To change: 1) remove the oil filler cap and oil drain plug located on the bottom of the engine and drain the transmission case. Note:...
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4) finally adjust the clutch cable adjuster again until 3 ,.._, 5 mm (0.4 ......, 0.7 in.) of play is left at the bottom of the clutch lever. Wclutch lever play carburetor throttle cable play this section describes the adjustment of throttle cable play. If there is no play, the engine speed will not...
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To adjust the ignition timing: 1) remove the spark plug from the cylinder head and screw in the dial gauge, special tool #09931 - 00111. 2) connect one of the lead wires of timing tester, special tool 09900 27002, to the black wire which is free near the fuse box and other one to the ground as shown...
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Air cleaner if the air cleaner is clogged with dust, the au flow is reduced causing increased fuel consumption and a fall off in power. To clean: 1) unscrew the air cleaner case bolt and move it forward slightly. Cd air cleaner fixing bolt 2) unscrew the three screws and remove the air cleaner case....
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8. Engine the engine is made as a single-unit including the clutch and transmission and is mounted to the frame by three mounting bolts. The engine may be removed by disconnecting the wiring system, fuel system, exhaust system, air intake system and final drive system, and removing the engine mounti...
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6. Removing air cleaner intake pipe required tool: small size slacken the intake pipe clamp screw on engine side and pull out the pipe. Cd air cleaner air cleaner intake pipe intake pipe damp 7. Removing carburetor inspection cap required tool: small size carburetor inspection cap 8. Slackening ca...
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12. Removing clutch cable 13. Disconnecting engine oil pipe required tool: small size disconnect the engine oil pipe from the oil tank outlet and block the outlet with a rubber cap. Cdoil tank (£)engine oil pipe 14. Removing muffler cover required tool: big size 22 15. Removing muffler required tool...
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18. Removing oil pump cover required tool: big size cd oil pump cover 19. Disconnecting oil pump cable disconnect the oil pump cable at the oil pump control lever by removing the cable end as shown in the illustration. Pull cdoil pump control lever (z)cable end 20. Removing engine mounting bolts r...
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Tightening torque: 300 - 400 kg-cm ( 22 - 29 ft-lb) hold the flywheel with the engine sprocket and fl yw heel holder and remove the rotor fixing nut. Cd engine sprocket and flywheel holder 4. Removing flywheel rotor required tool: and special tool #09930-30113 17mm & 19mm to remove the flywheel ...
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8. Removing neutral switch body required tool: small size cd neutral switch body 9. Removing neutral switch contact point required tool: big size (d neutral switch contact point 10. Removing cylinder head and cylinder required tool: °===, 10mm tightening torque: 60 "' 100 kg-cm (4.4 "' 7.3 ft-lb...
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13. Removing right crankcase cover required tool: big size and mallet or soft hammer after removing the kick starter lever, loosen the right crankcase cover fixing screws and remove the cover hitting with a mallet or a soft hammer. 14. Loosening clutch sleeve hub nut required tool: special tool #099...
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Q) primary pinion 19. Removing prnnary pinion lock nut required tool: and special tool #09910-20113 21 mm place the piston holder between the connecting rod and the crankcase in order to lock the crank shaft and loosen the primary pinion lock nut, (j) piston holder 20. Removing primary pinion key r...
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24. Disconnecting engine oil pipe required tool: 8mm tightening torque: '' 20 "' 30 kg-cm (1.4 - 2.2 ft-lb) disconnect the engine oil pipes by loosening each union bolt on both sides of the crankcase respec tively. Engine oil pipe 25. Loosening crankcase and oil pump screws required tool: special t...
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28. Removing transmission gears required tool: mallet or soft hammer remove the transmission gears together with the gear shifting cam from the right crankcase. 29. Removing crankshaft required tool: mallet or soft hammer hit the rightside end of the crankshaft gently with a mallet or a soft hammer....
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Necessary points on assembly this section describes tips on assembly in order to eliminate difficulties which will be encountered and the work to be done when assembling the engine. 1. Transmission and crankshaft for the installation of gears, circlips, washers and bearings, refer to the illustratio...
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2. Gear shifting cam to assemble the shifting forks to the gear shifting cam; 1) insert the short pin into the hole which is located opposite direction of the neutral switch contact point positioning groove. 2) apply engine oil to the shifting fork pins. Neutral switch contact point positioning groq...
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1dowel pin right wrong 6. Piston the piston pin hole is off-center and the piston skirt is cut according to the shape of the scaveng ing passage on the crankcase, therefore, the piston should be installed in the proper direction. 1) the arrow mark on the piston head indicates the exhaust side. Cd a...
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Oil reservoir plate 10. Engine oil pipe when the engine assembly is completed, the oil passages have to be filled with oil. If the engine is started and kept on running in this condition, the engine may suffer lack of lubrication causing bear ing failure or piston seizure. Therefore, it is necessar...
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Engine lubrication system the engine lubrication is the suzuki cci system as in all other suzuki models. The oil pump has 2 outlets connecting with respective oil feeding pipes and lubricate all the moving parts of the engine except the. Crankshaft right end bearing which is lubricated by transmissi...
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The discharge and suction of oil in the pump take place by a change in the inside volume caused by the strokes of plunger and differential plunger. The cam fitted on tight side of the pump body is to change the travel of the plungers and is connected with the oil pump control lever which moves accor...
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Carburetor an "amal" type carburetor is used. The best feature of this carburetor is that the air/fuel ratio which the engine requires is produced by varying the air and fuel passages according to the throttle valve opening. As air enters the carburetor, it passes under the throttle valve where a va...
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Adjustment of carburetion adequate carburetion is determined according to the result of various tests mainly in consideration of engine power, fuel consumption and fuel cooling effect to the engine, and jets settings are done so as to satisfy and balance all these conditions. Therefore, it is not re...
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Adjustment of idle speed the engine idling speed may be adjusted by turning the throttle valve stop screw and pilot air adjusting screw in the following procedure. 1) warm up the engine for about 5 minutes. 2) screw the pilot air adjusting screw in, (i) pilot air adjusting screw 3) adjust the thrott...
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Inside the kick starter pm1on is installed a ratchet mechanism consisting of a pawl, pawl roller and pawl spring. When the kick starter lever is depressed, the kick starter shaft turns in counter-clockwise direction as seen from the lever end of the shaft. When the kick starter shaft turns counter-c...
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1st position 3rd position 2nd position 4th position clutch system the function of the clutch is to transmit or disengage the power produced by the engine for the driving of the rear wheel through the transmission gears. The drive plates are turned by the clutch housing rotating in accordance with th...
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© @ @ ® clutch release torque cd primary gear (z)clutch housing driven plate @pressure plate ® clutch hub ® clutch spring air cleaner the element is made of washable spongy plastics and contains oil in it so as to further prevent dust from penetration. The construction is shown in the fi gu re. 41.
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9. Electrical ignition system the flywheel magneto type ignition system has the electrical wiring as shown in the fi gu re. When the fly wheel magneto is rotated a current is generated within the primary coil mounted on the stator. With the breaker points closed the current generated in the primary...
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Battery the battery used on this model is either a yuasa or furukawa made. Both are same type, 6n4-2a, and can be interchanged. Initial charge the battery is the dry-charged type unlike that of a large capacity battery, however, it must be initially charged at the specified rate before the battery i...
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Front forks the front suspension is the telescopic disassembly and assembly 1. Removing front wheel remove the front wheel and rear wheel" on page 46. 2. Removing the front fender required tool: 10 mm 3. Disconnecting horn 4. Removing the headlamp required tool: =:::m:::=: small 44 10. Body the cons...
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6. Removing required tool: steering stem lock nut stem lock nut vv'""'''"' tool #09940-10122 when the a amount grease on the steering ball races assemble the steel balls 22 on the upper 18 on exercise head so install the top cone race the steering stem lock nut so screw in ance between the in the ve...
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Front and rear wheels the rvso is equipped with 5.4 - 10 4pr low pressure tires. These tires are designed specifically for both off-the-road and paved road use. ' disassembfy and assembfy * front wheel 1. Loosening front axfe nut required tool: 14mm remove the front axle nut and pull out the axle. 2...
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* rear wheel 1. Removing torque link nut required tool: 12 mm and tightening torque: 90 ,.._, 140 kg-cm (6.6 - 10 ft-lb) pull out the "/3" type pin and loosen the torque link nut. 2. Loosening brake adjusting nut "{3" type pin ®brake adjusting nut 3. Removing cottepin and rear axle nut required tool...
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6. When installing the front and rear wheels to the front forks and rear swinging arms, be sure to put them in correctly with the air valves faced toward the right side respectively. Rear shock absorber the hydraulic damper is of sealed construction and works at a damping resistance of 30 and 6 kg/0...
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11. Specifications for inspection and repair engine part item standard limit operation remarks __ - cylinder warp on the below 0.03 mm rectify put emery paper on head joining (0.001 in) a flat surface plate surface and grind the head on the paper by sliding it evenly back and forth i i cylinder wear...
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Part item standard i limit operation remarks flywheel resistance, 2.0ft replace measure between magneto primary coil i black colored wire and the ground when inserting a insulating material to the points. Resistance, 0.7ft replace measure between charging coil i green colored wire and ground condens...
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Body part i item i standard limit operation remarks brake wear front & rear replace measur,e the diam- shoe 106mm eter when the shoes (4.17 in) are installed in place brake wear front & rear front & rear replace drum 110mm 110.7 mm (4.33 in) (4.36 in) drive slack 15-20 mm adjust chain (0.6-0.8 in} t...
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12. Tightening torque tightening torque part kg-cm lb-ft 1 front axle nut 360 "' 520 26 ""38 2 front brake cam lever bolt 50 ,..._. 80 3.6 '""'5.8 3 front fork upper bracket fixing bolts 200 ,...._, 300 14 -- 22 4 . Handlebar clamp bolts 120 "' 200 8.7 ,..._. 14 5 swinging arm pivot shaft nut 200 ,....
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Exploded view of engine.
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Periodic inspection list the chart below indicates time when inspections, adjust1nents and maintenance arc required based on the distance the motorcycle runs, that is initia1 1.000 km (750 mi), and every 3,000 km (2,000 mi), 6,000 km (4,000 mi) and 12,000 km (8,000 mi) thereafter. According to the c...
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8. Wiring diagram ol1 right front turn signal lamp (6v bwi turn signal indicator lamp {6v 1.7w) turn signal r fuse {15a) e . Ig .... Ignition ba .. , bauery ho ... Horn tl .. Tail lamp ... Chargingcoil ... Silicon rectifier ... Charging & lighting coil flywheel magneto cj .... Charging & lighting ...
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Suzuki ., fla111ama t s11-nisl1i 1 p,0.Box j h © 11-1978 9'73 printed iri jap,m.