Suzuki 2 stroke Service Manual

99563-01050-01E

FOREWORD

Among the 2005 SUZUKI motorcycles and vehicles with 4 & 2 stroke engines, many new models have been added, and even in the previous models many refinements have been made.

This service data manual gives service data for 2005 models of SUZUKI 4 & 2 stroke engine motorcycles and vehicles. These data have been prepared for experienced mechanics who inspect, adjust, repair and service SUZUKI motorcycles. For the methods of measurement and adjustment for the individual data, refer to the service manual for the particular model.

This data manual contains data which are up-to-data at the time it is issued. News of later modifications will be provided to the national distributors through service bulletins, etc., so if you have any inquiry, please contact your distributor.

4 STROKE

AN250 ..................................................................................................... 1

AN400/S ................................................................................................. 3

AN650 ..................................................................................................... 5

AN650A .................................................................................................. 7

DL650/UE ............................................................................................... 10

DL1000 ................................................................................................... 12

DR200SE (E-03, 28, 33) ......................................................................... 15

DR200SE (E-06, 24) ............................................................................... 17

DR650SE ................................................................................................ 19

DR-Z110 ................................................................................................. 21

DR-Z125/L .............................................................................................. 22

DR-Z250 (E-03, 28, 33) .......................................................................... 24

DR-Z250 (E-24) ...................................................................................... 26

DR-Z400E ............................................................................................... 28

DR-Z400S ............................................................................................... 31

DR-Z400SM ............................................................................................ 33

GS150TD ................................................................................................ 35

GS500/U/F/FU ........................................................................................ 36

GSF650/S ............................................................................................... 38

GSF650A/SA/UA/SUA ........................................................................... 40

GSF1200/Z ............................................................................................. 42

GSF1200S/SZ ........................................................................................ 44

GSX600F ................................................................................................ 47

GSX750F ................................................................................................ 49

GSX1300R/RUD/RUF ............................................................................ 52

GSX1400 ................................................................................................ 54

GSX-R600 .............................................................................................. 57

GSX-R600X ............................................................................................ 59

GSX-R750 .............................................................................................. 62

GSX-R750X ............................................................................................ 64

GSX-R1000 ............................................................................................ 67

GZ125 ..................................................................................................... 69

GZ250 ..................................................................................................... 71

LS650 ..................................................................................................... 73

LT-A400/F .............................................................................................. 75

LT-A500F ............................................................................................... 77

LT-A700X ............................................................................................... 79

LT-F160 .................................................................................................. 81

LT-F250F ................................................................................................ 83

LT-F400/F ............................................................................................... 85

LT-F500F ................................................................................................ 87

LT-V700F ................................................................................................ 89

LT-Z250 .................................................................................................. 92

LT-Z400 .................................................................................................. 94

QUV620F ................................................................................................ 96

RM-Z250 ................................................................................................. 98

RM-Z450 ................................................................................................. 99

RV125 .....................................................................................................101

SV650/S ..................................................................................................103

SV1000 ...................................................................................................105

SV1000S .................................................................................................108

UH125 .....................................................................................................110

UH150 .....................................................................................................112

CONTENTS

VL125/U ................................................................................................. 113

VL250 .................................................................................................... 115

VL800/T ................................................................................................. 116

VL1500 .................................................................................................. 119

VS800 .................................................................................................... 121

VS1400 .................................................................................................. 124

VZ800 .................................................................................................... 126

VZ1600 .................................................................................................. 129

2 STROKE

AY50A ................................................................................................... 131

JR50 ...................................................................................................... 133

JR80 ...................................................................................................... 134

LT50 ....................................................................................................... 135

LT80 ....................................................................................................... 136

LT-A50 ................................................................................................... 137

RM65 ..................................................................................................... 138

RM85/L .................................................................................................. 139

RM125 ................................................................................................... 141

RM250 ................................................................................................... 142

TS185ER ............................................................................................... 144

COUNTRY AND AREA CODE

These may be some differences amoung models depending on specifications. If the service data differ, it is noted there by using the following codes. The following codes stand for the applicable country(-ies) and area(-s).

CODE COUNTRY OR AREA CODE COUNTRY OR AREA E-01 General E-28, P-28 Canada E-02, P-02 U. K. P-31 Philippines E-03 P-03 U. S. A. (Except for California) E-33, P-33 California (U. S. A) E-06 South Africa P-37 Brazil

P-09 Colombia P-42 Pakistan E-13 Southeast Asia P-43 Saudi Arabia E-17 P-17 Sweden P-51 Korea E-19, P-19 E. U. E-54, P-54 Isurael

P-21 Belgium E-71, P-71 Mexico E-24, P-24 Australia

NOTE: These service data are current as of APRIL 2005, and they are subject to change without notice.

AN250

VALVE + VALVE GUIDE Unit: mm

Valve diam. IN. 28.3 —

Tappet clearance (when cold) IN. 0.08 – 0.13 —

Valve gui de to val ve stem clea rance

Valve guide I.D. IN. & EX. 5.000 – 5.012 — Valve stem O.D. IN. 4.975 – 4.990 —

Valve stem deflection IN. & EX. — 0.35 Valve stem runout IN. & EX. — 0.05 Valve head thickness IN. & EX. — 0.5 Valve stem end length IN. & EX. — 1.7 Valve seat width IN. & EX. 0.9 – 1.1 — Valve head radial runout IN. & EX. — 0.03 Valve spring free length IN. & EX. — 38.8 Valve spring tension

CAMSHAFT + C YLINDER HEAD Unit: mm

Cam height IN. 33.430 – 33.477 33.130

Camshaft journal oil clearance ¬22 0.032 – 0.066 0.15

Camsh aft jo urnal holder I. D. ¬22 22.012 – 22.025 —

Camsh aft jo urnal O.D. ¬22 21.959 – 21.980 —

Camshaft runout — 0.10 Rocker arm shaft I.D. IN. & EX. 12.000 – 12.018 — Rocker arm shaft O.D. IN. & EX. 11.973 – 11.984 — Cylinder head distortion — 0.05

ITEM STANDARD LIMIT

EX. 25.0 —

EX. 0.17 – 0.22 —

IN. 0.10 – 0.37 —

EX. 0.30 – 0.57 —

EX. 4.955 – 4.970 —

IN. & EX.

ITEM STANDARD LIMIT

EX. 33.500 – 33.547 33.200

¬17.5 0.028 – 0.059 0.15

¬17.5 17.512 – 17.525 —

¬17.5 17.466 – 17.484 —

182 – 210 N

(18.2 – 21.0 kgf)

at length 31.5 mm

—

CYLIN DER + PI STON + PISTO N RING Unit: mm

Compression pressure 1 250 – 1 650 kPa

Piston to cylinder clearance 0.04 – 0.05 0.120 Cylinder bore 73.000 – 73.015 73.090 Piston diam. 72.955 – 72.970

Cylinder distortion — 0.05 Piston ring free end gap 1s t R 9. 3 7.4

Piston ring end gap 1st 0.10 – 0.30 0.5

Piston ring to gr oove cle arance 1s t — 0.18

Piston ring groove width 1st 1. 01 – 1.0 4 —

Piston ring thickness 1st 0.97 – 0.99 —

Piston pin bore 19.002 – 19.008 19.030 Piston pin O.D. 18.996 – 19.000 19.980

CONROD + CRANKSHAFT Unit: mm

Conrod small end I.D. 19.006 – 19.014 19.04 Conrod deflection — 3.0 Conrod big end side clearance 0.10 – 0.75 1.0 Conrod big end width 21.95 – 22.00 — Width between crankshaft webs 59.9 – 60.1 — Crankshaft runout — 0.08

OIL PUMP

Oil pressure (at 60 °C) Above 80 kPa (0.8 kgf/cm

CLUTCH

Clutch wheel I.D. 135.0 – 135.2 135.5 Clutch shoe thickness 3.0 2.0 Engagement r/min 2 500 – 3 100 r/min — Lock-up r/min 4 400 – 5 400 r/min —

ITEM STANDARD LIMIT

(12.5 – 16.5 kgf/cm

Measure at 15 mm from the skirtend.

2nd R 7.2 5.7

2nd 0.35 – 0.50 1.0

2nd — 0.15

2nd 1.01 – 1.04 —

Oil 2.01 – 2.03 —

2nd 0.97 – 0.99 —

ITEM STANDARD LIMIT

Below1 60 kPa (1.6 kgf/cm

at 3 000 r/min

ITEM STANDARD LIMIT

)

1 050 kPa

(10.5 kgf/cm2)

72.880

—

Unit: mm

1/7 E-02, 19, 24, 38, 71

TRANSMISSION Unit: mm Except ratio

Reduction ratio 2.417 – 0.836 (variable change) — Final reduction ratio 8.066 (44/16 × 44/15) — Drive V-be lt width 22.6 21.6 Movable driven face spring free

length Movable drive face roller O.D. 23.72 – 23.88 —

INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR

Injector resistance 10 – 18 Ω at 20 °C — Fuel pump discharge amount 35 ml and more

Fuel pressure regulator operating set pressure

FI SENSORS

CKP se nsor re sist ance 180 – 2 80 Ω CKP sensor peak voltage 4.5 V and more (When cranking) IAP sensor input voltage 4.5 – 5.5 V IAP sensor output voltage Approx. 2.6 V at idle speed TP sensor input voltage 4.5 – 5.5 V TP sensor resistance Closed Approx. 0.6 kΩ

TP sensor output voltage Closed Approx. 0.6 V

ECT se nsor in put voltage 4.5 – 5.5 V ECT se nsor re sistance App rox. 1.14 kΩ at 4 0 °C IAT sensor input voltage 4.5 – 5.5 V IAT sensor resis tance A pprox . 1.14 kΩ at 40 ° C TO sensor resistance 19.1 – 19.7 kΩ TO sensor output voltage Normal 1.3 V and less

Injector voltage Battery voltage Ignition coil primary peak voltage

PAIR solenoid valve resistance 20 – 24 Ω at 20 °C

ITEM STANDARD LIMIT

150 142.5

ITEM SPECIFICATION N OTE

For 10 sec, at 300 kPa (3.0 kgf/cm

Approx. 300 kPa (3.0 kgf/cm

ITEM SPECIFICATION N OTE

Opened Approx. 3.8 kΩ

Opened Approx. 3.8 V

Leaning 3.8 V and more

150 V and more (when cranking)

)

)—

—

: G, : BI

: W

: Ground

2/7 E-02, 19, 24, 38, 71

THROTTLE BODY

ITEM

ID N o. 14G 0 14G 1 Bore size 31.2 mm ← Fast idle r/min 1 600 – 2 000 r/min ← Idle r/min 1 500 ± 100 r/min ← Idle air screw opening 2 and 1/8 turns out ← IAC valve resistanc e Ap prox. 3 – 9 Ω at 20 – 24 °C ← Throttle cable play 2.0 – 4.0 mm ←

THERMOSTAT + RADIATOR + FAN + COOLANT

Thermostat valve opening temperature

Thermostat valve lift Over 3.0 mm at 95 °C — Engine coolant temperature sensor

resistance

Radiator cap valve opening pressure

Cooling fan thermo-switch operating temperature

Engine coolant type Use an anti-freeze/coolant compatible with alumi-

Engine coolant including reserve Reserve

ITEM ST ANDARD/SPECIFICATION LIMIT

20 °C Approx. 2.58 kΩ 40 °C Approx. 1.14 kΩ — 80 °C Approx. 0.28 kΩ

100 °C Approx. 0.16 kΩ —

ON Approx. 98 °C —

OFF Appro x. 92 °C —

num radiator, mixed with distilled water only, at the ratio o f 50:50.

tank side

Engine side Approx. 1 300 ml —

SPECIFICATION

E-02, 19, 71, 24 E-38

Approx. 88 °C —

107.9 – 137.3 kPa (1.1 – 1 .4 kgf/cm

)

Approx. 250 ml —

ELECTRICAL

Spark plug

Spark performance 8.0 mm and over at 1 atm. CKP sensor resistance 180 – 288 Ω G – BI CKP sensor peak voltage 4.5 V and more Ignition coil resistance Primary 3 – 5 Ω

Ignition coil primary peak voltage

Generator coil resistance Charging 0.2 – 0.6 Ω Y – Y Gener ator no -load voltage

(When cold) Generator Max. output Approx. 375 W at 5 000 r/min Regulated voltage 14.0 – 15.5 V at 5 000 r/min

ITEM STANDARD/SPECIFICATION NOTE

Type

Gap 0.6 – 0.7

Secondary 17 – 30 kΩ

55 V and more at 5 000 r/min

NGK: CR7E

DENSO: U22ESR-N

150 V and more

: G, : BI

: W

: Ground

—

Unit: mm

3/7 E-02, 19, 24, 38, 71

4/7 E-02, 19, 24, 38, 71

Starter relay resistance 3 – 6 Ω Battery Type

Fuse size

WATTAGE Unit: W

Headlight HI 35 × 2 ←←←

Parkin g or positi on lig ht 5 5 Brake light/Taillight 21/5 × 2 ←←← Turn signal light 21 ←←← Front turn signal light/Position light 21/5 Rear turn signal light 21 ←←← License light 5 ←←← Instrument panel light 1.7 × 3 ←←← Oil change indicator light 1.7 ←←← FI indicator light 1.7 ←←← Brake lock indicator light 1.7 ←←← High beam indicator light 1.7 ←←← Turn signal indicator light 1.7 × 2 ←←← Trunk light 5 ←←← Immobilizer indicator light LED LED

ITEM STANDARD/SPECIFICATION NOTE

FT12A-BS

STANDARD/SPECIFICATI ON

ITEM

designation

Capasity 12 V 36 kC (10 Ah) /10 HR

HI 15 A

Head-

light

LO 15 A

Meter 10 A

Ignition 10 A

Turn signal 15 A

Power source 10 A

Main 30 A

E-02, 19 E-24 E-38 E-71

LO 35 × 2 ←←←

BRAKE + WHEEL Unit: mm

Brake disc thickness Front 4.5 ± 0.2 4.0

Brake disc runout — 0.30 Master cylinder bore Front 11.000 – 11.043 —

Master cylinder piston diameter Front 10.957 – 10.984 —

Brake caliper cylinder bore Front 33.960 – 34.010/22.650 – 22.700 —

Brake caliper piston diameter Front 33.878 – 33.928/22.568 – 22.618 —

Wheel rim runout Axial — 2.0

Wheel axle runout Front — 0.25

Wheel rim size Front 13M/C × MT3.00 —

SUSPENSION Unit: mm

Front fork stroke 100 — Front fork spring free length 330.4 324 Front fork oil type SUZUKI FORK OIL G-10 (#10) — Front fork oil capacily (each leg) 284 ml — Front fork oil level 96 — Rear wh eel travel 100 — Rear shock absorber spring

adjus ter

TIRE

Cold inflation tire pressure

Tire si ze Fron t 110/90 -13M/C 55 P —

Tire type Front BRIDGESTONE HOOP B03G —

Tire tread depth (Recommended depth)

ITEM STANDARD LIMIT

Rear 5. 5 ± 0.2 5.0

Rear 14.000 – 14.043 —

Rear 13.957 – 13.984 —

Rear 25.400 – 25.450 —

Rear 25.318 – 25.368 —

Radial — 2 .0

Rear — 0.25

Rear 13M/C × MT3.50 —

ITEM STANDARD LIMIT

3rd —

ITEM STANDARD LIMIT

Solo riding

Dual r idin g

Front

Rear

Front

Rear

Rear 13 0/70- 13M/C 63P —

Rear — — Front — 1.6 mm Rear — 2.0 mm

175 kPa

(1.75 kgf/cm

200 kPa

(2.00 kgf/cm

175 kPa

(1.75 kgf/cm

225 kPa

(2.25 kgf/cm

)

—

5/7 E-02, 19, 24, 38, 71

FUEL + OIL

Fuel type Gasoline used should be graded 91 octane or

Fuel tank capacity Including

Engine oil type SAE 10W-40, API SF or SG Engine oil capac ity Oil c hange 1. 9 L

Final gear oil capacity Oil change 190 ml

ITEM SPECIFICATION N OTE

higher. An unleaded gasoline is recommended.

reserve

Fuel meter

red zone

Filter change 2.0 L

Overhaul 2.3 L

Overhaul 200 ml

13.0 L

Approx. 3.0 L

6/7 E-02, 19, 24, 38, 71

7/7 E-02, 19, 24, 38, 71

AN400/S

VALVE + VALVE GUIDE Unit: mm (in)

Valve diam.

Tappet clearance (when cold)

Valve gui de to val ve stem clear ance

Valve guide I.D.

Valve stem O.D.

Valve stem deflection

Valve stem runout

Valve head thickness

Valve stem end length

Valve seat width

Valve head radial runout

Valve spring free length

Valve spring tension

ITEM STANDARD LIMIT

IN.

EX.

IN.

EX.

IN.

EX.

IN. & EX.

IN.

EX.

IN. & EX. —

IN. & EX.

IN. & EX. —

IN. & EX.

(18.2 – 21.0 kgf, 40.1 – 46.3 lbs)

30.6

(1.20)

27.0

(1.06)

0.08 – 0.13

(0.003 – 0.005)

0.17 – 0.22

(0.007 – 0.009)

0.10 – 0.37

(0.004 – 0.015)

0.30 – 0.57

(0.012 – 0.022)

5.000 – 5.012

(0.1969 – 0.1973)

4.975 – 4.990

(0.1959 – 0.1965)

4.955 – 4.970

(0.1951 – 0.1957)

0.9 – 1.1

(0.035 – 0.043)

182 – 210 N

at length 31.5 mm (1.24 in)

—

0.35

(0.014)

0.05

(0.002)

0.5

(0.02)

1.7

(0.07)

—

0.03

(0.001)

38.8

(1.53)

—

CAMSHAFT + C YLINDER HEAD Unit: mm (in)

Cam height

Camshaft journal oil clearance

Camsh aft jo urnal holder I. D.

Camsh aft jo urnal O.D.

Camshaft runout

Rocker arm shaft I.D.

Rocker a rm shaft O.D.

Cylinder head distortion

CYLIN DER + PI STON + PISTO N RING Unit: mm (in)

Compression pressure 860 – 900 kPa

Piston to cylinder clearance 0.045 – 0.055

Cylinder bore 83.000 – 83.015

Piston diam. 82.950 – 82.965 (3.2657 – 3.2663)

Cylinder distortion

Piston ring free end gap

Piston ring end ga p

Piston ring to gr oove cle arance

ITEM STANDARD LIMIT

IN.

EX.

¬22

¬17.5

¬22

¬17.5

¬22

¬17.5

IN. & EX.

ITEM STANDARD LIMIT

(8.6 – 9.0 kgf/cm², 122 – 128 psi)

Measure at 15 mm (0.6 in) from the skirtend.

1st R Approx. 11.3 (0.44)

2nd R Approx. 7.7 (0.30)

1st

2nd

1st —

2nd —

33.430 – 33.477 (1.316 – 1.318)

33.300 – 33.347 (1.311 – 1.313)

0.032 – 0.066

(0.001 – 0.003)

0.028 – 0.059

(0.001 – 0.002)

22.012 – 22.025

(0.8666 – 0.8671)

17.512 – 17.525 (0.689 – 0.690)

21.959 – 21.980

(0.8645 – 0.8654)

17.466 – 17.484

(0.6876 – 0.6883)

—

12.000 – 12.018 (0.472 – 0.473)

11.973 – 11.984 (0.471 – 0.472)

—

(0.0018 – 0.0022)

(3.2677 – 3.2683)

—

0.20 – 0.35

(0.008 – 0.014)

0.35 – 0.50

(0.014 – 0.020)

33.130 (1.304)

33.000 (1.299)

0.15

(0.006)

0.15

(0.006)

—

0.10

(0.004)

—

0.05

(0.002)

616 kPa

(6.16 kgf/ cm², 88 psi)

0.120

(0.005)

83.085 (3.271)

82.880 (3.263)

0.05

(0.002)

9.0

(0.35)

6.2

(0.24)

0.70

(0.03)

1.0

(0.04)

0.18

(0.007)

0.15

(0.006)

AN400 E-02, 03, 19, 28, 33, 54

1/8

Piston ring groove width

Piston ring thick ness

Piston pin bore 20.002 – 20.008

Piston pin O.D. 19.992 – 20.000

CONROD + CRANKSHAFT Unit: mm (in)

Conrod small end I.D. 20.006 – 20.014

Conrod deflection

Conrod big end side clearance 0.10 – 0.75

Conrod big end width 21.95 – 22.00

Width between crankshaft webs 59.9 – 60.1

Crankshaft runout

OIL PUMP

Oil pressure (at 60 °C, 140 °F) Above 80 kPa (0.8 kgf/cm², 11 psi)

CLUTCH

Clutch wheel I.D. 150.0 – 150.2

Clutch shoe thickness 3.0

Engagement r/min 2 300 – 2 900 rpm — Lock-up r/min 3 500 – 4 500 rpm —

ITEM STANDARD LIMIT

1st

2nd

Oil

1st

2nd

Below 160 kPa (1.6 kgf/cm², 23 psi)

(0.0398 – 0.0406)

(0.0791 – 0.0799)

(0.0382 – 0.0390)

(0.7874 – 0.7877)

(0.7871 – 0.7874)

(0.7876 – 0.7880)

(0.004 – 0.030)

(0.864 – 0.866)

(2.358 – 2.366)

at 3 000 r/min

(5.906 – 5.913)

(0.12)

AN400S E-02, 03, 19, 28, 33

1.01 – 1.03

2.01 – 2.03

0.97 – 0.99

—

20.030 (0.789)

19.980 (0.787)

20.040 (0.789)

3.0

(0.12)

1.0

(0.04)

—

0.08

(0.003)

—

Unit: mm (in)

150.5

(5.925)

2.0

(0.08)

AN400 E-02, 03, 19, 28, 33, 54

2/8

TRANSMISSION Unit: mm (in) Except ratio

Reduction ratio 2.203 – 0.854 (Variable change) — Final reduction ratio 6.168 (31/14 × 39/14) — Drive V-be lt width 21.8 5

Movable driven face spring free length

Movable drive face roller O.D. 23.72 – 23.88

Drive/Driven face wear

INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR

Injector resistance 10 – 18 Ω at 20 °C (68 °F) — Fuel pump discharge amount 35 ml and more

Fuel pressure regulator operating set pressure

FI SENSORS

TP sensor output voltage Closed Approx. 0.6 V

ECT se nsor in put voltage 4.5 – 5.5 V ECT se nsor re sistance A pprox. 1.1 4 kΩ at 40 °C (104 °F) IAT sensor input voltage 4.5 – 5.5 V IAT sensor resis tance A pprox. 1. 14 kΩ at 40 °C (104 °F) TO sensor resistance 19.1 – 19.7 kΩ TO sensor output voltage Normal 1.3 V and less

Injector voltage Battery voltage Ignition coil primary peak voltage

PAIR solenoid valve resistance 20 – 24 Ω at 20 °C (68 °F) HO2 sensor resistance 11.5 – 14.5 Ω at 23 °C (73.4 °F) HO2 sensor output voltage Idle speed 0.3 V and less

ITEM STANDARD LIMIT

(0.93 – 0.94)

ITEM SPECIFICATION N OTE

For 10 sec, at 300 kPa (3.0 kgf/cm², 43 psi)

Approx. 300 kPa (3.0 kgf/cm², 43 psi) —

ITEM SPECIFICATION N OTE

Opened Approx. 3.8 kΩ

Opened Approx. 3.8 V

Leaning 3.8 V and more

150 V and more (when cranking)

3 000 r/min 0.7 V and more

AN400S E-02, 03, 19, 28, 33

(0.86)

125

(4.92)

—

20.85 (0.82)

118.7 (4.67)

—

0.4

(0.02)

—

: G, : BI

: W

: Ground

AN400 E-02, 03, 19, 28, 33, 54

3/8

AN400S E-02, 03, 19, 28, 33

4/8

AN400 E-02, 03, 19, 28, 33, 54 AN400S E-02, 03, 19, 28, 33

THROTTLE BODY

ITEM

I.D. No. 15G0 15G1 Bore size 37.2 mm (1.46 in) ← Fast idle r/min 1 600 – 2 000 r/min ← Idle r/min 1 400 ± 100 r/min ← Idle air screw opening 2 turns out ← IAC valve resistance Approx. 3 – 9 Ω at 20 – 24 °C (68 – 75 °F) ← Throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) ←

THERMOSTAT + RADIATOR + FAN + COOLANT

Thermostat valve opening temperature

Thermostat valve lift Over 3.0 mm at 95 °C (203 °F) — Engine coolant temperature sensor

resistance

Radiator cap valve opening pressure

Cooling fan thermo-switch operating temperature

Engine coolant type Use an anti-freeze/coolant compatible with alumi-

Engine coolant in cluding re serve Reser ve

ELECTRICAL

Spark plug

Spark performance 8.0 mm (0.31 in) and over at 1 atm. CKP sensor resistance 180 – 288 Ω G – BI CKP sensor peak voltage

Ignition coil resistance Primary 3 – 5 Ω

Ignition coil primary peak voltage

ITEM ST ANDARD/SPECIFICATION LIMIT

ITEM ST ANDARD/SPECIFICATION NOTE

Approx. 82 °C (180 °F) ± 1.5 —

20 °C

(68 °F)

40 °C

(104 °F)

80 °C

(176 °F)

100 °C

(212 °F)

(1.1 – 1 .4 kgf/cm² , 16 – 20 psi )

ON 93 – 103 °C (199 – 217 °F) —

OFF 87 – 97 °C (189 – 207 °F) —

num radiator, mixed with distilled water only, at the ratio of 50:50.

tank side

Engine

Approx. 1 300 ml (4 3.9/45.8 US /Imp oz) —

side

Type

Gap

Secondary 17 – 30 kΩ

SPECIFICATION

E-02, 03, 19, 28, 54 E-33

Approx. 2.58 kΩ —

Approx. 1.14 kΩ —

Approx. 0.28 kΩ —

Approx. 0.16 kΩ —

107.9 – 137.3 kPa

Approx. 250 ml (8.5/8.8 US/Imp oz) —

Unit: mm (in)

NGK: CR7E

DENSO: U22ESR- N

0.7 – 0.8

(0.28 – 0.03 in)

4.5 V and more

150 and more

5/8

AN400 E-02, 03, 19, 28, 33, 54 AN400S E-02, 03, 19, 28, 33

: G/W

: BI

: W

: Ground

Generator coil resistance Charging 0.2 – 0.6 Ω Y – Y Gener ator no -load voltage

(When cold) Generator Max. output Approx. 375 W at 5 000 r/min Regulated voltage 14.0 – 15.5 V at 5 000 r/min Starter relay resistance 3 – 6 Ω Battery Type

Fuse size

WATTAGE Unit: W

Headlight HI 35 × 2 ←

—

Parkin g or positi on lig ht 5 Brake light/Taillight 21/5 × 2 ← Turn signal light 21 × 4 ← License light 5 ← Instrument panel light 1.7 × 3 ← Oil change indicator light 1.7 ← FI indicator light 1.7 ← Brake-lock indicator light 1.7 ← High beam indicator light 1.7 ← Turn signal indicator light 1.7 × 2 ← Trunk light 5 ← Immobilizer indicator light LED

ITEM ST ANDARD/SPECIFICATION NOTE

55 V and more at 5 000 r/min

FT12A-BS

STANDARD/SPECIFICATI ON

AN400 E-02, 03, 19, 28, 33, 54 AN400S E-02, 03, 19, 28, 33

ITEM

designation

Capasity 12 V 36 kC (10 Ah) /10 HR

HI 10 A

Headlight

LO 10 A

Meter 10 A

Ignition 10 A

Turn signal 15 A

Power source 10 A

Main 30 A

E-02, 19, 54 E-03, 28, 33

LO 35 × 2 ←

6/8

BRAKE + WHEEL Unit: mm (in)

Brake disc thickness

Brake disc runout

Master cylinder bore

Master cylinder piston diameter

Brake caliper cylinder bore

Brake caliper piston diameter

Wheel rim runout

Wheel axle runout

Wheel rim size Front 13M/C × MT3.00 —

SUSPENSION Unit: mm (in)

Front fork stroke 100 (3.94) — Front fork spring free length

Front fork oil type SUZUKI FORK OIL G-10 (#10) — Front fork oil capacily (each leg) 284 ml — Front fork oil level 96 (3.78) — Rear wheel travel 100 (3.94) — Rear shock absorber spring

adjus ter

ITEM STANDARD LIMIT

Front

Rear

Front

Rear

Front

Rear

Front

Rear

Front

Rear

Axial —

Radial —

Front —

Rear —

Rear 13M/C × MT3.50 —

ITEM STANDARD LIMIT

Standard

Range 17 turns (34 clicks) —

4.5 ± 0. 2

(0.18 ± 0.008)

5.5 ± 0. 2

(0.22 ± 0.008)

—

11.000 – 11.043 (0.433 – 0.435)

14.000 – 14.043 (0.551 – 0.553)

10.957 – 10.984 (0.431 – 0.432)

13.957 – 13.984 (0.549 – 0.551)

33.960 – 34.010/22.650 – 22.700 (1.337 – 1.339/0.892 – 0.894)

25.400 – 25.450 (1.000 – 1.002)

33.878 – 33.928/22.568 – 22.618 (1.334 – 1.336/0.889 – 0.890)

25.318 – 25.368 (0.997 – 0.999)

330.4 (13.01)

4 and 1/2 turns out

from softest position (9 clicks)

4.0

(0.16)

4.5

(0.18)

0.30

(0.01)

—

2.0

(0.08)

2.0

(0.08)

0.25

(0.01)

0.25

(0.01)

324

(12.76)

—

TIRE

Cold inflation tire pressure

Tire si ze Fron t 110/ 90-13 M /C 55P —

Tire type Front BRIDGESTONE HOOP B03G —

Tire tread depth (Recommended depth)

FUEL + OIL

Fuel type Gasoline used should be graded 91 octane or

Fuel tank capacity Including

Engine oil type SAE 10W-40, API SF or SG Engine oil capac ity

Final gear oil capacity

ITEM STANDARD LIMIT

ITEM SPECIFICATION N OTE

Front

Solo

riding

Rear

Front

Dual

riding

Rear

Rear 13 0/70-13 M /C 63P —

Rear BRIDGESTONE HOOP B02G —

Front —

Rear —

higher. An unleaded gasoline is recommended.

reserve

Fuel meter

red zone

Oil change

Filter

change

Overhaul

Oil change

Overhaul

175 kPa

(1.75 kgf/cm², 25 psi)

200 kPa

(2.00 kgf/cm², 28 psi)

175 kPa

(1.75 kgf/cm², 25 psi)

280 kPa

(2.80 kgf/cm², 40 psi)

13.0 L

(3.4/2.9 US/Imp gal)

Approx. 3.0 L (3.2/2.6 US/Imp qt)

1.9 L

(2.0/1.7 US/Imp qt)

2.0 L

(2.1/1.8 US/Imp qt)

2.3 L

(2.4/2.0 US/Imp qt)

190 ml

(6.4/6.7 US/Imp oz)

200 ml

(6.8/7.0 US/Imp oz)

1.6 mm

(0.06 in)

2.0 mm

(0.08 in)

—

AN400 E-02, 03, 19, 28, 33, 54

7/8

AN400S E-02, 03, 19, 28, 33

8/8

AN400 E-02, 03, 19, 28, 33, 54 AN400S E-02, 03, 19, 28, 33

AN650

VALVE + GUIDE Unit: mm (in)

Valve diam.

Tappet clearance (when cold)

Valve gui de to val ve stem clear ance

Valve guide I.D.

Valve stem O.D.

Valve stem deflection

Valve stem runout

Valve head thickness

Valve seat width

Valve head radial runout

Valve spring free length (IN. & EX.)

Valve spring tension (IN. & EX.)

ITEM STANDARD LIMIT

IN.

EX.

IN.

EX.

IN.

EX.

IN. & EX.

IN.

EX.

IN. & EX. —

IN. & EX.

IN. & EX. —

IN. & EX.

(13.6 – 15.6 kgf, 30.0 – 34.4 lbs)

29.5

(1.16)

25.0

(0.98)

0.10 – 0.20

(0.0039 – 0.0079)

0.20 – 0.30

(0.0079 – 0.0118)

0.010 – 0.040

(0.0004 – 0.0016)

0.030 – 0.060

(0.0012 – 0.0024)

4.500 – 4.515

(0.1772 – 0.1778)

4.475 – 4.490

(0.1762 – 0.1768)

4.455 – 4.470

(0.1754 – 0.1760)

0.9 – 1.1

(0.035 – 0.043)

136 – 156 N

at length 33.4 mm (1.31 in)

—

0.35

(0.014)

0.05

(0.002)

0.5

(0.02)

—

0.03

(0.001)

40.6

(1.60)

—

CAMSHAFT + C YLINDER HEAD Unit: mm (in)

Cam height

Camshaft journal oil clearance

Camsh aft jo urnal holder I. D.

Camsh aft jo urnal O.D.

Camshaft runout

Cam chain pin (at arrow “3”) 15th pin — Cylinder head distortion

CYLIN DER + PI STON + PISTO N RING Unit: mm (in)

Compression pressure 1 500 – 1 900 kPa

Compr ession pres sure diffe rence

Piston to cylinder clearance 0.045 – 0.055

Cylinder bore 75.500 – 75.515

Piston diam. 75.470 – 75 .485

Cylinder distortion

Piston ring free end gap

Piston ring end ga p

Piston ring to gr oove cle arance

Piston ring groove width

ITEM STANDARD LIMIT

IN.

EX.

IN. & EX.

IN. & EX. —

ITEM STANDARD LIMIT

(15.0 – 19.0 kgf/cm

Measure at 15 mm (0.6 in) from the skirt end.

1st R Approx. 11.6 (0.46)

2nd RN Approx. 8.6 (0.34)

1st

2nd

1st —

2nd —

1st

2nd

Oil

35.38 – 35.43

(1.393 – 1.395)

33.98 – 34.03

(1.338 – 1.340)

0.032– 0.066

(0.0013 – 0.0026)

24.012 – 24.025

(0.9454 – 0.9459)

23.959 – 23.980

(0.9433 – 0.9441)

—

, 213 – 270 psi)

—

(0.0018 – 0.0022)

(2.9724 – 2.9730)

(2.9705 – 2.9711)

—

0.06 – 0.18

(0.002 – 0.005)

0.06 – 0.18

(0.002 – 0.005)

1.01 – 1.03

(0.040 – 0.041)

1.01 – 1.03

(0.040 – 0.041)

2.01 – 2.03

(0.079 – 0.080)

35.10

(1.382)

33.70

(1.327)

0.150

(0.0059)

—

0.10

(0.004)

0.10

(0.004)

1 200 kPa

(12 kgf/cm2, 171 psi)

200 kPa

(2.0 kgf/cm

0.120

(0.0047)

Nicks or

scratches

75.380

(2.9677)

0.10

(0.004)

9.3

(0.37)

6.9

(0.27)

0.50

(0.020)

0.50

(0.020)

0.180

(0.007)

0.150

(0.006)

—

, 28 psi)

1/9 E-02, 03, 19, 24, 28, 33

Piston ring thick ness

Piston pin bore 1 6.002 – 16.008

Piston pin O.D. 15.995 – 16.000

CONROD + CRANKSHAFT Unit: mm (in)

Conrod small end I.D. 16.010 – 16.018

Conrod big end side clearance 0.10 – 0.20

Conrod big end width 19.950 – 20.000

Crank pin width 20.100 – 20.150

Conrod big end oil clearance 0.032 – 0.056

Crank pin O.D. 44.976 – 45.000

Crankshaft journal oil clearance 0.018 – 0.045

Crankshaft journal O.D. 47.985 – 48.000

Crankshaft thrust bearing thickness 2.025 – 2.175

Cranks haft thrus t clearanc e 0.10 – 0.1 5

Crankshaft runout

OIL PUMP

Oil pressure (at 60 °C, 140 °F) Above 350 kPa (3.5 kgf/cm

ITEM STANDARD LIMIT

1st

2nd

ITEM STANDARD LIMIT

Below 550 kPa (5.5 kgf/cm

0.97 – 0.99

(0.038 – 0.039)

0.97 – 0.99

(0.038 – 0.039)

(0.6300 – 0.6302)

(0.6297 – 0.6299)

(0.6303 – 0.6306)

(0.004 – 0.008)

(0.7854 – 0.7874)

(0.7913 – 0.7933)

(0.0013 – 0.0022)

(1.7707 – 1.7717)

(0.0007 – 0.0018)

(1.8892 – 1.8898)

(0.0797 – 0.0856)

(0.0039 – 0.0059)

—

at 3 000 r/min

, 49.8 psi)

, 78.2 psi)

—

16.030

(0.6311)

15.980

(0.6291)

16.040

(0.6315)

0.30

(0.012)

—

0.080

(0.0031)

—

0.080

(0.0031)

—

0.05

(0.002)

—

2/9 E-02, 03, 19, 24, 28, 33

CLUTCH Unit: mm (in)

Drive plate thickness 2.92 – 3.08

Drive p late claw wi dth 13. 85 – 13 .96

Driven plate No. 2 thickness 2.42 – 2.58

Driven plate distortion

Clutch spring free length 13.9

Clutch plate concaved washer heigh t

Clutch engagement 1 500 – 2 100 r/min — Clutch lock-up 3 200 – 3 800 r/min —

INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR

Injector resistance 11 – 13 Ω at 20 °C (68 °F) — Fuel pump discharge amount More than 0.9 L (0.95/0.79 US/Imp qt)

Fuel pressure regulator operating set pressure

FI/CVT-SENSORS

CMP sensor resistance 0.9 – 1.7 kΩ CMP sensor peak voltage More than 0.5 V (When cranking) : B/Y, : Br CKP sensor resistance 150 – 300 Ω CKP sensor peak voltage More than 2.0 V (When cranking) : Bl, : G IAP sensor input voltage 4.5 – 5.5 V IAP sensor output voltage Approx. 2.6 V at idle speed TP sensor input voltage 4.5 – 5.5 V TP sensor resistance Closed Approx. 1.1 kΩ

TP sensor output voltage Closed Approx. 1.1 V

ECT se nsor in put voltage 4.5 – 5.5 V ECT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F) IAT sensor input voltage 4.5 – 5.5 V IAT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F) AP sens or input vol tage 4.5 – 5.5 V AP sensor output voltage Approx. 3.6 V at 100 kPa (760 mmHg) TO sensor resistance 19.1 – 19.7 kΩ TO sensor output voltage Normal 0.4 – 1.4 V

Injector voltage Battery voltage

ITEM STANDARD LIMIT

(0.115 – 0.121)

(0.545 – 0.550)

(0.095 – 0.102)

—

(0.547)

3.2

(0.126)

ITEM SPECIFICATION NOTE

For 30 sec. at 300 kPa (3.0 kgf/cm

Approx. 300 kPa (3.0 kgf/cm

ITEM SPECIFICATION N OTE

Opened Approx. 4.2 kΩ

Opened Approx. 4.3 V

Leaning 3.7 – 4.4 V : B, : B/Br

, 43 psi)

, 43 psi) —

2.62

(0.103)

13.05

(0.514)

2.27

(0.089)

0.10

(0.004)

13.2

(0.520)

3.1

(0.12)

—

: B, : B/Br

3/9 E-02, 03, 19, 24, 28, 33

4/9 E-02, 03, 19, 24, 28, 33

Ignition coil primary peak voltage

HO2 sensor resistance 4 – 5 Ω at 23 °C (73.4 °F) HO2 sensor output voltage Idle speed Less than 0.4 V

PAIR solenoid valve resistance 20 – 24 Ω at 20 °C (68 °F) CVT primary pulley position sensor Compressed 1.9 – 2.3 kΩ

CVT primary pulley position sensor output voltage

CVT secondary pulley revolution sensor resistance

CVT secondary pulley revolution sensor peak voltage

THROTTLE BODY

I.D. No. 10G0 Bore size 32 mm (1.2 6 in) Fast idle r/min 1 300 – 1 600 r/min Idle r/min 1 200 ± 100 r/min Synchronizing screw opening 1 and 1/2 turns out IAC valve resistance Approx. 4 Ω at 20 – 24 °C (68 – 75 °F) Throttle cable play 2.0 – 4.0 mm

THERMOSTAT + RADIATOR + FAN + COOLANT

Thermostat valve opening temperature

Thermostat valve lift Over 8.0 mm (0.3 in) at 100 °C (212 °F) — Engine coolant temperature sensor

resistance

Radiator cap valve opening pressure

Eclectic fan thermo-switch operating temperature

Engine coolant type Use an anti-freeze/coolant compatible with alumi-

ITEM SPECIFICATION N OTE

More than 80 V (When cranking)

3 000 r/min More than 0.6 V

Extended 0.2 – 1.0 kΩ

: Idle speed Approx. 3.3 V

: 3 000 r/min Approx. 1.3 V

: 3 000 r/min Approx. 0.5 V

400 – 600 Ω

More than 5 V at idle speed

ITEM SPECIFICATION

(0.08 – 0.16 in)

ITEM ST ANDARD/SPECIFICATION LIMIT

Approx. 88 °C (190 °F) —

20 °C (68 °F) Approx. 2.45 kΩ — 50 °C (122 °F) Approx. 0.811 kΩ — 80 °C (176 °F) Approx. 0.318 kΩ —

110 °C (230 °F) Approx. 0.142 kΩ —

110 kPa ( 1.1 kgf /cm²) —

ON 93 – 103 °C (199 – 217 °F) —

OFF 87 – 97 °C (188 – 206 °F) —

num radiator, mixed with distilled water only, at the ratio of 50:50.

: W/Bl,

#1 : Ground #2 : B/Y,

: Ground

: Y, : W

Engine coolant including reserve Reverse

ELECTRICAL Unit: mm (in)

Firing order 1·2 Spark plug

Spark performance Over 8.0 (0.3) at 1 atm. CKP sensor peak voltage More than 2.0 V Ignition coil resistance Primary 0.8 – 2.5 Ω

Ignition coil primary peak voltage

Generator coil resistance CKP sensor 150 – 300 Ω G – BI

Gener ator no -load voltage (When cold)

Generator Max. output Approx. 500 W at 5 000 r/min Regulated voltage 14.0 – 15.5 V at 5 000 r/min Starter relay resistance 3 – 6 Ω Battery Type

Fuse size

ITEM ST ANDARD/SPECIFICATION LIMIT

tank side

Engine side

Approx. 250 ml

(0.264/0.220 US/Imp qt)

Approx. 1 350 ml

(1.427/1.188 US/Imp qt)

—

ITEM STD/SPEC. NOTE

Type

Gap

NGK: CR8E

DENSO: U24ESR-N

0.7 – 0 .8

(0.028 – 0.031)

: Bl, :G

Secondary 8 – 18 kΩ

Mor e than 80 V

#1 : W/Bl, : Ground #2 : B/Y, : Ground

Charging 0.1 – 1.0 Ω Y – Y

More than 50 V at 5 000 r/min

designation

Capac ity 12 V 43. 2 kC (1 2 Ah)/ 10 HR

Head-

light

HI 15 A

Fuel pump 10 A

Ignition 15 A

Turn signal 15 A

Fan m otor 1 5 A

Main 40 A CVT 40 A

Power source

FTX14-BS

15 A.......... E-03, 24, 28, 33

10 A.......... E-02, 19

10 A

—

5/9 E-02, 03, 19, 24, 28, 33

WATTAGE Unit: W

ITEM

Headlight HI 60 + 55 60 × 2

Parkin g or positi on lig ht 5 × 2 Brake light/Taillight 21/5 × 2 ← Turn signal light 21 × 4 ← License light 5 ← Instrument panel light 1.4 × 2 ← Engine coolant temp. indicator light 1.4 ← FI indicator light 1.4 ← Engine oil pressure indicator light 1.4 ← Brake-lock indicator light 1.4 ← High beam indicator light 1.4 ← Turn signal indicator light 1.4 × 2 ← Power mode indicator light 1.4 ← Drive indicator light 1.4 ← Gear position indicator light 1.4 × 5 ← Trunk light 5 ← Immobilizer indicator light LED Over drive indicator light 1.4 ←

LO 55 55 × 2

E-02, 19 E-03, 24, 28, 33

STD/SPEC.

BRAKE + WHEEL Unit: mm (in)

Brake disc thickness

Brake disc runout

Master cylinder bore

Master cylinder piston diameter

Brake caliper cylinder bore

Brake caliper piston diameter

Brake fluid type DOT 4 —

ITEM STANDARD LIMIT

Front

Rear

Front

Rear

Front

Rear

Front

Rear

Front

Rear

4.5 ± 0. 2

(0.1 77 ± 0.008)

5.5 ± 0. 2

(0.2 17 ± 0.008)

—

12.700 – 12.743

(0.5000 – 0.5017)

12.700 – 12.743

(0.5000 – 0.5017)

12.657 – 12.684

(0.4983 – 0.4994)

12.657 – 12.684

(0.4983 – 0.4994)

25.400 – 25.450

(1.0000 – 1.0020)

27.000 – 27.050

(1.0630 – 1.0650)

25.318 – 25.368

(0.9968 – 0.9987)

26.918 – 26.968

(1.0598 – 1.0617)

4.0

(0.16)

5.0

(0.20)

0.30

(0.012)

—

6/9 E-02, 03, 19, 24, 28, 33

Wheel rim runout

Wheel axle runout

Wheel rim size Front 15 M/C × MT3.50 —

ITEM STANDARD LIMIT

Axial —

Radial —

Front —

Rear —

2.0

(0.08)

2.0

(0.08)

0.25

(0.010)

0.25

(0.010)

Rear 14 M/C × MT4.50 —

SUSPENSION Unit: mm (in)

Front fork stroke 110

Front fork spring free length

Front fork oil type SUZUKI FORK OIL G-10 (#10) or

Front fork oil capacity (each leg) 458 ml — Front fork oil level 151

Front fork inner tube diam. 41

Rear wheel travel 100

Rear shock absorber spring adjus ter

ITEM STANDARD LIMIT

(4.3)

—

an equivalent fork oil

(5.9)

—

341

(13.4)

—

(1.61)

(3.9)

—

2nd —

TIRE

Cold inflation tire pressure

Tire size Front 120/70R15M/C 56H —

Tire type Front BRIDGESTONE TH01F —

Tire tread depth (Recommended depth)

ITEM STAN DARD LIMIT

Solo riding

Dual riding

Front

Rear

Front

Rear

225 kPa

(2.25 kgf/cm

250 kPa

(2.50 kgf/cm

225 kPa

(2.25 kgf/cm

280 kPa

(2.80 kgf/cm

, 33 psi)

, 36 psi)

, 33 psi)

, 41 psi)

—

Rear 160/60R14M/C 65H —

Rear BRIDGESTONE TH01R —

Front —

Rear —

1.6 mm

(0.06 in)

2.0 mm

(0.08 in)

7/9 E-02, 03, 19, 24, 28, 33

8/9 E-02, 03, 19, 24, 28, 33

FUEL + OI L

Fuel type Use only unleaded gasoline of at least 87 pump

Fuel tank capacity Including

Engine oil and transmission oil type SAE 10W-40, API SF/SG or SH/SJ with JASO MA Engine oil capac ity

Transmission oil capacity

Final gear oil type Hypoid gear oil SAE #90 API grade GL-5 Final gear oil capacity

ITEM SPECIFICATION NOTE

octane (R/2 + M/2) or 91 octane or higher rated by

the research method.

Gasoline containing MTBE (Methyl Tertiary Butyl

Ether), less than 10% ethanol, or less than 5%

methanol with appropriate cosolvents and corro-

sion inhibitor is permissible.

Gasoline used should be graded 91 octane or

higher. An unleaded gasoline is recommended.

reserve

Fuel meter

mark

flickering

Fuel meter

mark and

LCD

flickering

Oil change

Filter change

Overhaul

Oil change

Overhaul

Oil change

Overhaul

15.0 L (4.0/3.3 US/lmp gal)

Approx . 3.0 L (0.79 /0.66 US/l mp gal)

Approx . 1.5 L (0.40 /0.33 US/l mp gal)

2.6 L

(2.7 /2.3 US/l mp qt)

2.9 L

(3.1 /2.6 US/l mp qt)

3.4 L

(3.6/3.0 US/lmp qt)

360 ml

(12.2 /12.7 US/l mp oz)

400 ml

(13.5 /14.1 US/l mp oz)

300 ml

(10.1 /10.6 US/l mp oz)

430 ml

(14.5 /15.1 US/l mp oz)

E-03, 28, 33

The others

9/9 E-02, 03, 19, 24, 28, 33

AN650A

VALVE + GUIDE Unit: mm (in)

Valve diam.

Tappet clearance (when cold)

Valve gui de to val ve stem clear ance

Valve guide I.D.

Valve stem O.D.

Valve stem deflection

Valve stem runout

Valve head thickness

Valve seat width

Valve head radial runout

Valve spring free length (IN. & EX.)

Valve spring tension (IN. & EX.)

ITEM STANDARD LIMIT

IN.

EX.

IN.

EX.

IN.

EX.

IN. & EX.

IN.

EX.

IN. & EX. —

IN. & EX.

IN. & EX. —

IN. & EX.

(13.6 – 15.6 kgf, 30.0 – 34.4 lbs)

29.5

(1.16)

25.0

(0.98)

0.10 – 0.20

(0.0039 – 0.0079)

0.20 – 0.30

(0.0079 – 0.0118)

0.010 – 0.040

(0.0004 – 0.0016)

0.030 – 0.060

(0.0012 – 0.0024)

4.500 – 4.515

(0.1772 – 0.1778)

4.475 – 4.490

(0.1762 – 0.1768)

4.455 – 4.470

(0.1754 – 0.1760)

0.9 – 1.1

(0.035 – 0.043)

136 – 156 N

at length 33.4 mm (1.31 in)

—

0.35

(0.014)

0.05

(0.002)

0.5

(0.02)

—

0.03

(0.001)

40.6

(1.60)

—

CAMSHAFT + C YLINDER HEAD Unit: mm (in)

Cam height

Camshaft journal oil clearance

Camsh aft jo urnal holder I. D.

Camsh aft jo urnal O.D.

Camshaft runout

Cam chain pin (at arrow “3”) 15th pin — Cylinder head distortion

CYLIN DER + PI STON + PISTO N RING Unit: mm (in)

Compression pressure 1 500 – 1 900 kPa

Compr ession pres sure diffe rence

Piston to cylinder clearance 0.045 – 0.055

Cylinder bore 75.500 – 75.515

Piston diam. 75.470 – 75 .485

Cylinder distortion

Piston ring free end gap

Piston ring end ga p

Piston ring to gr oove cle arance

Piston ring groove width

ITEM STANDARD LIMIT

IN.

EX.

IN. & EX.

IN. & EX. —

ITEM STANDARD LIMIT

(15.0 – 19.0 kgf/cm

Measure at 15 mm (0.6 in) from the skirt end.

1st R Approx. 11.6 (0.46)

2nd RN Approx. 8.6 (0.34)

1st

2nd

1st —

2nd —

1st

2nd

Oil

35.38 – 35.43

(1.393 – 1.395)

33.98 – 34.03

(1.338 – 1.340)

0.032– 0.066

(0.0013 – 0.0026)

24.012 – 24.025

(0.9454 – 0.9459)

23.959 – 23.980

(0.9433 – 0.9441)

—

, 213 – 270 psi)

—

(0.0018 – 0.0022)

(2.9724 – 2.9730)

(2.9705 – 2.9711)

—

0.06 – 0.18

(0.002 – 0.005)

0.06 – 0.18

(0.002 – 0.005)

1.01 – 1.03

(0.040 – 0.041)

1.01 – 1.03

(0.040 – 0.041)

2.01 – 2.03

(0.079 – 0.080)

35.10

(1.382)

33.70

(1.327)

0.150

(0.0059)

—

0.10

(0.004)

0.10

(0.004)

1 200 kPa

(12 kgf/cm2, 171 psi)

200 kPa

(2.0 kgf/cm

0.120

(0.0047)

Nicks or

scratches

75.380

(2.9677)

0.10

(0.004)

9.3

(0.37)

6.9

(0.27)

0.50

(0.020)

0.50

(0.020)

0.180

(0.007)

0.150

(0.006)

—

, 28 psi)

1/9 E-02, 19

2/9 E-02, 19

Piston ring thick ness

Piston pin bore 1 6.002 – 16.008

Piston pin O.D. 15.995 – 16.000

CONROD + CRANKSHAFT Unit: mm (in)

Conrod small end I.D. 16.010 – 16.018

Conrod big end side clearance 0.10 – 0.20

Conrod big end width 19.950 – 20.000

Crank pin width 20.100 – 20.150

Conrod big end oil clearance 0.032 – 0.056

Crank pin O.D. 44.976 – 45.000

Crankshaft journal oil clearance 0.018 – 0.045

Crankshaft journal O.D. 47.985 – 48.000

Crankshaft thrust bearing thickness 2.025 – 2.175

Cranks haft thrus t clearanc e 0.10 – 0.1 5

Crankshaft runout

OIL PUMP

Oil pressure (at 60 °C, 140 °F) Above 350 kPa (3.5 kgf/cm

ITEM STANDARD LIMIT

1st

2nd

ITEM STANDARD LIMIT

Below 550 kPa (5.5 kgf/cm

0.97 – 0.99

(0.038 – 0.039)

0.97 – 0.99

(0.038 – 0.039)

(0.6300 – 0.6302)

(0.6297 – 0.6299)

(0.6303 – 0.6306)

(0.004 – 0.008)

(0.7854 – 0.7874)

(0.7913 – 0.7933)

(0.0013 – 0.0022)

(1.7707 – 1.7717)

(0.0007 – 0.0018)

(1.8892 – 1.8898)

(0.0797 – 0.0856)

(0.0039 – 0.0059)

—

at 3 000 r/min

, 49.8 psi)

, 78.2 psi)

—

16.030

(0.6311)

15.980

(0.6291)

16.040

(0.6315)

0.30

(0.012)

—

0.080

(0.0031)

—

0.080

(0.0031)

—

0.05

(0.002)

—

CLUTCH Unit: mm (in)

Drive plate thickness 2.92 – 3.08

Drive p late claw wi dth 13. 85 – 13 .96

Driven plate No. 2 thickness 2.42 – 2.58

Driven plate distortion

Clutch spring free length 13.9

Clutch plate concaved washer heigh t

Clutch engagement 1 500 – 2 100 r/min — Clutch lock-up 3 200 – 3 800 r/min —

INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR

Injector resistance 11 – 13 Ω at 20 °C (68 °F) — Fuel pump discharge amount More than 0.9 L (0.95/0.79 US/Imp qt)

Fuel pressure regulator operating set pressure

FI/CVT-SENSORS

TP sensor output voltage Closed Approx. 1.1 V

Injector voltage Battery voltage

ITEM STANDARD LIMIT

(0.115 – 0.121)

(0.545 – 0.550)

(0.095 – 0.102)

—

(0.547)

3.2

(0.126)

ITEM SPECIFICATION NOTE

For 30 sec. at 300 kPa (3.0 kgf/cm

Approx. 300 kPa (3.0 kgf/cm

ITEM SPECIFICATION N OTE

Opened Approx. 4.2 kΩ

Opened Approx. 4.3 V

Leaning 3.7 – 4.4 V : B, : B/Br

, 43 psi)

, 43 psi) —

2.62

(0.103)

13.05

(0.514)

2.27

(0.089)

0.10

(0.004)

13.2

(0.520)

3.1

(0.12)

—

: B, : B/Br

3/9 E-02, 19

Ignition coil primary peak voltage

HO2 sensor resistance 4 – 5 Ω at 23 °C (73.4 °F) HO2 sensor output voltage Idle speed Less than 0.4 V

PAIR solenoid valve resistance 20 – 24 Ω at 20 °C (68 °F) CVT primary pulley position sensor Compressed 1.9 – 2.3 kΩ

CVT primary pulley position sensor output voltage

CVT secondary pulley revolution sensor resistance

CVT secondary pulley revolution sensor peak voltage

THROTTLE BODY

THERMOSTAT + RADIATOR + FAN + COOLANT

Thermostat valve opening temperature

Thermostat valve lift Over 8.0 mm (0.3 in) at 100 °C (212 °F) — Engine coolant temperature sensor

resistance

Radiator cap valve opening pressure

Eclectic fan thermo-switch operating temperature

Engine coolant type Use an anti-freeze/coolant compatible with alumi-

ITEM SPECIFICATION N OTE

More than 80 V (When cranking)

3 000 r/min More than 0.6 V

Extended 0.2 – 1.0 kΩ

: Idle speed Approx. 3.3 V

: 3 000 r/min Approx. 1.3 V

: 3 000 r/min Approx. 0.5 V

ITEM SPECIFICATION

ITEM ST ANDARD/SPECIFICATION LIMIT

20 °C

(68 °F)

50 °C

(122 °F)

80 °C

(176 °F)

110 °C

(230 °F)

ON 93 – 103 °C (199 – 217 °F) —

OFF 87 – 97 °C (188 – 206 °F) —

num radiator, mixed with distilled water only, at the ratio o f 50:50.

400 – 600 Ω

More than 5 V at idle speed

(0.08 – 0.16 in)

Approx. 88 °C (190 °F) —

Approx. 2.45 kΩ —

Approx. 0.811 kΩ —

Approx. 0.318 kΩ —

Approx. 0.142 kΩ —

110 kPa ( 1.1 kgf /cm²) —

#1 : W/Bl, : Ground #2 : B/Y,

: Ground

: Y, : W

4/9 E-02, 19

Engine coolant in cluding re serve Rever se

ITEM ST ANDARD/SPECIFICATION LIMIT

tank side

Engine

side

Approx. 250 ml

(0.264/0.220 US/Imp qt)

Approx. 1 350 ml

(1.427/1.188 US/Imp qt)

—

ELECTRICAL Unit: mm (in)

Firing order 1·2 Spark plug

Spark performance Over 8.0 (0.3) at 1 atm. CKP sensor peak voltage More than 2.0 V Ignition coil resistance Primary 0.8 – 2.5 Ω

Ignition coil primary peak voltage

Generator coil resistance CKP sensor 150 – 300 Ω G – BI

Gener ator no -load voltage (When cold)

Generator Max. output Approx. 500 W at 5 000 r/min Regulated voltage 14.0 – 15.5 V at 5 000 r/min Starter relay resistance 3 – 6 Ω Battery Type

Fuse size

—

ITEM STD/SPEC. NOTE

Type

Gap

Secondary 8 – 18 kΩ

Charging 0.1 – 1.0 Ω Y – Y

More than 50 V at 5 000 r/min

desig nation

Capacity 12 V 43.2 kC (12 Ah)/10 HR

LO 15 A

Head-

light

HI 15 A

Fuel pump 10 A

Ignition 15 A

Turn signal 15 A

Fan motor 15 A

Main 40 A CVT 40 A

Power source

ABS 15 A × 2

NGK: CR8E

DENSO: U24ESR-N

0.7 – 0.8

(0.028 – 0.031)

More than 80 V

FTX14-BS

10 A

: Bl, :G

#1 : W/Bl, : Ground #2 : B/Y, : Ground

5/9 E-02, 19

6/9 E-02, 19

WATTAGE Unit: W

ITEM

Headlight HI 60 + 55 60 × 2

Parkin g or positi on lig ht 5 × 2 Brake light/Taillight 21/5 × 2 ← Turn signal light 21 × 4 ← License light 5 ← Instrument panel light 1.4 × 2 ← Engine coolant temp. indicator light 1.4 ← FI indicator light 1.4 ← Engine oil pressure indicator light 1.4 ← Brake-lock indicator light 1.4 ← High beam indicator light 1.4 ← Turn signal indicator light 1.4 × 2 ← Power mode indicator light 1.4 ← Drive indicator light 1.4 ← Gear position indicator light 1.4 × 5 ← ABS warning indicator light 1.4 Trunk light 5 ← Immobilizer indicator light LED Over drive indicator light 1.4 ←

LO 55 55 × 2

E-02, 19 E-03, 24, 28, 33

STD/SPEC.

BRAKE + WHEEL Unit: mm (in)

Brake disc thickness

Brake disc runout

Master cylinder bore

Master cylinder piston diameter

Brake caliper cylinder bore

Brake caliper piston diameter

Brake fluid type DOT 4 —

ITEM STANDARD LIMIT

Front

Rear

Front

Rear

Front

Rear

Front

Rear

Front

Rear

4.5 ± 0. 2

(0.1 77 ± 0.008)

5.5 ± 0. 2

(0.2 17 ± 0.008)

—

12.700 – 12.743

(0.5000 – 0.5017)

12.700 – 12.743

(0.5000 – 0.5017)

12.657 – 12.684

(0.4983 – 0.4994)

12.657 – 12.684

(0.4983 – 0.4994)

25.400 – 25.450

(1.0000 – 1.0020)

27.000 – 27.050

(1.0630 – 1.0650)

25.318 – 25.368

(0.9968 – 0.9987)

26.918 – 26.968

(1.0598 – 1.0617)

4.0

(0.16)

5.0

(0.20)

0.30

(0.012)

—

Wheel rim runout

Wheel axle runout

Wheel rim size Front 15 M/C × MT3.50 —

ITEM STANDARD LIMIT

Axial —

Radial —

Front —

Rear —

Rear 14 M/C × MT4.50 —

2.0

(0.08)

2.0

(0.08)

0.25

(0.010)

0.25

(0.010)

SUSPENSION Unit: mm (in)

Front fork stroke 110

Front fork spring free length

Front fork oil type SUZUKI FORK OIL G-10 (#10) or

Front fork oil capacity (each leg) 458 ml — Front fork oil level 151

Front fork inner tube diam. 41

Rear wheel travel 100

Rear shock absorber spring adjus ter

ITEM STANDARD LIMIT

(4.3)

—

an equivalent fork oil

(5.9)

(1.61)

(3.9)

2nd —

—

341

(13.4)

—

TIRE

Cold inflation tire pressure

Tire size Front 120/70R15M/C 56H —

Tire type Front BRIDGESTONE TH01F —

Tire tread depth (Recommended depth)

ITEM STANDARD LIMIT

Front

Solo

riding

Rear

Front

Dual

riding

Rear

Rear 160/60R14M/C 65H —

Rear BRIDGESTONE TH01R —

Front —

Rear —

225 kPa

(2.25 kgf/cm

250 kPa

(2.50 kgf/cm

225 kPa

(2.25 kgf/cm

280 kPa

(2.80 kgf/cm

, 33 psi)

, 36 psi)

, 33 psi)

, 41 psi)

—

1.6 mm

(0.06 in)

2.0 mm

(0.08 in)

7/9 E-02, 19

FUEL + OI L

Fuel type Gasoline used should be graded 91 octane or

Fuel tank capacity Including

Engine oil and transmission oil type SAE 10W-40, API SF/SG or SH/SJ with JASO MA Engine oil capac ity

Transmission oil capacity

Final gear oil type Hypoid gear oil SAE #90 API grade GL-5 Final gear oil capacity

ITEM SPECIFICATION NOTE

higher. An unleaded gasoline is recommended.

reserve

Fuel meter

mark

flickering

Fuel meter

mark and

LCD

flickering

Oil change

Filter change

Overhaul

Oil change

Overhaul

Oil change

Overhaul

15.0 L (4.0/3.3 US/lmp gal)

Approx . 3.0 L (0.79 /0.66 US/l mp gal)

Approx . 1.5 L (0.40 /0.33 US/l mp gal)

2.6 L

(2.7/2.3 US/lmp qt)

2.9 L

(3.1/2.6 US/lmp qt)

3.4 L

(3.6/3.0 US/lmp qt)

360 ml

(12.2 /12.7 US/l mp oz)

400 ml

(13.5 /14.1 US/l mp oz)

300 ml

(10.1 /10.6 US/l mp oz)

430 ml

(14.5 /15.1 US/l mp oz)

8/9 E-02, 19

9/9 E-02, 19

DL650/UE

VALVE + GUIDE Unit: mm (in)

Valve diam.

Valve clearance (when cold)

Valve gui de to val ve stem clea rance

Valve guide I.D.

Valve stem O.D.

Valve stem deflection

Valve stem runout

Valve head thickness

Valve seat width

Valve head radial runout

Valve spring free length (IN. & EX.)

Valve spring tension (IN. & EX.) INNER

ITEM STANDARD LIMIT

IN.

EX.

IN.

EX.

IN.

EX.

IN. & EX.

IN.

EX.

IN. & EX. —

IN. & EX.

IN. & EX. —

INNER —

OUTER —

OUTER

(1.2)

25.5 (1.0)

0.10 – 0.20

(0.004 – 0.008)

0.20 – 0.30

(0.008 – 0.012)

0.020 – 0.047

(0.0008 – 0.0019)

0.030 – 0.057

(0.0012 – 0.0022)

4.500 – 4.512

(0.1772 – 0.1776)

4.465 – 4.480

(0.1758 – 0.1764)

4.455 – 4.470

(0.1754 – 0.1760)

0.9 – 1.1

(0.035 – 0.043)

4.2 – 4.8 kgf

(9.26 – 10.58 lbs)

at length 29.9 mm (1.18 in)

17.0 – 19.6 kgf

(37.48 – 43.21 lbs)

at length 33.4 mm (1.31 in)

—

0.35

(0.014)

0.05

(0.002)

0.5

(0.02)

—

0.03

(0.001)

36.8

(1.45)

39.8

(1.57)

—

CAMSHAFT + C YLINDER HEAD Unit: mm (in)

Cam height

Camshaft journal oil clearance

Camsh aft jo urnal holder I. D.

Camsh aft jo urnal O.D.

Camshaft runout

Cam chain pin (at arrow “3”) 16th pin — Cylinder head distortion

CYLIN DER + PI STON + PISTO N RING Unit: mm (in)

Compression pressure 1 300 – 1 700 kPa

Compr ession pres sure diffe rence

Piston to cylinder clearance 0.055 – 0.065

Cylinder bore 81.000 – 81.015

Piston diam. 80.950 – 80.955

Cylinder distortion

Piston ring free end gap

Piston ring end ga p

Piston ring to gr oove cle arance

Piston ring groove width

ITEM STANDARD LIMIT

IN.

EX.

IN. & EX.

IN. & EX. —

ITEM STANDARD LIMIT

(13 – 17 kgf/cm

Measure at 20 mm (0.79 in) from the skirt end.

1st Approx. 9.5 (0.37)

2nd Approx. 11 (0.43)

1st

2nd

1st —

2nd —

1st

2nd

Oil

35.48 – 35.53

(1.3968 – 1.3988)

33.48 – 33.53

(1.3181 – 1.3201)

0.032 – 0.066

(0.0013 – 0.0026)

22.012 – 22.025

(0.8666 – 0.8671)

21.959 – 21.980

(0.8645 – 0.8654)

—

, 185 – 242 psi)

—

(0.0022 – 0.0026)

(3.1890 – 3.1896)

(3.1870 – 3.1872)

—

0.20 – 0.35

(0.008 – 0.014)

0.20 – 0.35

(0.008 – 0.0014)

1.21 – 1.23

(0.0476 – 0.0484)

1.01 – 1.03

(0.0398 – 0.0406)

2.01 – 2.03

(0.0791 – 0.0799)

35.18

(1.3850)

33.18

(1.3063)

0.150

(0.0059)

—

0.10

(0.004)

0.05

(0.002)

1 100 kPa

(11 kgf/cm2, 156 psi)

200 kPa

(2 kgf/cm2, 28 psi)

0.120

(0.0047)

Nicks o r

Scratches

80.88

(3.184)

0.05

(0.002)

7.6

(0.30)

8.8

(0.35)

0.70

(0.028)

0.70

(0.028)

0.180

(0.0071)

0.150

(0.0059)

—

1/9

Piston ring thick ness

Piston pin bore 20.002 – 20.008

Piston pin O.D. 19.992 – 20.000

CONROD + CRANKSHAFT Unit: mm (in)

Conrod small end I.D. 20.010 – 20.018

Conrod big end side clearance 0.170 – 0.320

Conrod big end width 20.95 – 21.00

Crank pin width 42.17 – 42.22

Conrod big end oil clearance 0.032 – 0.056

Crank pin O.D. 37.976 – 38.000

Crankshaft journal oil clearance 0.002 – 0.029

Crankshaft journal O.D. 41.985 – 42.000

Crankshaft runout

OIL PUMP

Oil pressure (at 60 °C, 140 °F) Above 100 kPa (1.0 kgf/cm², 14 psi)

CLUTCH

Clutch cable play 10 – 15

Clutch release screw 1/4 turns back — Drive plate thickness

Drive p late claw wi dth

Driven plate distortion

Clutch spring free length 53.1

ITEM STANDARD LIMIT

1st

2nd

(0.7875 – 0.7877)

(0.7871 – 0.7874)

(0.7878 – 0.7881)

(0.0067 – 0.0126)

(0.825 – 0.827)

(1.660 – 1.662)

(0.0013 – 0.0022)

(1.4951 – 1.4960)

(0.0001 – 0.0011)

(1.6529 – 1.6535)

Below 400 kPa (4.0 kgf/cm², 57 psi)

at 3 000 r/min

(0.4 – 0.6)

No. 1 & No. 2

DL650 E-02 , 03, 19 , 24, 28, 33 DL650UE E-19

1.17 – 1.19

(0.0461 – 0.0469)

0.97 – 0.99

(0.0382 – 0.0390)

—

2.92 – 3.08

(0.115 – 0.121)

13.7 – 13.8

(0.539 – 0.543)

—

(2.09)

—

20.030

(0.7886)

19.98

(0.7866)

20.040

(0.7890)

0.5

(0.02)

—

0.080

(0.0031)

—

0.080

(0.0031)

—

0.05

(0.002)

—

Unit: mm (in)

—

2.62

(0.103)

12.9

(0.507)

0.10

(0.004)

50.5

(1.99)

2/9

TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio

Primary reduction ratio 2.088 (71/34) — Final reduction ratio 3.133 (47/15) — Gear ratios Low 2.461 (32/13) —

Shift fork to groove clearance 0.1 – 0.3

Shift fork groove width 5.5 – 5.6

Shift fork thickness 5.3 – 5.4

Drive chain Type D.I.D.525V8 —

Drive chain slack (on side-stand) 20 – 30

Gears hift leve r height 25

THERMOSTAT + RADIATOR + FAN + COOLANT

Thermostat valve opening temperature

Thermostat valve lift Over 8.0 mm (0.31 in) at 100 °C (212 °F) — ECT se nsor re sistance 20 °C

Radiator cap valve opening pressure

Cooling fan thermo-switch operating temperature

Engine coolant type Use an antifreeze/coolant compatible with alumi-

Engine coolant in cluding re serve Reser ve

ITEM STANDARD LIMIT

2nd 1.777 (32/18) — 3rd 1.380 (29/21) —

4th 1.125 (27/24) — 5th 0.961 (25/26) —

Top 0.851 (23/27) —

(0.004 – 0.012)

(0.217 – 0.220)

(0.209 – 0.213)

Links 116 links —

20-pitch

length

(0.79 – 1.18)

ITEM STANDARD N OTE

OFF→ON Approx. 98 °C (208 °F) — ON→OFF Approx. 92 °C (198 °F) —

num radiator, mixed with distilled water only, at the ratio of 50:50.

Approx. 88 °C (190 °F) —

(68 °F)

40 °C

(104 °F)

60 °C

(140 °F)

80 °C

(176 °F)

tank side

Engine

side

95 – 125 kPa

(0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi)

(0.53/0.44 US/lmp qt)

(3.49/2.90 US/lmp qt)

DL650 E-02 , 03, 19 , 24, 28, 33 DL650UE E-19

(0.020)

—

(0.98)

Approx. 2.45 kΩ —

Approx. 1.148 kΩ —

Approx. 0.587 kΩ —

Approx. 0.322 kΩ —

Approx. 250 ml

Approx. 1650 ml

319.4

(12.57)

0.50

—

3/9

DL650 E-02 , 03, 19 , 24, 28, 33 DL650UE E-19

4/9

DL650 E-02 , 03, 19 , 24, 28, 33 DL650UE E-19

INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR

Injector resistance 11 – 13 Ω at 20 °C (68 °F) Fuel pump discharge amount Min. 168 ml (5.7/5.9 US/lmp oz)

Fuel pressure regulator operating set pressure

FI SENSORS+ SECONDARY THROTTLE VALVE ACTUATOR

CKP se nsor re sist ance 130 – 2 40 Ω W – G CKP sensor peak voltage 3.7 V (When cranking) and more IAP sensor input voltage 4.5 – 5.5 V IAP sensor output voltage

TP sensor input voltage 4.5 – 5.5 V TP sensor resistance Closed Approx. 1.12 kΩ

TP sensor output voltage Closed Approx. 1.12 V

ECT se nsor in put voltage 4.5 – 5.5 V ECT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F) IAT sensor input voltage 4.5 – 5.5 V IAT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F) TO sensor resistance 19.1 – 19.7 kΩ TO sensor voltage Normal 0.4 – 1.4 V

GP switch voltage 1.0 V and more (From 1st to Top) Injector voltage Battery voltage STP sensor input voltage 4.5 – 5.5 V STP sensor resistance Closed Approx. 0.58 kΩ

STP sensor output voltage Closed Approx. 0.58 V

STV actuator resistance 7 – 14 Ω PAIR solenoid valve resistance 20 – 24 kΩ at 20 °C (68 °F)

THROTTLE BODY

I.D. No. 2 7 G0 (Ot hers) , 27 G1 (For E- 33) Bore size 39 mm Fast idle r/min 1 800 – 2 400 r/min at 25 °C (77 °F) Idle r/min 1 300 ± 100 r/min/Warmed engine Throttle cable play 2.0 – 4.0 mm

ITEM SPECIFICATION N OTE

for 10 sec. at 300 kPa (30 kgf/cm², 43 psi)

Approx. 300 kPa (3.0 kgf/cm², 43 psi)

ITEM SPECIFICATION N OTE

Approx. 2.7 V at idle speed

Opened Approx. 4.26 kΩ

Opened Approx. 4.26 V

Leaning

65°

Opened Approx. 4.38 kΩ

Opened Approx. 4.40 V

ITEM SPECIFICATION

3.7 – 4.4 V

(0.08 – 0.16 in)

 G/B –

 B/Br

 P/W –

 B/Br

 Br/W –

 B/Br

Y – B

 Y –

 B/Br

ELECTRICAL Unit: mm (in)

Firing order 1.2 Spark plug

Spark performance Over 8 mm (0.3 in) at 1 atm. CKP sensor resistance 130 – 240 Ω W – G Ignition coil resistance Primary 2 – 5 Ω

CKP sensor peak voltage 3.7 V and more When cranking Ignition coil primary peak voltage 150 V and more Generator coil resistance 0.2 – 0.7 Ω Generator Max. output Approx. 375 W at 5 000 r/min Gener ator no -load voltage

(When cold) Regulated voltage 14.0 – 15.5 V at 5 000 r/min Starter relay resistance 3 – 6 Ω Batte ry Ty pe des igna-

Fuse size

WATTAGE Unit: W

Headli ght 12 V 60/55 W × 2 (H4) ← Position/Parking light 12 V 5 W × 2 Brake light/Taillight 12 V 21/5 W × 2 ← Turn signal light 12 V 21 W ← License light 12 V 5 W ← Speedometer light LED ← Turn signal indicator light LED ← High beam indicator light LED ← Neutral indicator light LED ← Oil pressure/Coolant temp./Fuel

injection warning

ITEM SPECIFICATION N OTE

Type

Gap

Secondary 24 – 37 kΩ

60 V (AC) and more at 5 000 r/min

tion

Capacity 12 V 36.0 kC (10 Ah)/10 HR

HI 15 A

Headlight

LO 15 A

Fuel 10 A

Ignition 10 A

Fan motor 15 A

Signal 15 A

Main 30 A

ITEM SPECIFICATION

E-03, 24, 28, 33 Others

NGK: CR8E

DENSO: U24ESR-N

0.7 – 0 .8 mm

(0.028 – 0.031 in)

YTX12-BS

LED ←

 tap –  tap

 tap – Plug

cap

5/9

BRAKE + WHEEL Unit: mm (in)

Rear brake pedal height 15 – 25

Brake disc thickness

Brake disc runout

Master cylinder bore

Master cylinder piston diam.

Brake caliper cylinder bore

Brake caliper piston diam.

Brake fluid type DOT 4 Wheel rim runout

Wheel rim size Front 19 M/C × MT2.50 —

Wheel axle runout

ITEM STANDARD LIMIT

(0.59 – 0.98)

Front

Rear

Front

Rear

Front

Rear

Front

Rear

Front

Rear

Axial —

Radial —

Rear 17 M/C × MT4.00 —

Front —

Rear —

DL650 E-02 , 03, 19 , 24, 28, 33 DL650UE E-19

(0.20)

—

15.870 – 15.913

(0.6248 – 0.6265)

14.000 – 14.043

(0.5512 – 0.5529)

15.827 – 15.854

(0.6231 – 0.6242)

13.957 – 13.984

(0.5495 – 0.5506)

30.230 – 30.306

(1.1902 – 1.1931)

38.180 – 38.256

(1.5031 – 1.5061)

30.150 – 30.200

(1.1870 – 1.1890)

38.098 – 38.148

(1.4999 – 1.5019)

—

4.5

(0.18)

4.5

(0.18)

0.3

(0.012)

—

2.0

(0.08)

2.0

(0.08)

0.25

(0.010)

0.25

(0.010)

6/9

TIRE

Cold inflation tire pressure (Solo riding)

Cold inflation tire pressure (Dual riding)

Tire size Front 110/80 R19 M/C (59 H) —

Tire type Front BRIDGESTONE: TW101 F —

Tire tread depth

SUSPENSION

Front fork stroke 150

Front fork spring free length 444.1 (17.5) 435 (17.1) Front fork oil level (without spring,

outer tube fully compressed) Front fork spring adjuster 3 groove from Top/

Front fork oil type SUZUKI FORK OIL SS-08 or

Front fork oil capacity (each leg) 524 ml

Rear shock absorber spring adjus ter

Rear shock absorber damping force adjuster

Rear wheel travel 150 mm

Swingarm pivot shaft runout

ITEM STD/SPEC. LIMIT

Front

Rear

Front

Rear

Rear 150/70 R17 M/C (69 H) —

Rear BR IDGESTONE: TW152 F —

Front —

Rear —

Spring adjuster height 9 mm (0.35 in)

Rebound

(2.25 kgf/cm², 33 psi)

(2.50 kgf/cm², 36 psi)

(2.25 kgf/cm², 33 psi)

(2.80 kgf/cm², 41 psi)

143 (5.63) —

equivalent fork oil

(17.7/18.5 US/Imp oz)

2 groo ve from bot tom —

1 turn back from stiffest position E-02, 19, 24

1 and 1 /2 tur ns bac k from

(5.9 in)

DL650 E-02 , 03, 19 , 24, 28, 33 DL650UE E-19

225 kPa

250 kPa

225 kPa

280 kPa

(5.9)

stiffest position

—

1.6

(0.06)

2.0

(0.08)

Unit: mm (in)

—

E-03, 28, 33

—

0.3

(0.01)

7/9

DL650 E-02 , 03, 19 , 24, 28, 33 DL650UE E-19

8/9

DL650 E-02 , 03, 19 , 24, 28, 33 DL650UE E-19

FUEL + OIL

Fuel type Use only unleaded gasoline of at least 87 pump

Fuel tank capacity 22 L (5.8/4.8 US/lmp gal) Engine oil type SAE 10W-40, API SF or SG Engine oil capac ity

ITEM STD/SPEC. NOTE

octane (R/2 + M/2) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible. Gasoline used should be graded 91 octane or higher. An unleaded gasoline is recommended.

Change

Filter change

Overhaul

2 300 ml

(2.4/2.0 US/lmp qt)

2 700 ml

(2.9/2.4 US/lmp qt)

3 100 ml

(3.3/2.7 US/lmp qt)

E-03, 28, 33

Others

9/9

DL650 E-02 , 03, 19 , 24, 28, 33 DL650UE E-19

DL1000

VALVE + GUIDE Unit: mm (in)

Valve diam.

Tappet clearance (when cold)

Valve gui de to val ve stem clea rance

Valve guide I.D.

Valve stem O.D.

Valve stem deflection

Valve stem runout

Valve head thickness

Valve seat width

Valve head radial runout

Valve spring free length

Valve spring tension

ITEM STANDARD LIMIT

IN.

EX.

IN.

EX.

IN.

EX.

IN. & EX.

IN.

EX.

IN. & EX. —

IN. & EX.

IN. & EX. —

IN. & EX.

(20.1 – 23.1 kgf, 44.3 – 51.0 lbs)

(1.42)

(1.30)

0.10 – 0.20

(0.004 – 0.008)

0.20 – 0.30

(0.008 – 0.012)

0.010 – 0.037

(0.0004 – 0.0015)

0.030 – 0.057

(0.0012 – 0.0022)

5.500 – 5.512

(0.2165 – 0.2170)

5.475 – 5.490

(0.2156 – 0.2161)

5.455 – 5.470

(0.2148 – 0.2154)

0.9 – 1.1

(0.035 – 0.043)

197 – 227 N

at length 35.6 mm (1.40 in)

—

0.35

(0.014)

0.05

(0.002)

0.5

(0.02)

—

0.03

(0.001)

39.6

(1.56)

—

CAMSHAFT + C YLINDER HEAD Unit: mm (in)

Cam height

Camshaft journal oil clearance

Camsh aft jo urnal holder I.D.

Camsh aft jo urnal O.D.

Camshaft runout

Cam drive idle gear/sprocket thrust clear ance

Cylinder head distortion

CYLIN DER + PI STON + PISTO N RING Unit: mm (in)

Compr ession pres sure (Automatic de-comp. actuated)

Compr ession pres sure diffe rence

Piston to cylinder clearance 0.015 – 0.025

Cylinder bore 98.000 – 98.015

Piston diam. 97.980 – 97.995

Cylinder distortion

Piston ring free end gap

Piston ring end ga p

Piston ring to gr oove cle arance

ITEM STANDARD LIMIT

IN.

EX.

IN. & EX.

IN. & EX. —

ITEM STANDARD LIMIT

(10 – 14 kgf/cm², 142 – 199 psi)

Measure at 10 mm (0.4 in) from the skirt end.

1st Approx. 8.8 (0.35)

2nd Approx. 10.1 (0.40)

1st

2nd RN

1st —

2nd —

36.28 – 36.32

(1.428 – 1.430)

35.68 – 35.72

(1.405 – 1.406)

0.019 – 0.053

(0.0007 – 0.0021)

22.012 – 22.025

(0.8666 – 0.8671)

21.972 – 21.993

(0.8650 – 0.8659)

0.15 – 0.29

(0.006 – 0.011)

—

1 000 – 1 400 kPa

—

(0.0006 – 0.0010)

(3.8583 – 3.8589)

(3.8575 – 3.8581)

—

0.15 – 0.35

(0.006 – 0.014)

0.30 – 0.45

(0.012 – 0.018)

35.98

(1.417)

35.38

(1.393)

0.150

(0.0059)

—

0.10

(0.004)

—

0.05

(0.002)

800 kPa

(8 kgf/cm², 114 psi)

200 kPa

(2 kgf/cm², 28 psi)

0.12

(0.0047)

Nicks or

Scratches

97.880

(3.8535)

0.05

(0.002)

7.0

(0.28)

8.1

(0.32)

0.5

(0.02)

0.7

(0.03)

0.18

(0.0071)

0.15

(0.0059)

1/10 E-02, 03, 19, 24, 28, 33

2/10 E-02, 03, 19, 24, 28, 33

Piston ring groove width

Piston ring thick ness

Piston pin bore I.D. 22.002 – 22.008

Piston pinO.D. 21.992 – 22.000

ITEM STANDARD LIMIT

1st

2nd

Oil

1st

2nd

0.93 – 0.95

(0.0366 – 0.0374)

1.55 – 1.57

(0.0610 – 0.0618)

1.01 – 1.03

(0.0398 – 0.0406)

2.51 – 2.53

(0.0988 – 0.0996)

0.86 – 0.91

(0.034 – 0.036)

1.38 – 1.40

(0.054 – 0.055)

0.97 – 0.99

(0.038 – 0.039)

(0.8662 – 0.8665)

(0.8658 – 0.8661)

—

22.0 30

(0.8673)

21.9 80

(0.8654)

CONROD + CRANKSHAFT Unit: mm (in)

Conrod small end I.D. 22.010 – 22.018

Conrod big end side clearance 0.17 – 0.32

Conrod big end width 21.95 – 22.00

Crank pin width 44.17 – 44.22

Conrod big end oil clearance 0.040 – 0.064

Crank pin O.D. 44.976 – 45.000

Crankshaft journal oil clearance 0.002 – 0.029

Crankshaft journal O.D. 47.985 – 48.000

Crankshaft journa

Crankshaft runout

ITEM STANDARD LIMIT

(0.8665 – 0.8668)

(0.007 – 0.013)

(0.864 – 0.866)

(1.739 – 1.741)

(0.0016 – 0.0025)

(1.7707 – 1.7717)

(0.0008 – 0.0011)

l holder width 25.2 – 25.4

l width 25.50 – 25.55

(1.8892 – 1.8898)

(0.99 – 1.00)

(1.004 – 1.006)

—

22.0 40

(0.8677)

0.50

(0.020)

—

0.080

(0.0031)

—

0.080

(0.0031)

—

0.05

(0.004)

OIL PUMP

Oil pressure (at 60 °C, 140 °F) Above 400 kPa

ITEM STANDARD LIMIT

Below 700 kPa (7.0 kgf/cm², 100

CLUTCH

Drive plate thickness

Drive plate claw width

Driven plate distortion

Clutch spring free length 61.5 – 62.5

Clutch master cylinder bore 14.000 – 14.043

Clutch master cylinder piston diam. 13.957 – 13.984

Clutch release cylinder bore 35.700 – 35.762

Clutch release cylinder piston diam.

ITEM STANDARD LIMIT

No. 1 and 3

No. 2

No. 1 and 3

No. 2

(4.0 kgf/cm², 57 psi)

at 3 000 r/min

2.92 – 3.08

(0.115 – 0.121)

3.72 – 3.88

(0.146 – 0.153)

13.85 – 13.96

(0.545 – 0.550)

13.90 – 14.00

(0.547 – 0.551)

—

(2.42 – 2.46)

(0.5512 – 0.5528)

(0.5495 – 0.5505)

(1.4055 – 1.4079)

35.650 – 35.675

(1.4035 – 1.4045)

psi)

Unit: mm (in)

THERMOSTAT + RADIATOR + FAN

Thermostat valve opening temperature

Thermostat valve lift Over 8 mm (0.31 in) at 100 °C (212 °F) — Radiator cap valve opening pres-

sure Cooling fan ther-

moswitch operating

Engine coolant temperatu re sens or resi stance

ITEM STANDARD LIMIT

ON→OFF Approx. 105 °C (221 °F) — ON→OFF Approx. 100 °C (212 °F) —

20 °C

(68 °F)

40 °C

(104 °F)

60 °C

(140 °F)

80 °C

(176 °F)

86.5 – 89.5 °C (188 – 1 93 °F)

110 kPa

(1.1 kgf/cm², 15.6 psi)

Approx. 2.45 kΩ —

Approx. 1.148 kΩ —

Approx. 0.587 kΩ —

Approx. 0.322 kΩ —

—

2.62

(0.103)

3.42

(0.135)

13.05

(0.514)

13.10

(0.516)

0.10

(0.004)

59.4

(2.34)

—

3/10 E-02, 03, 19, 24, 28, 33

DRIVE TRAIN Unit: mm (in) Expect ratio

Primary reduction ratio 1.838 (57/31) —

Final reduction r atio

Gear ratio

Shift fork to groove clearance

Shift fork groove width

Shift fork thickness

Drive chain

Drive chain slack

Gearshift lever height 25

ITEM STANDARD LIMIT

Low 3.000 (36/ 12) — 2nd 1.933 (29/15) —

3rd 1.500 (27/18) — 4th 1.227 (27/22) — 5th 1.086 (25/23) —

Top 0.913 (2 1/23) —

20-pitch length —

2.411 (41/17) —

0.1 – 0.3

(0.004 – 0.012)

5.0 – 5.1

(0.197 – 0.201)

4.8 – 4.9

(0.189 – 0.193)

Type RK525SMOZ7 —

Links 112 links, ENDLESS —

20 – 30

(0.8 – 1.2)

(1.0)

(0.020)

319.4

(12.6)

0.50

—

INJECTOR + FUEL PUMP + FUEL PRESSURE REGURATOR

Injec tor re sistan ce 12 – 18 Ω at 20 °C (68 °F) Fuel pump discharge amount Approx. 1.2 L (1.3/1.1 US/lmp qt)

Fuel pressure regulator operating set pressure

ITEM SPECIFICATION NOTE

for 1 minute at 300 kPa (3.0 kgf/cm², 43 psi)

Approx. 300 kPa (3.0 kgf/cm², 43 psi)

4/10 E-02, 03, 19, 24, 28, 33

FI-SENSORS

CMP sensor output voltage More than 3.7 V CKP sensor resistance 130 – 240 Ω CKP sensor peak voltage More than 3.7 V (When cranking) IAP sen sor input voltage 4. 5 – 5.5 V IAP sensor output voltage Approx. 2.5 V at idle speed TP sens or input vol tage 4. 5 – 5.5 V TP sensor resistance Closed Approx. 1.1 kΩ

TP sensor output voltage Closed Approx. 1.1 V

ECT se nsor in put voltage 4.5 – 5.5 V ECT se nsor re isitance Appr ox. 2.4 5 kΩ at 20 °C (68 °F) IAT sensor input volatage 4.5 – 5.5 V IAT sensor resis tance Approx 2.45 kΩ at 20 °C (68 °F) AP sens or input vol tage 4.5 – 5.5 V AP sensor output voltage Approx. 4.0 V at 760 mmHg (100 kPa) TO sensor resistance 19.1 – 19.7 kΩ TO sensor voltage Approx. 0.4 – 1.4 V GP switch voltage More than 1.0 V (From 1st to top) Injector voltage Battery voltage Ignition coil primary peak voltage More than 150 V (When cranking) STP sen sor input voltage 4.5 – 5 .5 V STP sensor resistance Closed Approx. 1.1 kΩ

STP sensor output voltage Closed Approx. 1.1 V

STV actuator resistance 4.8 – 7.2 Ω Heated oxygen sensor output volt-

age

PAIR solenoid valve resistance 20 – 24 Ω at 20 °C (68 °F)

THROTTLE BODY

ID No. 06G3 (For E-02, 19), 06G4 (For E-33), 06G5 (For E-03, 24, 28) Bore size 45 mm Fast idle r/min 1 500 – 2 100 r/min at 25 °C (77 °F) Idle r/min 1 200 ± 100 r/min/Warmed engine Throt tle ca ble play 2.0 – 4.0 r/m in

ITEM SPECIFICATION NOTE

Opened Approx. 4.3 kΩ

Opened Approx. 4.3 V

Opened Approx. 4.3 kΩ

Opened Approx. 4.3 V

Less t han 0.4 V at idle sp eed

(After warming up)

ITEM SPECIFICATION

(0.08 – 0.16 in)

European

marketsHeated oxygen sensor resistance 4 – 5 Ω at 23 °C (73.4 °F)

5/10 E-02, 03, 19, 24, 28, 33

6/10 E-02, 03, 19, 24, 28, 33

ELECTRICAL Unit: mm (in)

Ignition timing 4° B.T.D.C. at 1 200 r/min Firing order 1·2 Spark plug

Spark performance Over 8 (0.3) at 1 atm. Crankshaft position sensor resis-

tance Ignition coil resistance Primary 2 – 5 Ω

Crankshaft position sensor peak voltage

Ignition coil primary peak voltage More than 150 V When cranking Generator coil resistance 0.2 – 0.5 Ω Y – Y Generator Max. output Approx. 400 W at 5 000 r/min Gener ator no -load voltage

(When engine is cold) Regulated voltage 14.0 – 15.5 V at 5 000 r/min Start er relay re sistance 3 – 6 Ω Battery Type

Fuse size

ITEM SPECIFICATION NOTE

Type

Gap

Secondary 24 – 37 kΩ  tap – Plug cap

More than 75 V (AC) at 5 000 r/min

designation

Capacity 12 V 43.2 kC (12 Ah)/10 HR

Headlight

HI 15 A

LO 15 A

Turn signal 15 A

Ignition 10 A

Fan motor 15 A

Meter 10 A

Main 30 A

NGK: CR8EK

Denso: U24ETR

0.6 – 0.7

(0.024 – 0.028)

130 – 240 Ω Bl – G

More than 3.7 V When cranking

FTX14-BS

 tap –  tap

WATTAGE Unit: W

ITEM

Headlight Position/Parking light Brake light/Taillight Turn signal light 12 V 2 1 W ← License light Speedometer light LED ← Turn signal indicator light High beam indicator light Neutral indicator light Oil pressure/Coolant temp./Fuel

injection warning

BRAKE + WHEEL Unit: mm (in)

Rear brake pedal height 20 – 30

Brake disc thickness

Brake disc runout (Front & Rear)

Master cylinder bore

Master cylinder piston diam.

Brake caliper cylinder bore

Brake caliper piston diam.

Wheel rim runout (Front & Rear)

ITEM STANDARD LIMIT

E-03, 24, 28, 33 Others

12 V 60/55 W × 2 (H4) ←

12 V 21/5 W × 2 ←

Front

Rear

Front

Rear

Front

Rear

Front

Rear

Front

Rear

Axial —

Radial —

SPECIFICATION

12 V 5 W × 2

12 V 5 W ←

LED ←

(0.8 – 1.2)

5.0 ± 0. 2

(0.197 ± 0.008)

5.0 ± 0. 2

(0.197 ± 0.008)

—

15.870 – 15.913

(0.6248 – 0.6265)

14.000 – 14.043

(0.5512 – 0.5529)

15.827 – 15.854

(0.6231 – 0.6242)

13.957 – 13.984

(0.5495 – 0.5506)

30.230 – 30.306

(1.1902 – 1.1931)

38.180 – 38.230

(1.5031 – 1.5051)

30.150 – 30.200

(1.1870 – 1.1890)

38.098 – 38.148

(1.4999 – 1.5019)

—

4.5

(0.18)

4.5

(0.18)

0.30

(0.012)

—

2.0

(0.08)

2.0

(0.08)

7/10 E-02, 03, 19, 24, 28, 33

Wheel axle runout

Wheel rim size Front 19M/C × MT 2.50 —

Tire si ze Fron t 1 10/80R 19M/C 59H —

Tire type Front BRIDGESTONE: TW101 F —

Tire tread depth

SUSPENSION Unit: mm (in)

Front fork stroke 160

Front fork spring free length 433.6

Front fork oil l evel (without s pring, inner tube fully compressed)

Front fork oil type SUZUKI FORK OIL SS-08 or an equivalent fork oil Front fork oil capacity (each leg) 496.0 ml

Front fork spring adjuster 3rd groove from top — Rear shock absorber spring

adjus ter Rear shock absorber damping

force adjuster

Rear wheel travel

Swingarm pivot shaft runput

TIRE PRESSURE

ITEM STANDARD LIMIT

COLD INFLATION

TIRE PRESSURE

FRONT 250 2.50 36 250 2.50 36

REAR 250 2.50 36 280 2.80 41

Front —

Rear —

Rear 17M/C × MT 4.00 —

Rear 150/70R17M/C 69H —

Rear BRIDGESTONE: TW152 F —

Front —

Rear —

(6.3)

(17.07)

140.0 (5.51)

(16.76/17.46 US/lmp oz)

2nd groove from bottom —

Rebound 7/8 turn out from stiffest position —

SOLO RIDING DUAL RIDI NG

kPa

159

(6.3)

—

kgf/cm² psi

kPa

kgf/cm² psi

0.25

(0.010)

0.25

(0.010)

1.6

(0.06)

2.0

(0.08)

—

424

(16.7)

—

0.3

(0.01)

8/10 E-02, 03, 19, 24, 28, 33

FUEL + OIL + ENGINE COOLANT

Fuel type Use only unleaded gasoline of at least 87 pump

Fuel ta nk 17 L

Engine oil type SAE 10W-40, API SF or SG Engine oil capac ity

Brake fluid type DOT 4 Engine coolant type Use an anti-freeze/coolant compatible with alumi-

Engien coolant Reserve

ITEM SPECIFICATION NOTE

(4.5/3.7 US/lmp gal)

Change

Filter change

Overhaul

num radiator, mixed with distilled water only, at the ratio o f 50:50.

tank side

Engine side

2 700 ml

(2.9/2.4 US/lmp qt)

2 900 ml

(3.1/2.6 US/lmp qt)

3 300 ml

(3.5/2.9 US/lmp qt)

Approx. 250 ml

(0.3/0.2 US/lmp qt)

Approx. 1 950 ml

(2.1/1.7 US/lmp qt)

E-03, 28, 33

The others

9/10 E-02, 03, 19, 24, 28, 33

10/10 E-02, 03, 19, 24, 28, 33

DR200SE (E-03, 28, 33)

VALVE + GUIDE Unit: mm (in)

Valve diam.

Valve clearance (when cold)

Valve gui de to val ve stem clear ance

Valve stem deflection

Valve guide I.D.

Valve stem O.D.

Valve stem runout

Valve head thickness

Valve stem end length

Valve seat width

Valve head radial runout

Valve spring free length (IN. & EX.)

Valve spring tension (IN. & EX.) INNER

ITEM STANDARD LIMIT

IN.

EX.

IN. & EX.

IN.

EX.

IN. & EX. —

IN. & EX.

IN.

EX.

IN. & EX. —

IN. & EX.

IN. & EX. —

INNER —

OUTER —

(7.1 – 9.2 kgf, 15.7 – 20.3 lbs)

OUTER

(17.3 – 21.3 kgf, 38.1 – 47.0 lbs)

(1.3)

(1.1)

0.08 – 0.13

(0.003 – 0.005)

0.010 – 0.037

(0.0004 – 0.0015)

0.030 – 0.057

(0.0012 – 0.0022)

5.500 – 5.512

(0.2165 – 0.2170)

5.475 – 5.490

(0.2146 – 0.2161)

5.455 – 5.470

(0.2148 – 0.2154)

0.9 – 1.1

(0.04 – 0.05)

70 – 90 N

at len gth 32. 5 mm ( 1.28 in )

170 – 209 N

at len gth 36. 0 mm ( 1.42 in )

—

0.35

(0.014)

—

0.05

(0.002)

0.5

(0.02)

2.6

(0.1)

—

0.03

(0.001)

35.1

(1.38)

40.6

(1.60)

—

CAMSHAFT + C YLINDER HEAD Unit: mm (in)

Cam height

Camshaft journal oil clearance

Camsh aft jo urnal holder I.D.

Camsh aft jo urnal O.D.

Camshaft runout

Rocker arm I.D.

Rocker ar m shaft O.D.

Cylinder head distortion

Cylinder head cover distortion

CYLIN DER + PI STON + PISTO N RING Unit: mm (in)

Compr ession pres sure

Piston to cylinder clearance 0.040 – 0.050

Cylinder bore 66.000 – 66.015

Piston diam. 65.955 – 65.970

Cylinder distortion

Piston ring free end gap

Piston ring end ga p

Piston ring to gr oove cle arance

ITEM STANDARD LIMIT

IN.

EX.

IN. & EX.

IN. & EX. —

IN. & EX.

ITEM STANDARD LIMIT

Measure at 15 mm (0.59 in) from the skirt end.

1st R Approx. 7.5 (0.30)

2nd R Approx. 9.4 (0.37)

1st

2nd

1st —

2nd —

34.174 – 34.218

(1.3454 – 1.3472)

33.804 – 33.848

(1.3309 – 1.3326)

0.032 – 0.066

(0.0013 – 0.0026)

22.012 – 22.025

(0.8666 – 0.8671)

21.959 – 21.980

(0.8645 – 0.8654)

12.000 – 12.018

(0.4724 – 0.4731)

11.977 – 11.995

(0.4715 – 0.4722)

—

1 400 kPa

, 199 psi)

(14 kgf/cm

(0.0016 – 0.0020)

(2.5984 – 2.5990)

(2.5966 – 2.5972)

—

0.10 – 0.25

(0.004 – 0.010)

0.10 – 0.25

(0.004 – 0.010)

33.870

(1.3335)

33.500

(1.3189)

0.150

(0.0059)

—

0.10

(0.004)

—

0.05

(0.002)

0.05

(0.002)

980 kPa

(9.8 kgf /cm

139 psi)

0.120

(0.0047)

66.090

(2.6020)

65.880

(2.5937)

0.05

(0.002)

6.0

(0.24)

7.5

(0.30)

0.5

(0.02)

0.5

(0.02)

0.18

(0.007)

0.15

(0.006)

1/7 E-03, 28, 33

Piston ring groove width

Piston ring thick ness

Piston pin bore 16.002 – 16.008

Piston pin O.D. 15.996 – 16.000

ITEM STANDARD LIMIT

1st

2nd

Oil

1st

2nd

1.01 – 1.03

(0.040 – 0.041)

1.21 – 1.23

(0.047 – 0.048)

2.01 – 2.03

(0.079 – 0.080)

0.970 – 0.990

(0.038 – 0.039)

1.170 – 1.190

(0.046 – 0.047)

(0.6300 – 0.6302)

(0.6298 – 0.6299)

—

16.030

(0.6311)

15.980

(0.6291)

CONROD + CRANKSHAFT Unit: mm (in)

Conrod small end I.D. 16.006 – 16.014

Conrod deflection

Conrod big end side clearance 0.10 – 0.45

Conrod big end width 17.95 – 18.00

Crank web to web width 53.0 ± 0.1

Crankshaft runout

ITEM STANDARD LIMIT

(0.6302 – 0.6305)

—

(0.004 – 0.018)

(0.707 – 0.709)

(2.09 ± 0.004)

—

16.040

(0.6315)

3.0

(0.12)

1.00

(0.039)

—

0.08

(0.003)

OIL PUMP

Oil pump reduction ratio 2.000 (30/15) — Oil pressure (at 60 °C, 140 °F) Above 15 kPa (0.15 kgf/cm

CLUTCH

Clutch lever play 10 – 15

Clutch release screw 1/4

Clutch plate thickness

Driven plate distortion

Clutch spring free length

ITEM STANDARD LIMIT

, 2.1 psi)

Below 35 kPa (0.35 kgf/cm

at 3 000 r/min

ITEM STANDARD LIMIT

(0.4 – 0 .6)

1 pc.

5 pcs.

2.9 – 3 .1

(0.114 – 0.122)

2.95 – 3.15

(0.116 – 0.124)

, 4.9 ps i)

turn back —

—

Unit: mm (in)

—

2.6

(0.10)

0.10

(0.004)

31.0

(1.22)

2/7 E-03, 28, 33

TRANSMISSTION + DRIVE CHAIN Unit: mm (in) Except ratio

Primary reduction ratio 3.157 (60/19) — Final reduction ratio 3.000 (45/15) — Gear ratios Low 3.000 (33/11) —

Shift fork to groove clearance 0.10 – 0.30

Shift fork gro ove widt h

Shift fork thickness

Drive chain Type D.I.D. 520VC5 —

Drive c hain slack 2 5 – 40

CARBURETOR

Carburetor type MIKUNI BST31SS ← Bore size 31 mm ← I.D. No. 42AC 42AE Idle r/min 1 500 ± 100 r/min ← Float height 13.0 ± 1.0 mm (0.51 ± 0.04 in) ← Main jet (M.J. ) # ← Jet needle (J.N.) 5D77 ← Needle jet (N.J.) ← Throttle valve (Th.V.) #125 ← Pilot jet (P.J.) # ← Starter jet (G .S.) #25 ← Pilot screw (P.S.) PRE-SET ← Throt tle ca ble play 2 – 4 mm ( 0.08 – 0.16 in) ←

ITEM STANDARD LIMIT

2nd 1.933 (29/15) —

3rd 1.437 (23/16) — 4th 1.095 (23/21) —

Top 0.913 (21/23) —

(0.004 – 0.012)

5.0 – 5 .1

(0.20 – 0.21)

4.8 – 4 .9

(0.18 – 0.19)

(1.0 – 1.6)

SPECIFICATION

—

ITEM

No.1, 2, 3

Links 112 links —

20-pit ch

length

E-03, 28 E-33

—

319.4

(12.57)

—

3/7 E-03, 28, 33

4/7 E-03, 28, 33

ELECTRICAL Unit: mm (in)

Spark plug

Spark performance Over 8 mm (0.3) at 1 atm. Signal coil resitance 100 – 140 Ω G – Bl Ignition coil resistance

Generator coil resistance Charging 0.1 – 1.5 Ω Generator no-load voltage More than 60 V (AC) at 5 000 r/min Generator Max. output 150 W at 5 000 r/min Regulated voltage 13.0 – 16.0 V at 5 000 r/min Starter relay resistance 2 – 6 Ω Battery Type designation YTX7L-BS

Fuse size 20 A

WATTAGE Unit: W

Headlight

Brake light/Taillight 21/5 Turn signal light 21 Speedometer light 3.4 Turn signal indicator light 3.4 High beam indicator light 1.7 Neutral indicator light 3.4

ITEM SPECIFICATION N OTE

Capacity 12 V 21.6 kC (6 Ah)/10 HR

ITEM SPECIFICATION

Type

Gap

Primary 2 – 6 Ω

Secondary 20 – 30 kΩ

DENSO: X24ESR-U

NGK: CR8EA

0.6 – 0.7

(0.024 – 0.028)

60 55

Terminal –

Terminal

Plug cap –

Terminal

BRAKE + WHEEL Unit: mm (in)

Brake leve r play 0.1 – 0. 3

Rear brake pedal free travel 20 – 30

Rear brake pedal height 2.5

Brake drum I.D.

Brake lining thickness

Brake disc thickness

Brake disc runout

Master cylinder bore

Master cylinder piston diam.

Brake caliper cylinder bore

Brake caliper piston diam.

Wheel rim runout

Wheel axle runout

Wheel rim size Front J21 × 1.60 —

Tire size Front 70/100-21 M/C 44P —

Tire tread depth

ITEM STANDARD LIMIT

(0.004 – 0.010)

(0.8 – 1 .2)

Rear —

Front

Front —

Front

Axial —

Radial —

Front —

Rear —

Rear J18 × 2.15 —

Rear 100/90-18 M/C 56P —

Front —

Rear —

(0.10)

3.5 ± 0.2

(0.138 ± 0.008)

12.700 – 12.743

(0.5000 – 0.5017)

12.657 – 12.684

(0.4983 – 0.4994)

33.960 – 34.010

(1.3370 – 1.3390)

33.878 – 33.928

(1.3338 – 1.3357)

—

130.7 (5.15)

1.5

(0.06)

3.0

(0.12)

0.30

(0.012)

—

2.0

(0.08)

2.0

(0.08)

0.25

(0.010)

0.25

(0.010)

3.0

(0.12)

3.0

(0.12)

5/7 E-03, 28, 33

SUSPENSION Unit: mm (in)

Front fork stroke 205

Front fork spring free length

Front fork oil level 179.5

Rear shock absorber spring pre-set length

Rear wheel travel 205

Swingarm pivot shaft runout

ITEM STANDAR D LI MIT N OTE

(8.1)

—

(7.07)

231

(9.1)

(8.1)

—

561

(22.1)

—

0.6

(0.02)

TIRE PRESSUER

COLD INFLATION

TIRE PRESSURE

FRONT 150 1.50 22 150 1.50 22

REAR 175 1.75 25 200 2.00 29

SOLO RIDING DUAL RIDI NG

kPa kgf/cm

psi kPa k gf/cm2psi

FUEL + OIL

Fuel type Use only unleaded gasoline of at least 87 pump

Fuel tank capacity including

Engine oil type SAE 10 W-40, API SF or SG Engine oil capac ity

Front fork oil type Fork oil #10 Front fork oil capacity (each leg) 309 ml

Brake fluid type DOT 4

ITEM SPECIFICATION NOTE

reserve

Change

Filter change

Overhaul

13.0 L

(3. 4/2.9 U S/lmp qt)

12.5 L

(3. 3/2.7 U S/lmp qt)

2.5 L

(0. 7/0.5 U S/lmp qt)

850 ml

(0.90/0.75 US/lmp qt)

950 ml

(1.00/0.84 US/lmp qt)

1 100 ml

(1. 2/1.0 U S/lmp qt)

(10.4/10.9 US/lmp oz)

E-03, 28

E-33

6/7 E-03, 28, 33

7/7 E-03, 28, 33

DR200SE (E-06, 24)

VALVE + GUIDE Unit: mm (in)

Valve diam.

Valve clearance (when cold)

Valve gui de to val ve stem clear ance

Valve stem deflection

Valve guide I.D.

Valve stem O.D.

Valve stem runout

Valve head thickness

Valve stem end length

Valve seat width

Valve head radial runout

Valve spring free length (IN. & EX.)

Valve spring tension (IN. & EX.) INNER

ITEM STANDARD LIMIT

IN.

EX.

IN. & EX.

IN.

EX.

IN. & EX. —

IN. & EX.

IN.

EX.

IN. & EX. —

IN. & EX.

IN. & EX. —

INNER —

OUTER —

(7.1 – 9.2 kgf, 15.7 – 20.3 lbs)

OUTER

(17.3 – 21.3 kgf, 38.1 – 47.0 lbs)

(1.3)

(1.1)

0.08 – 0.13

(0.003 – 0.005)

0.010 – 0.037

(0.0004 – 0.0015)

0.030 – 0.057

(0.0012 – 0.0022)

5.500 – 5.512

(0.2165 – 0.2170)

5.475 – 5.490

(0.2146 – 0.2161)

5.455 – 5.470

(0.2148 – 0.2154)

0.9 – 1.1

(0.04 – 0.05)

70 – 90 N

at len gth 32. 5 mm ( 1.28 in )

170 – 209 N

at len gth 36. 0 mm ( 1.42 in )

—

0.35

(0.014)

—

0.05

(0.002)

0.5

(0.02)

2.6

(0.1)

—

0.03

(0.001)

35.1

(1.38)

40.6

(1.60)

—

CAMSHAFT + C YLINDER HEAD Unit: mm (in)

Cam height

Camshaft journal oil clearance

Camsh aft jo urnal holder I.D.

Camsh aft jo urnal O.D.

Camshaft runout

Rocker arm I.D.

Rocker ar m shaft O.D.

Cylinder head distortion

Cylinder head cover distortion

CYLIN DER + PI STON + PISTO N RING Unit: mm (in)

Compr ession pres sure

Piston to cylinder clearance 0.040 – 0.050

Cylinder bore 66.000 – 66.015

Piston diam. 65.955 – 65.970

Cylinder distortion

Piston ring free end gap

Piston ring end ga p

Piston ring to gr oove cle arance

ITEM STANDARD LIMIT

IN.

EX.

IN. & EX.

IN. & EX. —

IN. & EX.

ITEM STANDARD LIMIT

Measure at 15 mm (0.59 in) from the skirt end.

1st R Approx. 7.5 (0.30)

2nd R Approx. 9.4 (0.37)

1st

2nd

1st —

2nd —

34.174 – 34.218

(1.3454 – 1.3472)

33.804 – 33.848

(1.3309 – 1.3326)

0.032 – 0.066

(0.0013 – 0.0026)

22.012 – 22.025

(0.8666 – 0.8671)

21.959 – 21.980

(0.8645 – 0.8654)

12.000 – 12.018

(0.4724 – 0.4731)

11.977 – 11.995

(0.4715 – 0.4722)

—

1 400 kPa

, 199 psi)

(14 kgf/cm

(0.0016 – 0.0020)

(2.5984 – 2.5990)

(2.5966 – 2.5972)

—

0.10 – 0.25

(0.004 – 0.010)

0.10 – 0.25

(0.004 – 0.010)

33.870

(1.3335)

33.500

(1.3189)

0.150

(0.0059)

—

0.10

(0.004)

—

0.05

(0.002)

0.05

(0.002)

980 kPa

(9.8 kgf /cm

139 psi)

0.120

(0.0047)

66.090

(2.6020)

65.880

(2.5937)

0.05

(0.002)

6.0

(0.24)

7.5

(0.30)

0.5

(0.02)

0.5

(0.02)

0.18

(0.007)

0.15

(0.006)

1/7 E-06, 24

Piston ring groove width

Piston ring thick ness

Piston pin bore 16.002 – 16.008

Piston pin O.D. 15.996 – 16.000

ITEM STANDARD LIMIT

1st

2nd

Oil

1st

2nd

1.01 – 1.03

(0.040 – 0.041)

1.21 – 1.23

(0.047 – 0.048)

2.01 – 2.03

(0.079 – 0.080)

0.970 – 0.990

(0.038 – 0.039)

1.170 – 1.190

(0.046 – 0.047)

(0.6300 – 0.6302)

(0.6298 – 0.6299)

—

16.030

(0.6311)

15.980

(0.6291)

CONROD + CRANKSHAFT Unit: mm (in)

Conrod small end I.D. 16.006 – 16.014

Conrod deflection

Conrod big end side clearance 0.10 – 0.45

Conrod big end width 17.95 – 18.00

Crank web to web width 53.0 ± 0.1

Crankshaft runout

ITEM STANDARD LIMIT

(0.6302 – 0.6305)

—

(0.004 – 0.018)

(0.707 – 0.709)

(2.09 ± 0.004)

—

16.040

(0.6315)

3.0

(0.12)

1.00

(0.039)

—

0.08

(0.003)

OIL PUMP

Oil pump reduction ratio 2.000 (30/15) — Oil pressure (at 60 °C, 140 °F) Above 15 kPa (0.15 kgf/cm

CLUTCH

Clutch lever play 10 – 15

Clutch release screw 1/4 turn back —

Clutch plate thickness

Driven plate distortion

Clutch spring free length

ITEM STANDARD LIMIT

, 2.1 psi)

Below 35 kPa (0.35 kgf/cm

at 3 000 r/min

ITEM STANDARD LIMIT

(0.4 – 0 .6)

1 pc.

5 pcs.

2.9 – 3 .1

(0.114 – 0.122)

2.95 – 3.15

(0.116 – 0.124)

, 4.9 ps i)

—

Unit: mm (in)

—

2.6

(0.10)

0.10

(0.004)

31.0

(1.22)

2/7 E-06, 24

TRANSMISSTION + DRIVE CHAIN Unit: mm (in) Except ratio

Primary reduction ratio 3.157 (60/19) — Final reduction ratio 3.916 (47/12) — Gear ratios Low 3.000 (33/11) —

Shift fork to groove clearance 0.10 – 0.30

Shift fork gro ove widt h

Shift fork thickness

Drive chain Type D.I.D. 520VC5 —

Drive c hain slack 2 5 – 40

CARBURETOR

Carbur etor ty pe M IKUNI B ST31SS Bore size 31 mm I.D. No. 42AA Idle r/min 1 500 ± 100 r/min Float height 13.0 ± 1.0 mm (0.51 ± 0.04 in) Main jet (M.J. ) #122. 5 Main air jet (M.A.J) 0.8 mm Jet needle (J.N.) 5D26-3rd Needle jet (N.J.) P-5 Throttle valve (Th.V.) #125 Pilot jet (P.J.) #40 Valve seat (V.S.) 1.5 mm Starter jet (G .S.) #25 Pilot screw (P.S.) 1 and 1/2 turns out Throttle cable play 2 – 4 mm (0.08 – 0.16 in)

ITEM STANDARD LIMIT

2nd 1.933 (29/15) —

3rd 1.437 (23/16) — 4th 1.095 (23/21) —

Top 0.913 (21/23) —

(0.004 – 0.012)

No.1, 2, 3

Links 112 links, ENDLESS —

20-pit ch

length

ITEM SPECIFICATION

(0.20 – 0.21)

(0.18 – 0.19)

(1.0 – 1.6)

5.0 – 5 .1

4.8 – 4 .9

—

319.4

(12.57)

—

3/7 E-06, 24

4/7 E-06, 24

ELECTRICAL Unit: mm (in)

Ignition timing 7°B.T.D.C. Below at 1 500 r/min Spark plug

Spark performance Over 8 mm (0.3) at 1 atm. Signal coil resitance 100 – 140 Ω G – Bl Ignition coil resistance

Signal coil peak voltage

Ignition coil primary peak voltage

Generator coil resistance Charging 0.1 – 1.5 Ω — Generator no-load voltage More than 70 V (AC) at 5 000 r/min Regulated voltage 13.0 – 16.0 V at 5 000 r/min Starter relay resistance 2 – 6 Ω Battery Type designation YTX7L-BS

Fuse size 20 A

WATTAGE Unit: W

Headlight

Brake light/Taillight 21/5 Turn signal light

(For South Africa) Speedometer light 1.7 Turn signal indicator light

(Fpr South Afriaca) High beam indicator light 2 Neutral indicator light 2

ITEM SPECIFICATION N OTE

Type

Gap

Primary 0.14 – 0.18 Ω

Secondary 15 – 18 kΩ

Capacity 12 V 21.6 kC (6 Ah)/10 HR Standard

electrolyte S.G.

ITEM SPECIFICATION

DENSO: X24ESR-U

NGK: CR8EA

0.6 – 0.7

(0.024 – 0.028)

3.0 – 4.6 V

125 – 195 V

1.32 at 20 °C (68 °F)

Terminal –

Terminal

Plug cap –

Terminal

 G/W –  Bl/Y

 Whit e –  Ground

60 55

BRAKE + WHEEL Unit: mm (in)

Brake leve r play 0.1 – 0. 3

Rear brake pedal free travel 20 – 30

Rear brake pedal height 2.5

Brake drum I.D.

Brake lining thickness

Brake disc thickness

Brake disc runout

Master cylinder bore

Master cylinder piston diam.

Brake caliper cylinder bore

Brake caliper piston diam.

Wheel rim runout

Wheel axle runout

Tire size Front 70/100-21 44M —

Tire tread depth

SUSPENSION Unit: mm (in)

Front fork stroke 205

Front fork spring free length

Front fork oil level 179.5

Rear shock absorber spring pre-set length

Rear wheel travel 205

Swingarm pivot shaft runout

ITEM STANDARD LIMIT

(0.004 – 0.010)

(0.8 – 1 .2)

(8.1)

—

(7.07)

231

(9.1)

(8.1)

—

(0.10)

3.5 ± 0.2

(0.138 ± 0.008)

12.700 – 12.743

(0.5000 – 0.5017)

12.657 – 12.684

(0.4983 – 0.4994)

33.960 – 34.010

(1.3370 – 1.3390)

33.878 – 33.928

(1.3338 – 1.3357)

561

(22.1)

(0.02)

—

0.6

Rear —

Front

Front —

Front

Axial —

Radial —

Front —

Rear —

Rear 90/100-18 54M —

Front —

Rear —

ITEM STANDAR D LI MIT N OTE

—

130.7 (5.15)

1.5

(0.06)

3.0

(0.12)

0.30

(0.012)

—

2.0

(0.08)

2.0

(0.08)

0.25

(0.010)

0.25

(0.010)

(0.16)

4.0

(0.16)

5/7 E-06, 24

TIRE PRESSUER

E-24

E-06

COLD INFLATION

TIRE PRESSURE

FRONT 100 1.0 15

REAR 100 1.0 15

COLD INFLATION

TIRE PRESSURE

FRONT 100 1.0 15 100 1.0 15

REAR 100 1.0 15 100 1.0 15

SOLO RIDING

kPa kgf/cm

SOLO RIDING DUAL RIDI NG

kPa kgf/cm

psi

psi kPa k gf/cm2psi

FUEL + OIL

Fuel type Gasoline used should be graded 85 – 95 octane or

Fuel tank capacity including

Engine oil type SAE 10 W-40, API SF or SG Engine oil capac ity

Front fork oil type Fork oil #10 Front fork oil capacity (each leg) 309 ml

Brake fluid type DOT 4

ITEM SPECIFICATION NOTE

higher. An unleaded gasoline is recommended.

reserve

Change

Filter change

Overhaul

13.0 L

(3. 4/2.9 U S/lmp qt)

2.5 L

(0. 7/0.5 U S/lmp qt)

950 ml

(1. 0/0.8 U S/lmp qt)

1 050 ml

(1. 1/0.9 U S/lmp qt)

1 200 ml

(1. 3/1.1 U S/lmp qt)

(10.4/10.9 US/lmp oz)

6/7 E-06, 24

7/7 E-06, 24

DR650SE

VALVE + GUIDE Unit: mm (in)

Valve diam.

Valve clearance (when engine is cold)

Valve gui de to val ve stem clea rance

Valve stem deflection

Valve guide I.D.

Valve stem O.D.

Valve stem runout

Valve head thickness

Valve stem end length

Valve seat width

Valve head radial runout

Valve spring free length (IN. & EX.)

Valve spring tension (IN. & EX.)

ITEM STANDARD LIMIT

IN.

EX.

IN.

EX.

IN.

EX.

IN. & EX. —

IN. & EX.

IN.

EX.

IN. & EX. —

IN. & EX.

IN. & EX. —

INNER —

OUTER —

INNER

OUTER

(5.9 – 6.7 kgf, 13.0 – 14.8 lbs)

(13.8 – 15.8 kgf, 30.4 – 34.8 lbs)

(1.3)

(1.1)

0.08 – 0.13

(0.003 – 0.005)

0.17 – 0.22

(0.0067 – 0.0087)

0.010 – 0.037

(0.0004 – 0.0015)

0.030 – 0.057

(0.0012 – 0.0022)

5.500 – 5.512

(0.2165 – 0.2170)

5.475 – 5.490

(0.2156 – 0.2161)

5.455 – 5.470

(0.2148 – 0.2154)

0.9 – 1.1

(0.035 – 0.043)

58 – 66 N

at length 27.5 mm (1.1 in)

135 – 155 N

at length 31.0 mm (1.2 in)

—

0.35

(0.014)

—

0.05

(0.002)

0.5

(0.02)

2.7

(0.11)

—

0.03

(0.001)

34.4

(1.35)

38.1

(1.50)

—

CAMSHAFT + C YLINDER HEAD Unit: mm (in)

Cam height

Camshaft journal oil clearance Right &

Camshaft journal holder I.D. Right &

Camshaft journal O.D. Right &

Camshaft runout

Rocker arm I.D.

Rocker a rm shaft O.D.

Cylinder head distortion

Cylinder head cover distortion

ITEM STANDARD LIMIT

IN.

EX.

Center

Left

Center

Left

Center

Left

IN. & EX.

33.710 – 33.750

(1.3272 – 1.3287)

33.700 – 33.740

(1.3268 – 1.3283)

0.032 – 0.066

(0.0013 – 0.0026)

0.028 – 0.059

(0.0011 – 0.0023)

22.012 – 22.025

(0.8666 – 0.8671)

17.512 – 17.525

(0.6894 – 0.6900)

21.959 – 21.980

(0.8645 – 0.8654)

17.466 – 17.484

(0.6877 – 0.6883)

—

12.000 – 12.018

(0.4724 – 0.4731)

11.973 – 11.984

(0.4714 – 0.4718)

—

33.410

(1.3154)

33.400

(1.3150)

0.150

(0.0059)

0.150

(0.0059)

—

0.10

(0.004)

—

0.05

(0.002)

0.05

(0.002)

CYLIN DER + PI STON + PISTO N RING Unit: mm (in)

Piston to cylinder clearance 0.020 – 0.030

Cylinder bore 100.000 – 100.015

Piston diam. 99.975 – 99.990

Cylinder distortion

Piston ring free end gap

Piston ring end ga p

Compr ession pres sure (Automatic decomp. actuated)

ITEM STANDARD LIMIT

(0.0008 – 0.0012)

(3.9371 – 3.9376)

Measure at 21 mm (0.8 in) from the skirt end.

1st R App rox. 13.5 (0 .53)

2nd R Approx. 11.4 (0.45)

(3.9360 – 3.9366)

—

1st

2nd

Approx. 850 kPa (8.5 kgf/cm

(0.012 – 0.018)

(0.018 – 0.024)

0.30 – 0.45

0.45 – 0.60

, 120 psi) —

0.120

(0.0047) Nicks or

Scratches

99.880

(3.9323)

0.05

(0.002)

10.8

(0.43)

9.1

(0.36)

0.50

(0.039)

1.00

(0.039)

1/8 E-03, 24, 28, 33

Piston ring to groove clearance

Piston ring groove width

Piston ring thick ness

Piston pin bore 23.002 – 23.008

Piston pin O.D. 22.996 – 23.000

CONROD + CRANKSHAFT Unit: mm (in)

Conrod small end I.D. 23.006 – 23.014

Conrod deflection

Conrod big end side clearance 0.10 – 0.65

Conrod big end width 24.95 – 25.00

Crankshaft runout

Crank web to web width 71.0 ± 0.1

OIL PUMP

Oil pump reduction ratio 1.633 (61/28 × 30/20 × 15/30) — Oil pressure (at 60 °C, 140 °F) Above 30 kPa (0.3 kgf/cm

ITEM STANDARD LIMIT

1st —

2nd —

1st

2nd

Oil

1st

2nd

Below 70 kPa (0.7 kgf/cm

1.230 – 1.250

(0.048 – 0.049)

1.210 – 1.230

(0.047 – 0.048)

2.810 – 2.830

(0.110 – 0.111)

1.170 – 1.190

(0.0461 – 0.0469)

1.150 – 1.170

(0.0453 – 0.0461)

(0.9056 – 0.9058)

(0.9054 – 0.9055)

(0.9057 – 0.9061)

—

(0.004 – 0.026)

(0.982 – 0.984)

—

(2.795 ± 0.004)

at 3 000 r/min

, 4.3 ps i)

, 10.0 psi)

0.180

(0.0071)

0.150

(0.0059)

—

23.030

(0.9067)

22.980

(0.9047)

23.040

(0.9071)

3.0

(0.12)

1.00

(0.039)

—

0.05

(0.002)

—

2/8 E-03, 24, 28, 33

CLUTCH Unit: mm (in)

Clutch lever play 10 – 15

Drive plate thickness No. 1 &

Driven plate distortion

Clutch spring free length

DRIVE TRAIN Unit: mm (in) Except ratio

Primary reduction ratio 2.178 (61/28) — Final reduct ion ra tio E-03, 28, 33 2.8 00 (42/15) —

Gear ra tios Low 2.416 ( 29/12) —

Shift fork to groove clearance 0.10 – 0.30

Shift fork groove width 5.0 – 5.1

Shift fork thickness 4.8 – 4.9

Drive chain Type DAIDO: D.I.D. 525V9 —

Drive c hain slack 30 – 45

ITEM STANDARD LIMIT

(0.4 – 0 .6)

No. 2

ITEM STANDARD LIMIT

E-24 2.733 (41/15) —

2nd 1. 625 (2 6/16) — 3rd 1.2 38 (26/ 21) — 4th 1.0 00 (21/21) — Top 0. 826 (1 9/23) —

Links 110 —

20-pitch length —

2.9 – 3.1

(0.11 – 0.12)

—

(0.004 – 0.012)

(0.197 – 0.200)

(0.189 – 0.193)

(1.2 – 1.8)

—

2.6

(0.10)

0.10

(0.004)

33.0

(1.30)

0.50

(0.020)

—

319.4

(12.57)

—

3/8 E-03, 24, 28, 33

4/8 E-03, 24, 28, 33

CARBURETOR

ITEM

Carburetor type MIKUNI

Bore size 40 mm ←← I.D. No. 32E1 32E6 32E3 Idle r/min 1 500 ± 100 r/min ←← Float height 14.7 ± 1.0 mm

Main jet (M.J. ) # ← #140 Jet needle (J.N.) 6F23 ← 6F19-3rd Needle jet (N.J.) ← Y- 5 Throttle valve (Th.V.) #95 ←← Pilot jet (P.J.) # ← #42.5 Starter jet (S.J.) #40 ←← Pilot screw (P.S.)

Throt tle ca ble play (pulling cable)

E-03, 28 E-33 E-24

BST40SS

(0.58 ± 0.04 in)

PRE-SET ←

2.0 – 4.0 mm

(0.08 – 0.16 in)

ELECTRICAL

Spark plug

Spark performance Over 8 (0.3) at 1 atm. Ignition coil resistance Primary 0.07 – 0.12 Ω B – B/W

Generator coil resistance Charging 0.5 – 0.9 Ω Y – Y

Gener ator no -load voltage Mo re than 75 V (AC) at 5 000 r/ min Generator Max. output Approx. 200 W at 5 000 r/min Regulated voltage 13.0 – 16.0 V at 5 000 r/min Starter relay resistance 3 – 5 Ω Battery Type designation YTX9-BS

Fuse size Main 30 A

ITEM SPECIFICATION NOTE

Capacity 12 V 28.8 kC (8 Ah)/10 HR Standard

electrolyte S.G.

Headlight (H) 10 A Head light (L) 10 A

Type

Gap

Secondary 23 – 25 kΩ

Power

source

Pick-up 170 – 256 Ω Bl – G

SPECIFICATION

←←

ND.: U31ESR-N

N.G.K.: CR10E

0.7 – 0.8

(0.028 – 0.031)

0.1 – 0.2 Ω B – W

1.320 at 20 °C (68 °F)

PRE-SET

(1.0 turn back)

Unit: mm (in)

Plug cap –

Plug cap

WATTAGE Unit: W

ITEM

Headlight HI 60

Parkin g or positi on lig ht Brake light/Taillight 21/5 Turn signal light 21 Speedometer light 1.7 Turn signal indicator light 2 High beam indicator light 2 Neutral indicator light 2 License light 5

LO 55

SPECIFICATION

E-03, 24, 28, 33

BRAKE + WHEEL Unit: mm (in)

Rear brake pedal height 5

Brake disc thickness

Brake disc runout

Master cylinder bore

Master cylinder piston diam.

Brake caliper cylinder bore

Brake caliper piston diam.

Wheel rim runout

Wheel axle runout

ITEM STANDARD LIM IT

(0.2)

Front

Rear

Front

Rear

Front

Rear

Front

Rear

Front

Rear

Axial —

Radial —

Front —

Rear —

4.0 ± 0. 2

(0.1 57 ± 0.008)

4.5 ± 0. 2

(0.1 77 ± 0.008)

—

12.700 – 12.743

(0.5000 – 0.5017)

12.700 – 12.743

(0.5000 – 0.5017)

12.657 – 12.684

(0.4983 – 0.4994)

12.657 – 12.684

(0.4983 – 0.4994)

27.000 – 27.050

(1.0630 – 1.0650)

30.23 – 30.28

(1.1902 – 1.1921)

26.90 – 26.95

(1.0591 – 1.0610)

30.16 – 30.18

(1.1874 – 1.1882)

—

3.5

(0.14)

4.0

(0.16)

0.30

(0.012)

—

2.0

(0.08)

2.0

(0.08)

0.25

(0.010)

0.25

(0.010)

5/8 E-03, 24, 28, 33

Tire rim size Front 21 × 1.85 —

Tire size Front 90/90-21M/C 54S —

Tire tread depth

ITEM

Rear 17M/C × MT2.50 —

Rear 120/ 90-17M /C 64S —

Front —

Rear —

STANDARD

LIMIT

3.0

(0.12)

3.0

(0.12)

SUSPENSION Unit: mm (in)

Front fork stroke 260

Front fork spring free length

Front fork oil level 164

Rear shock absorber spring pre-set length

Rear wheel travel 260

Swingarm pivot shaft runout

ITEM STANDARD LIMIT NOTE

(10.2)

220

(8.7)

—

(6.5)

150

(5.9)

247.5 (9.74)

(10.2)

220

(8.7)

—

— Low seat

548

(21.6)

—

— Low seat

—

— Low seat

0.3

(0.01)

TIRE PRESSURE

COLD INFLATION

TIRE PRESSURE

FRONT 1 50 1.50 22 175 1.75 25

REAR 175 1.75 25 200 2.00 29

SOLO RIDIN G DUAL RIDING

kPa kgf/cm

psi kPa kgf/cm2psi

6/8 E-03, 24, 28, 33

FUEL + OIL

Fuel type Use only unleaded gasoline of at least 87 pump

Fuel tank capacity

Engine oil type SAE 10W-40, API SF or SG Engine oil capac ity

Front fork oil type Fork oil #10 Front fork oil capacity (each leg) 565 ml

Brake fluid type DOT 4

ITEM SPECIFICATION NOTE

octane (R/2 + M/2) or 91 octane or higher rated by the reserch method. Gasoline containing MTBE (MethyI Tertiary ButyI Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible. Gasoline used should be graded 91 octane or higher. An unleaded gasoline is recommended.

Including

reserve

Only reserve

Oil change

Oil and

filter change

Engine

overhaul

(19.1 /19.9 U S/lmp o z)

(19.0/19.8 US/Imp oz)

12 L

(3.2/2.6 US/Imp gal)

13 L

(3.4/2.9 US/Imp gal)

3.0 L

(0.8/0.7 US/Imp gal)

2 300 ml

(2.4/2.0 US/lmp qt)

2 400 ml

(2.5/2.1 US/lmp qt)

2 600 ml

(2.7/2.3 US/lmp qt)

563 ml

E-03, 28, 33

E-24

E-33

Others

Low seat

7/8 E-03, 24, 28, 33

8/8 E-03, 24, 28, 33

DR-Z110

ENGINE TOP END Unit: mm (in)

Cam height

Camshaft chain 20-link length 127.00 – 127.48

Rocker arm inside diameter 10.000 – 10.015

Rocker arm shaft diameter 9.980 – 9.995

Cylinder compression Usable range

Cylinder head warp

Valve clearance

Valve head thickness

Valve stem bend

Valve stem diameter

Valve guide inside diameter

Valve/valve guide clearance (Wobble m ethod)

Valve seat cutting angle 45°, 32°, 60°, 67.5° — Valve seat width

Valve seat surface outside diameter

Valve spring free length 36.75

Cylinder inside diameter 52.997 – 53.009

ITEM STANDARD LIMIT

IN.

EX.

(8.8 – 13.5 kgf/cm

IN.

EX.

IN.

EX.

IN.

EX.

IN. & EX.

IN.

EX.

IN. & EX.

IN.

EX.

28.984 – 29.164

(1.1411 – 1.1482)

29.021 – 29.201

(1.1426 – 1.1496)

(5.000 – 5.014)

(0.3937 – 0.3943)

(0.3929 – 0.3935)

865 – 1 320 kPa

, 125 – 192 psi)

at 5 kick s

—

0.04 – 0.08

(0.0016 – 0.0031)

0.04 – 0.08

(0.0016 – 0.0031)

0.85 – 1.15

(0.0335 – 0.0453)

1.15 – 1.45

(0.0453 – 0.0571)

TIR 0.01 (0.0004) or less

4.475 – 4.490

(0.1762 – 0.1768)

4.462 – 4.472

(0.1757 – 0.1761)

4.500 – 4.512

(0.1772 – 0.1776)

0.02 – 0.07

(0.0008 – 0.0028)

0.06 – 0.11

(0.002 – 0.004)

0.80 – 1.15

(0.0315 – 0.0453)

22.9 – 23.1

(0.902 – 0.909)

19.9 – 20.1

(0.784 – 0.791)

(1.447)

(2.0865 – 2.0870)

28.88

(1.137)

28.92

(1.139)

128.9

(5.075)

10.05

(0.396)

9.95

(0.392)

—

0.05

(0.002)

—

0.5

(0.02)

0.5

(0.02)

TIR 0.05

(0.002)

4.46

(0.176)

4.44

(0.175)

4.55

(0.179)

0.12

(0.0047)

0.19

(0.007)

—

35.5

(1.40)

53.10

(2.091)

Piston outside di ameter 52.981 – 52.993

Piston/cylinder clearance 0.010 – 0.022

Oversize piston and rings +0.50 (0.0197), +1.0 (0.0394) — Piston ring/gro ove cle arance

Piston ring groove width

Piston ring thickness Top &

Piston ring end ga p

Piston pin diameter 12.995 – 13.000

Piston pin hole ins ide diame ter 13. 001 – 13.00 7

Connecting rod small end inside diameter

CRANKSHAFT/TRANSMISSION Unit: mm (in)

Connecting rod big end radial clear ance

Connecting rod big end side clearance

Crankshaft runout

Shift fork ear thickness 3.9 – 4.0

Gear s hift for k groove widt h 4.05 – 4.15

Shift fork guide pin diameter 4.9 – 5.0

Shift drum groove width 5.05 – 5.20

ITEM STANDARD LIMIT

(2.0859 – 2.0863)

(0.0004 – 0.0009)

Top

Second

Top

Second

Top

Second

Oil

ITEM STANDARD LIMIT

Less than 0.03 mm (0.001 in) TIR

0.02 – 0.06

(0.0008 – 0.0024)

0.01 – 0.05

(0.0004 – 0.0020)

0.81 – 0.83

(0.0319 – 0.0327)

0.80 – 0.82

(0.0315 – 0.0323)

0.77 – 0.79

(0.0303 – 0.0311)

0.15 – 0.30

(0.0059 – 0.0118)

0.30 – 0.45

(0.0118 – 0.0177)

0.10 – 0.60

(0.0039 – 0.0236)

(0.5116 – 0.5118)

(0.5118 – 0.5121)

13.003 – 13.014

(0.5119 – 0.5124)

0.006 – 0.020

(0.0002 – 0.0008)

0.1 – 0.2

(0.004 – 0.008)

(0.154 – 0.157)

(0.159 – 0.163)

(0.193 – 0.197)

(0.199 – 0.205)

52.83

(2.080)

—

0.16

(0.0063)

0.15

(0.0059)

0.90

(0.035)

0.90

(0.035)

0.7

(0.028)

0.6

(0.024)

0.8

(0.032)

0.9

(0.035)

12.96

(0.5102)

13.07

(0.5146)

13.05

(0.5138)

0.07

(0.0028)

0.4

(0.016)

0.08

(0.003)

3.8

(0.15)

4.3

(0.17)

4.8

(0.19)

5.3

(0.21)

1/5 P-19, 24, 28, 33

CLUTCH Unit: mm (in)

Primary clutch housing inside diameter Primary clutch shoe groove depth 1.0

Secondary clutch friction plate thickness Secondary clutch friction plate war p Secondary clutch steel plate warp

Clutch spring free length 22.04

Kick shaft diameter 15.941 – 15.968

Kick gear inside diameter 16.000 – 16.018

ITEM STANDARD LIMIT

104.0 – 104.2

(4.094 – 4.102)

(0.04)

3.1 – 3 .3

(0.12 – 0.13)

0.2 mm (0.008 in) or less

0.15 mm (0.006 in) or less

(0.87)

(0.6276 – 0.6287)

(0.6299 – 0.6306)

104.5

(4.114)

0.5

(0.02)

2.9

(0.11)

0.3

(0.01)

0.3

(0.01)

20.35 (0.80)

15.92

(0.6268)

16.04

(0.6315)

FINAL DRIVE Unit: mm (in)

Drive chain Type DAI DO: D.I.D. 420MBK1 —

Drive c hain slack 0 – 5

Engline sprocket diameter 49.1 – 49.3

Rear sprocket diameter 126.24

Rear spr ocket warp

ITEM STANDARD LIMIT

Links 86 links —

20-link length

Less t han 0.4 mm (0.016 i n)

254.0 – 254.6

(10.00 – 10.02)

(0 – 0.2)

(1.93 – 1.94)

(4.97)

259

(10.20)

—

48.4

(1.91)

125.4 (4.94)

0.5

(0.020)

FUEL SYSTEM Unit: mm (in)

Throttole grip free play 2 – 3 (0.08 – 0.12) — Carbur etor t ype KEIHIN PB18 — Main jet #80 — Jet needle NCFA — Throttle valve cutaway 3.0 — Pilot jet #38/38 — Air screw 1 and 1/4 turns out — Idle speed 1 250 – 1 350 r/min (rpm) — Servise fuel level (below the bottom edge of carburetor body) Float height 10.7 ± 2 (0.42 ± 0.08) — Air cleaner element oil High quality foam air filter oil —

ITEM STANDARD LIMIT

3.0 ± 1 (0.12 ± 0.04) —

2/5 P-19, 24, 28, 33

ELECTRICAL SYSTEM Unit: mm (in)

Pickup coil resistance 50 – 200 Ω B l/Y – G round Air gap 0.7 (0.028) — Ignition coil Primary

Excite r coil resi stance 0.2 – 1.0 Ω W – Ground

Spark plug type NGK CR6HSA —

Ignition coil (primary) peak voltage 100 V or above — Pickup coil peak voltage 4.6 V or above — Exciter coil peak voltage 15 V or above —

ITEM STANDARD NOTE

winding

resistance

Second-

ary wi nd-

ing

resistance

gap 0.6 – 0.7 (0.024 – 0.028) —

0.19 – 0.23 Ω —

2.5 – 3.7 kΩ —

0.1 – 0 .8 Ω Y – Ground

BRAKES Unit: mm (in)

Brake lever free play 4 – 5 (0.16 – 0.20) — Brake pedal free play 20 – 30 (0.79 – 1.18) — Brake shoe lining thickness

Brake shoe spring free length

Brake drum inside diameter

Brake camshaft diameter

Brake ca mshaft ho le insi de diameter

Brake cam lever angle 80 – 90° —

ITEM STANDARD LIMIT

Front

Rear

Front

Rear

Front

Rear

Front

Rear

Front

Rear

2.10 – 3.00

(0.08 – 0.12)

3.85 – 4.15

(0.152 – 0.163)

30.8 – 31.2

(1.213 – 1.228)

32.5

(1.280)

90.000 – 90.087 (3.543 – 3.547)

110.000 – 110.087 (4.331 – 4.334)

11.957 – 11.984 (0.471 – 0.472)

14.957 – 14.984 (0.589 – 0.590)

12.000 – 12.027 (0.472 – 0.474)

15.000 – 15.027 (0.591 – 0.592)

1.2

(0.05)

2.0

(0.08)

32.6

(1.28)

34.1

(1.34)

90.75

(3.57)

110.75 (4.36)

11.88

(0.468)

14.88

(0.586)

12.15

(0.478)

15.15

(0.596)

3/5 P-19, 24, 28, 33

4/5 P-19, 24, 28, 33

WHEELS/TIRES Unit: m m (in)

Wheel rim runout (Front & Rear)

Axle runout Front

Front tire Size 2.50-14MC 4PR —

Rear tire Size 3.00-12 4PR —

Tire air pressure

ITEM STANDARD LIMIT

Axial 0.5 mm (0.02 in) or less

Radial 0.8 mm (0.03 in) or less

(/100 mm)

Rear

(/110 mm)

Make CH ENG SHIN —

Type C803 —

Make CH ENG SHIN —

Type C803 —

Front &

Rear

0.1 (0.004)

100 kPa

(1.0 kgf/cm

, 14 psi)

(0.08)

0.2

(0.008)

0.2

(0.008)

— —

SUSPENSIONS Unit: mm (in)

Front fork oil viscosity SS-8 or SAE 10W-20 — Front fork oil capacity

(completely dry) Front fork oil level

(fully compressed, spring removed) Front fork spring free length 439.7

ITEM STAN DARD LIMIT

163 ± 2.5 ml

(5.51 ± 0.08 US oz) 89 ± 2 (3.50 ± 0.08)

from top of inner tube

(17.31)

—

430.9

(16.96)

ENGINE OIL Unit: mm (in)

Engine oil type API SE, SF or SG

Engine oil viscosity SAE 10W-40 — Engine oil capacity When engine is

Engine oil level Between upper and lower level lines —

ITEM STANDA RD LIMIT

API SH or SJ with JASO MA

completely dry

When filter is

removed

When filter is

not removed

1.1 L (1.2 US qt) —

1.0 L (1.1 US qt) —

0.9 L (1.0 US qt) —

—

5/5 P-19, 24, 28, 33

DR-Z125/L

VALVE + GUIDE Unit: mm (in)

Valve diam.

Valve clearance (when cold)

Valve gui de to val ve stem clear ance

Valve guide I.D.

Valve stem O.D.

Valve stem deflection

Valve stem runout

Valve head thickness

Valve stem end length

Valve seat width

Valve head radial runout

Valve spring free length (IN. & EX.)

Valve spring tension (IN. & EX.) INNER

ITEM STANDARD LIMIT

IN.

EX.

IN.

EX.

IN.

EX.

IN. & EX.

IN.

EX.

IN. & EX. —

IN. & EX.

IN. & EX. —

INNER —

OUTER —

(7.8 – 9.2 kgf, 17.2 – 20.3 lbs)

OUTER

(18.9 – 22.3 kgf, 41.7 – 49.2 lbs)

(1.2)

(1.0)

0.08 – 0.13

(0.003 – 0.005)

0.13 – 0.18

(0.005 – 0.007)

0.010 – 0.037

(0.0004 – 0.0015)

0.030 – 0.057

(0.0012 – 0.0022)

5.500 – 5.512

(0.2165 – 0.2170)

5.475 – 5.490

(0.2156 – 0.2161)

5.455 – 5.470

(0.2148 – 0.2154)

0.9 – 1.1

(0.035 – 0.043)

76 – 90 N

at len gth 32. 5 mm ( 1.28 in )

186 – 219 N

at len gth 36. 0 mm ( 1.42 in )

—

0.35

(0.014)

0.05

(0.002)

0.5

(0.014)

2.5

(0.10)

—

0.03

(0.001)

36.0

(1.42)

39.3

(1.55)

—

CAMSHAFT + C YLINDER HEAD Unit: mm (in)

Cam height

Camshaft journal oil clearance

Camsh aft jo urnal holder I.D.

Camsh aft jo urnal O.D.

Camshaft runout

Rocker arm I.D.

Rocker ar m shaft O.D.

Cylinder head distortion

Cylinder head cover distortion

CYLIN DER + PI STON + PISTO N RING Unit: mm (in)

Compression pressure 1 200 – 1 600 kPa

Piston to cylinder clearance 0.020 – 0.030

Cylinder bore 57.000 – 57.015

Piston diam. 56.975 – 56.990

Cylinder distortion

Piston ring free end gap

Piston ring end ga p

Piston ring to gr oove cle arance

Piston ring groove width

ITEM STANDARD LIMIT

IN. & EX.

IN. & EX. —

IN. & EX.

ITEM STANDARD LIMIT

(12 – 16 kgf/cm

Measure at 12 mm (0.5 in) from the skirt end.

1st R Approx. 7.0 (0.28)

2nd R Approx. 8.5 (0.33)

1st

2nd

1st —

2nd —

1st

2nd

Oil

33.13 – 33.17

(1.304 – 1.306)

0.032 – 0.066

(0.0013 – 0.0026)

22.012 – 22.025

(0.8666 – 0.8671)

21.959 – 21.980

(0.8645 – 0.8654)

12.000 – 12.018

(0.4724 – 0.4731)

11.977 – 11.995

(0.4715 – 0.4722)

—

, 171 – 228 psi)

(0.0008 – 0.0012)

(2.2440 – 2.2447)

(2.2431 – 2.2437)

—

0.10 – 0.25

(0.004 – 0.010)

0.10 – 0.25

(0.004 – 0.010)

1.21 – 1.23

(0.047 – 0.048)

1.21 – 1.23

(0.047 – 0.048)

2.51 – 2.53

(0.099 – 0.100)

32.83 (1.29)

0.150

(0.0059)

—

0.10

(0.004)

—

0.05

(0.002)

0.05

(0.002)

1 000 kPa

(10 kgf/cm2, 142 psi )

0.120

(0.0047)

57.110

(2.2484)

56.880

(2.2394)

0.05

(0.002)

5.6

(0.22)

6.8

(0.27)

0.5

(0.02)

0.5

(0.02)

0.18

(0.007)

0.15

(0.006)

—

1/7 E-28, 33

2/7 E-28, 33

Piston ring thick ness

Piston pin bore 14.002 – 14.008

Piston pin O.D. 13.994 – 14.002

ITEM STANDARD LIMIT

1st

2nd

1.175 – 1.190

(0.0463 – 0.0469)

1.170 – 1.190

(0.0461 – 0.0469)

(0.5513 – 0.5515)

(0.5509 – 0.5513)

—

14.030

(0.5524)

13.980

(0.5504)

CONROD + CRANKSHAFT Unit: mm (in)

Conrod small end I.D. 14.004 – 14.012

Conrod deflection

Conrod big end side clearance 0.10 – 0.45

Conrod big end width 15.95 – 16.00

Crank web to web width 53.0 ± 0.1

Crankshaft runout

ITEM STANDARD LIMIT

(0.5513 – 0.5517)

—

(0.004 – 0.018)

(0.628 – 0.630)

(2.09 ± 0.004)

—

14.040

(0.5528)

3.0

(0.12)

1.0

(0.04)

—

0.08

(0.003)

OIL PUMP

Oil pressure (at 60°C, 140°F) Above 15 kPa (0.15 kgf/cm

ITEM STANDARD LIMIT

Below 35 kPa (0.35 kgf/cm

at 3 000 r/min

CLUTCH

Clutch lever play 10 – 15

Drive plate thickness 2.90 – 3.10

Drive plate claw width 11.8 – 12.0

Driven plate distortion

Clutch spring free length 32.6

ITEM STANDARD LIMIT

(0.4 – 0 .6)

(0.114 – 0.122)

(0.46 – 0.47)

—

(1.28)

, 2.1 psi)

, 4.9 ps i)

—

Unit: mm (in)

—

2.60

(0.102)

11.5

(0.45)

0.10

(0.004)

31.0

(1.22)

DRIVE TRAIN + DRIVE CHAIN Unit: mm (in) Except ratio

Primary reduction ratio 3.470 (59/17) — Final reduction ratio DR-Z125 3.642 (51/14) —

Gear ratios Low 3.000 (33/11) —

Shift fork to groove clearance 0.10 – 0.30

Shift fork groove width

Shift fork thickness

Countershaft length (Low to 2nd)

Drive chain Type D.I.D. 428HG —

Drive chain slack 35 – 45

Gearshift lever height 5 – Above 5

ITEM STANDARD LIMIT

DR-Z125L 4.071 (57/14) —

2nd 1.857 (26/14) —

3rd 1.368 (26/19) — 4th 1.095 (23/21) —

Top 0.923 (24/26) —

(0.004 – 0.012)

No. 1

No. 2

No. 1

No. 2

DR-Z125 122 —

Links

DR-Z125L 130 —

20-pitch

length

5.0 – 5.1

(0.196 – 0.201)

5.5 – 5.6

(0.217 – 0.224)

4.8 – 4.9

(0.189 – 0.193)

5.3 – 5.4

(0.209 – 0.213)

+0.1

3.46

88.0

-0

(

—

(1.4 – 1 .8)

(0.2 – Above 0.2)

+0.004

-0

)

0.50

(0.02)

—

259.0

(10.20)

—

CARBURETOR

Carbur etor t ype MI KUNI VM20S S Bore size 20 mm (0 .8 in) I.D. No. 0 8G0 Idle r/min 1 700 ± 100 r/min Float height 18.9 ± 1.0 mm (0.74 ± 0.04 in) Main jet (M.J.) #102.5 Jet needle (J.N.) 5HGM74-1 Needle jet (N.J.) N-6M Pilot jet (P.J.) #17.5 Pilot screw

Throt tle ca ble play 2.0 – 4. 0 mm (0. 08 – 0.16 in)

ITEM SPECIFICATION

(P.S.)

PRE-SET

(2 and 1/4 turns back)

3/7 E-28, 33

ELECTRICAL

Spark plug

Spark performance Over 8 mm (0.3 in) at 1 atm. Ignition coil resistance Primary 0.1 – 0.8 Ω W/Bl – B/W

Generator coil resistance Charging 13 – 22 Ω Y – Y/R

Pick-up coil peak voltage More than 2.0 V Ignition coil primary peak voltage More than 150 V : B /W, : W/Bl

BRAKE + WHEEL

Brake lever play

Front brake cable play

Rear brake pedal free travel 20 – 30

Rear brake pedal height 10 – 0

Brake drum I.D.

Brake disc thickness

Brake disc runout

Master cylinder bore

Master cylinder piston diam.

Brake caliper cylinder bore

Brake caliper piston diam.

Brake fluid type Front DR-Z125L DOT 4 — Wheel rim runout

Wheel axle runout

ITEM SPECIFICATION NOTE

Type

Gap

Secondary 13 – 18 kΩ Plug cap – W/Bl

Pick-up coil 140 – 230 Ω G – B/W

ITEM STANDARD/SPECIFICATION LIMIT

DR-Z125

Front DR-Z125 —

Rear —

Front DR-Z125L

Front DR-Z125L —

Front DR-Z125L

Axial —

Radial —

Front —

Rear —

DENSO: X24ESR-U

NGK: DR8EA

0.6 – 0.8 mm

(0.024 – 0.031 in)

0.1 – 0.3

(0.004 – 0.012)

15 – 25

(0.6 – 1.0)

(0.8 – 1 .2)

(0.4 – 0)

3.5 ± 0.2

(0.14 ± 0.008)

11.000 – 11.043

(0.4331 – 0.4348)

10.957 – 10.984

(0.4314 – 0.4324)

30.230 – 30.306

(1.1902 – 1.1931)

30.150 – 30.200

(1.1870 – 1.1890)

: G, : B/W

Unit: mm (in)

—

110.7 (4.36)

3.0

(0.12)

0.30

(0.012)

—

2.0

(0.08)

2.0

(0.08)

0.25

(0.010)

0.25

(0.010)

4/7 E-28, 33

Wheel rim size

Tire size

Tire tread depth

ITEM STANDARD/SPECIFICATION LIMIT

DR-Z125 J17 × 1.40 —

Front

DR-Z125L J19 × 1.40 —

DR-Z125 J14 × 1.60 —

Rear

DR-Z125L J16 × 1.60 —

DR-Z1 25 70/ 100-17 40M —

Front

DR-Z125L 70/100-19 42M —

DR-Z1 25 90/ 100-14 49M —

Rear

DR-Z125L 90/100-16 52M —

Front —

Rear —

4.0

(0.16)

4.0

(0.16)

SUSPENSION Unit: mm (in)

Front fork stroke 180

Front fork spring free length 599.1

Front fork oil level 173

Front fork oil type SUZUKI FORK OIL SS-08 (#10) or

Front fork oil capacity (each leg) 172 ml (4.3/4.5 US/lmp oz) — Front fork inner tube O.D. 30

Rear shock absorber spring pre-set length

Rear wheel travel

Swingarm pivot shaft runout

ITEM STANDARD/SPECIFICATION LIMIT

(7.1)

(23.59)

(6.8)

an equivalent fork oli

(1.2)

DR-Z125

DR-Z125L

DR-Z125

DR-Z125L

240.5 (9.47)

241.1 (9.49)

160

(6.3)

170

(6.7)

—

587

(23.1)

—

0.6

(0.02)

TIRE PRESSURE

COLD INFLATION

TIRE PRESSURE

FRONT 100 1.0 14

REAR 100 1.0 14

kPa kgf/cm

psi

5/7 E-28, 33

6/7 E-28, 33

FUEL + OIL

Fuel type Use only unleaded gasoline of at least 87 pump

Fuel tank capacity including

Engine oil type SAE 10 W-40, API SF or SG Engine oil capacity Change 850 ml (0.9/0.7 US/lmp qt)

ITEM SPECIFICATION NOTE

reserve reserve 1.7 L (0.4/0.4 US/lmp qt)

6.6 L (1.7/1.5 US/lmp qt)

Filter

change

Overhaul 1 100 ml (1.2/1.0 US/lmp qt)

950 ml (1.0/0.8 US/lmp qt)

7/7 E-28, 33

DR-Z250 (E-03, 28, 33)

VALVE + GUIDE Unit: mm (in)

Valve diam.

Tappet clearance (when cold)

Valve gui de to val ve stem clear ance

Valve stem deflection

Valve guide I.D.

Valve stem O.D.

Valve stem runout

Valve head thickness

Valve seat width

Valve head radial runout

Valve spring free length (IN. & EX.)

Valve spring tension (IN. & EX.) INNER

CAMSHAFT + C YLINDER HEAD Unit: mm (in)

Cam height

ITEM STANDARD LIMIT

IN.

EX.

IN.

EX.

IN.

EX.

IN. & EX. —

IN. & EX.

IN.

EX.

IN. & EX. —

IN. & EX.

IN. & EX. —

INNER —

OUTER —

OUTER

(13.3 – 15.3 kgf, 29.3 – 33.7 lbs)

IN.

EX.

28.5

(1.12)

25.0

(0.98)

0.10 – 0.20

(0.004 – 0.008)

0.20 – 0.30

(0.008 – 0.012)

0.010 – 0.037

(0.0004 – 0.0015)

0.030 – 0.057

(0.0012 – 0.0022)

4.500 – 4.512

(0.1772 – 0.1776)

4.475 – 4.490

(0.1762 – 0.1768)

4.455 – 4.470

(0.1754 – 0.1760)

0.9 – 1.1

(0.035 – 0.043)

48 – 58 N

(4.8 – 5.8 kgf, 10.6 – 12.8 lbs)

at len gth 29. 9 mm ( 1.18 in )

133 – 153 N

at length 33.4 mm (1.32 in)

35.32 – 35.36

(1.391 – 1.392)

35.22 – 35.26

(1.387 – 1.388)

—

0.35

(0.014)

—

0.05

(0.002)

0.5

(0.02)

—

0.03

(0.001)

38.6

(1.52)

40.6

(1.60)

—

35.02

(1.379)

34.92

(1.375)

Camsh aft jo urnal oil clearan ce 0. 032 – 0.066

Camshaft journal holder I.D. 22.012 – 22.025

Camshaft journal O.D. 21.959 – 21.980

Camshaft runout

Cam chain pin (at arrow “3”) 17th pin — Cylinder head distortion

ITEM STANDARD LIMIT

(0.0013 – 0.0026)

(0.8666 – 0.8671)

(0.8645 – 0.8654)

—

0.150

(0.0059)

—

0.10

(0.004)

0.05

(0.002)

CYLIN DER + PI STON + PISTO N RING Unit: mm (in)

Compr ession pres sure

Piston to cylinder clearance 0.015 – 0.025

Cylinder bore 73.000 – 73.015

Piston diam. 72.980 – 72.995

Cylinder distortion

Piston ring free end gap

Piston ring end ga p

Piston ring to groove clearance

Piston ring groove width

Piston ring thick ness

Piston pin bore 19.002 – 19.008

Piston pin O.D. 18.992 – 19.000

ITEM STANDARD LIMIT

Measure at 15 mm (0.6 in) from the skirt end.

1st R Approx. 7.6 (0.30)

2nd R Approx. 7.7 (0.31)

1st & 2nd

1st & 2nd —

1st & 2nd

Oil

1st & 2nd

1 300 kPa

, 185 psi)

(13 kgf/cm

(0.0006 – 0.0010)

(2.8740 – 2.8746)

(2.8732 – 2.8738)

—

0.08 – 0.20

(0.003 – 0.008)

1.01 – 1.03

(0.040 – 0.041)

2.01 – 2.03

(0.079 – 0.080)

0.97 – 0.99

(0.038 – 0.039)

(0.7481 – 0.7483)

(0.7477 – 0.7480)

910 kPa

(9.1 kgf/cm2,

129 psi)

0.120

(0.0047)

Nicks or

scratches

72.880

(2.8693)

0.05

(0.002)

6.1

(0.24)

6.2

(0.25)

0.50

(0.02)

0.180

(0.007)

—

19.030

(0.7492)

18.980

(0.7472)

1/7 E-03, 28, 33

2/7 E-03, 28, 33

CONROD + CRANKSHAFT Unit: mm (in)

Conrod small end I.D. 19.006 – 19.014

Conrod deflection

Conrod big end side clearance 0.10 – 0.55

Conrod big end width 19.95 – 20.00

Crank web to web width 64.0 ± 0.1

Crankshaft runout

ITEM STANDARD LIMIT

(0.7483 – 0.7486)

—

(0.004 – 0.022)

(0.785 – 0.787)

(2.52 ± 0.004)

—

19.040

(0.7496)

3.0

(0.12)

1.0

(0.04)

—

0.08

(0.003)

OIL PUMP

Oil pump reduction ratio 1.571 (33/21) — Oil pressure (at 60 °C, 140 °F) Above 50 kPa (0.5 kgf/cm

CLUTCH

Clutch lever play 10 – 15

Drive plate thickness 2.92 – 3.08

Drive plate claw width 13.7 – 13.8

Driven plate distortion

Clutch spring free length

ITEM STANDARD LIMIT

, 7.1 psi)

Below 150 kPa (1.5 kgf/cm

at 3 000 r/min

ITEM STANDARD LIMIT

(0.4 – 0 .6)

(0.115 – 0.121)

(0.539 – 0.543)

, 21.3 psi)

—

Unit: mm (in)

—

2.62

(0.103)

12.9

(0.51)

0.10

(0.004)

39.0

(1.54)

TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio

Primary reduction ratio 3.190 (67/21) — Final reduction ratio 3.769 (49/13) — Gear ratios Low 2.416 (29/12) —

ITEM STANDARD LIMIT

2nd 1.733 (26/15) —

3rd 1.333 (24/18) — 4th 1.111 (20/18) — 5th 0.952 (20/21) —

Top 0.826 (19/23) —

Shift fork to groove clearance 0.1 – 0.3

Shift fork gro ove widt h No. 1, No. 2

Shift fork thickness No. 1, No. 2

Drive chain Type D.I.D. 520V2 —

Drive chain slack 30 – 45

ITEM STANDARD LIMIT

(0.004 – 0.012)

& No. 3

Links 112 —

20-pitch length —

5.0 – 5.1

(0.197 – 0.201)

4.8 – 4.9

(0.189 – 0.193)

(1.2 – 1 .8)

0.5

(0.02)

319.4

(12.57)

CARBURETOR

ITEM

Carbur etor t ype TM 28SS BSR3 2 Bore size 28 mm 32 mm I.D. No. 13E3 13E4 Idle r/min 1 600 ± 100 r/min 1 500 ± 100 r/min Float h eight 14.2 ± 1.0 mm

Main jet (M.J. ) #127.5 # Jet needle (J.N.) 6FN3-3rd 5DH46 Needle jet (N.J.) P-6M Pilot jet (P.J.) #37.5 # Pilot screw (P.S.) 1 and 1/4 turns back PRE-SET Throt tle ca ble play

(pulling cable)

E-03, 28 E-33

(0.56 ± 0.04 in)

2.0 – 4.0 mm

(0.08 – 0.16 in)

ELECTRICAL

Spark plug

Spark performance Over 8 (0.3) at 1 atm. Ignition coil resistance

Ignition coil primary peak voltage More than 150 V Generator coil resistance Charging 0.7 – 1.5 Ω Y – Y

ITEM SPECIFICATION NOTE

Type

Gap

Primar y 0.1 – 1.5 Ω

Secondary 12 – 20 kΩ

Signal coil 0.1 – 1.2 Ω W – B

Pick-up coil 390 – 620 Ω G – Bl

SPEC IFICATION

NGK: CR9E

DENSO: U27ESR-N

0.7 – 0 .8

(0.028 – 0.031)

13.0 ± 1.0 mm

(0.51 ± 0.04 in)

←

Unit: mm (in)

Terminal –

Plug cap –

Terminal

: B/W, : W/Bl

Ground

—

3/7 E-03, 28, 33

Pickup coil p eak vol tage Mo re than 5 V Signal coil peak voltage More than 1.2 V : W, : B Gener ator no -load voltage

(when engine is cold) Regulated voltage 14.0 – 15.5 V at 5 000 r/min Starter relay resistance 3 – 5 Ω Battery Type designation FTZ5L-BS

Fuse size 10 A

ITEM SPECIFICATION NOTE

More than 75 V (AC) at 5 000 r/min

Capacity 12 V 16.2 kC (4.5 Ah)/10 HR

: G, : Bl

WATTAGE Unit: W

Headlight 35 Taillight 5

ITEM SPECIFICATION

BRAKE + WHEEL Unit: mm (in)

Brake leve r play 0.1 – 0. 3

Rear brake pedal height 5

Brake disc thickness

Brake disc runout

Master cylinder bore

Master cylinder piston diam.

Brake caliper cylinder bore

Brake caliper piston diam.

Brake fluid type DOT 4 —

ITEM STANDARD/SPECIFICATION LIMIT

(0.004 – 0.010)

(0.2)

Front

Rear

Front

Rear

Front

Rear

Front

Rear

Front

Rear

3.0 ± 0.2

(0.118 ± 0.008)

4.0 ± 0.2

(0.157 ± 0.008)

—

11.000 – 11.043

(0.4331 – 0.4348)

14.000 – 14.043

(0.5512 – 0.5529)

10.957 – 10.984

(0.4314 – 0.4324)

13.957 – 13.984

(0.5495 – 0.5506)

27.000 – 27.050

(1.0630 – 1.0650)

30.230 – 30.280

(1.1902 – 1.1921)

26.900 – 26.950

(1.0591 – 1.0610)

30.160 – 30.180

(1.1874 – 1.1882)

—

2.5

(0.098)

3.5

(0.138)

0.3

(0.012)

—

4/7 E-03, 28, 33

Wheel rim runout

Wheel axle runout

Wheel rim size Front J21 × 1.60 —

ITEM STANDARD/SPECIFICATION LIMIT

Axial —

Radial —

Front —

Rear —

Rear J18 × 2.15 —

(0.010)

TIRE

Cold inflation tire pressure (Solo riding)

Tire size Front 80/100-21 51M —

Tire tread depth

ITEM STANDARD/SP ECIFICATION LI MIT

Front

Rear

Rear 100/100-18 59M —

Front —

Rear —

SUSPENSION

Front fork stroke 280

Front fork spring free length 502.6

Front fork oil level 143

Front fork oil type SUZUKI fork oil SS-07 or an equivalent fork oil — Front fork oil capacity

(each leg) Front fork damping force adjuster Rebound 8 clicks turns back —

Rear shock absorber gas press ure

Rear shock absorber spring pre-set length

Rear shock absorber damping force adjuster

Rear wheel travel 285

Swingarm pivot shaft runout

ITEM STANDARD/SPECIFICATION LIMIT

(17.8/18.5 US/Imp oz)

Compre ssion 7 clic ks turns b ack —

Rebound 3 turns back —

Compression 1 and 1/4 turns back —

(1.00 kgf/cm

(1.00 kgf/cm2, 14 psi)

(11.0)

(19.79)

(5.6)

526 ml

1 000 kPa

(10 kgf/cm

269.4 (10.6)

(11.2)

—

100 kPa

, 142 psi)

, 14 psi)

4.0 mm (0.16 in)

4.0 mm

(0.16 in)

Unit: mm (in)

2.0

(0.08)

2.0

(0.08)

0.25

—

492

(19.4)

—

0.3

(0.01)

5/7 E-03, 28, 33

6/7 E-03, 28, 33

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