Suzuki FD 110 XCS, FD 110 XCSD, FD 110 XCD, FD110, FD 110 XC Service Manual

FD110

FD110







GROUP INDEX

GENERAL INFORMATION

1

PERIODICAL MAINTENANCE

2

ENGINE

3

FUEL AND LUBRICATION SYSTEM

4

CHASSIS

5

ELECTRICAL SYSTEM

6

SERVICING INFORMATION

7

COOLING AND LUBRICATION SYSTEM

8

CHASSIS

9

ELECTRICAL SYSTEM

10

SERVICING INFORMATION

11

EMISSION CONTROL INFORMATION

12

VZR1800K7 (’07-MODEL)

13

VZR1800ZK7 (’07-MODEL)

14

VZR1800NK8 (’08-MODEL)

15

VZR1800K8 (’08-MODEL)

16

VZR1800ZK8/ZK9 (’08, ’09-MODEL)

17

VZR1800K9/NK9 (’09-MODEL)

18

VZR1800/ZL0/ZL1 (’10, ’11-MODEL)

19

VZR1800/ZL2 (’12-MODEL)

20

WIRING DIAGRAM

21

FOREWORD

This manual contains an introductory description On
SUZUKI FD 110 and procedures for Its inspec­tion/service and overhaul of its main components.
Other information considered as generally known is
not included. Read GENERAL INFORMATION sec­tion to Familiarize yourself with outline of the vehicle
and MAINTENANCE and other sections to use as a
guide for proper inspection and service. This man­ual will help you now the vehicle better so that you
can assure your customers of your optimum and
quick service.



© COPYRIGHT SUZUKI MOTOR CORPORATION 2012

*This manual has been prepared on the basis

of the latest specifications at the time of publi­cation.
If modifications have been made since then,
differences may exist between the content of
this manual and the actual motorcycle.

*IIIustrations in this manual are used to show

the basic principles of operation and work
procedures. They may not represent the
actual motorcycle exactly in detail.

*This manual is written for persons who have

enough knowledge, skills and tools, including
special tools, for servicing SUZUKI motorcy­cles. If you do not have the proper knowledge
and tools, ask your authorized SUZUKI
motorcycle dealer to help you.

Inexperienced mechanics or mechanics
Without the proper tools and equipment
may not be able to properly perform the
service described I this manual. Improper
repair may result I injury to the mechanic
and may render the motorcycle unsafe for
the rider and passenger.

HOW TO USE THIS MANUAL

TO LOCATE WHAT YOU ARE LOOKING FOR :

1. The text of this manual is divided into sections.

2. As the title of these sections are listed on the previous page
as GROUP INDEX, select the section where what you are
looking for belong.

3. Holding the manual as shown as the right will allow

4. On the first page of each section, its contents are listed. Find
the item and page you need.

COMPONENT PARTS AND WORK TO BE DONE

Under the name of each system or unit, its exploded view provided with work instruction and other service
information such as the tightening torque, lubricating and locking agent points.

Example:

LEFT RIGHT

22.0-35.0 N-m

SYMBOL

Listed in the table below are the symbols indicating instructions and other information necessary for servic­ing and meaning associated with them respectively.

SYMBOL DEFINITION SYMBOL DEFINITION

To rq u e co n tr o l r eq ui r ed .
Data beside it indicates
Specified torque.

Apply THREAD LOCK SUPER “1303”
99000-32030

Apply oil, Use engine oil unless
otherwise specified.

Apply THREAD LOCK “1342”
99000-32050

Apply SUZUKI SUPER GREASE “A”
99000-25010

Apply or use brake fluid.

Apply SUZUKI SILICONE GREASE.
99000-25100

Measure in voltage range.

Apply SUZUKI MOLY PASTE.
99000-25140

Measure in resistance range.

Apply SUZUKI BOND “1215”
99000-31110

Measure in current range.

Apply THREAD LOCK SUPER “1322”
99000-31110

Use special tool.

Apply THREAD LOCK SUPER “1360”
99000-32130

Use fork oil.
99000-99044-10G

GENERAL INFORMATION

1-1

GENERAL INFORMATION

CONTENTS

1

WARNING/CAUTION/NOTE........................................................................... 1-2

GENERAL PRECAUTIONS ............................................................................ 1-2

SUZUKI FD 110 XC / XCS / XCD / XCSD....................................................... 1-4

SERIAL NUMBER LOCATION ....................................................................... 1-4

FUEL AND OIL RECOMMENDATIONS .................................................. 1-4

FUEL ..................................................................................................... 1-4

ENGINE OIL.......................................................................................... 1-5

FRONT FORK OIL ................................................................................ 1-5

BREAK-IN PROCEDURES............................................................................. 1-5

SPECIFICATIONS........................................................................................... 1-6

1-2

GENERAL INFORMATION

WARNING/CAUTION/NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol
and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes­sages highlighted by these signal words.



Indicates a potential hazard that could result in death or injury.



Indicates a potential hazard that could result in vehicle damage.

NOTE:
Indicates special information to make maintenance easier or instructions clearer.

Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all
potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARN­INGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you
are unsure about how to perform a particular service operation, ask a more experienced mechanic for
advice.

GENERAL PRECAUTIONS



*Proper service and repair procedures are important for the safety of the service mechanic and

the safety and reliability of the vehicle.
*When 2 or more persons work together, pay attention to the safety of each other.
*When it is necessary to run the engine indoors, make sure that exhaust gas is forced

outdoors.
*When working with toxic or the flammable materials, make sure that the area you work in is

well ventilated and that you follow all of the material manufacturer’s instructions.
*Never use getting burned, do not touch the engine, engine oil or exhaust system during or for

a while after engine operation.
*After servicing fuel, oil, exhaust or brake systems, check all lines and fittings related to the

system for leaks.

GENERAL INFORMATION

1-3



*If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their

equivalent.

*When removing arts that are to be reused, keep them arranged in an orderly manner so that

they may be reinstalled in the proper order and orientation.
*Be sure to use special tools when instructed.
*Make sure that all parts used in reassembly are clean, and also lubricated when specified.
*When use of a certain type of lubricant, bond, or sealant is specified be sure to sue the

specified type.
*When removing the battery, disconnect the negative cable first and then positive cable. When

reconnecting the battery, connect the positive cablefirst and then negative cable, and replace

the terminal cover on the positive terminal.
*When performing service to electrical arts, if the service procedures not require use of battery

power, disconnect the negative cable of the battery.
*Tighten cylinder head case bolts and nuts, beginning with larger diameter and ending with

smaller diameter, from inside to outside diagonally, to the specified tightening torque.
*Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, cotter pins, cir-

clips and certain other parts as specified, be sure to replace them with new ones. Also, before

installing these new parts, be sure to remove any left over material from the mating surfaces.
*Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger

than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is

completely seated in its groove and securely fitted.
*Do not use self-locking nuts a few times over.
*Use a torque wrench to tighten fasteners to the torque values when specified. Wipe off grease

or oil if a thread is smeared with them.
*After reassembly, check parts for tightness and operation.

* To protect environment, do not unlawfully dispose of used motor oil and other fluids:

batteries, and tires.
*To protect Earth’s natural resources, properly dispose of used vehicles and parts.

1-4

GENERAL INFORMATION

SUZUKI FD 110 XB517QD/XB517QSC

•Difference between illustrations and actual motorcycles depends on the markets.

SERIAL NUMBER LOCATION

The frame serial number or V.I.N. (Vehicle Identification Number) is stamped on the left side of the steering
head tube. The engine serial number is located on the upper right side of the crankcase. These numbers are
required especially for registering the machine and ordering spare parts.

FUEL AND OIL RECOMMENDATIONS

FUEL

Gasoline used should be graded 91 (Research Method)_ or higher. An unleaded gasoline type is recom­mended.

GENERAL INFORMATION

1-5

ENGINE OIL

Be sure the engine oil you use comes under API classification of
SF or SG and that its viscosity rating is SAE 40. If an SAE 40
motor oil is not available, select an alternate according to the right
chart

BRAKE FLUID
Specification and classification: DOT 4



FRONT FORK OIL

Use fork oil # 10.

BREAK-IN PROCEDURES

During manufacture only the best possible materials are used and all machined parts are finished to a very
high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine
to maximum stresses. The future performance and reliability of the engine depends on the care and restraint
exercised during its early life. The general rules are as follows.

•Keep to this break-in throttle position. Initial 500 km: less than ½ throttle Up to 1,600 km: Less than ¾
throttle

•Upon reaching an odometer reading of 1,600 km you can subject the motorcycle to full throttle operation
for short periods of time.

Since the brake system of this motorcycle is filled with a glycol-based brake fluidby the manu­facturer, do not use or mix different types of fluid such as silicone-based and petroleum-based
fluid for refilling the system, otherwise serious damage will result.
Do not use any brake fluid taken from old or used or unsealed containers.
Never re-use brake fluid left over from a previous servicing, which has been stored for a long
period.

1-6

GENERAL INFORMATION

SPECIFICATIONS

DIMENSIONS AND DRY MASS

Overall length.............................................................. 1,932 mm

Overall width .............................................................. 650 mm

Overall height ............................................................. 1,062 mm

Seat height ................................................................. 755 mm

Wheel base ................................................................ 1,230 mm

Ground clearance ...................................................... 153 mm

Dry mass .................................................................... 96 kg

ENGINE

Type ........................................................................... Four-stroke, air-cooled, SOHC

Number of cylinder ..................................................... 1

Bore ........................................................................... 53.5 mm

Stroke ......................................................................... 48.8 mm

Piston Displacement .................................................. 109.6 cm3

Compression ration .................................................... 9.6 : 1

Carburetor .................................................................. MIKUNI VM17

Air cleaner .................................................................. Paper

Starter system Electric starter & Kick starter
starter Lubrication system Wet sump

Valve clearance ......................................................... IN : 0.04-0.07 mm.

EX : 0.04-0.07 mm.

TRANSMISSION

Clutch ......................................................................... Wet shoe, automatic, centrifugal type

Transmission .............................................................. 4-speed constant mesh

Gearshift pattern ........................................................ All-down

Primary reduction ratio ............................................... 3.666 (77/21)

Final reduction ratio ................................................... 2.428 (34/14)

Gear ratios, Low ......................................................... 3.000 (33/11)

2nd ......................................................... 1.875 (30/16)

3rd .......................................................... 1.368 (26/19)

Top ......................................................... 1.052 (20/19)

Drive chain ................................................................. DIADO D.I.D 428, 98 links

GENERAL INFORMATION

1-7

CHASSIS

Frame ......................................................................... SSRF (SUZUKI SINGLE RECTANGULAR FRAME)

Front suspension ........................................................ Telescopic, coil spring, oil damped

Rear suspension ........................................................ Swing arm type, coil spring

Steering angle ............................................................ 45° (right & left)

Caster ......................................................................... 27°

Trail ............................................................................ 65 mm

Front brake ................................................................. Disc brake, hydraulically operated

Expanding, drum, brake.

Rear brake ................................................................. Internal expanding, drum brake

Front tire size ............................................................. 2.25 – 17 NR72 33L

Rear tire size .............................................................. 2.50 – 17 NR72 38L

Front fork stroke ......................................................... 90 mm

Rear wheel travel ....................................................... 79 mm

ELECTRICAL

Ignition type................................................................. DC-CDI

Spark plug .................................................................. ND: U20FS-U

NGK: C6HS

Batter .......................................................................... 12 V 5AH 10HR

Fuse ............................................................................ 10 A

Headlight ..................................................................... 12 V 35/35 W

Turn signal light........................................................... 12 V 10 W

Taillight/Brake light ..................................................... 12 V5/21W

Speedometer light ...................................................... 12 V 3 W

High beam indicator light ............................................ 12 V 1.7 W

Turn signal indicator light ........................................... 12 V 1.7 W

Neutral, gear position indicator light ........................... 12 V 1.7 W

CAPACITY

Fuel tank .................................................................... 4.2 L

Engine oil, oil change ................................................. 800 ml

with filter change ........................................................ 900 ml

overhaul ..................................................................... 1,000 ml

Front fork oil ............................................................... 70 ml

These specifications are subject to change without notice.

1-8

GENERAL INFORMATION

PERIODICAL MAINTENANCE 2-1

CONTENTS

2

PERIODICAL MAINTENANCE

PERIODICAL MAINTENANCE SCHEDULE ................................................. 2-2

PERIODIC MAINTENANCE CHART....................................................... 2-2

LUBRICATION POINTS .......................................................................... 2-3

MAINTENANCE AND TUNE-UP PROCEDURES ......................................... 2-4

BATTERY ................................................................................................ 2-4

EXHAUST PIPE BOLTS.......................................................................... 2-5

AIR CLEANER ........................................................................................ 2-5

VALVE CLEARANCE.............................................................................. 2-6

SPARK PLUG.......................................................................................... 2-8

ENGINE OIL ............................................................................................ 2-9

OIL FILTER.............................................................................................. 2-9

FUEL HOSE........................................................................................... 2-10

FUEL FILTER ........................................................................................ 2-10

CARBURETOR...................................................................................... 2-10

DRIVE CHAIN........................................................................................ 2-11

BRAKE .................................................................................................. 2-13

TIRE ....................................................................................................... 2-16

STEERING............................................................................................. 2-16

FRONT FORK........................................................................................ 2-17

REAR SUSPENSION ............................................................................ 2-17

CHASSIS BOLTS AND NUTS .............................................................. 2-18

COMPRESSION PRESSURE CHECK ........................................................ 2-20

OIL PRESSURE CHECK ............................................................................. 2-21

AUTOMATIC CLUTCH INSPECTION ......................................................... 2-22

2-2 PERIODIC MAINTENANCE

PERIODICAL MAINTENANCE SCHEDULE

The chart below lists the recommended intervals for all the required periodic service work necessary t keep
the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilometers
and time for your convenience.

NOTE:
More frequent servicing may be performed on motorcycles that are used under severe conditions.

PERIODIC MAINTENANCE CHART

NOTE:
I: Inspection and adjust, clean, Lubricate or replace as necessary
C: Clean R: Replace T: Tighten

Interval

Km

1,000 4,000 8,000 12,000 16,000 20,000 24,000

Item

Months

161218243036

Battery

IIIIIII

Exhaust pipe bolts

TTTTTTT

Air cleaner

—C C R C C R

Valv e clea ranc e

IIIIIII

Spark

IIRIRIR

Engine oil

RRRRRRR

Replace every 4,000 km

Engine oil filter

R—R— R I R

Replace every 8,000 km

Fuel hose

IIIIIII

Clutch

IIIIIII

Fuel filter

IIIIIII

Engine idle rpm (Carburetor) I I I I I I I

Throttle cable play (Carburetor)

IIIIIII

Drive chain I I I I I I I

Brakes

IIIIIII

Tires

IIIIIII

Steering I I I I I I I

Cylinder head nut

TTTTTTT

Suspension

—— I — I — I

Chassis bolts and nuts

TTTTTTT

PERIODIC MAINTENANCE 2-3

LUBRICATION POINTS

Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.
Major lubrication points are indicated below.

NOTE:
*Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.
*Lubricate exposed parts which are subject to rust, with a rust preventative spry whenever the motorcycle

has been operated under wet or rainy condition.

SPEEDOMETER
GEARBOX
FRONT WHEEL
BEARING
AXLE SHAFT
FRONT BRAKE CAM

SPEEDOMETER
CABLE

SIDE STAND PIVOT
AND SPRING HOOK

CENTER STAND PIVOT
AND SPRING HOOK

DRIVE CHAIN

BRAKE LEVER
HOLDER

THROTTLE CABLE

STEERING STEM
BEARING

KICK STARTER LEVER
PIVOT

BRAKE PEDAL
PIVOT

REAR BRAKE CAM
REAR WHEEL
BEARING
AXLE SHAFT

2-4 PERIODIC MAINTENANCE

MAINTENANCE AND TUNE-UP PROCEDURES

This section describes the servicing procedures for each item of the Periodic Maintenance requirements.

BATTERY

•The battery must be removed to check the electrolyte level
and specific gravity.

•Open the seat.

•Remove battery - and + leads at the battery terminals.



•Remove battery from the frame.

• Check electrolyte for level and specific gravity. Add distilled
water, as necessary, to keep the surface of the electrolyte
above the LOWER. Level line but not above the UPPER.
Level line.

For checking specific gravity, use a hydrometer to determine the
charged condition.



09900-28403: Hydrometer

Battery type ….GM3-3B

Battery type …. YB5L-B

An S.G. reading of 1.22 [YB5L-B] 1.20 [GM 3-3B] (AT 20oC) or
under means that the battery needs recharging off the machine:
Take if off and charge it from a recharge. Charging the battery in
place can lead to failure of the regulator or rectifier.

•To install the battery, reverse the procedure cribbed above.

Inspect initially at 1,000 km (1 month) and Every
4,000 km (4 months) thereafter.

When removing the battery, disconnect the negative
cable first and then the positive cable.

Standar d specific gravity 1.26 at 20 °C

Standar d specific gravity 1.28 at 20 °C

Hydrometer

PERIODIC MAINTENANCE 2-5



•Make sure that the breather pipe is tightly secured and
undamaged, and is routed as shown in the photograph.

EXHAUST PIPE BOLTS

•Tighten the exhaust pipe clamp bolts and muffler mounting
bolts to the specified torque with a torque wrench.



Exhaust pipe nut: 1.1 kg-m
Muffler mounting bolt: 2.6 kg-m

AIR CLEANER

If the air cleaner is clogged with dust, intake resistance will be
increased with a resultant decrease in output and an increase
the fuel consumption. Check and clean the element in the
following manner.

•Loosen the 3 screw.

•Take off the air cleaner cover.

•Remove the element from the case.

When installing the battery lead wires fix the +

Led

first and -

lead last.

Tighten Initially at 1,000 km (1 month) and Inspect
Every 4,000 km (6 months) thereafter.

BATTERY

BATTERY BREATHER HOSE

Clean Every 4,000 km (6 months).

2-6 PERIODIC MAINTENANCE

•Loosen the four screw and remove the air cleaner cover.

•Remove the air cleaner element.

•Carefully use an air hose to blow the dust form the cleaner
element inside.

•Reinstall the cleaned or new cleaner element in the reverse
order of removal.





VALVE CLEARANCE

Excessive valve clearance results in valve noise and insufficient
valve clearance results in valve damage and reduced power. At
the distances indicated above, check and adjust the clearance to
the following specification.

Clean Every 4,000 km (6 months).
Valve clear ance (When cold):
IN.: 0.04 - 0.07 mm
EX.: 0.04 - 0.07 mm

•Remove the center leg shield.

•Remove the leg shields, left and right.

•Remove the carburetor by loosening the screws

The procedure for adjusting the valve clearance is as follows:

NOTE:
*The piston must be at (TDC) on the compression stroke in order

to check the valve clearance or to adjust valve clearance.

*The clearance specification is for GOLD state.

Always use air pressure on the side of the steel sheet.

If driving under dusty condition, clean the air cleaner
element more frequently. The surest way to accelerate
engine wear is to use the engine without the element
or to use a ruptured element. Make sure that the air
cleaner is in good condition at all times. Life of the
engine depends largely on this component !

Inspect Initially at 1,000 km (1 month) and Every
4,000 km (6 months) thereafter.

PERIODIC MAINTENANCE 2-7

•Remove spark plug, valve inspection caps 1 and valve timing
inspection plug 2.

•Remove the magneto cover cap and rotate the magneto rotor
with box wrench to set the piston at (TDC) of the compression
stroke. (Rotate the rotor until the “T” line on the rotor is
aligned with the center of hole on the magneto cover.

•Insert the thickness gauge to the clearance between the valve
stem end and the adjusting screw on the rocker arm.



09900-20803: Thickness gauge

•If clearance is off the specification, bring it into the specified
range by using the special tool.

•Reinstall spark plug, valve inspection caps, valve timing
inspection plug and magneto cover cap.



09917-14910: Tappet adjust driver

NOTE:
*The clearance specification is for GOLD state

1

2

Rockerarm

Adjuster Screw

Valve clearance

2-8 PERIODIC MAINTENANCE

SPARK PLUG

•Carbon deposits on the spark plug will prevent good sparking
and cause misfiring. Clean the deposits off periodically

•If the center electrode is fairly worn down, the plug should be
replaced and the plug gap set to the specified gap using a
thickness gauge.



09900-20803: Thickness gauge

•Check spark plug for burnt condition. If abnormal, replace the
plug as indicated below.

•Tighten the spark plug in the cylinder head with the specified
torque by using special tool.

 Spark plug: 1.1 kg-m
 9930-10121: Spark plug socket wrench set



Inspect at 4,000 km (6 month) Replace Every
8,000 km (12 months).

Spark plug gap 0.6 - 0.7 mm

NGK NIPPON DENSO REMARKS

CR6HSA 0.6 - 0.7 mm 0.6 - 0.7 mm

Confirm the thread size and reach when replacing the
plug. If the reach is too short, carbon will be deposited
on the screw portion of the plug hole and engine dam­age may result.

0.6-0.7 mm.

mm.

PERIODIC MAINTENANCE 2-9

ENGINE OIL

After a long period of use, the engine oil will deteriorate and
quicken the wear of sliding and interlocking surfaces. Replace
the transmission oil periodically following the procedure below.

• Start the engine to warm up the oil, this will facilitate draining
of oil, Turn off the engine.

•Unscrew the oil filler cap 1 and drain plug 2 and drain the oil
completely.

•Tighten the drain plug.

•Supply the good quality SAE 40 motor oil.

•Start up the engine and allow it to run for several minutes at
idling speed.

•Turn off the engine and wait about one minute.

•Check the oil level with the dipstick.

The level found in the dipstick should be between “L” (Low) and
“F” (Full) lines
Oil viscosity and classification: SAE 40, API: SF, SG



Oil drain plug: 1.8 kg-m

NOTE:
To check the oil level, holding the motorcycle vertically, reinsert
the dipstick until the threads touch filler neck, but do not screw
the cap in.

OIL FILTER

The engine oil should be changed while the engine is hot. Oil
filter replacement at the above intervals should be done together
with engine oil change.

•Keep the motorcycle upright with Center stand.

•Place an oil pan under the engine.

•Remove the oil filter cap 1 by removing the bolts.

•Remove the oil filter 2 and install the new one.

•Replace the filter and tighten the bolts securely

NOTE:
Before installing the new oil filter and filter cap, check to be sure
that the spring

3

and new o-rings 4,5 are installed correctly.

Replace Initially at 1,000 km (1 month) and Every
4,000 km thereafter.

1

!

LOWER UPPER

1

2

3

4

5

2-10 PERIODIC MAINTENANCE

NECESSARY AMOUNT OF ENGINE OIL

OIL CHANGE: 800 ml
OIL FILTER CHANGE: 900 ml
OVER HAUL: 1,000 ml

FUEL HOSE

FUEL FILTER

CARBURETOR

IDLE RPM (Idling adjustment)

•Adjust the throttle cable play.

•Warm up the engine

NOTE:

Make this adjustment when the engine is hot.

•Connect an electric tachometer.

•Start up the engine and set its speed at any where between
1,500 and 1,600 r/min by turning adjust screws.

Engine idle speed: 1,500 ± 100 r/min



09900-26006: Tachometer

THROTTLE CABLE PLAY

Throttle cable play A should be 2-4 mm as measured at throttle
grip when turning the throttle grip lightly. If the play A in the
throttle cable is incorrect, adjust it in the following way:

•Loosen the lock nut 1 and turn the adjuster 2 in or out until
the specified play is obtained.

•Tighten the lock nut 1 while holding the adjuster 2.

Throttle cable play A: 2- 4 mm.

Inspect at 4,000 km (6 month) Replace Every 4 years

Clean Every 8,000 km (12 months).

Inspect Initially at 1,000 km (1 month) and Every
4,000 km (6 months) thereafter.

A

2

1

PERIODIC MAINTENANCE 2-11



DRIVE CHAIN

Visually inspect the drive chain for the below listed possible
malconditions.

•Loose pins

•Damaged rollers

• Rusted links

•Twisted or seized links
Excessive wear

If any defects are found, the drive chain must be replaced.

Checking

•Remove the chain case by loosening four screws 1
and bolt 2.



•Count out 21 pins (20-pitch) on the chain measure the
distance between the two. If the distance exceed following
limit, the chain must be replaced.

Drive chain 20-pitch length: 259 mm

After the adjustment is completed, check that handlebar movernent does not raise the engine
idle speed and that the throttle grip returns smoothly and automatically.

Inspect Initially at 1,000 km (1 month) and Every
4,000 km (6 months) thereafter. Clean and lubricate
Every 1,000 km

The standard drive chain is DAIDO DID 428. SUZUKI
recommends that this standard drive chain should be
used for the replacement.

1

2

1 2 3

19 20 21

2-12 PERIODIC MAINTENANCE

NOTE:

When replacing the drive chain, replace the drive chain and
sprockets as a set.

CLEANING AND LUBRICATING

Wash the drive chain in cleaning solvent and lubricate it with
chain lube or motor oil. If the motorcycle operates under dusty
conditions, frequent rapid acceleration or at sustained high
speeds, the drive chain should be cleaned and lubricated more
often.

ADJUSTING

•Loosen the nut 1.

•Loosen or tighten the adjusters 2 until the chain has 15-25

mm of slag at the middle between engine and rear sprockets,
the mark 3 on the swing arm must be at the same position
the scale mark on both chain adjuster 4 to ensure that the
front and rear wheels are correctly aligned.

•Tighten the axle nut 1 after adjusting the drive chain and
tighten the adjuster nuts 2.



Rear axle nut: 4.5 kg-m

2

3

4 1

1

15-25 MM

PERIODIC MAINTENANCE 2-13

BRAKE

FRONT BRAKE (DISC TYPE)

•Keep the motorcycle upright and place the handlebars
straight.

•Check the brake fluid level by observing the lower limit line on
the front brake fluid reservoir.

•When the level is below the lower limit line, remove the front
handlebar’s cover and replenish with brake fluid that meets
the following specification.



Specification and Classification: DOT 4



BRAKE PADS (DISC TYPE)

The extent to brake pad wear can be checked by observing the
grooved limit line 1 on the pad. When the wear exceeds the
grooved limit line, replace the pads with new ones. (Refer to
page 5-12.)



(BRAKE)
Inspect Initially at 1,000 km (1 month) and Every
4,000 km (6 months) thereafter.

(BRAKE HOSE AND BRAKE FLUID)
Inspect Every 4,000 km (6 month) Replace houses
Every 4 years. Replace Fluid Every 2 years.

The brake system of this motorcycle is filled with a
glycol-based brake fluid. Do not use or mix different
types of fluid such as silicone-based or petroleum­based. Do not use any brake fluid taken from oil, used
or unsealed containers. Never re-use brake fluid left
over from the last servicing or stored for a long period.
Brake fluid, if it leaks, will interfere with safe running
and immediately discolor painted surfaces. Check the
brake hoses and hose joints for cracks and oil leakage
before riding.

Replace the brake pad as a set, otherwise braking
performance will be adversely affected.

2-14 PERIODIC MAINTENANCE

AIR BLEEDING THE BRAKE FLUID CIRCUIT
(DISC BRAKE)

Air trapped in the fluid circuit acts like a cushion to absorb a
large proportion of the pressure developed by the master cylin­der and thus interferes with the full braking performance of the
brake caliper. The presence of air is indicated by “sponginess”
of the brake lever and also by lack of braking force.
Considering the danger to which such trapped air exposes the
machine and rider, it is essential that, after remounting the brake
and restoring the brake system to the normal condition, the
brake fluid circuit be purged of air in the following manner.

•Fill up the master cylinder reservoir to the upper end of the
inspection window. Replace the reservoir cap to prevent entry
of dirt.

•Attach a pipe to the caliper bleeder valve, and insert the free
end of the pipe into a receptacle.

•Front brake: Bleed air from the air bleeder valve.

•Squeeze and release the brake lever several times in rapid
succession and squeeze the lever fully without releasing it.
Loosen the bleeder valve by turning it a quarter of a turn so
that the bleeder valve by turning it a quarter of a turn so that
the brake fluid runs into the receptacle; this will remove the
tension of the brake lever causing it to touch the handlebar
grip. Then, close the valve, pump and squeeze the lever, and
open the valve.

•Repeat this process until the fluid flowing into the receptacle
no longer contains air bubbles.

NOTE:
Replenish the brake fluid in the reservoir as necessary
while bleeding the brake system. Make sure that there is
always some fluid visible in the reservoir.

•Close the bleeder valve, and disconnect the pipe. Fill the
reservoir with brake fluid to the “UPPER” end of the inspection
window.



Air bleeder valve: 8.0 N-m (0.8 kg-m)



BRAKE LEVER PLAY ADJUSTING(DRUM TYPE)

Adjust by turning the adjusting nut 1 so that the play 2 is
15-25 mm as follows.

Handle brake fluid with care: the fluid reacts chemi­cally with paint, plastics, rubber materials etc.

64

65

2

66

1

PERIODIC MAINTENANCE 2-15

REAR BRAKE ADJUSTING

Adjust the free travel 1 to 15-25 mm. by turning the adjusting
nut 2.

REAR BRAKE SHOE WEAR

This motorcycle is equipped with brake lining wear limit indica­tor. As shown in Fig., at the condition of normal lining wear, the
extension line of the index mark on the brake camshaft should
be within the range embossed on the brake panel with brake on.

To check wear of the brake lining, perform the following steps.

•First check if the brake system is properly adjusted.

•While operating the brake, check to see that the extension
line of the index mark is within the range on the brake panel

•If the index mark is beyond the range as shown in the Fig., the
brake shoe assembly should be replaced with a new set of
shoes.

1

2

2-16 PERIODIC MAINTENANCE

TIRE

TIRE TREAD CONDITION

Operating the motorcycle with excessively worn tires will
decrease riding stability and consequently invite a dangerous
ours situation. It is highly recommended to replace a tire when
the remaining depth of tire tread reaches the following specifica­tion.
Tire tread depth limit: 1.6 mm



09900-2080: Tire depth gauge

TIRE PRESSURE

If the tire pressure is too high or too low, steering will be adversely
affected and tire wear increased. Therefore, maintain the correct
tire pressure for good readability of shorter tire life will result. Cold
inflation tire pressure is follows.



STEERING

Ball type bearings are equipped on the steering system. Steer­ing should be adjusted properly for smooth turning of handlebars
and safe running. Over tight steering prevents smooth fuming of
the handlebars and too loose steering will cause poor stability.
Check that there is no play in the front fork assembly by support­ing the machine so that the front wheel is off the ground, with the
wheel straight ahead, grasp the lower fork tubes near the axle
and pull forward. If play is found, perform steering. bearing
adjustment as described in page 5-25 of this manual.

Inspect Every 4,000 km (6 months).

COLD INFLATION TIRE

PRESSURE

kPa kg/cm3

FRONT 175 1.75

REAR 225 2.25

The standard tire fitted on this motorcycle is 2.50-17
for front and 2.75-17 for rear. The use of tires other
than those specified may cause instability. It is highly
recommended to use a SUZUKI Genuine Tire.

Inspect Initially at 1,000 km (1 month) and Every
8,000 km (12 months) thereafter.

PERIODIC MAINTENANCE 2-17

FRONT FORK

Inspect the front forks oil leakage, scoring or scratches on the
outer surface of the inner tubes. Replace any defective parts, if
necessary. (Refer to page 5-19)

REAR SUSPENSION

Inspect the rear shock absorber for oil leakage and damage.
Replace any defective parts, if necessary.

Inspect Every 8,000 km (12 months).

Inspect Every 8,000 km (12 months).

2-18 PERIODIC MAINTENANCE

CHASSIS BOLTS AND NUTS

The nuts and bolts listed below are important safety related parts. They must be retightened when neces­sary to the specified torque with a torque wrench. (Refer to page 2-18 for the locations of the following nuts
and bolts on the motorcycle.)

Tighten Initially at 1,000 km (1 month) and Every
4,000 km (6 months) thereafter.

ITEM kPa kg/cm3

1Front axle nut 30.0-47.0 3.0-4.0

2Steering stem lock nut 25.0-35.0 8.0

3Handlebars clamp bolt 50.0-60.0 8.3

4--- --- ---

5Front fork cap bolt 23 2.3

6Rear axle nut 42.0-66.0 4.5

7Engine mounting nut/bolt 50.0-66.0 5.5

8Brake cam lever nut 7.0 0.7

9Front footrest bolt 20.0-31.0 1.3

10 Swing arm pivot nut 27.0-43.0 3.5

11 Rear t o rque l ink n ut 10.0-16.0 1.3

12 Rear shock absorber nut 22.0-35.0 2.9

13 Rear sprocket mounting nut 18.0-28.0 2.3

14 Spoke nipple 2.0 0.2

PERIODIC MAINTENANCE 2-19

1

5

9

13

14

6

11

8

7

10

12

2

3

2-20 PERIODIC MAINTENANCE

COMPRESSION PRESSURE CHECK (FD110XC / XCS / XCD / XCSD)

The compression of a cylinder is a good indicator of its internal condition.
The decision to overhaul the cylinder is often based on the results of a compression test.

Periodic maintenance records kept at your dealership should include compression readings foreach
maintenance service.

COMPRESSION PRESSURE SPECIFICATION

Low compression pressure can indicate any of the following conditions:

•Excessively worn cylinder wall

•Worn-down piston or piston rings

•Piston rings stuck in grooves

•Poor seating of valves

•Ruptured or otherwise defective cylinder head gasket

COMPRESSION TEST PROCEDURE

NOTE:
*Before testing the engine for compression pressure, make sure that the cylinder head nuts are tightened

to the specified torque values and valves are properly adjusted.
*Have the engine warmed up by idling before testing.
*Be sure that the battery used is in fully-charged condition.

Remove the parts concerned and test the compression pressure
in the following maner.

•Support the motorcycle with the center stand.

•Remove the spark plug.

•Fit the compression gauge in the plug hole, while taking care
that the connection tight.

•Keep the throttle grip in full-open position.

•While cranking the engine a few seconds with the starter, and
record the maximum gauge reading as the compression of
that cylinder.



09915-64510: Compression gauge
09915-63310: Adaptor

Standard Version

14.0 kg/cm

2

FD110 XC, XCS

15.0 kg/cm

2

FD110 XC, XCS

PERIODIC MAINTENANCE 2-21

OIL PRESSURE CHECK

Check periodically the oil pressure in the engine to judge roughly the condition of the moving parts.

OIL PRESSURE SPECIFICATION

If the oil pressure is lower or higher than the specification, the following causes may be considered.

LOW OIL PRESSURE

•Clogged oil filter

•Oil leakage from the oil passage way

•Damaged O-ring

•Defective oil pump

•Combination of above items

HIGH OIL PRESSURE

•Used an engine oil which is too high viscosity

•Clogged oil passage way

•Combination of above items

OIL PRESSURE TEST PROCEDURE

Check the oil pressure in the following manner.

•Support the motorcycle with the center stand.

•Install the oil pressure gauge with adapter in the position
shown in the figure.

•Connect an electric tachometer.

•Warm up the engine as follows: Summer 10 min. at
2,000 r/min. Winter 20 min. at 2,000 r/min.

•After warming up, increase the engine speed to 3,000 r/min.
(with the electric tachometer), and read the oil pressure
gauge.

09915-64510: Oil pressure gauge



09915-74531: Adaptor
09900-26006: Tachometer

Above 0.1 kg/cm.

2

Below 0.3 kg/cm.2

at 3,000 r/min., Oil temp. at 60°C

2-22 PERIODIC MAINTENANCE

AUTOMATIC CLUTCH INSPECTION

This motorcycle is equipped with an automatic clutch.
The engagement of the clutch is Gove med by engine RPM and
centrifugal mechanism located in the clutch.
To insure proper performance and longer lifetime of the clutch
assembly it is essential that the clutch engages smoothly and
gradually. The following inspections must be performed:

1. INITIAL ENGAGEMENT INSPECTION

•Warm up the engine to normal operating temperature.

•Connect an electric tachometer.

•Seated on the motorcycle with the motorcycle on level ground,
increase the engine RPM slowly and note the RPM at which
the motorcycle begins to move forward.



09900-26006: Tachometer

Engagement r/min: 1,900 - 2,300 r/min

2. CLUTCH “LOCK-UP” INSPECTION

Perform this inspection to determine if the clutch is engaging
fully and not slipping.

•Apply the rear brake as firm as possible.

•Briefly open the throttle fully and note the maximum engine

RPM



Lock-up r/min: 3,150 – 3,850 r/min

Do not apply full power for more than 3 seconds or
damage to the clutch or engine may occur.

ENGINE 3-1

ENGINE

CONTENTS

3

ENGINE COMPONENTS REMOVABLE WITH THE ENGINE

IN PLACE....................................................................................................... 3-2

ENGINE REMOVAL AND REINSTALLATION.............................................. 3-3

ENGINE REMOVAL ................................................................................ 3-3

ENGINE REINSTALLATION ................................................................... 3-5

ENGINE DISASSEMBLY ............................................................................... 3-6

CYLINDER HEAD.................................................................................. 3-12

GEAR SHIFTING CLUTCH ................................................................... 3-14

CLUTCH COVER AND CLUTCH ADJUSTMENTS .............................. 3-15

ENGINE COMPONENTS INSPECTION AND SERVICE............................. 3-15

FIRST CLUTCH ..................................................................................... 3-15

GEAR SHIFTING CLUTCH ................................................................... 3-16

GEAR SHIFT FORK .............................................................................. 3-17

CRANKCASE BEARING AND OIL SEAL ............................................ 3-18

CYLINDER HEAD RELATED PARTS .................................................. 3-19

ROCKER ARM AND SHAFT................................................................. 3-19

VALVE AND VALVE SPRING DISASSEMBLY.................................... 3-20

CYLINDER HEAD.................................................................................. 3-20

VALVE ................................................................................................... 3-21

CAMSHAFT ........................................................................................... 3-26

CAMSHAFT BEARING ......................................................................... 3-26

CYLINDER DISTORTION...................................................................... 3-27

CYLINDER BORE ................................................................................. 3-27

PISTON DIAMETER .............................................................................. 3-27

PISTON PIN........................................................................................... 3-29

CONROD ............................................................................................... 3-29

STARTER CLUTCH AND STARTER DRIVEN GEAR BEARING ........ 3-30

ENGINE REASSEMBLY .............................................................................. 3-31

3-2 ENGINE

ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE

The part listed below can be removed and reinstalled without removing the engine from the frame.
Refer to the page listed in each section for removal and reinstallation instructions.

ENGINE CENTER

Exhaust pipe
Carburetor
Cam chain tensioned adjuster
Cylinder head
Piston
Cylinder
Camshaft

ENGINE LEFT SIDE

Engine sprocket
Magneto cover
Rotor
Gearshift switch
Starter clutch
Starter idle gear
Starter motor
Cam drive chain
Oil filter
Oil filter cover

ENGINE RIGHT SIDE

Clutch cover
First clutch
Primary drive gear
Oil sump filter
Oil pump assembly
Shift cam
Gearshift shaft
Oil pump drive gear

ENGINE 3-3

ENGINE REMOVAL AND
REINSTALLATION

ENGINE REMOVAL

Before taking the engine out of the frame, wash the engine with
a steam cleaner. The procedure of engine removal is sequen­tially explained in the following steps.

•Support the motorcycle with the center stand.

•Remove the oil drain plug 1 to drain out engine oil.

(See page 2-8)

•Open the seat and disconnect the battery( - ) lead wire.
(See page 6-2 and 6-6)

•Remove the leg shields, left and right. (See page 5-1.)

•Remove the frame covers, left and right.

•Remove the footrest bar. See page 2-8.)

•Remove the exhaust pipe by removing its clamp bolts and
muffler mounting bolts.

•Remove the engine sprocket cover.

•Remove the chain case by loosening four bolts 1 and one
bolt 2.

88

89

1

90/91

92

93

1

2

3-4 ENGINE

•Remove the engine sprocket by loosen the bolt 1 and
sprocket lock plate 2.

•Remove the sprocket.

•Disconnect the several lead wires.

•Magneto lead wire coupler 3.

•Gearshift indicator lead wire coupler 4.

•Engine ground coupler

•Disconnect the engine breather pipe.

•Disconnect the spark plug cap 5.

•Disconnect the starter motor ( + ) lead coupler.

•Disconnect the fuel hose 6.

•Disconnect the fuel tap vacuum hose 7 from the intake pipe.



•Remove the carburetor with intake pipe.

•Remove the engine mounting bolts and dismount the engine.

Gasoline is very explosive. Extreme care must
be taken.

3

1

2

4

5

6 7

ENGINE 3-5

ENGINE REINSTALLATION

Reinstall the engine in the reverse of engine removal.

•Install the engine mounting bolts and tighten the nuts to the
specification.



Engine mounting nut: 55 N-m (5.5 kg-m)

•Install the drive chain.



•Tighten the exhaust pipe clamp bolts and muffler mounting
bolts to specified torque.



•After remounting the engine, following adjustments are
necessary.

* Throttle cable............................. (Page: 2-9)

* Drive chain................................. (Page: 2-10)

* Rear brake pedal....................... (Page: 2-12)

* Idling speed............................... (Page: 2-9)

•Pour 1,000 ml of engine oil SAE 40 graded SF or SG into the
engine after overhauling engine. Start up the engine and
allow it run for several seconds at idle speed. About one min­ute after stopping engine, check oil level. If the level is below
the “L” line, add oil until the level reaches the “F” line.
(See page 2-8).

The drive chain joint clip should be attached in the
way that the slit end will face opposite to the direction
of rotation.

Check the wire, cable and hose routing.
(See page 7-10.)

UPPER

LOWER

3-6 ENGINE

ENGINE DISASSEMBLY

The procedure for engine disassembly is sequentially explained
in the following steps.

•Remove the gearshift lever and kick starter lever.

•Remove the cam pocket cover.

•Remove the cap and insert the screwdriver into the slotted
end of the cam chain tension adjuster and turn it clockwise to
lock the spring tension.

NOTE:
When remove the camshaft, the piston must be at (TDC) on
compression stroke.

•Remove the cam.

•Loosen and remove the cylinder head nut and bolt.

•Remove the cylinder head.

ENGINE 3-7

•Remove the chain guide and gasket.

•Loosen the cylinder nut and remove the cylinder.

•Place a clean rag over the cylinder base to prevent piston pin
circlip from dropping into the crankcase and then, remove the
piston pin circlip with a long-nose pliers.

•Remove the piston pin and piston.

•Remove the clutch cover.

•Remove the bush 2, spring 1 and washer 3 shaft gear shift.

1

2

3

3-8 ENGINE

•Loosen the nut by using the special tool.



09910-20115: Con-rod stopper

•Remove the first clutch assembly, circlip and primary drive
gear.

•Remove the clutch bearing.

•Loosen the nut by using the special tool.



09930-40113: Rotor holder

•Loosen the spring mousing bolt by using the special tool

•Remove the clutch pressure and spring clutch

•Remove the clutch sleeve hub 1.

•Remove the oil pump 2.

•Remove the oil sump filter 3.

2

3

1

ENGINE 3-9

•Remove the oil washer and oil pump drive gear.

•Remove the shift cam stopper bolt 1.

•Remove the shift cam pin bolt 2.

•Remove the shift cam stopper plate, shift cam pin guide and
pins.

•Remove the outer bearing, clutch bearing, and gearshift shaft
and plate shift cam.

•Remove the starter motor and magneto cover.

•Remove the oil filter.

1

2

3-10 ENGINE

•Loosen the rotor nut by using the special tool.

 09930-44550: Rotor holder

•Loosen the rotor by using the special tool.



09930-34951: Rotor remover

•Loosen the screw and remove the starter clutch plate

•Remove the starter driven gear.

•Remove the starter driven idle gear by removing the circlip 1

and washer.



09900-06107: Snap ring-pliers

•Remove the camshaft drive chain.

•Remove the gearshift switch, gearshift pin and spring.

1

ENGINE 3-11

•Remove the crankcase screws.

•Separate the right and left crankcase by using the special
tool.



09920-13120: Crankcase/crank shaft separator

•Remove the kick starter shaft by turning it.

•Remove the gearshift fork shaft, gearshift fork and gearshift
cam.

•Remove the transmission assembly.

3-12 ENGINE

•Remove the crankshaft by using a plastic mallet.

•Remove the oil seals and bearings by using the special tools.

09914-79610: Bearing installer
09921-20210: Bearing puller
09930-30102: Sliding shaft



09913-76010: Bearing installer
09925-98221: Bearing installer
09913-75520: Bearing installer
09913-75821: Bearing installer

CYLINDER HEAD

•Remove the chain guide by loosening the bolt.

•Remove the cylinder head right cover and valve inspection
caps.

ENGINE 3-13

•Remove the rocker arm shafts by using an 8 mm thread bolt.

NOTE:
Intake and exhaust rocker arm shafts differ in the length.

•Remove the rocker arms

•Remove the wave washer

•Remove the spring valve by compress the valve springs with
the special tools.



09916-14510: Valve spring compressor
09916-14521: Attachment

•Remove the two valve cotter halves from the valve stem by
using the special tool.



09916-14511: Tweezers

•Remove the valve spring retainer, inner spring and outer
spring

•Pull out the valve from the other side.
For reassembling the valve and valve springs, refer to page
3-24.



3-14 ENGINE

•Remove the stem seal 1 with a long nose pliers.

•Take out the spring seat 2.

For installing the valve spring seat and valve stem seal, refer to
pages 3-21 and 22.

•Remove the valve guide by using the special tool.



09916-44310: Valve guide remover

For servicing the valve guide, refer to page 3-21.

GEAR SHIFTING CLUTCH

1

2

ENGINE 3-15

CLUTCH COVER AND CLUTCH
ADJUSTMENTS

•Loosen the lock nut and remove clutch release arm.

CLUTCH ADJUSTMENT

•Loosen the lock nut 1.

•First, turn the adjusting bolt clockwise by a one turn and turn it
counterclockwise until resistance is felt, then turn it clockwise
by a 1/8 turn.

•Tighten the lock nut.

ENGINE COMPONENTS INSPECTION
AND SERVICE

FIRST CLUTCH

CLUTCH SHOE INSPECTION

Inspect the linings for crack, uneven wear or burning. Measure
the lining thickness with a venire calipers. If any defects are
found or measurement exceeds the limit, replace the clutch
shoe assembly with a new one.
Service Limit: No groove



09900-20101: Venire calipers

•Clutch springs-visually inspect the clutch springs for stretched
coils or broken coils.



Clutch shoes or springs must be changed as a set and
never individually.

3-16 ENGINE

•Clutch wheel-inspect visually the condition of the inner clutch
wheel surface for scoring, cracks, or uneven wear.

CLUTCH HOUSING INSPECTION

Inspect the inner surface of clutch housing for deep scratches or
discoloration caused by burning.
If any defects are found, replace the clutch housing with a new
one.

Inspect each roller and one way clutch retainer for abnormal
wear or damage.
If any defects are found, replace them as a set.
1 Clutch wheel
2 One way clutch spring
3 One way clutch roller
4 One way clutch retainer
5 One way clutch inner race

GEAR SHIFTING CLUTCH

DRIVE PLATE AND DRIVEN PLATES

Clutch plates in service remain in oily condition as if they were
lubricated with oil. Because of this condition, both drive and
driven plates are subject to little wearing action and therefore
last much longer. Their life depends largely on the quality of oil
used in the clutch and also on the way the clutch is operated.
These plates are expendable, they are meant to be replaced
when found whom down or the respective limit: use a caliper to
check thickness.



09900-20101: Venire calipers

Drive plate

Item Service Limit

Thickness 2.60 (No groove)

Claw width 11.20 mm

ENGINE 3-17

Drive plate distortion

GEAR SHIFT FORK

Using a thickness gauge, check the shifting fork clearance in
the groove of its gear.this clearance for each of the two shifting
forks plays an important role in the smoothness and positive
ness of shifting action. each fork has its prongs fitted into the
annular groove provided in itsgear. in operation, there is sliding
contact betweenfork and gear axially. too much a clearance is,
therefore , liable to clearance check is noted toexceed the limit
specified, replace the fork its gear,or both.



09900 – 2088803: thickness gauge

Shift fork – groove clearance

Shift fork – groove with

Shift fork thickness

Item Service Limit

No. 1, 2 0.1 mm

Item Service Limit

No. 1

0.5 mm.

No. 2

Item 4.5 – 4.6 mm.

Item 4.3 – 4.4 mm.

3-18 ENGINE

CRANKCASE BEARING AND OIL SEAL

BEARING INSPECTION

Rotate the bearing inner race by finger to inspect
for abnormal play, noise and smooth rotation while
the bearings are in the crankcase.
Replace the bearing in the following procedure if
there is anything unusual.

LEFT CRANKCASE OIL SEAL AND BEARING
DISASSEMBLY

•Remove the left crankcase oil seal by using the special tool.



09913-50121: Oil seal remover



•Remove the left crankcase bearing by using the special tool.



09930-30102: Sliding shaft
09913-76010: Bearing installer
09921-20210: Bearing puller
09925-98221: Bearing installer

NOTE:
If abnormal noise does not occur, it is necessary to remove the
bearing.

LEFT CRANKCASE BEARING REASSEMBLY

•Install the left crankcase bearing into the crankcase by using
the special tool.



09913-75520: Bearing installer
09913-75821: Bearing installer
09914-79610: Bearing installer

LEFT CRANKCASE BEARING REASSEMBLY

•Install the oil seal into the crankcase using the special tool.



09913-75821: Bearing installer

•Apply a small quantity of SUZUKI SUPER GREASE “A”
TO THE LIP OF OIL SEAL.



99000-25010: SUZUKI SUPER GREASE “A”

The removed oil seal should be replaced with
a new one.

clearance

clearance



ENGINE 3-19

RIGHT CRANKCASE BEARING DISASSEMBLY

•Remove the right crankcase bearing by using the special tool.



09913-75821: Bearing installer
09921-20210: Bearing puller
09930-30102: Sliding shaft

RIGHT CRANKCASE BEARING REASSEMBLY

•Install the right crankcase bearing into the crankcase by using
the special tool.



09913-70122: Bearing installer
09914-79610: Bearing installer
0991375821: Bearing installer

CYLINDER HEAD RELATED PARTS

ROCKER ARM AND SHAFT

DISASSEMBLY

•Pull out the intake and exhaust rocker arm shafts by using an
8 mm thread bolt.

3-20 ENGINE

Measure the diameter of rocker arm shaft with a micrometer
Standard: 9.981 - 9.990 mm



09900-20205: Micrometer (0-25 mm)

When checking the valve rocker arm, the inside diameter of the
valve rocker arm and wear of the camshaft contacting surface
should be checked.
Standard: 10.003-10.018 mm



09900-20605: Dial calipers

REASSEMBLY

•Apply engine oil to the rocker arm shafts.

•Install the rocker arms and shafts to the cylinder.

NOTE:

•The exhaust rocker arm shaft is shorter than the intake one.

•Be sure to bring the threaded side of the rocker arm shaft to
the outside when installing it.

•Reassembly the spring rocker arm exhaust only.

VALVE AND VALVE SPRING DISASSEMBLY

•Compress the valve springs with the valve spring compressor.

•Remove the valve cotters from the valve stem.

09916-14510: Valve spring compresso



09916-14521: Attachment
09916-84511: Tweezers

•Remove the valve spring retainer and valve springs.

For reassembling the valve and valve springs, refer to page 3-24

CYLINDER HEAD

DISTORTION

De-carbon the combustion chamber.
Check the gasket surface of the cylinder head for distortion with a
straightedge and thickness gauge, taking a clearance reading at
several places as indicated. If the largest reading at any position
of the straightedge exceeds the limit, replace the cylinder head.



Service Limit: 0.05 mm
09900-20803: Thickness gauge

ENGINE 3-21

VALVE

VALVE FACE WEAR

Measure the thickness “T” and, if the thickness is found to have
been reduced to the limit, replace the valve.

NOTE:
Visually in sport each valve for wear of its seating face, Replace
any valve with an abnormally worm face.

Service Limit : 0.05 mm

VALVE STEM RUNOUT

Support the valve with “V” blocks, as shown, and check its run
out with a dial gauge. The valve must be replaced if the run out
exceeds the limit.

Service Limit: 0.05 mm



09900-20701: Magnetic stand
09900-20606: Dial gauge (1/100 mm)
09900-21304: V-block (100 mm)

VALVE HEAD RADIAL RUNOUT

Place the dial gauge at right angles to the valve head, and mea­sure the valve head radial run out. If it measures more than limit,
replace the valve

Service Limit: 0.03 mm

VALVE STEM DEFLECTION

Lift the valve about 10 mm (0.39 in) from the valve seat. Mea­sure the valve stem deflection in two directions “X” and “Y”, per­pendicular to each other, by positioning the dial gauge as
shown. If the deflection measured exceeds the limit, (see below)
then determine whether the valve or the guide should be
replaced with the new one.

Service Limit Intake and exhaust valves: 0.35 mm

VALVE STEM WEAR

If the valve stem is worn down to the limit, when measured with
a micrometer, and the clearance is found to be in excess of the
limit indicated previously, replace the valve, if the stem is with in
the limit, then replace the guide. After replacing valve or guide,
be sure to re-check the clearance.

Valve stem O.D.

IN: 4.975-4.990 mm

Standard EX: 4.955-4.970 mm

 09900-20205: Micrometer (0-25 mm)

3-22 ENGINE

VALVE GUIDE SERVICE

•Remove the valve guide with the valve guide remover.



09916-44310: Valve guide remover

•Re-finish the valve guide holes in cylinder head with a reamer
1 and handle 2.



09916-34580: Valve guide remover (10.8 mm)
09916-34542: Handle

•Fit a ring to each valve guide.

•Lubricate each valve guide with oil, and drive the guide into
the guide hole using the valve guide installer.

 09916-44310: Valve guide installer

NOTE:
Only oversized valve guides are available as replacement parts.



•After fitting the valve guides, re-finish their guiding bores with
the reamer 1 and handle. 2 Be sure to clean an oil the guides
after reaming.



09916-34570: Valve guide reamer (5.0 mm)
09916-34542: Handle

•Install the valve spring seat 3. Be careful not to confuse the
lower seat with the spring retainer 4.

Be sure to use new valve guide ring and valve guide.

3

4

ENGINE 3-23

•Lubricate valve stem seal with oil, and press-fit the seal into
position with a finger tip.



VALVE SEAT WIDTH

•Coat the valve seat uniformly with Prussian blue. Fit the valve
and tap the coated seat with the valve face in a rotating man­ner, in order to obtain a clear impression of the seating con­tact. In this operation, use the valve lapper to hold the valve
head.

•The ring-like dye impression left of the valve face must be
continuous-without any break. In addition, the width of the dye
ring, which is the visualized seat “width”, must be within the
following specification:

Standard

Valve seat width W: 0.9-1.1 mm

If either requirement is not met, correct the seat by servicing it
as follows.

VALVE SEAT SERVICE

The valve seat for both intake and exhaust valves are machined
to four different angles. (The seat contact surface is cut 45°)

09916-21110: Valve seat cutter set



(N-111,126,121,122)
09916-24311: Solid pilot: (N-100-5.0)

NOTE:
The valve set contact area must be inspected after each cut.

09916-20630: Valve seat cutter set (N-126)



09916-24311: Solid pilot (N-100-5.0)
09916-21110: Valve seat cutter set

Do not reuse the stem seals.

INTAKE

SIDE

EXHAUST SIDE

45° N -12 45° N - 122

30° N - 126 15° N - 121

60° N - 111

INTAKE

EXHAUST

VALVE SEAT

VALVE SEAT

3-24 ENGINE

•Insert the solid pilot with a slight rotation. Seat the pilot
snugly. Install the 45° cutter, attachment and T-handle.

•Using the 45° cutter, rescale and clean up the seat with one
or row turns.

•Inspect the seat by the previously described seat width mea­surement procedure. If the seat is pitted or burned, additional
seat conditioning with the 45° cutter is required

NOTE:
Cut only the minimum amount necessary from the seat to
prevent the possibility of the valve stem becoming too close to
the rocket arm for correct valve contact angle.

•If the contact area is too high on the valve or if it is too wide,
use the 15° cutter (for exhaust side) and30°/60° cutters (for
intake side) to lower and narrow the contact area.

•If the contact area is too low or too narrow, use the 45° cutter to
raise and widen the contact area. After the desired seat posi­tion and width is achieved, use the 45° cutter very lightly to
clean up any burrs caused by the previous cutting operations.



•Clean and assemble the head and valve components. Fill the
intake and exhaust ports with gasoline to check for leaks. If
any leaks, occur, inspect the valve seat and face for burrs or
other things that could prevent the valve from sealing.



NOTE:
After servicing the valve seats, be sure to check the valve
clearance after the cylinder has been reinstalled (See page 2-5)

DO NOT use lapping compound after the final cut is
made. The finished valve seat should have a velvety
smooth finish and not a highly polished or shiny
finish. This will provide a soft surface for the final
seating of the valve which will occur during the first
few seconds of engine operations.

Always use extreme caution when handling gasoline.

SOLID PILOT

CONTACT AREA TOO HIGH AND TOO
WIDE ON FACE OF VALVE

CONTACT AREA TOO LOW AND TOO
NARROW ON FACE OF VALVE

ENGINE 3-25

VALVE STEM END CONDITION

Inspect the valve stem end face for pitting and wear. If pitting or
wear of the stem end face are present, the valve stem end may
be resurfaced, providing that the length 1 will not be reduced to
less than 2 mm. If this length becomes less than 2.4 mm, the
valve must be replaced. After installing a valve whose stem end
has been ground off as above, check to ensure that the face 2
of the valve stem end is above the cotters 3.

VALVE SPRING

Check the springs for strength by measuring their free lengths
and also the force required to compress them. If the limit indi­cated below is exceeded by the free length reading or if the
measured force does not fail within the range specified, replace
both the inner and outer springs as a set.

Valve spring free length
Service Limit: 30.09 mm.



09900-20201: Venire calipers

Valve spring tens ion Standard: 147 nm. HEIGHT 25.80 mm.

VALVE AND VALVE SPRING REASSEMBLY

•Insert the valves, with their stems coated with (SUZUKI
MOLY PASTE) all around and along the full stem length with­out any break. Similarly oil the lip of the stem seal.

 99000-25140: SUZUKI MOLY PASTE



When inserting each valve, take care not to damage the lip
of the stem seal.

•Install the valve springs, making sure that the close pitch end
1 of each spring goes in first to rest on the head. The coil
pitch of both inner and outer springs very: the pitch decreases
from top to bottom, as shown in the illustration.

N

MM.

TOWARDS

HEAD

3-26 ENGINE

•Fit a valve spring retainer, compress the springs with a valve
spring compressor and fit the cotter halves to the stem end.

09916-14510: valve spring compressor



09916-14521: Attachment
09916-84511: Tweezers

CAMSHAFT

CAM WEAR

Worn-down cams are often the cause of mistimed valve opera­tion resulting in reduced output power. The limit of cam wear is
specified for both intake and exhaust cams in terms of cam
height “H” , which is to be measured with a micrometer.
Replace the camshaft if found it worn down to the limit.

Cam height “H”

Intake cam: 27.66 mm
Exhaust cam: 27.47 mm



09900-20202 : Micrometer (25-50 mm)

CAMSHAFT BEARING

Rotate the camshaft bearing outer race by finger to inspect for
abnormal play, nose and smooth rotation.
Replace the bearing in the following procedure if there is any­thing unusual.

• Remove the bearings with a bearing puller.



09913-60910: Bearing puller

NOTE:
Avoid removing the came sprocket flange and right-side bearing
from the camshaft unless you really need to do so, for example,
removing the damaged right-side bearing.



•Press in the bearing to the camshaft with a bearing installer.



09951-76010 : Bearing installer

The removed bearing should be replaced with a
new one.

ENGINE 3-27

NOTE:
*Before reassembling the cam sprocket flange onto the camshaft, apply the internal face of the cam

sprocket flange with THREAD LOCK SUPER “1303”.
*This procedure may be performed only once before camshaft replacement is required.
*Installation of the cam sprocket flange requires exact alignment to severe correction of the valve timing.
*The camshaft has automatic DE-COMPRESSOR INSTALLED. (FD 110 XC ONLY) Press in the cam

sprocket flange to the camshaft as shown in the illustration.

CYLINDER DISTORTION

Check the gasket surface of the cylinder for distortion with a
straightedge and thickness gauge, taking a clearance reading at
several places as indicated. If the largest reading at any position
of the straightedge exceeds the limit, replace the cylinder.

Service limit: 0.05 mm.



09900-20803: Thickness gauge

CYLINDER BORE

Measure the cylinder bore diameter at six places. If any one of
the measurements exceeds the limit, overhaul the cylinder and
replace the piston with an oversize, or replace the cylinder.

Service Limit: 53.595 mm



09900-20508: Cylinder bore gauge set

PISTON DIAMETER

Using a micrometer, measure the piston outside diameter at the
place 11 mm from the skirt end as shown in Fig. If the measure­ment is less than the limit, replace the piston.

Service Limit: 53.380 mm
Piston oversize: 0.5, 1.0 mm



09900-20203: Micrometer (50-75 mm)

MM.

3-28 ENGINE

PISTON CYLINDER CLEARANCE

As a result of the above measurement, if the piston to cylinder
clearance exceeds the following Limit, overhaul the cylinder and
use an oversize piston, or replace both cylinder and piston.
Service Limit: 0.120 mm

PISTON RING-GROOVE CLEARANCE

Using a thickness gauge, measure the side clearance of the 1st
and 2nd rings. If any of the clearances exceeds the limit, replace
both piston and piston rings.

Piston ring - groove clearance

Service limit: 1 st: 0.180 mm

2nd: 0.150 mm

Piston ring groove width

standard 1 st : 1.01-1.03 mm.

2 nd : 1.01-1.03 mm.
Oil : 2.01-2.03 mm.

Piston ring thickness

Standard 1 st and 2nd : 0.97 - 0.99 mm



09900-20803 : Thickness gauge

NOTE:
Using a soft-metal scraper, de-carbon the crown of the piston.
Clean the ring grooves similarly.

PISTON RING END GAP

Fit the ring in the cylinder, and measure each ring end gap using
a thickness gauge.
If any ring has an excess end gap, replace the ring.
Piston ring end gap
Service Limit 1 st and 2 nd : 0.50 mm



09900-20803: Thickness gauge

ENGINE 3-29

OVERSIZE RINGS

•Oversize piston ring The following two types of oversize pis­ton ring are used. They bear the following identification num­bers.

Piston ring 1 st. and 2nd 0.5 mm: 50

1.0 mm: 100

•Oversize oil ring
The following two types of oversize oil ring are used.
They bear the following identification marks.

Oil ring 0.5 mm: Painted red

1.0 mm: Painted yellow

•Oversize side rail
Just measure outside diameter to identify the side rail as there
is no mark or numbers on it.

PISTON PIN

PIN BORE

Using a caliper gauge, measure the piston pin bore inside diam­eter, and using a micrometer measure the piston pin outside
diameter. If the difference between these two measurements is
more than the limits, replace both piston and piston pin.

Piston pin bore

Service Limit: 14.030 mm

Piston pin O.D.

Service Limit: 13.980 mm

 09900-20605: Dial calipers

09900-20205: Micrometer (0-25 mm)

CONROD

SMALL END I.D.

Using a caliper gauge, measure the con rod small end inside
diameter.

Service Limit: 14.040 mm



09900-20605: Dial calipers

If the con rod small end bore inside diameter exceeds the limits,
replace control.

PAINT

OIL RING
SPACER

3-30 ENGINE

CONROD DEFLECTION AND CONROD BIG END
SIDE CLEARANCE

Wear on the big end of the con rod can be estimated by check­ing the movement of the small end of the rod. This method can
also check the extent of wear on the parts of the con rod’s big
end.

Service Limit: 3.0 mm

09900-20701: Magnetic stand



09900-20606: Dial gauge (1/100 mm)
09900-21304: V-block

Push the big end of the control to one side and measure the side
clearance with a thickness gauge.

Standard : 0.10-0.45 mm
Service Limit: 1.00 mm

 09900-20803 : Thickness gauge

Where the limit is exceeded, replace crankshaft assembly or
reduce the deflection and the side clearance to within the limit by
replacing the worn parts-con rod, big end bearing and crank pin
etc.

CRANK SHAFT RUNOUT

Support the crankshaft with “V” blocks as shown, with the two
end journals resting on the blocks. Position the dial gauge, as
shown, and rotate the crankshaft slowly to read the run out. Cor­rect or replace the crankshaft if the run out is greater than the
limit.

Service Limit. 0.08 mm

STARTER CLUTCH AND STARTER DRIVEN
GEAR BEARING

STARTER CLUTCH

Install the starter driven gear onto the starter clutch and turn the
starter driven gear by hand to inspect the starter clutch for a
smooth movement. The gear turns one direction only. If a large
resistance is felt to rotation, inspect the starter clutch for
damage or inspect the starter clutch contacting surface of the
starter driven gear for wear or damage. If they are found to be
damaged, replace them with new ones.

STARTER DRIVEN GEAR BEARING

Install the starter driven bearing and gear on to the crankshaft
and turn the starter driven gear by hand to inspect the starter
driven gear bearing for a smooth rotation and abnormal noise. If
abnormal noise does not occur, it is not necessary to replace the
bearin

1) STARTER IDLE GEAR

2) PUSH PIECE

3) ROLLER

4) SPRING

5) STARTER CLUTCH HUB SHIM

6) ROTOR

7) STARTER CLUTCH HOLDER

8) SHAFT

9) STARTER GEAR

ENGINE 3-31

ENGINE REASSEMBLY

The engine is reassembled by carrying out the steps of disassembly in the reversed order, but there are a
number of steps which demand special description or precautionary measures.

NOTE:
Apply engine oil to each running and sliding part before reassembling.

CRANKSHAFT

•Decide the width between the webs referring to the figure
below when rebuilding the crankshaft.

Standard width between webs: 42.0 ± 0.1 mm

•When installing the crankshaft into the crankcase, it is
necessary to pull its left end into the left crankcase by using
the special tools.

•Apply engine oil to the crankshaft bearings.



09910-32812: Crankshaft installer
09910-32820: Spacer
09911-11310: Attachment



Never install the crankshaft into the crankcase by
striking it with a plastic hammer. Always use the
special tool, otherwise crankshaft alignment accuracy
will be affected

MM.

3-32 ENGINE

CRANKSHAFT SHIM SELECTION

•Degrease the right crankshaft web, shim and inner race of the
right crankshaft bearing.

•Place the removed shim 1 on the right crankshaft.

•Put the plastic-gauges (special tool) cut out about 10 mm.
on the shim, as shown in the photograph at right.



09900-22302: Plastic gauge

•Install the right crankshaft and tighten the crankcase screws.

•Remove the crankcase screws and separate the crank case
into 2 parts, left and right, with the special tool.
(See page 3-10)



09920-13120: Crankcase separator

•Measure the width of compressed plastic-gauge with the
envelope scale.

Standard Thrust clearance: 0.01-0.07 mm

• If the thrust clearance is not within specification, select the
proper size of shim.
The shim size is printed on the shim surface.

•After selecting the proper size of shim, place it on the right
crankshaft.

LIST OF SHIMS

Part No. Shim thickness Part No. Shim thickness

09181-25051 0.60 mm 09181-25059 1.00 mm

09181-25052 0.65 mm 09181-25060 1.05 mm

09181-25051 0.70 mm 09181-25061 1.10 mm

09181-25054 0.75 mm 09181-25062 1.15 mm

09181-25055 0.80 mm 09181-25063 1.20 mm

09181-25056 0.85 mm 09181-25064 1.25 mm

09181-25057 0.90 mm 09181-25065 1.30 mm

09181-25058 0.95 mm

219

ENGINE 3-33

KICK STARTER

•Align the punch mark 1 of kick starter shaft with punch mark
2 of kick starter

•Turn the kick starter shaft counter-clockwise and then lock the
kick starter with kick starter guide.

*(A) : THREAD LOCK SUPER
“1322”

3-34 ENGINE

TRANSMISSION



•Seat the circlip in the groove and its ends A should
be located as shown in the photo.

•When mounting circlip, pay attention to the direc­tion of the circlip. Fit it to the rounded side against
the gear surface

CIRCILP

SHAFT

GEAR

ENGINE 3-35

GEARSHIFT FORK

•NO.1 gearshift fork drive and NO.2 driven

•Install the transmission assembly and gearshift forks

•Install the gearshift cam.

•Install the gearshift fork shafts.

CRANKCASE

•Wipe the crankcase mating surfaces (both surfaces)
with a cleaning solvent.

•Fit the dowel pins on to the left half of the crankcase.

•Apply engine oil to con rod big end and T/M. gears.

•Apply BOND NO. 1215 to the mating surface of the left
crankcase.



 99000-31110: SUZUKI BOND NO.1215

•Assemble the crankcases within few minutes.

NOTE:

•After crankcase crews have been tightened, check if crank­shaft rotate smoothly.

•If a large resistance is felt to rotation, try to free the shafts by
tapping the drive shaft or countershaft with a plastic hammer
as shown in photograph.

NO.1

NO.2

228

3-36 ENGINE

SHIFT CAM RETAINER

•install the shift cam retainer after applying THREAD LOCK
SUPER “1322” to the screws.



99000-32110: THREAD LOCK SUPER “1322”

ROTOR AND STATOR

•Install the stator magneto cover.

STARTER CLUTCH

•Apply a small quantity of THREAD LOCK SUPER “1303” to
the starter clutch bolts and tighten them to the specified toque
by holding the crankshaft.



99000-32030: THREAD LOCK SUPER “1303”



Starter clutch boil: 10 Nm. (1.0 kg-m)

•install the starter idle gear shaft after applying THREAD
LOCK SUPER “1322” to the screws.



99000-32030: THREAD LOCK SUPER “1303”

•install the idle gear and washer.

•Fix the idle gear circlip by using a special tool.



99000-06107: Snap ring pliers

•Install the cam chain.

232

ENGINE 3-37

•Wipe the tapered portion of the crankshaft and also the
generator rotor with a cleaning solvent.

•Install the key to the crankshaft.

•Install the rotor assembly after resembling the rotor and
starter gear.

•Apply THREAD LOCK SUPER “1303” to the thread and
tighten the nut by using the special tool.

 99000-32030: THREAD LOCK SUPER “1303”


09930-44512: Generator Rotor Holder



Rotor nut: 80 N.m (8.0 kg-m)

GEARSHIFT

Kg-m

3-38 ENGINE

•When installing the gearshift lever, align the stopper bolt with
gearshift lever relating part.

NOTE:
Install the bearing as shown in the photograph.

•When install the shift cam pin bolt, apply THREAD LOCK
SUPER “1322” to thread.



99000-32110: THREAD LOCK SUPER “1322”

•When install the shift cam stopper bolt, apply THREAD LOCK
SUPER “1342” to thread.



99000-32050: THREAD LOCK SUPER “1342



When installing the cam stopper as illustrated.

241 242

244

correct

incorrect

ENGINE 3-39

OIL PUMP

•When Installing the oil pump, use dowel pin and new O-rings.

•Apply THREAD LOCK “1342” to the oil pump securing
screws.



99000-32050: THREAD LOCK SUPER “1342”

GEAR SHIFTING CLUTCH

•Install the gear shifting clutch by using the circlip.

•Apply engine oil to push piece and drive plates.

3-40 ENGINE

FIRST CLUTCH

•When installing the clutch shoe in the clutch housing align the

boss 1 of one way clutch inner with slit 2 of clutch shoes.

•Fix the primary drive gear to clutch housing, circlip by using a
special tool.



99000-06107: Snap ring pliers

ENGINE 3-41

•Installing the first clutch to the crankshaft.

•Tighten the first clutch shoe nut to specified torque by using
the special tool.



First clutch shoe nut: 5 N-m (5.0 kg-m)

 9915-20115: Conrod holder

NOTE:
Clean the oil filter when reassembling it.

CLUTCH ADJUSTMENT

Refer to page 3-14.

PISTON AND RING

•Install space 1 into the bottom ring groove first. Then install
both side rails 2 , one on each side of the spacer. The spacer
and side rails do not have a specific top or bottom when they
are new. When reassembling used parts, install them in their
original place and direction



•1st ring and 2nd ring differ in the shape of ring face and the
face of 1st ring is chrome-plated whereas that of 2nd ring is
not. the color of 2nd ring appears darker than that of the 1st
ring.

When installing the spacer, be careful not to allow its
two ends to overlap in the groove.

correct

incorrect

3-42 ENGINE

•1st and 2nd rings have the letter “RN” marked on the top. Be
sure to bring the marked side to the top when fitting them to
the piston.

•Position the gaps of the three rings as shown. Before inserting
piston into the cylinder, check that the gaps are so located.

The following are reminders for piston installation:

•Rub a small quantity of SUZUKI MOLY PASTE on to the pis­ton pin.

•Place a clean rag over the cylinder base to prevent piston pin
circlip from dropping into crankcase, and then fit the piston pin
circlip with long nose pliers.

•When fitting the piston, turn point mark on the piston head to
exhaust side.



Use a new piston pin circlip to prevent circlip failure
which will occur with a bent one.

EXHAUST SIDE

ENGINE 3-43

CYLINDER

Before mounting the cylinder block, oil the big end and small end
of the conrod and the sliding surface of the piston.

•Inspect the oil orifice for cragged.

•Fit dowel pins to crankcase and then fit gasket.



•Hold each piston ring with the piston ring section properly and
insert them the cylinder.

•Check to ensure that the piston rings are properly inserted
into the cylinder skirt.

•Temporarily tighten the cylinder base nut.

NOTE:
When mounting the cylinder, after attaching camshaft drive
chain, keep the camshaft drive chain taut. The camshaft drive
chain must not be caught between cam drive chain sprocket and
crankcase when crankshaft is rotated.

NOTE:
There is a holder for the bottom end of cam chain guide cast in
the crankcase. Be sure that the guide is inserted property or
binding of the cam chain and guide may result.

CYLINDER HEAD

•Fit the dowel pins 1 to the cylinder and then, attach the
gasket to the cylinder.



•Copper washer 2 is positioned as shown in the photograph.

To prevent oil leakage. do not use the old gasket
again, always use a new one.

To prevent oil leakage. do not use the old gasket
again, always use a new one.

3-44 ENGINE

•Tighten the cylinder head nut to the specified torque.

 Cylinder head nut: 20 N.m (2.0 kg-m)

Cylinder head nut: 10 N.m (1.0 kg-m)
Cylinder base nut: 10 N.m (1.0 kg-m)

IGNITION TIMING

•Position “T” mark 1 on the magneto rotor with the center of
magneto cover hole 2 keeping the camshaft drive chain
pulled up ward.

NOTE:
If crankshaft is turned without drawing the camshaft drive chain
upward, the chain will be caught between crankcase and cam
chain drive sprocket.

•Engage the chain on the cam sprocket and then install
the cam sprocket on the camshaft, after align top mark
5 of cam sprocket with top mark 4 of cylinder head.

NOTE:
*Do not rotate magneto rotor while doing this.

When the sprocket is not positioned correctly, turn the
sprocket.

264

ENGINE 3-45

CAM CHAIN TENSION ADJUSTER

•Install a new gasket and the cam chain tension adjuster to the
cylinder with the two bolts and tighten them to the specified
torque.



chain tension adjuster bolt : 1.2 kg-m

NOTE:
*Before installing the cam chain tension adjuster, lock the

tension spring with a screwdriver.

*Before installing the cam chain tension adjuster, turn the

crankshaft normal direction to remove the cam chain slack
between the crank sprocket and exhaust sprocket

•After installing the cam chain tension adjuster, turn a
screwdriver counter clockwise. As the slotted of the cam
chain tension adjuster turns, the tension rod is advanced
under spring force and pushes the cam chain tension adjuster
against the cam chain.



VALVE CLEARANCE

•Check and adjust the valve clearance. Refer to page 2-5 for
procedures.

After installing the cam chain tension adjuster, check
to be sure that the adjuster work properly by checking
the slack of cam chain.

3-46 ENGINE

SHAFT DRIVE 4-1

CONTENTS

4

FUEL AND LUBRICATION SYSTEM

DRIVELINE/AXLE

FUEL SYSTEM ................................................................................................. 4-2

FUEL TANK, FUEL VALVE, FUEL FILTER AND FUEL LEVEL GAUGE ....... 4-3

FUEL TANK AND FUEL VALVE REMOVAL ......................................... 4-3

FUEL FILTER REMOVAL ....................................................................... 4-3

INSPECTION AND CLEANING .............................................................. 4-4

CARBURETOR ................................................................................................. 4-5

SPECIFICATIONS ............................................................................................ 4-5

I.D. NO. LOCATION ................................................................................ 4-5

CARBURETOR ....................................................................................... 4-6

SLOW SYSTEM ...................................................................................... 4-7

MAIN SYSTEM ........................................................................................ 4-7

STARTER SYSTEM ................................................................................ 4-8

FLOAT SYSTEM ..................................................................................... 4-8

TRANSIENT ENRICHMENT SYSTEM .................................................... 4-9

CARBURETOR REMOVAL .................................................................. 4-10

CARBURETOR JET INSPECTION ....................................................... 4-11

NEEDLE VALVE INSPECTION ............................................................ 4-11

FLOAT HEIGHT ADJUSTMENT ........................................................... 4-12

LUBRICATION SYSTEM ................................................................................ 4-13

OIL PRESSURE .................................................................................... 4-13

OIL FILTER ........................................................................................... 4-13

OIL SUMP FILTER ................................................................................ 4-13

ENGINE LUBRICATION SYSTEM CHART ......................................... 4-14

LUBRICATION SYSTEM ..................................................................... 4-15

4-2 FUEL AND LUBRICATION SYSTEM

FUEL SYSTEM

When tuning the starter motor, a negative pressure is generated in the combustion chamber. This negative
pressure draws on the fuel tap diaphragm, (through a passage way in the carburetor intake pipe) and vac­uum hose. Due to this, the negative pressure increases behind the fuel tap diaphragm, until it is higher than
the valve spring pressure. The fuel valve in the fuel tap is then forced to open (due to this diaphragm opera­tion) and allows fuel to flow into the carburetor float chamber.

FUEL TANK

FUEL HOSE

FUEL HOSE

VACUUM HOSE

CARBURETOR

FUEL VALVE

JET

NEGATIVE PRESSURE

FUEL

FUEL AND LUBRICATION SYSTEM 4-3

FUEL TANK, FUEL VALVE, FUEL FILTER
AND FUEL LEVEL GAUGE

FUEL TANK AND FUEL VALVE REMOVAL

•Remove the leg side shields/frame covers, left and right.
(See page 5-1.)

•Remove the seat by removing its mounting nuts 1.

•Remove the fuel tank mounting bolts 2.

•Remove the fuel tank mounting nuts 3 left and right.

•Disconnect the fuel hose 4 and vacuum hose 5 from the fuel
valve 6

•Remove the fuel valve mounting bolt

•Disconnect the fuel level gauge lead wire 8.

•Remove the fuel tank along with the fuel valve.

•Drain the fuel.



FUEL FILTER REMOVAL

•Remove the left leg side shield/left frame cover.
(See page 5-1.)

•Drain the fuel by disconnecting the fuel hose 9.

•Remove the fuel filter 0 from the fuel hose 9.



Gasoline is very explosive. Extreme care must be
taken.

Gasoline is very explosive. Extreme care must be
taken.

4-4 FUEL AND LUBRICATION SYSTEM

FUEL LEVEL GAUGE REMOVAL

•Remove the right leg side shield/right frame cover.
(See page 5-1.)

•Disconnect the fuel level gauge lead wire coupler 1.

•Remove the fuel level gauge 2 by removing the mounting
screws.

For inspecting the fuel level gauge, refer to page 6-18.

INSPECTION AND CLEANING

FUEL FILTER

If the fuel filter is dirty with sediment or rust, fuel will not flow
smoothly and loss in engine power may result. Clean the fuel fil­ter with a compressed air.

FUEL VALVE

Connect the vacuum pump gauge to the vacuum port of the fuel
valve as shown in the illustration. Apply negative pressure to the
fuel valve and blow the fuel inlet port. If air does not flow out,
replace the fuel valve with a new one.

Specified vacuum: 22 mm Hg



09917-47910: Vacuum pump gauge



Use a hand operated vacuum pump. Do not apply high
negative pressure to prevent the fuel tap damage.

IN

OUT

FUEL AND LUBRICATION SYSTEM 4-5

CARBURETOR
SPECIFICATIONS

I.D. NO. LOCATION

The carburetor has I.D. Number A stamped on the carburetor
body according to its specifications.

ITEM SERVICE LIMIT

Carburetor type MIKUNI VM 17

Bore size 17 mm

I.D. No. 09GF

Idle r/min

1,500  100 r/min

Float height

16 1.0 mm

Main jet (M.J.) #92.5

Main air jet (M.A.J.) 1.65 mm.

Jet needle (J.N.) 4 PA11-2

Needle jet (N.J.) E-0M

Pilot jet (P.J.) #15

Pilot outlet (P.O.) 0.7 mm.

Pilot screw (P.S.) 1 1/2 turns out

Valve seat (V.S.) 1.5 mm.

Starter jet (G.S.) # 30

4-6 FUEL AND LUBRICATION SYSTEM

CARBURETOR

1) JET NEEDLE

2) THROTTLE VALVE

3) NEEDLE JET

4) MAIN JET

5) PILOT JET

6) FLOAT

7) NEEDLE VALVE

8) FLOAT PIN

9) THROTTLE VALVE ADJUSTER
SCREW

10) PLUNGER

11) OVERFLOW PIPE

12) PILOT AIR SCREW

13) JET NEEDLE LOCKER





FUEL AND LUBRICATION SYSTEM 4-7

SLOW SYSTEM

This system supplies fuel to the engine operation with the piston valve 5 close or slightly opened. The fuel
from the float chamber 6 is metered by the pilot jet 8. Where it mixes with air coming in the pilot air jet #1
and pilot air passage 9. This mixture, rich with fuel, then goes up through to pilot air screw 4. The mixture
is discharged into the pilot air passage.

MAIN SYSTEM

This system supplies fuel during engine operation when the piston valve is ¼ -- full open. The fuel passes
through the main jet 1 and mixes with air metered by the main air jet 2. The mixture passes by the clear­ance between the needle jet 3 and jet needle 4, and then exits into the main bore after being metered by
the jet needle.

AIR

VACUUM

FUEL

1) VACUUM

2) ----

3) ----

4) PILOT SCREW

5) PISTON

6) FLOAT CHAMBER

7) PILOT AIR JET

8) PILOT JET

9) PILOT AIR PASSAGE

AIR

VACUUM

FUEL

4-8 FUEL AND LUBRICATION SYSTEM

STARTER SYSTEM

When the starter plunger 1 is lifted, the fuel metered by the starter jet 2 is mixed with the air coming from
the float chamber 3. The mixture, rich in fuel content, reaches plunger area and mixes again with air com­ing from the starter air passage 4.
The two successive mixings of fuel with air are such that a proper fuel/air mixture for starting is produced
when the mixture is sprayed out through the starter outlet 5 into the main bore.

FLOAT SYSTEM

The floats 1 and needle valve 2 are associated with the same
mechanism, so that, as the floats move up and down, the needle
valve 2 too moves likewise. When the fuel level is up in the float
chamber 3, the floats 1 are up and the needle valve 2
remains pushed up against valve seat. Under this condition, no
fuel enters the float chamber(.As the fuel level falls, the floats 1
go down and the needle valve unseats itself to admit fuel into
the chamber 3. In this manner, the needle valve 2 admits and
shuts off fuel alternately to maintain a practically constant fuel
level inside the float chamber 3.

AIR

MIXTURE

FUEL

FUEL

FUEL AND LUBRICATION SYSTEM 4-9

TRANSIENT ENRICHMENT SYSTEM

The transient enrichment system is a device which keeps fuel/air mixture ratio constant in order not to gen­erate unstable combustion when the throttle grip is returned suddenly during high speed driving. When the
throttle valve is closed suddenly, large negative pressure generated on cylinder side works on to a dia­phragm 2. The ball 0 held by the diaphragm 2 closes the air passage 3, therefore, the fuel/air mixture
becomes rich with fuel.
This system is to keep the combustion condition constant by varying the air/flue mixture ratio by
controlling air flow from the pilot air jet.

FUEL

AIR

VACUUM

MIXTURE

1) -----

2) ----

3) -----

4) PILOT SCREW

5) PISTON VALVE

6) FLOAT CHAMBER

7) PILOT AIR JET

8) PILOT JET

9) PILOT AIR PASSAGE

4-10 FUEL AND LUBRICATION SYSTEM

CARBURETOR REMOVAL

• Remove the center leg shield. (See page 5-1.)

• Remove the leg shields, left and right. (See page 5-1.)

• Remove the carburetor intake pipe 1.

• Disconnect the fuel hose 2 and 3 vacuum hose.

• Remove the starter plunger 4 from the carburetor body.

• Loosen the belt 5.

• Remove the throttle cable assembly 6.

CARBURETOR DISASSEMBLY

•Remove the carburetor intake pipe by remove the bolt.

•Remove the carburetor capby removing the screws.



09900-09003: Impact driver set

•Remove the o-ring



Replace the o-ring with a new one

FUEL AND LUBRICATION SYSTEM 4-11

•Remove the float assembly 1 by removing the pin 2.



•Remove the main jet 3.

•Remove the pilot jet 4.



•Remove the pilot air jet 5.

NOTE:
Before removing the pilot air screw, determine the setting by
slowing turning it clockwise and count the number of turns
required to lightly seat the screw. This counted number is impor­tant when reassembling pilot screw to original position.

CARBURETOR JET INSPECTION

Check following items for any damage or clogging.
* Pilot jet * Float
* Main jet * Needle valve
* Main air jet * starter jet
* Pilot screw * Gasket and o-ring
* Needle jet air bleeding hole * Pilot outlet and by- pass holes

NEEDLE VALVE INSPECTION

If foreign matter is caught between the valve seat and the
needle, the gasoline will continue flowing and cause it to
overflow. If the seat and needle are worn beyond the permissibly
limits, similar trouble will occur. Conversely, if the needle sticks,
the gasoline will not flow into the float chamber. Clean the float
chamber and float parts with gasoline. If the needle is worn as
shown in the illustration, replace it together with a valve seat.
Clean the fuel passage of the mixing chamber with compressed
air.

Do not use a wire for cleaning of passage and jets.

Do not use a wire for cleaning of passage and jets.

4-12 FUEL AND LUBRICATION SYSTEM

FLOAT HEIGHT ADJUSTMENT

To check the float height, invert the carburetor body, with the
float arm kept free, measure the height A while float arm is just
in contact with needle valve by using calipers. Bend the tongue
1 as necessary to bring the height A to this value.

Float height A: 16 ± 1.0 mm



09900-20101: Vernier calipers

JET NEEDLE ADJUSTMENT

•Remove the throttle cable.

•Remove the jet needle locker by screwdriver

•Remove the jet needle.

JET NEEDLE ADJUSTING

•Slide the circlip upper, this mixture is diluted.

• Slide the circlip lower, this mixture is rich.

REASSEMBLY

Reassemble and remount the carburetor in the reverse order of
removal and disassembly.



Replace the o-ring with a new one

FUEL AND LUBRICATION SYSTEM 4-13

LUBRICATION SYSTEM

OIL PRESSURE

Refer to page 2-18

OIL FILTER

Refer to page 2-8.

OIL SUMP FILTER

When you replace the engine oil, check to be sure that the oil
sump filter is free from any sign of rupture, also wash the oil
sump filter clean periodically.



Replace the clutch cover gasket with a new one to
prevent oil leakage.

4-14 FUEL AND LUBRICATION SYSTEM

ENGINE LUBRICATION SYSTEM CHART

CAMSHAFT

IN.ROCKER ARM

AND SHAFT

CAM FACES

EX.ROCKER ARM

AND SHAFT

CAM SPROCKET

ADN

CAM DRIVE CHAIN

PISTON AND

PISTON PIN

BY PASS

OIL SUMP FIL

TER

OIL PAN

OIL PUMP

OIL FILTER

OIL ORIFICE

CYLINDER

OIL COOLER

CYLINDER HEAD

CONROD SMALL END

CYLINDER

WALL

CONROD BIG END

BEARING

CRANKSHAFT

PRIMARY DRIVE

GEAR

FIRST CLUTCH

DRIVESHAFT LEFT

SIDE BEARING

DRIVE SHAFT

GEARS

CLUTCH

COUNTER SHAFT

GEARS

COUNTER SHAFT

LEFT SIDE BEARING

FUEL AND LUBRICATION SYSTEM 4-15

LUBRICATION SYSTEM

CHASSIS 5-1

CONTENTS

5

CHASSIS

EXTERIOR PARTS ........................................................................................ 5-3

REMOVAL ............................................................................................... 5-5

REINSTALLATION.................................................................................. 5-6

REMOVAL AND DISASSEMBLY ........................................................... 5-7

INSPECTION AND DISASSEMBLY ....................................................... 5-8

REASSEMBLY AND REMOUNTING.................................................... 5-10

FRONT WHEEL AND FRONT BRAKE (DISC BRAKE).............................. 5-12

REMOVAL AND DISASSEMBLY ......................................................... 5-12

INSPECTION AND DISASSEMNBLY................................................... 5-12

REASSEMBLY AND REMOUNTING.................................................... 5-13

BRAKE PAD REPLACEMENT ............................................................. 5-14

CALIPER REMOVAL AND DISASSEMBLY......................................... 5-14

CALIPER INSPECTION ........................................................................ 5-15

CALIPER REASSEMBLY AND REMOUNTING ................................... 5-15

MASTER CYLINDER INSPECTION...................................................... 5-17

MASTER CYLINDER REASSEMBLY AND REMOUNTING ................ 5-17

HANDLEBAR............................................................................................... 5-19

REMOVAL ............................................................................................. 5-19

REASSEMBLY ...................................................................................... 5-20

FRONT FORK AND STEERING .................................................................. 5-21

REMOVAL AND DISASSEMBLY ......................................................... 5-22

INSPECTION ......................................................................................... 5-25

REASSEMBLY AND REMOUNTING.................................................... 5-26

REAR WHEEL AND REAR BRAKE............................................................ 5-29

REMOVAL AND DISASSEMBLY ......................................................... 5-29

INSPECTION AND DISASSEMBLY. .................................................... 5-32

REASSEMBLY AND REMOUNTING.................................................... 5-33

REAR SUSPENSION................................................................................... 5-35

SWING ARM AND SHOCK ABSORBER ............................................. 5-35

REMOVAL ............................................................................................. 5-35

INSPECTION AND DISASSEMBLY ..................................................... 5-36

REASSEMBLY AND REMOUNTING.................................................... 5-37

FI SYSTEM DIAGNOSIS 5-2

5-3 CHASSIS

EXTERIOR PARTS

CENTER LEG

SHIELD

REAR FRAME COVER

UPPER COVER

LEFT FRAME COVER

REAR FENDER

BATTERY BOX

LEFT LEG SHIELD

FRONT FENDER

FRAME HEAD COVER

RIGHT LEG SHIELD

CHASSIS 5-4

FRONT HANDLEBAR’S COVER

REAR HANDLEBAR’S COVER