Suzuki RM85 (2020) User guide

FOREWORD

This manual is presented as a means whereby you
can maintain your RM85 in top working condition at
all times. Your riding skill and the maintenance steps
outlined in this manual will assure you of top perfor­mance from your machine under any type of compe­tition.

We sincerely wish you and your Suzuki motorcycle a
successful partnership for many years of happy riding.

All information, illustrations, photographs and speci­fications contained in the manual are based on the
latest product information available at the time of
publication. Due to improvements or other changes,
there may be some discrepancies in this manual.
Suzuki reserves the right to make production changes
at any time, without notice and without incurring any
obligation to make the same or similar changes to
vehicles previous built or sold.

Suzuki Motor Corporation believes in conservation
and protection of Earth’s natural resources. To that
end, we encourage every vehicle owner to recycle,
trade in, or properly dispose of, as appropriate, used
motor oil, engine coolant, and other fluid, and tires.





WARNING/





CAUTION/

NOTICE/NOTE

Please read this manual and follow its instructions
carefully. To emphasize special information, the sym-

bol  and the words WARNING, CAUTION,

NO-

TICE

and

NOTE

have special meanings. Pay par­ticular attention to messages highlighted by these
signal words:

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

Indicates a potential hazard that could re­sult in minor or moderate injury.

Indicates a potential hazard that could re­sult in vehicle or equipment damage.

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

 WARNING

CAUTION

NOTICE

GENERAL CONSIDERATIONS

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

Your eyesight is equally valuable. Wearing suitable
eye protection can help keep your vision unblurred
by the wind and help shield your eyes from
branches and airborne matter like bugs, dirt, or
pebbles kicked up by tires. Wear a helmet and eye
protection every time you ride.

• Wear protective gear
Wear proper clothing when you ride. Avoid loose
clothes or scarves, which could get caught in mov­ing parts. Abrasion injuries can be minimized by
wearing protective clothing including gloves, strong
boots that fit over the ankle, long pants, and a long
sleeve shirt or jackets. Experienced riders often
wear a kidney belt and chest or back protector for
additional comfort and protection.

• Inspect your machine before riding
Before each use, perform an inspection per “PERI­ODIC MAINTENANCE” section starting on page
2-2.

• No Passengers
Suzuki RMs are designed for the rider only.

• Weight limit
55 kg (120 lbs)

• Ride with teammates
Share the fun of motocross riding. A riding partner
can also be great help if one of you gets stranded
or injured. Of course, your friends will need their
own motorcycles because motocross models are
not designed for passengers. If none of your
friends rides motocross, ask your Suzuki dealer
how to go about joining a club. If your friends do
ride, you can all join a club – or start one of your
own!

• Practice before competing
Before you begin competing, you should practice
the skills you need to ride safely.

Review the controls on your motorcycle before
riding.

• Know your limits
Always ride within the boundaries of your own skills.
Knowing these limits and staying within them will
help you avoid accidents. Ride only in events ap­propriate for your experience.

Safely competing on a motorcycle requires that your
mental and physical skills are fully part of the ex­perience. You should not attempt to operate a mo­tor vehicle, especially one with two wheels, if you
are tired or under the influence of alcohol or other
drugs. Alcohol, illegal drugs, and even some pre­scription and over-the-counter drugs and cause
drowsiness, loss of coordination, loss of balance,
and loss of good judgement. If you are tired or un­der the influence of alcohol or other drugs, PLEASE
DO NOT RIDE your motorcycle.

• Conclusion.
The actions of other riders are unpredictable. Your
motorcycle’s condition can change. These factors
can best be dealt with by giving every ride your full
attention.

Circumstances beyond your control could lead to
an accident. You need to prepare for the unexpected
by wearing a helmet and other protective gear, and
practicing safe riding techniques to minimize the
damage to you and your machine.

May all of your rides on your new Suzuki be winning
rides!

SERIAL NUMBER LOCATION

The frame number 1 is stamped on the steering head. The engine serial number 2 is stamped on the right
side of the crankcase assembly.
Write down the serial numbers here for your future reference.

Frame No.

Engine No.

LOCATION OF LABELS

Read and follow all of the warnings labeled on your motorcycle. Make sure you understand all of the labels.
Keep the labels on your motorcycle. Do not remove them for any reason.

’

3

USE 30:1 PRE-MIXTURE OF GASOLINE AND
RECOMMENDED OIL.

SE SERVIR D’UNE PROPORTION PREMELANGEE
30:1 D’ESSENCE ET D’HUILE RECOMMANDEE.

2

Failure to follow these safety precautions may
increase your risk of injury;

• This competition motorcycle is only for use by
those with the physical and mental maturity to ride
safely.

• Adult must supervise operation.

• Wear a helmet, eye protection, and bright
protective clothing.

• Don’t ride after consuming alcohol or other drugs.

• Closed course competition use only – do not use
on public streets, roads, or highways. This motor­cycle does not meet federal and state safety (and
other) standards for street use or off-road use.

• Single rider only – weight limit 120 pounds (55 kg).

• Slow down on slippery surfaces, unfamiliar terrain,
or when visibility is reduced.

• Do not touch any moving parts or heated areas.

• Read owner’s manual carefully.

88

88

8 WARNING

• The owner’s manual contains important safety
information and instructions. If the motorcycle
has been resold, obtain the owner’s manual
from the previous owner or contact your local
Suzuki dealer for assistance.

• This motorcycle is sold “AS IS” with NO
WARRANTY OF ANY KIND. The purchaser
assumes all responsibilities concerning quality,
performance, maintenance, and repair.

THIS MOTORCYCLE IS DESIGNED FOR CLOSED COURSE
COMPETITION USE ONLY. IT DOES NOT CONFORM TO
U.S. EPA NOISE STANDARDS.

MFD BY : S UZUKI MOTOR CORPORATION

MADE IN TAIWAN

WARNINGS FOR SERVICING

Never run the engine indoors or in a garage.
Exhaust gas contains carbon monoxide, a
gas that is colorless and odorless and can
cause death or severe injury.

Only run the engine outdoors where there
is fresh air.



Hot engine and muffler can burn you.

Wait until the engine and muffler cools be­fore servicing.

Fuel can catch on fire if you do not handle
it properly. Gasoline vapors can catch fire
easily.

Do not smoke when servicing the machine.
Do not service the machine in an area where
there are open flames or sparks.



Brake fluids and engine coolant can be haz­ardous to humans and pets. Brake fluid and
engine coolant are harmful or fatal if swal­lowed, and harmful if it comes in contact with
your skin or eyes.

Keep brake fluid and engine coolant away
from children. Call your doctor immediately
if swallowed, and induce vomiting. Flush
eyes or skin with water if either brake fluid
or
engine coolant gets in eyes or comes in con­tact with skin.

 WARNING  WARNING

 WARNING

 CAUTION

Servicing the machine with engine running
can be hazardous. You can be caught in the
moving parts such as the drive chain,
sprockets, etc.

Be sure to stop the engine when servicing
the machine.

PRECAUTIONS FOR SERVICING

• Replace gaskets, circlips, O-rings and cotter pins
with new ones.

• Take care not to expand the end gap larger than
required to slip the circlip over the shaft when in­stalling a circlip.

• Use special tools where specified.

• Use genuine SUZUKI parts and recommended
oil.

• When two or more persons work together, pay
attention to the safety of each other.

• After reassembly, inspect parts for tightness and
operation.

Servicing the machine without proper
clothes and protective gear can be hazard­ous. You can be injured if you do not wear
proper clothes and protective gear.

Be sure to wear proper clothes and shoes
for servicing and wear protective glasses,
mask or gloves as necessary.

REPLACEMENT PARTS

Use only genuine SUZUKI replacement parts or their
equivalent. Genuine SUZUKI parts are high quality
parts which are designed and built specially for
SUZUKI vehicles.

NOTE: Use of replacement parts which are not
equivalent in quality to genuine SUZUKI parts can
lead to performance problems and damage.

 WARNING

 WARNING

SYMBOL MARKS AND MATERIALS

SYMBOL MARK MATERIALS

Apply SUZUKI SUPER GREASE “A”
99000-25030

Apply SUZUKI SILICONE GREASE
99000-25100

Apply THREAD LOCK “1342”
99000-32050

Apply SUZUKI BOND “1207B”
99104-31140

Use or apply DOT4 Brake fluid.

Apply THREAD LOCK SUPER “1303”
99000-32030

Use SUZUKI FORK OIL SS-05
99000-99001-SS5

SYMBOL MARK MATERIALS

Use SUZUKI REAR SUSPENSION OIL SS-25
99000-99001-S25

Use engine coolant.

Apply engine oil or transmission oil.

Tighten a nut or bolt to the specified
torque.

Replace a part with a new one when
reassembling.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

GROUP INDEX

GENERAL INSTRUCTIONS

PERIODIC MAINTENANCE

TROUBLESHOOTING

MACHINE TUNING

ENGINE REMOVAL AND INSTALLATION

CYLINDER, PISTON AND

EXHAUST VALVE

CLUTCH

KICK STARTER

GEARSHIFTING

TRANSMISSION AND CRANKSHAFT

FUEL SYSTEM

COOLING SYSTEM

ELECTRICAL SYSTEM

FRONT AND REAR WHEELS

FRONT AND REAR BRAKES

FRONT FORK AND STEERING

REAR SUSPENSION

SERVICING INFORMATION

GROUP INDEX

GENERAL INSTRUCTIONS 1-1

GENERAL INSTRUCTIONS

LOCATION OF PARTS ...................................................................... 1- 2

FUEL AND OIL RECOMMENDATION .............................................. 1- 3

INSTRUCTING YOUNG RIDERS ...................................................... 1- 4

CONTENTS

1

1-2 GENERAL INSTRUCTIONS

LOCATION OF PARTS

1 Clutch lever
2 Engine stop switch
3 Front brake fluid reservoir
4 Throttle grip
5 Front brake lever

6 Fuel tank cap
7 Fuel valve
8 Carburetor starter knob
9 Gearshift lever

0 Rear brake fluid reservoir
A Rear suspension compression damping

adjuster

B Kick starter lever
C Front suspension compression damping

adjuster

D Front suspension rebound damping

adjuster

E Rear brake pedal
F Rear suspension rebound damping

adjuster

RM85L exists only L2 model.

GENERAL INSTRUCTIONS 1-3

FUEL AND OIL RECOMMENDATION

This motorcycle is of the two-stroke design, which requires a
premixture of gasoline and oil.

Gasoline : Unleaded gasoline minimum 90 pump ( ) oc-

tane.

Engine oil : SUZUKI CCI SUPER 2-CYCLE MOTOR LUBRI-

CANT or an equivalent Two Cycle Racing Lubricant.
Mixing ratio: 30 : 1
Fuel tank capacity: 5.0 L (1.3/1.1 US/lmp gal)

A mixture containing too little oil will cause piston sei­zure. Too much oil will cause excessive carbon formation
resulting in preignition, fouled spark plug and loss of
engine power.

Mix fuel and the engine oil at the ratio of 30:1.

NOTE:
* Mix gasoline and the engine oil thoroughly when the tempera-

ture is below 0°C (32°F). Vegetable-based oils can separate
easier than mineral oils.

* Use premixture oil as soon as possible after mixing, or lubrica-

tion performance of the engine oil can decrease.
* Do not mix vegetable-based oil and mineral oil.
* Insert the end of the breather hose into the steering stem head

after refueling.
* SUZUKI highly recommends the use of ECSTAR brand engine

oil. ECSTAR has been specially formulated for your SUZUKI

product and contributes to the desired motorcycle performance

and ideal riding experience.

NOTICE

Gasoline Oil

(L) (ml)

5.0 166

10.0 333

15.0 500

20.0 666

Gasoline Oil

( gal.) (oz)

1.0 5.4

2.0 10.7

3.0 16.0

4.0 21.4

R + M
2

1-4 GENERAL INSTRUCTIONS

Allowing a child to operate this competition motorcycle
without adult supervision can be hazardous. Without su­pervision, the child may ride beyond his or her abilities
and lose control of the motorcycle. Take action if your
child begins to ride beyond his or her abilities.

Children differ in skills, strength, and judgment and some
children may not be able to operate youth-size competi­tion motorcycles safely. You should always supervise your
child’s use of the motorcycle. Use of the motorcycle
should be controlled by the parents in relation to the
rider’s age, physique, and operating intelligence and ma­turity. Permit continued use only if you determine that the

child has the ability to operate the motorcycle safely.

INSTRUCTING YOUNG RIDERS

IMPORTANT ADVICE TO PARENTS

Safety is important. The sight of a new motorcycle excites a child’s
imagination; and the anticipation of riding is often so great as to
make them forget the importance of safety precautions. Please go
through this manual with your child, page by page, and help your
child understand not only the mechanism but also the rules of cour­tesy and safety precautions. The RM85 requires the parent’s co­operation and supervision to ensure safe riding.

OPERATING SKILL

Rule 1. Know the mechanism. Memorize the name of each con­trol. The name suggests its function. Know the route of drive from
engine to wheels. Learn the order of INSPECTING THE MOTOR­CYCLE BEFORE each use. It is highly recommended that the
parent teach by demonstration.

Rule 2. Your child should be a skilled motorcycle rider before riding
a competition motorcycle for the first time. Rehearse before riding
for the first time. Let the child mount the machine and do a dry
rehearsal. Watch how the child operates the controls, particularly
throttle, clutch, and brake. Make sure gearshift pattern and shifting
sequence are memorized. Smooth simultaneous braking with the
front and rear brakes is very important.

Rule 3. Learn the technique of standing-start and stopping with
brakes. Practice makes perfect. Let the child repeat the procedure
many times until you are sure the child has learned the technique
thoroughly.

 WARNING

Here are six riding rules in two groups. Please impress these rules
on all young riders before allowing them to operate the motor­cycle.

GENERAL INSTRUCTIONS 1-5

NOTE:
Practice on level ground, free of traffic and spacious enough to
permit driving several yards with the engine powered. Let your
child develop skills gradually.

CLOTHING

Rule 4. Wear clothes that fit. Loose fitting clothes are unsafe for
riding. Loose belts, shirts and scarves, etc can be dangerous.

Rule 5. Wear protective clothing. A large part of riding fatigue
comes from loss of body heat due to wind.

NOTE:
Helmet, gloves, boots, goggles, a long-sleeved jersey, and full­length racing pants are essential items of clothing.

Rule 6. Avoid stiff clothes. Make sure that knee and elbow move­ment is free, and that torso bending is not interfered with. Free
body movements are essential for safe riding.

STARTING ENGINE

STARTING COLD ENGINE

• Turn the fuel valve lever from OFF to ON.

• Jerk the machine back and forth and be sure the gear is in neu-

tral. The machine will resist the jerking if the gear is not in neu-

tral.

HELMET

GOGGLES

GLOVES

BOOTS

OFF

ON

OFF

OFF

OFF

ON

1-6 GENERAL INSTRUCTIONS

• Pull the starter knob out.

• Close the throttle. Kick the kick starter lever to start the engine. If
the engine fails to fire up, kick again. If third or fourth attempt
fails, then push back starter knob to original position, and open
the throttle wider by turning the throttle grip fully. Then kick the
kick starter lever again. As this motorcycle has a primary kick
start system, the engine can be started with the transmission in
any gear position, only if the clutch is disengaged by squeezing
the clutch lever.

• Upon starting the engine, run it for 30 to 60 seconds to stablize
its speed.

• Push the starter knob back to original position.

STARTING WARM ENGINE

• Shift the transmission into neutral.

• Open the throttle partially (1/8 – 1/4).

NOTE:
Operation of the starter knob is not necessary to start the warm
engine.

• Kick the kick starter lever.

GENERAL INSTRUCTIONS 1-7

 WARNING

STARTING OFF

• Pull in the clutch lever fully and push the gearshift lever down to
change the gear from neutral to low position.

• Release the clutch lever gently while twisting the throttle grip
slowly.

Twisting the throttle grip fully in standing start can jump
the machine and it can throw you off the seat.

Twist the throttle grip gradually when starting off.

• Pick up speed just a little on low. Twist throttle grip forward and
pull in clutch lever; kick up gearshift lever while twisting back the
throttle grip. Now pick up speed on second. Repeat this sequence
to shift upward step by through third, fourth and fifth to top.

BRAKING

• To slow down, (1) twist throttle grip forward, and (2) brake front
and rear wheels. Just before you come to a stop, pull-in clutch
lever and shift down into NEUTRAL.

1-8 GENERAL INSTRUCTIONS

• An attempt to slow down by braking alone is dangerous, particu­larly braking of the front wheel alone. The front wheel may slide
out (front wheel braking) or rear wheel might skid sidewise (rear
wheel braking).

Braking when making a turn can lose balance and con­trol.

Brake only when riding straight.

 WARNING

1/2

STOPPING ENGINE

• Twist the throttle grip forward.

• Pull in the clutch lever and shift into neutral.

• Hold in engine stop switch until the engine stops.

• Turn the fuel valve lever from ON to OFF.

BREAK-IN (RUNNING-IN)

WHEN THE MOTORCYCLE IS NEW

1)Warm up the engine bofore starting off.

2)Ride for 1 hour using less than 1/2 throttle opening with various
throttle opening.

3)Ride for 1 hour using less than 3/4 throttle opening with various
throttle opening.

• The break-in (running-in) period is the period of greatest wear.

• The bolts and nuts of the new machine can loosen quickly. Be
sure to retighten the bolts and nuts during the break-in (running­in) period.

WHEN ENGINE PARTS ARE REPLACED

Follow the same produce when any of the following parts are re­placed:

Piston
Piston ring
Cylinder
Crankshaft
Crankshaft bearing

PERIODIC MAINTENANCE 2-1

PERIODIC MAINTENANCE

INSPECTION BEFORE PRACTICE/RACE ...................................... 2- 2

PERIODIC MAINTENANCE CHART ................................................ 2- 3

SPARK PLUG .................................................................................... 2- 4

AIR CLEANER .................................................................................. 2- 4

TRANSMISSION OIL ........................................................................ 2- 6

ENGINE COOLANT .......................................................................... 2- 7

CLUTCH CABLE ............................................................................... 2- 8

THROTTLE CABLE........................................................................... 2- 9

FUEL HOSE ...................................................................................... 2- 9

FUEL VALVE ..................................................................................... 2- 9

CYLINDER HEAD, CYLINDER AND PISTON .................................. 2-10

EXHAUST VALVE .............................................................................. 2-10

EXHAUST SILENCER....................................................................... 2-11

DRIVE CHAIN AND SPROCKETS ................................................... 2-11

DRIVE CHAIN GUIDE, BUFFER, TENSIONER ROLLER ................ 2-13

BRAKES ............................................................................................ 2-14

FRONT FORK ................................................................................... 2-15

REAR SUSPENSION ........................................................................ 2-15

WHEELS AND TIRES ....................................................................... 2-16

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

LUBRICATION .................................................................................. 2-17

TIGHTENING TORQUE ..................................................................... 2-18

CONTENTS

2

2-2 PERIODIC MAINTENANCE

INSPECTION BEFORE RACE

WHAT TO CHECK CHECK FOR

All items of inspection
before practice above plus.

Air cleaner Cleanliness

Clutch Clutch disc plates wear and distortion

Brake pads Wear

Sprockets Wear

Fuel tank • Leakage

• Fuel filter clogging

Fuel hose Damage

Exhaust pipe Damage

Piston and Cylinder • Combustion chamber carbon deposit

• Piston head carbon deposit

• Piston and cylinder wear

Front fork • Smooth operation

• Front fork air pressure

INSPECTION BEFORE PRACTICE

WHAT TO CHECK CHECK FOR

Spark plug • Heat range, fouled electrode, tightness

• Loose high-tension cord

Air cleaner element Lubrication

Transmission oil Oil level

Engine coolant Engine coolant level

Cooling system • Radiator hose damage

• Engine coolant leak

Clutch • Play

• Smooth operation

Throttle • Play

• Smooth operation

Brake fluid Fluid level
Brakes • Brake lever position brake pedal height

• Brake lever/pedal play

• Operation

Drive chain Slack, lubrication, chain joint clip condition

Drive chain guide/buffer Wear, damage

Suspension • Smooth operation

• Front fork air pressure

Wheels • Spoke tension

• Rim lock tightness

Tires Tire pressure

Steering Smoothness, play
Exhaust pipe Firm fixation

Bolts and nuts Tightening torque

PERIODIC MAINTENANCE 2-3

PERIODIC MAINTENANCE CHART

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

Interval

races

Every Every Every

race 3 races 9 races

Service

hours

Every Every Every

Remarks

Item

2 hours 6 hours 18 hours

Spark plug I R –

Air cleaner C – –

Replace air cleaner element as
necessary.

Transmission oil – R – Change after 1st initial break-in.

Replace radiator hose and engine

Cooling-system I – – coolant every year.

Flushing for overhaul or storage.

Clutch I – – Replace clutch plates as necessary.
Throttle cable and

clutch cable

I & L – –

Carburetor I – –
Fuel hose I – – Replace every 4 years.
Piston – – R
Piston ring – R –
Cylinder head, cylinder

–C–
Exhaust valve – C –
Muffler I – –
Drive chain I & L R – Adjust slack every 30 minutes.
Engine sprocket I – –

Check and retighten sprocket bolts

Rear sprocket I – – at initial and subsequent 10 minutes of

riding and each race thereafter.
Drive chain buffer – R –
Drive chain guide – R –
Kick starter lever I & L – –
Brake I – – Replace brake hose and fluid every year.
Front fork oil – R – Change after 1st initial break-in.

Front fork I – –

Check front fork inner tube frequently

for abnormality. Check the air pressure.
Rear suspension Check rear suspension system

system pivoting I – – frequently and apply the grease to the
portion pivoting portion as necessary.

Tire I – –

Spoke nipple

I––

Inspect every 20 min. up to initial

2 hours then check before each ride.
Steering I – –
Bolts and nuts T – – Retighten every 1 hour.

NOTE: R = Replace, C = Clean, T = Tighten, I = Inspect and clean, adjust lubricate or replace if necessary,

L = Lubricate.

2-4 PERIODIC MAINTENANCE

SPARK PLUG

• Inspect the spark plug condition, electrode color, carbon de­posits, spark plug gap, and washer damage, after removing the
spark plug.

NOTE:
Remove the dirt around the spark plug before removing the spark
plug to prevent dirt from entering the combustion chamber.

• Inspect the porcelain tip color.

Porcelain tip color Cause

• Hot type spark plug

• Advanced ignition timing

White (overheated)

• Lean air/fuel mixture

• Deteriorated fuel

• Cold type spark plug

• Retarded ignition timing

Black (fouled)

• Rich air/fuel mixture

• Rich oil/gasoline mixture

• Check the spark plug gap with a thickness gauge.

 Spark plug gap: 0.7 – 0.8 mm (0.028 – 0.031 in)
 Standard Spark plug

NGK BR10ES

Changing the spark plug heat range improperly can dam­age the engine.

Select the spark plug heat range only after adjusting the
ignition timing, carburetor setting and oil/gasoline mix­ture.

• Tighten the spark plug with specified tightening torque after tight­ening the spark plug temporarily with fingers.

 Spark plug: 28 N

.

m (2.8 kgf.m, 20.5 lb-ft)

NOTICE

AIR CLEANER

AIR CLEANER ELEMENT REMOVAL

• Remove the seat.

• Remove the air cleaner cap 1.

• Remove the wing nut 2.

• Remove the element from the element holder.

0.7 – 0.8 mm
(0.028 – 0.031 in)

PERIODIC MAINTENANCE 2-5

WASHING

• Fill a washing pan large enough to hold the element with a

non-flammable cleaning solvent A. Immerse the element in
the solvent and wash it.

A: MOTUL AIR FILTER CLEAN or equivalent cleaning solvent

• Squeeze the element by grasping it to remove excess solvent.
Do not twist or wring the element or it will develop cracks.

• Dry the element in a plastic bag, pour in some foam filter oil B
and work the oil into the element.

B: MOTUL AIR FILTER OIL or equivalent filter oil

• Squeeze the element to remove excess oil.

INSTALLATION

• Apply grease to the element base where it contacts the air
cleaner box.

• Fit the element onto the element holder.

• Install the element in the air cleaner box.

Improper element installation allows dust and dirt to en­ter the combustion chamber. It can result in piston and
cylinder wear.

Be sure to check the element seals properly after in­stalling the elements.

• Install the air cleaner cap.

NOTE:
Running the engine without the air cleaner cap can vary the car­buretion. Do not run the engine without the air cleaner cap.

NOTICE

NOTE:
Follow the instructions below to keep the air cleaner element dry
when cleaning the motorcycle.

• Cover the element with vinyl bag.

• Install the seat.

• Do not spray high pressure water to the air cleaner box.

2-6 PERIODIC MAINTENANCE

TRANSMISSION OIL

Transmission oil and exhaust pipes can be hot enough
to burn you.

Wait until the oil drain plug and exhaust pipes are cool
enough to touch with bare hands before draining oil.

8 WARNING

New and used oil and solvent can be hazardous. Chil­dren and pets may be harmed by swallowing new or used
oil or solvent. Repeated, prolonged contact with used
engine oil may cause skin cancer. Brief contact with
used oil or solvent may irritate skin.

• Keep new and used oil and solvent away from children
and pets.

• Wear a long-sleeve shirt and waterproof gloves.

• Wash with soap if oil or solvent contacts your skin.

NOTE:
* Recycle or properly dispose of used oil and solvent.
* Before starting the work, check that there is not any dust, mud,

or foreign object inside the oil jug.

TRANSMISSION OIL LEVEL INSPECTION AND
REPLENISHMENT

• Run the engine for a few minutes and stop it. Wait 5 minutes.

• Place the motorcycle on level ground and hold the motorcycle
vertically.

• Remove the oil level screw 1. Check that oil comes out of the
hole.

• If oil does not come out of the hole, open oil filler cap 2 and
add the specified oil. Tighten the filler cap and oil level screw
firmly and inspect again as above procedure.

• Tighten the filler cap and oil level screw firmly.

" Oil level screw: 5.5 N.m (0.55 kgf.m, 4.0 lb-ft)

TRANSMISSION OIL CHANGE

• Warm up the engine.

• Place the motorcycle on the level ground and hold the motor­cycle vertically.

• Remove filler cap 1 and drain plug 2. Drain oil thoroughly.

• Tighten the drain plug firmly.

" Oil drain plug: 23 N.m (2.3 kgf.m, 16.5 lb-ft)

• Pour specified amount of motor oil.

" Oil change 550 ml (1.2/1.0 US/Imp pt) Transmission oil
type: SAE 10W-40, API SG,SH,SJ,SL,SM or SN with JASO MA

• Tighten the filler cap.

• Run the engine for a few minutes and stop it. Wait a few minutes.

• Inspect the oil level. (2-6)

8 CAUTION

8 WARNING

PERIODIC MAINTENANCE 2-7

Antifreeze density Freezing point

50% –31°C (–24°F)
55% –40°C (–40°F)
60% –55°C (–67°F)

* SUZUKI highly recommends the use of ECSTAR brand cool-

ant. ECSTAR has been specially formulated for your SUZUKI
product and contributes to the desired motorcycle performance
and ideal riding experience.

 WARNING

NOTICE

Freezing point

Density (%)

Fig. 1 Engine coolant density-boiling point

ENGINE COOLANT

ENGINE COOLANT LEVEL CHECK

You can be injured by scalding fluid or steam if you
open the radiator cap when the engine is hot.

Do not open the radiator cap when the engine is hot.
Wait until engine cools.

• Remove the radiator cap 1.

• Check that the engine coolant level is at the bottom of the inlet
hole. If not, replenish the radiator with specified engine cool­ant.

• Tighten the radiator cap securely.

Improperly tightening the radiator cap will prevent the
cooling system from reaching the specified operating
pressure and will cause coolant overflow.

Tighten the radiator cap until it locks firmly.

NOTE:
* This motorcycle does not have an overflow tank at the end of

breather hose. Therefore, engine coolant level may decrease
while riding. Check the engine coolant level every time before
riding.

* When replenishing engine coolant, be sure to use engine cool-

ant mixed with distilled water at the ratio of 50 : 50. Adding only
water will dilute engine coolant and it may decrease cooling
performance.

* If the motorcycle is to be exposed to temperatures below –

31°C (–24°F), the percentage of antifreeze should be increased
to 55% or 60%, according to figure 1.

2-8 PERIODIC MAINTENANCE

COOLING SYSTEM INSPECTION

Inspect the following items before practice and races.

• Engine coolant leakage

• Radiator hose cracks and deterioration

• Radiator mounting condition

• Radiator breather hose condition

• Radiator fin condition

CLUTCH CABLE

Adjust the clutch cable play as follows:

MAJOR ADJUSTMENT

• Loosen lock nut 1.

• Turn adjuster 2 so the clutch lever has 10 – 15 mm (0.4 – 0.6

in) play at the clutch lever end before pressure is felt.

• Tighten lock nut 1.

 Clutch lever play: 10 – 15 mm (0.4 – 0.6 in)

MINOR ADJUSTMENT

• Loosen lock nut 3.

• Turn adjuster 4 so the clutch lever has 10 – 15 mm (0.4 – 0.6

in) play at the clutch lever end before pressure is felt.

• Tighten lock nut 3.

 Clutch lever play: 10 – 15 mm (0.4 – 0.6 in)

10 – 15 mm
(0.4 – 0.6 in)

 WARNING

ENGINE COOLANT REPLENISHMENT

• Drain engine coolant. (12-3)

• Pour engine coolant. (12-3)

• Use an anti-freeze and Summer engine coolant which is com­patible with aluminum radiator, mixed with distilled water at the
ratio of 50 : 50.

NOTE: The radiator, cylinder and cylinder head are made of alu­minum alloy. Using non-recommended engine coolant may cor­rode aluminum alloy and may clog the coolant passageways.

Engine coolant is harmful if swallowed or if it comes in
contact with your skin or eyes.

Keep engine coolant away from children and pets. Call
your doctor immediately if engine coolant is swallowed
and induce vomiting. Flush eyes or skin with water if en­gine coolant gets in eyes or comes in contact with skin.

PERIODIC MAINTENANCE 2-9

FUEL HOSE

• Inspect the fuel hose for damage and fuel leakage. If any de­fects are found, the fuel hose must be replaced with a new one.

• Repalce the fuel hose every four years.

THROTTLE CABLE

Inadequate throttle cable play can cause engine speed
to rise suddenly when you turn the handlebars. This can
lead to loss of rider control.

Adjust the throttle cable play so that engine speed does
not rise due to handlebar movement.

Adjust the throttle cable play as follows:

• Loosen lock nut 1.

• Turn adjuster 2 so the throttle grip has 2 – 4 mm (0.08 – 0.16
in) play in circumference.

• Tighten lock nut 1.

 Throttle cable play: 2 – 4 mm (0.08 – 0.16 in)

• Remove the throttle housing cover.

• Apply oil to the throttle cable.

• Apply grease to the throttle cable spool.

 WARNING

2 – 4 mm
(0.08 – 0.16 in)

2 – 4 mm
(0.08 – 0.16 in)

FUEL VALVE

• Drain the fuel.

• Disconnect the fuel hose 1 and remove the fuel valve 2.

Gasoline is highly flammable and explosive.

Keep heat, sparks and flames away from gasoline.

 WARNING

• Clean the fuel filter with compressed air.

NOTE:
The O-ring

3

must be replaced with a new one to prevent fuel

leakage.

NOTE:
If the fuel filter is dirty with sediment, fuel will not flow smoothly.

2-10 PERIODIC MAINTENANCE

PISTON

• Remove the piston. (6-4)

• Remove carbon deposits from the top surface of the piston.

• Check for scratches, cracks, and wear around the piston bosses.

• Remove minor scuffs with #1 000 – #1 200 sand paper.

• Check piston ring wear. Remove carbon deposits from the pis­ton ring groove.

EXHAUST VALVE

• Remove the exhaust valve. (6-4)

• Remove carbon deposits from the exhaust valve and exhaust
valve guide.

• Check for wear and damage.

• Inspect the breather hose for clogging with tar. If clogging is
found, clean up it.

NOTE:
Using several brands of engine oil may cause tar to drip from the
breather hoses.

CYLINDER HEAD, CYLINDER AND PISTON

CYLINDER HEAD

• Remove the cylinder head. (6-3)

• Remove carbon deposits from the combustion chamber sur­face.

• Inspect for pinholes, cracks and other damage.

CYLINDER

• Remove the cylinder. (6-3)

• Remove carbon deposits from the exhaust port.

• Check for scratches and wear on the cylinder sleeve.

PERIODIC MAINTENANCE 2-11

EXHAUST SILENCER

SILENCER INSPECTION AND REPLACEMENT

• Remove the seat and the right frame cover.

• Loosen the silencer mounting bolts and remove the silencer.

• Remove three bolts and extract the black frontal pipe from the
aluminum case.

• Inspect the glass wool 1 for clogging with carbon deposit or
tar.

• Replace the glass wool 1 with a new one, if necessary.

SILENCER REASSEMBLY

• Install the glass wool 1 and the black frontal pipe to the alumi­num case.

• Tighten three bolts.

NOTE:
To seal between the black frontal pipe flange and the aluminum
case, apply SUZUKI BOND 1207B to the contact area of the flange.

 99104-31140: SUZUKI BOND 1207B

DRIVE CHAIN AND SPROCKETS

DRIVE CHAIN SLACK

• Place the motorcycle on the side stand.

• Inspect the drive chain slack at the middle point between the
two sprockets.

 Drive chain slack: 40 – 50 mm (1.6 – 2.0 in)

2-12 PERIODIC MAINTENANCE

NOTE:
Reassemble the drive chain clip so the slit end faces opposite the
direction of rotation.

• Adjust the drive chain slack. (above)

Direction of travel

DRIVE CHAIN ADJUSTMENT

• Loosen the axle nut 1.

• Loosen the lock nut 2.

• Adjust the drive chain slack to the specification by turning the

adjusters 3.

• Check that both right and left alignment marks 4 are at the

same position.

• Tighten the axle nut 1 and lock nut 2.

• Replace the cotter pin 1 with a new one.

 Axle nut: 72 N

.

m (7.2 kgf.m, 52.0 lb-ft)

NOTE:
Pull the upper drive chain tight and lock it by placing a bar be­tween the drive chain and rear sprocket while tightening the axle
nut. This will help prevent the chain adjusters from coming to have
play.

20TH PITCH LENGTH

• Pull the drive chain tight and measure the 20th pitch length.

 Service Limit: 259 mm (10.2 in)

DRIVE CHAIN LUBRICATION

• Remove the chain clip and master link from the drive chain and
remove the drive chain.

NOTE:
Be careful not to bend the chain clip.

• Inspect for wear and damage of the drive chain and replace it if
necessary.

• Clean the drive chain with non-flammable cleaning solvent.

• Do not use gasoline to clean the drive chain.

• Dry the drive chain.

• Apply Suzuki Chain Lube or an equivalent to the link plates and
rollers.

• Reassemble the drive chain.

PERIODIC MAINTENANCE 2-13

Normal wear Excessive wear

SPROCKET INSPECTION

• Inspect the engine sprocket and rear sprocket for wear and
cracks. Replace the sprockets if necessary.

NOTE:
When replacing a worn sprocket, it is likely that the drive chain will
need to be replaced as well.

DRIVE CHAIN GUIDE, BUFFER, TENSIONER ROLLER

DRIVE CHAIN GUIDE

• Inspect the drive chain guide 1 for bends and damage.

NOTE:
The drive chain can hit a bent guide causing noise and drive chain
wear.

• Inspect the chain guide defense 2 for wear.

DRIVE CHAIN GUIDE BUFFER

• Inspect the drive chain guide buffer 3 for wear and cracks.

NOTE:
The drive chain can touch the swingarm directly if the chain guide
buffer is worn out. This will cause drive chain and swingarm dam­age.

DRIVE CHAIN TENSIONER ROLLER

• Inspect the drive chain tensioner rollers 4 for wear.

• Inspect the tensioner roller bolts for tightness.

 Drive chain tensioner roller bolts: 41 N

.

m

(4.1 kgf.m, 29.5 lb-ft)

2-14 PERIODIC MAINTENANCE

BRAKES

BRAKE FLUID LEVEL

• Inspect the brake fluid level in both front and rear reservoirs. If
the brake fluid level is lower than LOWER (LWR) mark, replen­ish the reservoir with the specified brake fluid to the UPPER
level. Inspect brake pad wear and brake fluid leakage if the brake
fluid level decreases.

 Brake fluid: DOT 4

Brake fluid can be hazardous to humans and pets. Brake
fluid is harmful or fatal if swallowed, and harmful if it
comes in contact with your skin or eyes.

Keep brake fluid away from children. Call your doctor
immediately if brake fluid is swallowed, and induce vom­iting. Flush eyes or skin with water if brake fluid gets in
eyes or comes in contact with skin.

The use of any fluid except DOT4 brake fluid from a sealed
container can damage the brake system and lead to an
accident.

Use only DOT4 brake fluid from a sealed container. Never
use or mix different types of brake fluid.

Spilled brake fluid can damage painted surfaces and
plastic parts.

Be careful not to spill any fluid when filling the brake
fluid reservoir. Wipe spilled fluid up immediately.

NOTE:
SUZUKI highly recommends the use of ECSTAR brand brake
fluid. ECSTAR has been specially formulated for your SUZUKI
product and contributes to the desired motorcycle performance
and ideal riding experience.

 WARNING

 WARNING

NOTICE

BRAKE PAD

• Inspect the brake pads for wear. If the brake pads are worn,

replace them with new ones. (15-4)

NOTE:
* Pump the brake lever/pedal several times to restore the brake

pads after replacing the brake pads.

* Replace both right and left pads together when replacing the

brake pads.

Wear limit

Wear limit

PERIODIC MAINTENANCE 2-15

FRONT BRAKE LEVER ADJUSTMENT

Adjust the brake lever play as follows:

• Loosen locknut 1.

• Turn in or out adjuster 2 to obtain the specified play.

 Brake lever play: 5 – 20 mm (0.20 – 0.79 in)

• Tighten the locknut 1.

Brake lever play less than 5 mm (0.20 in) can cause brake
dragging.

Do not adjust the brake lever play less than 5 mm (0.20
in).

BRAKE PEDAL HEIGHT ADJUSTMENT

Adjust the rear brake pedal height as follows:

• Loosen locknut 1.

• Adjust the brake pedal height by turning the adjuster 2 to

locate the pedal 0 – 10 mm (0 – 0.4 in) below the top face of the
footrest.

• Tighten locknut 1.

 Rear master cylinder rod locknut: 18 N

.

m

(1.8 kgf.m, 13.0 lb-ft)

FRONT FORK

• Move the front fork up and down several times and inspect for
smooth movement.

• Inspect for damage and oil leaks.

• Place a stand under the chassis tube to lift the front wheel off
the ground.

• Remove the air bleed screw and equalize the air pressure in

the front forks to atmospheric pressure. (4-8)

• Refit the air bleed screw.

• Inspect the bolts and nuts for tightness.

REAR SUSPENSION

• Move the rear suspension up and down several times and in­spect for smooth movement.

• Inspect for damage and oil leaks.

• Inspect the bolts and nuts for tightness.

5 – 20 mm
(0.20 – 0.79 in)

0 – 10 mm
(0 – 0.4 in)

 WARNING

2-16 PERIODIC MAINTENANCE

WHEELS AND TIRES

WHEEL RIM

• Inspect the wheel bearing for rattles. Replace the bearings if

necessary. (14-3 and 14-5)

• Inspect the wheel rim runout. (14-3 and 14-5)

SPOKE NIPPLE AND RIM LOCK

• Inspect the spokes for tension by squeezing the spoke nipples.

• Retighten the spoke nipples with a spoke nipple wrench so as
all spokes have same tension.

 Spoke nipple: 4 N

.

m (0.4 kgf.m, 2.9 lb-ft)

Improperly tightening the spoke nipples can damage
the wheel.

Tighten the spoke nipples less than 1/2 turn at a time.
Inspect the spoke tension and then retighten the spoke
nipple.

• Inspect the rim lock 1 for tightness.

TIRE PRESSURE

• Inspect front and rear tire pressure.

 Tire pressure (cold): 70 – 110 kPa

(0.7 – 1.1 kgf/cm

2

, 10 – 16 psi)

NOTICE

STEERING

• Inspect the steering by moving the front forward and backward,
and right and left. If the steering has play or binds, inspect steer-

ing stem head nut tightness and steering bearings. (16-13)

PERIODIC MAINTENANCE 2-17

LUBRICATION

Apply grease or oil to the moving parts to increase durability and prevent wear.

No. ITEM LUBRICANT FREQUENCY COMMENTS

Inner cable Pre-race and between Run oil through cables until it

1 ends, lever A every race exits the lower end. Lube the

cable ends where they pivot.

Throttle grip, Pre-race Lightly oil the inside of throttle

2 throttle housing, A spool. Keep free from dirt.

cable

3

Rear brake

C

Pre-race Grease the brake pedal pivot.

pedal
Swingarm Every 3 races/More Clean and pack the bearings.

4 C often according to Keep seals fresh.

conditions Grease the seals.

Rear suspen- Every 3 race/More Clean and pack the bearings.

5 sion linkage C often according to Keep seals fresh.

pivot points conditions Grease the seals.
Steering stem Every 5 races/More Clean and pack the bearings.

6 bearings C often according to Keep seals fresh.

conditions

7 Starter shaft A Pre-race Lightly oil the starter shaft.

Drive chain Pre-race and between Keep chain thoroughly lubed at

8 B every race all times. Always check wear

and alignment.

The following materials are necessary:
A. Lightweight oil such as WD-40 or penetrating oil.
B. Suzuki chain lube or an equivalent
C. Water-proof wheel bearing grease.

Follow the schedule closely. The disassembly necessary to lubricate many components is in itself valuable
preventative maintenance. It allows you to inspect for wear, fatigue, adjustment and fastener tightness and
it allows you to clean out the grit which otherwise cannot be gotten out.

Lubricating switches can damage the switches.

Do not apply grease and oil to the switches.

NOTICE

2-18 PERIODIC MAINTENANCE

TIGHTENING TORQUE

PART N.mkgf

.

m lb-ft

Cylinder head nut 28 2.8 20.5

Magneto rotor nut 35 3.5 25.5

Cylinder nut 25 2.5 18.0

Crankcase bolt 10 1.0 7.3

Clutch sleeve hub nut 70 7.0 50.5

Primary drive gear nut 70 7.0 50.5

Spark plug 28 2.8 20.5

Transmission oil drain plug 23 2.3 16.5

Transmission oil level screw 5.5 0.55 4.0

Water pump drain plug 5.5 0.55 4.0

Handlebars clamp bolt 26 2.6 19.0

Front fork upper clamp bolt (right and left) 23 2.3 16.5

Front fork lower clamp bolt (right and left) 23 2.3 16.5

Steering stem head nut 65 6.5 47.0

Front fork center bolt 55 5.5 40.0

Fork cylinder inner rod locknut 20 2.0 14.5

Front fork cap bolt 35 3.5 25.5

Master cylinder mounting bolt (front) 10 1.0 7.3

Master cylinder mounting bolt (Rear) 10 1.0 7.3

Rear master cylinder rod locknut 18 1.8 13.0

Brake hose adaptor (front) 18 1.8 13.0

Brake hose union bolt (front and rear) 23 2.3 16.5

Brake caliper mounting bolt (front) 23 2.3 16.5

Brake caliper mounting bolt (rear) 23 2.3 16.5

Brake bleeder valve (front and rear) 7.5 0.75 5.5

Disc mounting screw (front and rear) 8.5 0.85 6.0

Disc mounting nut (front) 8.5 0.85 6.0

Front axle nut 44 4.4 32.0

Engine mounting nut (front) 45 4.5 32.5

Engine mounting nut (middle) 43 4.3 31.0

Rear axle nut 72 7.2 52.0

Rear sprocket nut 40 4.0 29.0

Drive chain tensioner roller bolt 41 4.1 29.5

Spoke nipple 4 0.4 3.0

Rear swingarm pivot nut (engine mounting) 58 5.8 42.0

Rear shock absorber mounting nut (upper and lower) 60 6.0 43.5

Rear cushion lever center nut 80 8.0 58.0

Rear cushion lever front nut 60 6.0 43.5

Rear cushion rod nut 80 8.0 58.0

PERIODIC MAINTENANCE 2-19

For other bolts and nuts not listed in the table, refer to this chart.

Bolt

Conventional or “4” marked bolt “7” marked or crown headed bolt

Diameter

(mm) N.m kgf.m lb-ft N.m kgf.m lb-ft

4 2.0 0.2 1.5 2.0 0.2 1.5

5 3.0 0.3 2.0 5.0 0.5 3.5

6 6.0 0.6 4.5 10.0 1.0 7.0

8 13.0 1.3 9.5 23.0 2.3 16.5

10 29.0 2.9 21.0 50.0 5.0 36.0

12 45.0 4.5 32.5 85.0 8.5 61.5

14 65.0 6.5 47.0 135.0 13.5 97.5

16 105.0 10.5 76.0 210.0 21.0 152.0
18 160.0 16.0 115.5 240.0 24.0 173.5

– MEMO –

3

TROUBLESHOOTING

TROUBLESHOOTING 3-1

CONTENTS

TROUBLESHOOTING ......................................................................... 3- 2

ENGINE ......................................................................................... 3- 2

CHASSIS....................................................................................... 3- 5

3-2 TROUBLESHOOTING

TROUBLESHOOTING

ENGINE

Complaint Possible Cause Remedy

Engine does not start Fuel deterioration Replace.
or hard to start. No fuel flow to the carburetor

• Fuel valve clogged Clean.

• Fuel hose clogged Clean or replace.

• Fuel tank cap breather hose clogged Clean.

• Carburetor float valve malfunction Replace.
Carburetor overflow pipe clogged Clean.
Carburetor air vent pipe colgged Clean.
Too rich air/fuel mixture in combustion chamber Scavange.
Incorrect ignition timing Adjust.
No spark at spark plug 13-1
Low compression

• Piston ring worn or stuck Replace.

• Cylinder worn Replace or rebore.

• Air leak from cylinder gasket Replace.

• Air leak from crankshaft oil seal Replace.

Engine stalls. Fuel deterioration Replace.

Fouled spark plug Clean or replace.
Fuel hose clogged Clean or replace.
Air cleaner clogged Clean or replace.
Carburetor jets clogged Clean.
Low compression

• Piston ring worn or stuck Replace.

• Cylinder worn Replace or rebore.

• Air leak from cylinder gasket Replace.

• Air leak from crankshaft oil seal Replace.
Incorrect ignition timing Adjust.
Carburetor fuel level maladjustment Adjust.

Insufficient power Carburetor fuel level maladjustment Adjust.

Fuel deterioration Replace.
Brake dragging Adjust.
Exhaust pipe cracked or clogged with carbon Replace or clean.
Exhaust valve maladjustment Adjust.
Exhaust valve carbon deposits Clean.
Air cleaner element clogged Clean or replace.
Carburetor jets clogged Clean or replace.
Incorrect fuel level in carburetor Adjust.
Incorrect spark plug gap Adjust or replace.
Cylinder or piston ring worn Replace.
Reed valve malfunction Replace.
Incorrect ignition timing Adjust.

Engine runs poorly in Wide spark plug gap Adjust or replace.
low speed range. Carburetor air screw maladjustment Adjust.

Incorrect carburetor fuel level Adjust.
Improper jet needle size Replace.
Incorrect ignition timing Adjust.
CDI unit malfunction Replace.
Ignition coil damage Replace.
Magneto malfunction Replace.
Magneto short circuit Replace.

TROUBLESHOOTING 3-3

Complaint Possible Cause Remedy

Engine runs poorly in Narrow spark plug gap Adjust or replace.
high speed range. Incorrect carburetor fuel level Adjust.

Retarded ignition timing Adjust.
CDI unit malfunction Replace.
Ignition coil damage Replace.
Air cleaner element clogged Clean or replace.
Magneto short circuit Replace.
Exhaust pipe cracked Replace.
Exhaust valve malfunction Clean, adjust or.

replace.

Piston ring stuck Replace.

Exhaust valve does Carbon deposits on exhaust valve Clean.
not work. Exhaust valve damage Replace.

Governer damage Replace.
Exhaust valve shaft damage Replace.
Valve spring damage Replace.

Spark plug does not Ignition coil malfunction Replace.
ignite. Spark plug malfunction Replace.

Generator malfunction Replace.
CDI unit malfunction Replace.
Wide spark plug gap Adjust.
Engine stop switch malfunction Repair or replace.

Carbon deposits on Too rich air/fuel mixture Adjust.
spark plug porcelain. Too rich oil/gasoline mixture Adjust.

Improper spark plug heat range Replace.

Spark plug electrode Improper spark plug heat range Replace.
damage Overheating Below

Incorrect ignition timing Adjust.
Loose spark plug Tighten.
Too lean air/fuel mixture Adjust.

Overheating Low engine coolant level Replenish.

Engine coolant leak Repair.
Too lean air/fuel mixture Adjust.
Incorrect ignition timing Adjust.
Water pump malfunction Adjust or replace.
Cylinder head carbon deposits Clean.
Cylinder head O-ring damage Replace.
Exhaust pipe carbon deposits Clean or replace.
Improper spark plug heat range Replace.
Fuel deterioration Replace.
Clutch slipping Adjust or replace.
Radiator cap loose Tighten.
Radiator fins damaged Repair or replace.

Excessive coolant Radiator hose cracked or damaged Replace.
level decrease Loose radiator hose connection Repair.

Radiator cracked or damaged Repair or replace.
Water pump cover mating surface damage Replace.
Water pump cover crack Replace.
Water pump cover gasket damage Replace.
Water seal wear or damage Replace.
Radiator cap seal damage Replace.
Incorrect radiator cap valve pressure Replace.
Cylinder or cylinder head cracked Replace.
Cylinder or cylinder head O-rings damage Replace.

3-4 TROUBLESHOOTING

Complaint Possible Cause Remedy

Clutch does not Clutch lever play maladjustment Adjust.
disengage. Clutch spring damage Replace.

Clutch plates distortion Replace.

Clutch slipping Clutch cable play maladjustment Adjust.

Weakened clutch spring Replace.
Clutch pressure plate wear Replace.
Clutch plate distortion Replace.
Clutch plates worn Replace.

Transmission does not Gearshift cam damage Replace.
shift. Gearshift fork distortion Replace.

Gearshift pawl wear Replace.

Transmission gears Gearshift fork groove wear or damage Replace.
jump out. Gearshift fork distortion or wear Replace.

Gearshift cam stopper damage Replace.

Gearshift lever does not Weakened gearshift return spring Replace.
return. Gearshift lever sticking Repair or replace.

TROUBLESHOOTING 3-5

CHASSIS

Complaint Possible Cause Remedy

Heavy handling Steering stem nut overtightened Adjust.

Steering head bearings damaged or rusted Replace.
Steering stem distortion Replace.

Front wheel wobbling Loose spoke nipples Adjust.

Wheel distortion Replace.
Front wheel bearing damage Replace.
Incorrect axle tightening torque Retighten.

Rear wheel wobbling Loose spoke nipples Adjust.

Wheel distortion Replace.
Rear wheel bearing damage Replace.
Swingarm pivot bearing damage Replace.
Incorrect axle tightening torque Retighten.
Incorrect swingarm tightening torque Retighten.

Soft front suspension Weakened spring Replace.

Low oil level Replenish.
Low fork oil viscosity Replace.
Damping force maladjustment Adjust.
Damping valve malfunction Replace.
Stardard spring too soft * Use optional spring.

Hard front suspension High fork oil level Adjust.

High fork oil viscosity Replace.
Damping force maladjustment Adjust.
Inner tube distortion Replace.

Soft rear suspension Weakened spring Replace.

Damping force maladjustment Adjust.
Low gas pressure Adjust.
Standard spring too soft * Use optional spring.

Hard rear suspension Damping force maladjustment Adjust.

Damper rod distortion Replace.
Rear suspension pivoting portion out of grease Lubricate.
Standard spring too stiff * Use optional spring.

Poor braking Brake pads worn Replace.

Improper air bleeding Bleed air.
Dirty pads and disc Clean.
Brake fluid leak Repair.

Brake noise Brake pads worn Replace.

Brake disc worn Replace.
Dirty brake pads and disc Clean.

* Optional stiffer and softer springs are available.

– MEMO –

4

MACHINE TUNING

CONTENTS

MACHINE TUNING 4-1

CARBURETOR TUNING .................................................................. 4- 2

PRINCIPLES OF CARBURETOR TUNING .................................. 4- 2

CARBURETOR TUNING IN PRACTICE....................................... 4- 5

FRONT FORK TUNING ..................................................................... 4- 8

FRONT FORK ................................................................................ 4- 8

FRONT FORK SPRING REPLACEMENT AND OIL LEVEL

ADJUSTMENT ............................................................................... 4- 9

REAR SUSPENSION TUNING ......................................................... 4-13

REAR SUSPENSION..................................................................... 4-13

SUSPENSION BALANCE................................................................. 4-16

4-2 MACHINE TUNING

CARBURETOR TUNING

The carburetion of your motorcycle was carefully
selected after extensive testing. You will find that the
carburetion will function smoothly under many var­ied operating conditions. For best results we recom­mend that the adjustments and carburetion jetting
be left “as is” from the factory.

Some riders may operate their motorcycle under
extreme operating conditions such as; very high al­titudes or extreme cold and hot temperatures. In
these circumstances the jetting of the carburetor or
other adjustments may need to be altered slightly.
Riders who are not familiar with the operation and
jetting procedures of the KEIHIN carburetor should
have their local authorized Suzuki dealer perform
these alterations. Mechanically experienced riders
can alter the carburetor settings based on the fol­lowing information and specifications.

Carburetor Specifications

Bore 28 mm
Main jet #128
Jet needle 24NAAH-3rd
Slow jet #50
Air screw 2 turns out
Float height 19 mm (0.75 in)

Setting parts
(included parts)
main jet: # 125, # 130, # 135

PRINCIPLES OF CARBURETOR
TUNING

CARBURETOR COMPONENTS AND
FUNCTIONS

The carburetor consists of a number of parts as
shown below. The asterisk (*) marked parts are pre­cisely machined, which meter the intake air (oxy­gen) and fuel so that the air/fuel mixture ratio is con­trolled accurately. They can be divided by three op­eration-related groups; pilot (slow) system, interme­diate system and main system, and they achieve
their functions in each corresponding throttle open­ing range. It is necessary to have a full understand­ing of them for proper carburetor tuning.

1. Top cap

2. Spring

3. * Clip

4. * Jet needle

5. Throttle valve

6. Starter knob

7. Throttle stop screw

8. * Air screw

9. * Main jet

10. * Slow jet

11. Needle valve

12. Float

13. Float chamber

14. Jet holder

1

2

3
4

5

8

7

6

11

12

14

10

9

13

MACHINE TUNING 4-3

When performing carburetor turning first find out in
what throttle opening range an improper air/fuel
mixture is supplied, by checking the color of exhaust
smoke, spark plug, throttle response, power, etc.
Second, replace or adjust the part(s) related to the
throttle opening range by referring to the following
instructions. The sizes referred to in the illustrations
are those of standard setting.

SLOW JET

The pilot jet meters the fuel supplied to the pilot
system. Each jet size is indicated by a number.
Larger number means a larger bore diameter and
fitting a larger numbered pilot jet enriches the air/
fuel mixture.

AIR SCREW

The pilot air screw is located in the inlet air passage
and meters the air for the pilot system. As it has a
right-hand thread, tightening it makes the passage
narrower, allowing less amount of intake air to flow
and resulting in richer air/fuel mixture. Air flow adjust­ment is effective within a range of 1/2 – 2 and 1/4
turns out.

JET NEEDLE

When the throttle opening is 1/4 to 3/4, the air/fuel
mixture ratio varies depending on the fuel volume
which the vacuum at the needle jet draws through
the needle jet-to-needle clearance.

Rich

Lean

As shown below, each tuning parts is located between the air/fuel passage and has its own air/fuel mixture
adjustable range in terms of the throttle valve opening. The chart indicats that the carburetor can supply
correct air/fuel mixture to the engine in any range because of the overlapping adjustable range of the each
part.

TUNING PARTS THROTTLE VALVE OPENING

MAIN JET

NEEDLE JET

NEEDLE CLIP POSITION

SLOW JET AND AIR SCREW

THROTTLE OPENING

1/8 1/4 1/2 3/4

1 MAIN SYSTEM 2 INTERMEDIATE SYSTEM 3 SLOW SYSTEM

50

4-4 MACHINE TUNING

The main jet, like the pilot jet, meters fuel flow.

Lean

Rich

Needle
clip

1
2
3
4
5

Needle Clip Position

The jet needle is linked to the throttle valve by means
of the needle clip. Its lower part is tapered and it has
five grooves cut in the upper part where the needle
clip fits.

To adjust the air/fuel mixture with the jet needle,
change position of the needle clip which is set in the
3rd groove. The lower groove the clip is moved to,
the higher the jet needle rises and the larger the
clearance with the needle jet becomes, resulting in
a richer air/fuel mixture ratio.

The needle clip position can be changed by half to
fine-tune the setting. To change the needle clip posi­tion by half, change jet needle from 24NAAH type to
24NCDH type. This change will move the needle po­sition by half to the leaner side.

Air/fuel mixture

Needle type and

clip position

Lean 24NCDH-1st

24NAAH-1st

24NCDH-2nd

24NAAH-2nd

24NCDH-3rd

24NAAH-3rd

24NCDH-4th

24NAAH-4th

24NCDH-5th

Rich 24NAAH-5th

Jet Needle

Needle number

24NAAH

O.D.

Changing the needle itself controls air/fuel mixture
ratio particulary on lower mid-throttle opening. The
smaller the O.D., the richer the air/fuel mixture be­comes.

Air/fuel mixture Needle Number O.D.

Lean 24NAAK/24NCDK 2.415 mm

24NAAJ/24NCDJ 2.405 mm

24NAAH/24NCDH 2.395 mm

24NAAG/24NCDG 2.385 mm

Rich 24NAAF/24NCDF 2.375 mm

MAIN JET

O.D. of Needle

Clip

128

MACHINE TUNING 4-5

CARBURETOR TUNING IN PRACTICE

In the previous section, basic principles of carburetor tuning have been discussed. Described in this section
are the bases for carburetor tuning required when coping with variations in air (oxygen) concentration.

VARIATION IN AIR (OXYGEN) CONCENTRATION AND CARBURETOR CONDITIONS

As the air, affected by the temperature, altitude and humidity, gets expanded or compressed, air (oxygen)
concentration varies accordingly. Each of these three factors affects the air in different ways, and the following
graphs show their effects respectively in terms of the oxygen concentration.

In the above graphs, oxygen concentration is graduated on the vertical axis while the temperature, altitude
and humidity are on the horizontal axis respectively. Oxygen concentration is set 100% under the conditions
of 20 °C (68 °F), 0 m (0 ft) and 50% humidity. The standard carburetor setting is chosen to obtain the best
engine performance under these conditions.

The graph at the left shows that the oxygen concentration changes about 10% in the 0 to 40 °C temperature
difference, the one in the center shows about 20% change in the 0 to 2 000 m altitude difference and the
one at the right shows about 5% change in the 0 to 100% humidity difference. As for humidity, its normal
range is from 20 to 95%. Therefore the possible effect of humidity on the oxygen concentration is so little
that it can be disregarded. Consequently, we can say that the oxygen concentration varies by as much as
20% depending on the temperature and altitude under normal riding conditions. On the other hand, differ­ent from the air, the fuel (gasoline) hardly changes in volume even when such environmental conditions
change. Therefore, increase in oxygen concentration will make the air/fuel mixture richer and decrease will
make it lean.

As the carburetor mixes gasoline and air, which are metered by each jet in varying proportions to suit throttle
opening, the air/fuel mixture is affected if the air concentration itself varies as described above. Then proper
engine power output can not be attained and, should the mixture become too lean, a piston seizure may
result. To compensate for such change in the air concentration, it is required to carry out carburetor tuning
beforehand. This requirement applies to all models of motorcycles and ATVs if they are used in areas where
temperature and altitude range widely. The next section describes the procedure of the above tuning in
detail.

OXYGEN CONCENTRATION [%]

-10 0 10 20 30 40 [˚C]
10 30 50 70 90 110 [˚F]

ATOMOSPHERIC TEMPERATURE

500 1000 1500 2000 2500[m] 20 40 60 80 100 [%]

1600 3200 5000 6500 8200 [ft]

ALTITUDE HUMIDITY

100

90

80

[%]

100

90

80

4-6 MACHINE TUNING

JUDGING AIR/FUEL MIXTURE

For proper carburetor tuning, it is necessary to know
how to judge the air/fuel mixture made in the carbu­retor; whether too rich, too lean or properly mixed.
Given below are the symptoms observed when the
engine is not supplied with the proper air/fuel mix­ture ratio from the carburetor. Check each item as
reference for judging the air/fuel mixture condition.

When air/fuel mixture is too rich

1)The engine noise is dull and intermittent.

2)The engine condition becomes worse when the
starter is applied.

3)The engine condition becomes worse as it is
warmed up.

4)The engine condition improves when the air
cleaner is removed.

5)The spark plug is fouled with carbon (wet and oily).

6)The exhaust gas produces heavy smoke.

When air/fuel mixture is too lean

1)The engine overheats.

2)The engine condition improves when the starter
is applied.

3)Acceleration is poor.

4)The spark plug is burned white.

5)The speed of the engine fluctuates and lack of
power is noticed.

6)Detonation and pinging are experienced.

TUNING PROCEDURE

The following indicates the correct tuning procedure
for this motorcycle. Understand the procedure by
first riding the motorcycle where it will be used and
adjust the engine to the best condition after judging
the air/fuel mixture.

Carburetor standard setting

Main jet : #128
Jet needle : 24NAAH-3rd
Slow jet : #50
Air screw : 2 turns out

INCLUDED PARTS AND OPTIONAL PARTS
Main Jet

Air/fuel

mixture

SIZE P/NO

Lean #115 09491-23027

#118 09491-23028

#120 09491-24030

* #122 09491-24031

#125 09491-25019

#128 09491-25020

* #130 09491-26017

#132 09491-26018

* #135 09491-27016

#138 09491-27017

#140 09491-28019

#142 09491-28020

Rich #145 09491-29014

Slow Jet

Air/fuel

mixture

SIZE P/NO

Lean #45 09492-45032

#48 09492-48013

#50 09492-50023

#52 09492-52011

#55 09492-55017

Rich #58 09492-58001

Jet Needle

Air/fuel

mixture

SIZE P/NO

Lean 24NCDK 13383-03B90

24NAAK 13383-03B40

24NCDJ 13383-03B80

24NAAJ 13383-03B30

24NCDH 13383-03B70

24NAAH 13383-03B20

24NCDG 13383-03B60

24NAAG 13383-03B10

24NCDF 13383-03B50

Rich 24NAAF 13383-03B00

NOTE:
SHADED: STANDARD
* : INCLUDED PARTS
NONE : OPTIONAL PARTS

MACHINE TUNING 4-7

1 Adjustment of slow system

1) Set the air screw as specified.

2) See if the selected slow jet is correct or not by
judging the air/fuel mixture. If air/fuel mixture is
rich, replace it with smaller one. If air/fuel mixture
is lean, replace it with larger one.

Ex. Pilot jet #50

If air/fuel mixture is rich, replace it with #48
slow jet. If air/fuel mixture is lean, replace
it with #52 slow jet.

2 Adjustment of main system
With the throttle opened 3/4 to full, make main sys­tem adjustment monitoring the air/fuel mixture con­dition after completion of pilot system settings.
* If selection of the main jet is between the columns,

take the larger number main jet first to prevent the
piston seizure.

* Make sure to adjust the main system before ad-

justing the intermediate system.

Ex. Main jet #128

If air/fuel mixture is rich, replace it with
#125 main jet. If air/fuel mixture is lean,
replace it with #130 main jet.

3 Adjustment of intermediate system
Monitor the air/fuel mixture condition and adjust the
intermediate system by selecting the proper needle
size. Changing standard needle within one size
(larger or smaller) will cover almost any race condi­tion.

4 Final adjustment of slow system
After a proper standard setting has been obtained
by the procedure 1 through 3, fine tune the carbu­retor according to the actual race conditions.

1) Adjust the air/fuel mixture by tuning the air screw
within 1/2 – 2 turns out.
1/2 turn out
1 – 1/2 turns out
2 turns out

2) If the mixture can not be adjusted by the air screw
within 1/2 – 2 and 1/4 turns out range, readjust
the pilot system 3.

7 Final adjustment of intermediate system
Fine tune the intermediate system by changing the
clip position.

Lean

STD

Rich

1
2
3
4
5

4-8 MACHINE TUNING

FRONT FORK TUNING

FRONT FORK

The front fork compression and rebound damping force, and oil
quantity are adjustable for rider’s preference, rider’s weight and
course condition.

NOTE:

•

Break-in new front forks before attempting adjustment.

•

Be sure to adjust both right and left front forks equally.

COMPRESSION DAMPING FORCE ADJUSTMENT

• Turn the adjuster screw 1 clockwise until it stops. It is the stiff-

est position.

NOTE:
To set the adjuster, you must gently turn the adjuster screw clock­wise until it stops, then back it out the recommended number of
turns. Do not force the adjuster screw past the stopped position
or you may damage the adjuster.

• Turn the adjuster screw out to the standard position.

 Standard setting: 7 clicks out from the stiffest position.

REBOUND DAMPING FORCE ADJUSTMENT

• Turn the adjuster screw 2 clockwise until it stops. It is the stiff-

est position.

NOTE:
To set the adjuster, you must gently turn the adjuster screw clock­wise until it stops, then back it out the recommended number of
turns. Do not force the adjuster screw past the stopped position
or you may damage the adjuster.

• Turn the adjuster screw out to the standard position.

 Standard setting: 1 and 1/2 turns out from the stiffest

position

AIR PRESSURE ADJUSTMENT

• Place a block under the chassis tube to lift the front wheel off
the ground.

• Remove the air bleed screw 3 and equalize the air pressure in
the front forks to atmospheric pressure.

• Re-fit the air bleed screw.

MACHINE TUNING 4-9

FRONT FORK SPRING REPLACEMENT AND
OIL LEVEL ADJUSTMENT

• Remove the front forks, left and right. (16-3)

• Thoroughly clean the fork before disassembly.

Scratches or other damage on the inner tube or on the
oil seal lip will cause oil leak.

Avoid scratching or damaging the inner tube or the oil
seal. Use a mild detergent or car wash soap and sponge
out dirt with plenty of water.

NOTICE

• Drain fork oil. (16-4)

• Place the front fork vertically without spring.

• Compress it fully.

• Pour specified front fork oil up to the top level of the outer tube.

• Move the inner rod slowly with the special tool more than ten
times until no more bubbles come out from the oil.

 09940-52841: Inner rod holder

NOTE:
Refill front fork oil up to the top of the outer tube to find bubbles
while bleeding air.

4-10 MACHINE TUNING

• Refill specified front fork oil up to the top level of the outer tube
again. Move the outer tube up and down several strokes until
no more bubbles come out from the oil.

• Keep the front fork vertically and wait 5 – 6 minutes.

NOTE:
* Always keep oil level over the cartridge top end, or air may

enter the cartridge during this procedure.

* Take extream attention to pump out air completely.

• Hold the front fork vertically and adjust fork oil level with the
special tool.

NOTE:
When adjusting the fork oil level, compress the outer tube fully
without the fork spring.

 09943-74111: Front fork oil level gauge
 99000-99001-SS5: SUZUKI FORK OIL SS-05

or an equivalent fork oil

• Pull up the inner rod with the special tool.

 09940-52841: Inner rod holder

• Install the fork spring.



SPRING

STANDARD OIL OIL LEVEL

LEVEL ADJUSTABLE RANGE

STANDARD SPRING: 124 mm 114 – 147 mm

2.8 N/mm (0.28 kgf/mm) (4.88 in) (4.49 – 5.79 in)

SOFTER SPRING: OPTIONAL SPRING: 120 mm 110 – 144 mm

2.6 N/mm (0.26 kgf/mm) 51171-03B30 (4.72 in) (4.33 – 5.67 in)
STIFFER SPRING: OPTIONAL SPRING: 130 mm 117 – 148 mm

3.0 N/mm (0.30 kgf/mm) 51171-03B60 (5.12 in) (4.60 – 5.83 in)

NOTE:
* Be sure to adjust the fork oil level within the above-mentioned range, the front fork performance will deterio-

rate.

* The oil level should be increased or decreased by 3 mm (0.12 in) at a time.

* Make sure that the oil level is the same as both fork legs.

MACHINE TUNING 4-11

• Adjust the height H of the inner rod threads by turning the lock
nut 1.
H: 14 mm

• Set the rebound damping adjuster 1.5 mm (0.06 in) as shown
before assembling the front fork cap.

• Slowly turn the fork cap bolt 2 to seat at the locknut 3 by hand
tightening.

NOTE:
Be sure to adjust the rebound damping force adjuster to the soft­est position before installing the fork cap bolt.

• Hold the fork cap bolt and tighten the locknut to the specified
torque.

 Inner rod lock nut: 20 N

.

m (2.0 kgf.m, 14.5 lb-ft)

• Apply fork oil to the fork cap’s O-ring.

• Tighten the fork cap bolt to the specified torque.

 Fork cap bolt: 35 N

.

m (3.5 kgf.m, 25.5 lb-ft)

• Remount the front forks to the steering stem. (16-10)

OPTIONAL SPRING

The number of end coils shows the fork spring rate.

SOFTER SPRING STANDARD SPRING STIFFER SPRING

2.6 N/mm 2.8 N/mm 3.0 N/mm

(0.26 kgf/mm) (0.28 kgf/mm) (0.30 kgf/mm)

2 turns

2 turns

2 turns

1 turn

1 turn

1 turn

1.5 mm
(0.06 in)

1.5 mm
(0.06 in)

4-12 MACHINE TUNING

FRONT FORK TUNING PROCEDURE

Test ride the motorcycle and find out how the front suspension reacts on various types of surface. According
to the symptom noticed, adjust the front fork to the best setting for rider and race track conditions. To adjust,
attempt changing fork oil capacity and compression/rebound damping following the instructions below.

SYMPTOM SECTION ADJUSTMENT PROCEDURE

Feels too hard overall • Jump 1. Adjust both the compression and rebound

• Large bumps damping to a softer setting.

• Series of medium 2. Decrease fork oil capacity.
bumps 3. Replace the spring with an optional softer one.

Feels too soft overall • Jump 1. Adjust the compression damping to a stiffer
and bottoms • Large bump setting.

• When braking 2. Increase fork oil capacity.

3. Replace the spring with an optional stiffer one.

Feels too hard near end • Jump 1. Decrease fork oil capacity.
of travel

Feels too soft near end • Jump 1. Adjust the compression damping to a stiffer
of travel and bottoms • Large bump settting.
harshly 2. Increase fork oil capacity.

Feels too hard in the • Jump 1. Adjust the compression damping to a softer
beginning of stroke • Large bump setting.

• Series of medium 2. Replace the spring with on optional softer one.
bumps

• Series of small bumps

Feels too soft and • Series of medium 1. Adjust the compression and rebound damping
unstable bumps to a stiffer setting.

• Series of small bumps

Bounces • Jump 1. Adjust the rebound damping to a stiffer setting.

• Large bump

Bounces • Series of small bumps 1. Adjust the rebound damping to a softer setting.

NOTE:
When adjusting the front fork oil level, make sure that the oil level is within the specified range. Also, the oil
level should be increased or decreased by not more than 3 mm (Approx. 2.6 ml) at a time.
When adjusting the damping setting, attempt turning the adjuster 1 to 2 click (or 1/4 turn) at a time for each
adjustment.

MACHINE TUNING 4-13

REAR SUSPENSION

The rear suspension compression and rebound damping force,
and spring pre-load are adjustable for rider’s preference, rider’s
weight and course condition.

NOTE:
Break-in the rear suspension when riding with a new rear cush­ion unit.

COMPRESSION DAMPING FORCE ADJUSTMENT

Fully turn the damping force adjuster 1 clockwise. It is at stiffest
position and turn it out to standard setting.

NOTE:
Do not force the adjuster screw past the stopped position or the
adjuster may be damaged.

 Standard setting: 3/4 turns out from stiffest position

REBOUND DAMPING FORCE ADJUSTMENT

Fully turn the dampring force adjuster 2 clockwise. It is at stiff­est position and turn it out to standard setting.

NOTE:
Do not force the adjuster screw past the stopped position or the
adjuster may be damaged.

 Standard setting: 2 turns out from stiffest position

REAR SUSPENSION LABEL

This unit contains high-pressure nitrogen gas.
Mishandling can cause explosion.
* Keep away from fire and heat.
* Read owner’s manual for more information.

 WARNING

REAR SUSPENSION TUNING

4-14 MACHINE TUNING

REAR SUSPENSION TUNING PROCEDURE

• Adjust the rear suspension acording to the rider’s weight and
preference by referring to the table below.

(Spring replacement 17-4)

• Measure the distance L1 from the seat bolt to the chain ad­juster lock nut with the motorcycle on the stand and the rear
wheel lifted off the ground.

• Measure the distance L2 from the seat bolt to the chain ad­juster lock nut with the motorcycle off the stand and riding the
motorcycle normally in full riding gear.

• Find the sag by subtracting L2 from L1. Standard sag range is
85 – 95 mm (3.3 – 3.7 in).

Spring Spring rate Part No./Marking paint

Soft 44 N/mm (4.4 kgf/mm) RM85 62211-03B80/GREEN (2 line)

(Option) 46 N/mm (4.6 kgf/mm) RM85L 62211-03B90/GREEN

Standard

46 N/mm (4.6 kgf/mm) RM85 62211-03B90/GREEN
48 N/mm (4.8 kgf/mm) RM85L 62211-03BA0/BLACK

Hard 48 N/mm (4.8 kgf/mm) RM85 62211-03BA0/BLACK

(Option) 50 N/mm (5.0 kgf/mm) RM85L 62211-03BB0/RED

L1

SPRING PRE-LOAD ADJUSTMENT

• Remove the seat frame covers and frame side tube.

• Remove the cleaner box.

• Loosen the locknut 1 .

• Turn the adjuster 2 clockwise or counterclockwise to change

the spring pre-load.

• Tighten the locknut 1 .

 Standard spring set length:

3.1 mm (0.12 in) compressed from spring free length
(RM85)

4.8 mm (0.19 in) compressed from spring free length
(RM85L)

 Spring set length adjustable range:

2 – 12 mm (0.08 – 0.47 in) compressed from spring
free length

NOTE:
Turning the adjuster

2

without loosening the lock nut 1 can dam-

age the rear cushion unit.

• To remount the rear frame assembly reverse the sequence as
described.

MACHINE TUNING 4-15

SYMPTOM SECTION ADJUSTMENT PROCEDURE

Bottoms • Jump 1. Adjust the compression damping to a harder (H)

• Large bump setting. (See note below.)

2. Adjust the sag to a smaller measurement. (closer to
85 mm)

3. Replace the spring with an optional stiffer one.

Kicks up • Medium to large bumps 1. Adjust the rebound damping to a harder (H) setting.

• Small to medium bumps (See note below.)

• Decelerating or braking 2. Adjust the sag to a larger measurement. (closer to
95 mm)

3. Replace the spring with an optional softer one.

Hits bumps too harshly • Jump 1. Adjust the compression damping to a softer (S)

• Large bump setting. (See note below.)

• Series of medium bumps 2. Adjust the sag to a larger measurement. (closer to
95 mm)

3. Replace the spring with an optional softer one.

Feels harsh and tends to • Series of medium bumps 1. Adjust the rebound damping to a softer (S) setting.
sink • Series of small bumps (See note below.)

Feels too soft and unstable • Series of medium bumps 1. Adjust the rebound damping to a harder (H) setting.

• Series of small bumps

Provides poor traction • Accelerating 1. Adjust the compression and rebound damping to a

• Series of small bumps softer setting, one at a time alternatively until the
optimum settings are obtained.

2. Replace the spring with an optional softer one.

NOTE:
When adjusting the damping setting, attempt turning the adjuster 1/4 to 1/2 urn at a time for each adjust­ment.

When the sag

measured is:

Adjustment procedure

Less than 85 mm Increase spring pre-set length by turning
(3.3 in) the spring adjuster nut.

More than 95 mm Reduce spring pre-set length by turning
(3.7 in) the spring adjuster nut.

REAR SUSPENSION

After the sag measurement has been set between 85 mm (3.3
in) to 95 mm (3.7 in), test ride the motorcycle and adjust the
suspension for the rider and track conditions referring to the
guide below.

L2

4-16 MACHINE TUNING

SUSPENSION BALANCE

Balancing the front to rear suspension properly is the most critical adjustment for suspension performance.
If the front forks are adjusted harder than the rear suspension, such as changing to heavier front fork oil,
stiffer compression and rebound setting, air pressure build up in the forks and so on, the front forks will
collapse less on bumps. This transfers more of the motorcycle and rider weight rearward, possibly causing
the rear suspension to bottom, where as it felt fine before the front fork adjustment was made.

BALANCE TEST

Stand next to the motorcycle on level ground. Place one foot on the foot rest closest to you. Sharply push
down. The front and rear suspensions should both collapse equally.

BALANCING TIPS

• Check for air pressure build-up in front forks. Heat and altitude will increase air pressure in the front forks.

• Always stay within sag measurement limits, 85 – 95 mm (3.3 – 3.7 in), when using spring pre-set to stiffen
or soften rear suspension. If this is not possible, the next stiffer or softer accessory spring is needed.

• The rear shock compression damping can be used to fine tune suspension balance and is easy to ac­cess.

ENGINE REMOVAL AND INSTALLATION 5-1

ENGINE REMOVAL AND INSTALLATION

ENGINE REMOVAL AND INSTALLATION ...................................... 5- 2

ENGINE REMOVAL ....................................................................... 5- 2

ENGINE INSTALLATION .............................................................. 5- 5

CONTENTS

5

5-2 ENGINE REMOVAL AND INSTALLATION

ENGINE REMOVAL AND INSTALLATION

REMOVAL

• Remove the frame covers 1 (left & right) and seat 2.

• Remove the clamps 3.

• Turn the fuel valve lever to the “OFF” position and disconnect
the fuel hose.

• Remove the radiator cover 4.

• Remove the fuel tank mounting bolts 5, left and right.

• Remove the fuel tank by unhooking the band 6 from the hooked
part.

• Drain transmission oil. (2-7)

• Drain engine coolant. (12-3)

• Remove the exhaust pipe fitting springs with the special tool.

 09920-20310: Spring hook

ENGINE REMOVAL AND INSTALLATION 5-3

• Remove the muffler mounting bolts.

• Remove the exhaust pipe and muffler.

• Remove the exhaust pipe and gasket.

• Disconnect the radiator hose 1.

• Disconnect the radiator hose 2.

• Remove the spark plug cap 3 and spark plug 4.

• Disconnect the magneto lead wire coupler 5.

• Remove the lead wire/hose clamp.

5-4 ENGINE REMOVAL AND INSTALLATION

• Remove the drive chain.

• Remove the engine mounting bolts.

• Remove the magneto cover.

• Remove the clutch release arm 1 and disconnect the clutch

cable.

• Loosen the carburetor clamp screws and remove the carbure­tor.

ENGINE REMOVAL AND INSTALLATION 5-5

• Loosen the swingarm pivot nut.

• Extract three quarters of the swingarm pivot shaft so as to
keep the swingarm in position.

NOTE:
The swingarm will come off when the swingarm pivot shaft is com­pletely removed.

• Remove the engine from the frame.

INSTALLATION

• Fit the swingarm in its position and hold it with the swingarm
pivot shaft.

• Mount the engine on the frame.

• Tighten the engine mounting nuts.

 Tightening torque

N.m kgf.m lb-ft

1 58 5.8 42.0

2 43 4.3 31.0

3 45 4.5 32.5

NOTE:
Replace the self-locking nuts with new ones.

• Reassemble the removed parts in the reverse order of removal.

NOTE:
Route the cables and lead wires correctly. (



18-15 and 18-16)

5-6 ENGINE REMOVAL AND INSTALLATION

• Fit the projection of the carburetor to the depression on intake
pipe.

• Apply a small quantity of engine oil to the exhaust pipe O-ring.

• Install the exhaust gasket and exhaust pipe.

After mounting the engine, inspect the following items.

• Transmission oil level (2-6)

• Engine coolant level (2-7)

• Throttle cable play (2-9)

• Clutch lever play (2-8)

• Drive chain slack (2-12)

Direction of travel

• Reassemble the drive chain clip so the slit end faces opposit
the direction of rotation.

6

CYLINDER, PISTON AND EXHAUST VALVE

CONSTRUCTION ............................................................................. 6- 2

CYLINDER, PISTON AND EXHAUST VALVE ............................. 6- 2

ENGINE TOP SIDE ............................................................................ 6- 3

CYLINDER HEAD REMOVAL ...................................................... 6- 3

CYLINDER REMOVAL .................................................................. 6- 3

PISTON REMOVAL ....................................................................... 6- 4

EXHAUST VALVE REMOVAL ....................................................... 6- 4

CYLINDER HEAD INSPECTION .................................................. 6- 5

CYLINDER INSPECTION ............................................................. 6- 5

PISTON AND PISTON RING INSPECTION.................................. 6- 6

EXHAUST VALVE INSPECTION .................................................. 6- 7

CONROD INSPECTION ................................................................ 6- 8

PISTON RING AND PISTON REASSEMBLY ............................... 6- 8

EXHAUST VALVE REASSENBLY ............................................... 6- 8

CYLINDER REASSEMBLY .......................................................... 6-10

EXHAUST VALVE GOVERNOR REMOVAL

AND DISASSEMBLY ..................................................................... 6-12

EXHAUST VALVE GOVERNOR INSPECTION ............................ 6-13

EXHAUST VALVE GOVERNOR REASSEMBLY

AND INSTALLATION ..................................................................... 6-14

CONTENTS

CYLINDER, PISTON AND EXHAUST VALVE 6-1

6-2 CYLINDER, PISTON AND EXHAUST VALVE

CONSTRUCTION

CYLINDER, PISTON AND EXHAUST VALVE

28 N.m
(2.8 kgf.m, 20.5 lb-ft)

28 N.m
(2.8 kgf.m, 21.0 lb-ft)

25 N.m
(2.5 kgf.m, 18.0 lb-ft)

CYLINDER, PISTON AND EXHAUST VALVE 6-3

ENGINE TOP SIDE

CYLINDER HEAD REMOVAL

• Remove the frame covers and seat. (5-2)

• Remove the radiator covers and fuel tank. (5-2)

• Remove the muffler. (5-2)

• Drain engine coolant. (12-3)

• Loosen the clamp and disconnect the radiator hose 1.

• Remove the spark plug cap 2 and spark plug 3.

• Remove the cylinder head 4.

NOTE:
Loosen the cylinder head nuts diagonally to prevent cylinder head
distortion.

CYLINDER REMOVAL

• Remove the cylinder head. (above)

• Remove the exhaust pipe. (5-2)

• Remove the cylinder head O-rings 1 and 2.

• Remove the exhaust valve rod cover 3 and gasket.

• Remove the bolt 4 and disconnect the exhaust valve rod.

Loosening the bolt without setting the pin can damage
the valve shaft arm spring.

Set the pin A, provided with machine, to the lever be­fore loosening the bolt 4.

NOTICE

6-4 CYLINDER, PISTON AND EXHAUST VALVE

• Remove the gasket 3 and dowel pins 4.

PISTON REMOVAL

• Remove the cylinder head and cylinder. (6-3)

• Remove the piston pin circlip 1.

NOTE:
Place cloth on the crankcase to prevent the piston pin circlip from
dropping into the crankcase chamber.

• Remove the piston pin 2.

• Remove the piston 3.

• Remove the conrod small end bearing 4.

• Remove the piston ring.

EXHAUST VALVE REMOVAL

• Remove the cylinder head and cylinder. (6-3)

• Remove the breather hoses.

• Remove the exhaust valve cover 1.

• Remove the exhaust valve shaft stop retainer 2.

• Loosen the four cylinder nuts 1.

• Remove the cylinder 2.

NOTE:
Loosen the cylinder nuts diagonally.

CYLINDER, PISTON AND EXHAUST VALVE 6-5

• Loosen the bolt 3. Draw out the shaft.

• Remove the spacers 4, springs 5 and valve shaft arm 6.

• Remove the exhaust valve assembly 7.

CYLINDER HEAD INSPECTION

• Remove carbon deposits from the cylinder head.

• Inspect the cylinder head for cracks around the spark plug
hole.

• Inspect for cylinder head distortion.

 Cylinder head distortion

Service Limit: 0.05 mm (0.002 in)

CYLINDER INSPECTION

• Remove carbon deposits from the exhaust port.

• Inspect the cylinder for cracks and replace the cylinder, if
necessary.

• Inspect the cylinder bore for wear, nicks and scratches.

NOTE:
Chrome-plated cylinder bore can not be modified such as boring
and honing.

• Inspect for cylinder distortion.

 Cylinder distortion

Service Limit: 0.05 mm (0.002 in)

6-6 CYLINDER, PISTON AND EXHAUST VALVE

• Fit the piston ring into the cylinder and measure the piston ring
end gap with a thickness gauge.

 Piston ring end gap

Service Limit: 0.80 mm (0.031 in)

PISTON AND PISTON RING INSPECTION

• Remove the piston ring from the piston ring groove.

• Remove carbon deposits from the piston.

• Inspect the piston for wear, scratches and damage.

• Measure the piston outer diameter 16 mm (0.63 in) from the
skirt end.

 Piston outer diameter

Service Limit: 47.880 mm (1.8850 in)

 09900-20202: Micrometer (25 – 50 mm)

• Remove carbon deposits from piston ring and piston ring groove.

• Fit the piston ring into the ring groove and measure the clear­ance with a thickness gauge.

 Piston ring to groove clearance

Standard: 0.020 – 0.060 mm (0.0008 – 0.0024 in)

 09900-20803: Thickness gauge

• Measure the piston pin bore and piston pin diameter.

 Service Limit

Piston pin bore 14.030 mm (0.5524 in)

Piston pin O.D. 13.980 mm (0.5504 in)

 09900-20605: Dial gauge

09900-20205: Micrometer (0 – 25 mm)

16 mm
(0.63 in)

• Measure the cylinder bore for wear with a cylinder gauge 15
mm (0.59 in) from the top surface.

NOTE:
The cylinder bore must be measured perpendicular to the crank­shaft axis direction.

 Cylinder bore

Standard: 48.000 – 48.015 mm (1.8898 – 1.8904 in)

 09900-20508: Cylinder gauge set (40 – 80 mm)

15 mm
(0.59 in)

CYLINDER, PISTON AND EXHAUST VALVE 6-7

• Measure the piston ring free end gap.

 Piston ring free end gap

Service Limit: 3.2 mm (0.13 in)

EXHAUST VALVE INSPECTION

• Remove carbon deposits from the exhaust valve and valve guide.

• Inspect the exhaust valve and valve guide for wear and scratches.

• Inspect the exhaust valve shaft and arm for damage.

• Inspect the exhaust valve breather hoses for clogging with tar.
If clogging is found, clean up it.

NOTE:
Using several brands of engine oil may cause tar to drip from the
breather hoses.

6-8 CYLINDER, PISTON AND EXHAUST VALVE

EX

• Tighten the exhaust valve retainer bolts.

• Face the depression on the piston top to the exhaust port side

and install the piston 1.

• Install the piston pin 2 and piston pin circlips 3. End gap of the

circlip should not be aligned with the cutaway in the piston pin
bore.

NOTE:
* Replace the piston pin circlip with a new one.
* Place cloth on the crankcase to prevent piston pin circlip

from dropping into the crankcase chamber.

PISTON RING AND PISTON REASSEMBLY

• Apply engine oil to the piston ring and piston ring groove.

• Install the piston ring into the piston ring groove so the piston
ring end comes to the piston ring locating pin.

• Apply engine oil to the piston pin and bearing.

• Install the bearing to the conrod small end.

CONROD INSPECTION

• Measure the conrod small end bore.

 Conrod small end bore

Service Limit: 18.040 mm (0.7102 in)

 09900-20605: Dial gauge

• Fit the piston pin and bearing into the conrod small end and
check the play.

EXHAUST VALVE REASSEMBLY

• Apply engine oil to the exhaust valves.

• Assemble the exhaust valves and the exhaust valve retainer.

• Install the exhaust valves into the cylinder.

CYLINDER, PISTON AND EXHAUST VALVE 6-9

• Install the spacers 1, springs 2, valve shaft arm 4 and shaft.

• Tighten the bolt 3.

• Tighten the stopper bolt 5.

• Install the gasket and cover.

6-10 CYLINDER, PISTON AND EXHAUST VALVE

31

24

If the piston pin end is not at the proper position, you
can not insert the piston into the cylinder properly and
the piston ring will be damaged.

Locate the piston ring end to the locating pin and insert
the piston into the cylinder.

• Tighten the cylinder nuts to the specified torque according
to the specified tightening order as shown.

 Cylinder nut: 25 N

.

m (2.5 kgf.m, 18.0 lb-ft)

• Tighten the nut 2.

NOTICE

Correct

Incorrect

• Install the exhaust rod cover and gasket.

CYLINDER REASSEMBLY

• Install the new gasket. Install the dowel pins 1.

• Apply engine oil to the cylinder bore.

• Hold the piston and piston ring, and insert the piston into
the cylinder.

Tightening the bolt without setting the pin can damage
the valve shaft arm spring.

Set the pin A, provided with machine, to the lever be­fore tightening the bolt 2.

NOTICE

CYLINDER, PISTON AND EXHAUST VALVE 6-11

• Install the new O-rings onto the cylinder.

• Install the cylinder head.

• Tighten the cylinder head nuts to the specified torque accord­ing to the specified tightening order as shown.

 Cylinder head nut: 28 N

.

m (2.8 kgf.m, 20.5 lb-ft)

• Reassemble the exhaust pipe. (5-6)

• Reassemble the spark plug and spark plug cap.

• Connect the radiator hose and tighten the hose clamp.

• Pour engine coolant. (12-3)

• Inspect engine coolant leak.

6-12 CYLINDER, PISTON AND EXHAUST VALVE

• Remove the exhaust valve actuator 2.

• Remove the pin 3 by pushing the retainer 4 down.

EXHAUST VALVE GOVERNOR REMOVAL
AND DISASSEMBLY

• Drain transmission oil. (2-7)

• Drain engine coolant. (12-3)

• Remove the exhaust pipe. (5-2)

• Remove the rear brake pedal. (15-12)

• Remove the clutch cover. (7-3)

• Remove the exhaust valve bolt. (6-4)

• Remove the exhaust valve governor 1.

CYLINDER, PISTON AND EXHAUST VALVE 6-13

• Remove the spring 5, retainer 6 and bearing 7.

• Remove the washers 8, spacer 9 bearing 0 and stator A.

• Remove the balls B.

EXHAUST VALVE GOVERNOR INSPECTION

• Inspect the bearing for wear.

• Replace the bearing if there is anything unusual.

6-14 CYLINDER, PISTON AND EXHAUST VALVE

• Inspect the balls and their grooves of governor and actuator
for wear or damage.

• If they are worn or damaged, replace them with the new ones.

EXHAUST VALVE GOVERNOR REASSEMBLY
AND INSTALLAION

Installation is in the reverse order of removal and disassembly.
Pay attention to the following points:

• Apply transmission oil to the exhaust valve gevernor.

• Install the exhaust valve actuator 1.

• Install the exhaust valve governor with the groove A engaged
with the actuator arm B.

• Install the actuator lever and exhaust valve rod cover.

(6-10)

• Install the brake pedal. (15-12)

• Pour transmission oil. (2-7)

• Pour enigne coolant. (2-7)

CLUTCH

CONSTRUCTION ............................................................................. 7- 2

CLUTCH ........................................................................................ 7- 2

CLUTCH ............................................................................................ 7- 3

CLUTCH PLATE REMOVAL ........................................................ 7- 3

CLUTCH PLATE INSPECTION .................................................... 7- 3

CLUTCH SPRING INSPECTION .................................................. 7- 4

CLUTCH RACK AND PINION INSPECTION ............................... 7- 4

CLUTCH PLATE REASSEMBLY ................................................. 7- 4

CLUTCH SLEEVE HUB REMOVAL ............................................. 7- 5

CLUTCH SLEEVE HUB INSPECTION ........................................ 7- 6

CLUTCH SLEEVE HUB REASSEMBLY ..................................... 7- 6

CONTENTS

CLUTCH 7-1

7

7-2 CLUTCH

CONSTRUCTION

CLUTCH

70 N.m
(7.0 kgf.m, 50.5 lb-ft)

CLUTCH 7-3

CLUTCH

CLUTCH PLATE REMOVAL

• Drain transmission oil. (2-7)

• Drain the engine coolant. (12-3)

• Remove the rear brake pedal. (15-12)

• Remove the clutch release arm 1.

• Remove the kick starter lever 2.

• Remove the clutch cover.

• Loosen the bolts diagonally and remove them.

• Remove the clutch springs.

• Remove the pressure plate.

• Remove the rack 3 and bearing 4 from the pressure plate.

• Remove the drive plates and driven plates.

CLUTCH PLATE INSPECTION

• Measure the drive plate thickness.

 Drive plate thickness

Service Limit: 2.4 mm (0.094 in)

• Inspect the drive plates for wear, distortion and discoloration.

• Measure the driven plate distortion.

 Driven plate distortion

Service Limit: 0.10 mm (0.004 in)

• Inspect the driven plates for wear and discoloration.

7-4 CLUTCH

CLUTCH SPRING INSPECTION

• Measure the clutch spring free length.

 Clutch spring free length

Service Limit: 39.4 mm (1.55 in)

NOTE:
Replace five clutch springs together even if only one spring is
exceed the service limit.

CLUTCH RACK AND PINION INSPECTION

• Inspect the clutch release rack and pinion for wear and dam­age.

• Inspect the clutch release arm for smoth movement and oil leak­age around the oil seal.

CLUTCH PLATE REASSEMBLY

• Apply transmission oil to the drive plates 1 and driven plates
2 and install them to the clutch sleeve hub.

• Install the rack 3 and bearing 4.

NOTE:
The roller side of the bearing must face to the rack side.

• Install the pressure plate 1.

• Install the clutch springs and bolts.

• Tighten the bolts diagonally.

CLUTCH 7-5

• Align the clutch release rack teeth with the pinion gear.

• Align the water pump empeller to the crankshaft end.

• Install the clutch cover.

• Tighten the bolts diagonally.

• Reassemble the rear brake pedal. (15-12)

• Install the clutch release arm 1.

• Install the kick starter lever 2.

• Pour transmission oil. (2-8)

• Pour engine coolant. (2-8)

• Inspect the clutch cable play. (2-8)

CLUTCH SLEEVE HUB REMOVAL

• Remove the pressure plate and clutch plates. (7-3)

• Flatten the lock washer 1.

• Hold the clutch sleeve hub with the special tool and loosen
the nut.

 09920-53740: Clutch sleeve hub holder

• Remove the clutch sleeve hub 2.

• Replace the gasket with a new one.

• Install the dowel pins.

7-6 CLUTCH

• Remove the needle bearing 3 and washer 4.

• Remove the snap ring 5 and kick idle gear 6.

CLUTCH SLEEVE HUB INSPECTION

• Inspect the clutch sleeve hub and primary driven gear ass’y
for wear and cracks.

CLUTCH SLEEVE HUB REASSEMBLY

• Install the washer 2 and needle bearing 1.

• Apply transmission oil to the needle bearing 1.

• Install the kick idle gear 3 and snap ring 4.

• Inspect the kick idle gear and needle bearing for damage and
wear.

• Remove the washer 1, primary driven gear ass’y 2.

CLUTCH 7-7

• Install the primary driven gear ass’y and washer.

• Install the clutch sleeve hub, lock washer 1 and clutch sleeve
hub nut 2.

• Tighten the clutch sleeve hub nut with the special tool to
the specified torque.

 09920-53740: Clutch sleeve hub holder
 Clutch sleeve hub nut: 70 N

.

m (7.0 kgf.m, 51.0 lb-ft)

• Bend the lock washer to secure the nut 1.

• Reassemble the clutch plates and pressure plate. (7-4)

• Install the dowel pins.

• Replace the gasket with a new one.

• Install the clutch cover and bolts. Tighten the clutch cover bolts

diagonally. (7-5)

• Connect the radiator hose.

• Install the clutch release arm and kick starter lever.

• Reassemble the rear brake pedal. (15-12)

• Pour transmission oil. (2-7)

• Pour engine coolant. (2-8)

– MEMO –

8

KICK STARTER

CONSTRUCTION .............................................................................. 8- 2

KICK STARTER ............................................................................. 8- 2

KICK STARTER ................................................................................. 8- 3

REMOVAL ...................................................................................... 8- 3

INSPECTION ................................................................................. 8- 4

REASSEMBLY ............................................................................... 8- 4

CONTENTS

KICK STARTER 8-1

8-2 KICK STARTER

CONSTRUCTION

KICK STARTER

KICK STARTER 8-3

KICK STARTER

REMOVAL

• Drain transmission oil. (2-7)

• Drain engine coolant.

• Remove the kick starter lever.

• Remove the clutch assembly. (7-5)

• Remove the snap ring 1.

• Remove the kick idle gear 2.

• Remove the kick starter drive gear 3.

• Install the kick starter lever temporally to remove the kick starter
shaft.

• Turn the kick starter lever counterclockwise until the kick starter
4 come off the kick starter guide 5.

• Remove the following parts from the kick starter shaft:
Spacer 6
Kick return spring 7
Washer 8
Kick starter 9
Spring 0
Kick starter shaft A

• Remove the kick starter guide B and kick starter stopper.

8-4 KICK STARTER

INSPECTION

• Inspect the oil seal 1 for oil leakage and oil seal lip damage.

• Inspect the return spring 2 for damage.

• Inspect the kick shaft 3 and drive gear for contact surface wear.

• Inspect the kick drive gear teeth for damage.

• Inspect the kick drive gear ratchet part for wear and damage.

• Inspect the kick starter stopper 4.

REASSEMBLY

• Install the kick starter stopper and kick starter guide.

• Apply THREAD LOCK “1342” to the bolt.

• Tighten the bolt.

99000-32050: THREAD LOCK “1342”

• Install the return spring 1 into the kick shaft’s hole.

• Install them to the crankcase.

KICK STARTER 8-5

• Install the kick shaft assembly to the crankcase.

• Hook the return spring to the crankcase’s hole.

• Install the kick starter to the kick shaft.

NOTE:
Be sure to align the punch marks on the kick starter and kick starter
shaft when installing the kick starter.

• Reassemble the kick idle gear.

• Reassemble the primary driven gear ass’y and clutch. (7-6)

• Reassemble the kick starter lever as shown.

A: CORRECT

B: INCORRECT

• Reassemble the clutch release arm.

• Reassemble the rear brake pedal. (15-12)

• Pour transmission oil. (2-8)

• Pour engine coolant. (2-8)

• Inspect the clutch lever play.

• Inspect for transmission oil leaks.

• Inspect the kick starter for smooth movement.

– MEMO –

GEARSHIFTING

CONSTRUCTION .............................................................................. 9- 2

GEARSHIFT LINKAGE.................................................................. 9- 2

GEARSHIFT LINKAGE ..................................................................... 9- 3

REMOVAL ...................................................................................... 9- 3

INSPECTION ................................................................................. 9- 4

REASSEMBLY ............................................................................... 9- 4

CONTENTS

GEARSHIFTING 9-1

9

9-2 GEARSHIFTING

CONSTRUCTION

GEARSHIFT LINKAGE

19 N.m
(1.9 kgf.m, 13.5 lb-ft)

23 N.m
(2.3 kgf.m, 16.5 lb-ft)

GEARSHIFTING 9-3

GEARSHIFT LINKAGE

REMOVAL

• Drain transmission oil. (2-7)

• Drain engine coolant. (12-3)

• Remove the kick starter lever and clutch assembly. (7-5)

• Remove the gearshift lever.

• Remove the gearshift shaft 2.

• Remove the two screws. Remove the pawl lifter 3.

• Remove the gearshift cam shifter 4.

NOTE:
Be careful that the pins and springs do not fly off.

• Remove the gearshift pawls 5, pins 6 and springs 7.

• Loosen the gearshift cam bolt 8 and remove the stopper plate

9.

9-4 GEARSHIFTING

• Remove the gearshift cam stopper 1.

• Remove the spring 2.

INSPECTION

• Inspect the gearshift shaft 1 for bends and damage.

• Inspect the return spring 2 for damage.

• Inspect the pawls 3, springs 4 and pins 5 for damage.

REASSEMBLY

• Reassemble the washer 1 and gearshift cam stopper 2 and
the spring 3.

• Inspect the gearshift cam stopper.

GEARSHIFTING 9-5

• Align the pin groove A with the pin B when installing the stop­per plate 1.

• Install the springs, pins and pawls to the shifter. Wider side A of
pawl should be positioned outside.

• With the pawls held in pushed position, install the pawl lifter 3.

• Tighten the gear shift cam bolt 2.

 Gearshift cam bolt: 23 N

.

m (2.3 kgf.m, 16.5 lb-ft)