Suzuki TS200R Service Manual

FOREWORD

GROUP INDEX

The

SUZUKI generation motorcycle to the TS-models. packed

including a valve, a

(A.

E.

T.C.) a Digital C.D. ignition system a rear suspension. Combined easy

handling the TS200R provides excellent perfor-

mance and outstanding riding comfort.

This service manual

for

experienced mechanics whose adjust, repair Apprentice mechanics and mechanics extremely useful guide.

The TS200R, manufactured to standard specifications, However, the TS200R machines distributed

country standard-specification and, some consequence concerned) had to be made to statutory

is

minor

TS200R

with

might

highly

liquid

Automatic

and

will

the main subject

differ

modifications (which are

in

requirements

has

advanced design concepts

cooled engine, a crankcase reed

Exhaust Timing

has

service

also

find

in

most

cases

of

been developed

with

precise

been produced

job

SUZUKI

"do

this manual to be an

matter

minor

if

your

of

respects from the

they do,

as

far

comply

country.

as a new

Control

link

control

primarily

is

to

inspect,

motorcycle.

it

yourself"

this manual.

ih

it

is

because

of

as

servicing

with

It

type

and

your

no

the

GENERAL

is

PERIODIC MAINTENANCE

INFORMATION

AND

TUNE-UP PROCEDURE

ENGINE n

I

L___

_

Llc_o_o_L_IN

I

FUEL

__

G_s_v_s_~_EM

AND

LUBRICATION SYSTEM

__

·--~-------~

g

II

I ELECTRICAL SYSTEM Ill

CHASSIS

is

I L

s_E_R_"'_Jc_I_N_G_IN_F_o_R_M_~_~_~_o_N

___

B

This manual contains up-to-date

of

its

time

changes utor

in respective markets, to whom requested if

any.

©COPYRIGHT SUZUKI MOTOR CORPORATION 1990

issue.

will

be explained to

to

make query

SUZUKI MOTOR CORPORATION

Later made modifications and

about

Motorcycle Overseas Service

information

each

SUZUKI

you

updated

Department

at

distrib-

are

kindly

information,

Division

the

L..._T._S_2_o_o_R_N_f_'9_2_-M_O_D_E_L_J

TS200RP

L_____

('93-MODEL)

_

___

______jllliil

___.q

~

VIEW

OF

TS200R

For

Conventional

front

fork

model

For

Inverted

front fork

model

GENERAL

~----------------CONTENTS----------------~

VIN

AND

SERIAL NUMBER

INFORMATION

LOCATIONS..............................

1-1

FUEL, OIL

RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

BREAKING-IN PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

SPECIAL MATERIALS... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

PRECAUTIONS SPECIFICATIONS

AND

COOLING SOLUTION

AND

GENERAL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . 1-5

..............................................................

1-j'

frame

,:The

Number)

serial These machine

CD

number

numbers

and

serial

ordering

number or V.I.N. (Vehicle Identification

stamped on the steering

is

the

®

is

are

located

required

spare

on

especially

parts.

left

pipe. The engine

head

the crankcase.

of

side

registering the

for

FUEL,

OIL

AND

COOLING SOLUTION

RECOMMENDATIONS

FUEL

CANADA

For

only

Use

~M

( R

Research

other

For Gasoline

unleaded gasoline

An

ENGINE OIL

SUZUKI

Use formulated

bustion chamber deposits, least preignition,

plug life and best quality

TWO-STROKE OIL (non-diluent

TRANSMISSION OIL

Use a

good

model

unleaded gasoline

method) or

Method. models

should

used

"CCI"

give

to

quality

91

be graded

is recommended.

or

oil

engine

best

lubrication.

SAE

at

of

octane

or higher rated by

85-95

SUZUKI CCI

performance

they

If

20W/40

multi-grade

87

least

octane or higher.

Super

not

are

type)

pump

They

oil.

least

with

maximum

available,

should

motor

octane

the

are

com-

spark

a good

be used.

oil.

FRONT FORK OIL

0.

1

#

oil

fork

Use

99000-99044-10G

BRAKE FLUID

classification :

Specification

99000-2311

and

SUZUKI BRAKE

:

0

SUZUKI FORK

:

OIL#

DOT

FLUID

10

4

COOLING SOLUTION

Summer coolant compatible:·

Use an aluminum radiator, mixed

50:

of

WATER FOR MIXING Use corrode and

anti;.freeze

50.

distilled

water

clog

&

Water

only.

aluminum radiator.

the

distilled

with

other than distilled

water

only,

water

at

with ratio

can

GENERAL

INFORMATION

1-2

SUMMER

ANTI-FREEZE

coolant

The

anti-freeze. Therefore, the coolant should be used at

as

even

times

not

does

SUZUKI

1200NA ble, use an equivalent radiator.

99000-99032-10X

REQUIRED Solution

CAUTION: Mixing

60%.

freeze

inhibiting

above not

of

·Mixing

&

30%

down

go

&

performs

though

go

recommends

anti-freeze

AMOUNT

capacity

anti-freeze

summer

performance is greatly

even

the atmospheric temperature in

down

to

&

:SUZUKI

{Non-Amine type)

{total) :

&

beyond

to

it

coolant

though

freezing point.

COOLANT

corrosion and

as

freezing point.

SUZUKI GOLDEN CRUISER

of

use

the

summer coolant.

which

OF

summer

would

is compatible

GOLDEN CRUISER 1200NA

WATER/COOLANT

ml {0.95/0.79 US/Imp

900

coolant

reduce

mixing

atmospheric temperature does

the

rustinhibitor

If

should be

efficitmcy.

its

ratio is

reduced,

this

below

Be

is

with

sure

not

30%,

well

as

all

area

your

availa-

aluminum

qt)

the

anti-

rust

mix

to

it

limited

If

to

BREAKING-IN PROCEDURES

During manufacture only the best possible materials.are used

a very high standard,

the

to

of

speed

to

moving

maximum

engine depends on

the

limits.

000

"BREAK-

to

parts

stresses. The

early life. The

its

r/min r/min r/min

all machined parts are finished

and

allow

necessary

still

is

it

but

before subjecting

IN" future the general rules are

•

Initial 800 Up Over

performance and reliability

care and restraint exercised during

breaking-in engine

these

to

Keep

{500

km

{1

km

600

1

to

{1

km

600

1

to

engine

the

follows.

as

miles) : Below 5 000

miles) : Below 7

000

miles) : Below 12 000

000

GENERAL

1·3

INFORMATION

SPECIAL MATERIALS

needed

materials listed below

The

ready

for

hand and the

SUZUKI GREASE 99000-25010

like.

Material

SUPER

"A"

use.

How

to

They

use

are

supplement

and

them

Throttle

•

• Clutch lever Speedometer cable

• tachometer Speedometer

•

• Brake

• Side stand

•

pedal

Kick starter Crankcase

where

grip

cable

gear

shaft

lever

oil

for

such

to

Part

and

box

seal

maintenance

them

materials

are

standard use

on the

work

cleaning fluids, lubrications,

as

described in the

Page

2

222- 2

27-

7· 2-

223-27

• Wheel

2

Steering stem bearing and

•

1 2

Swingarm bearing and dust

•

2 2

Cushion

•

2

TS200R,

of

text

Part

bearings

and rod bearing

lever

and

this

should

manual.

race

seal

kept on

be

emery

cloth

Page

2

2-

1

7-

2

77-31 7-25

7-29 7-40 7-47 7-40 7-47

SUZUKI 99000-31140

SUZUKI 99000-3111 0

THREAD "1322" 99000-3211 0

BOND

LOCK

No. 1207B

No. 1215

SUPER

mechanical

pump

Water

•

Crankcase mating surface

• thermo-gauge

Water

•

gear

arm·

bolt

arm screw

stopper

Engine sprocket

•

Exhaust

•

Exhaust

•

• 2nd drive

Gearshift

•

pulley valve

seal

4-

3-31

4-

3· 33-18 3-26

3-32

8

9

bolt

lever

Kick

•

5 6

3-40

THREAD "1303" 99000-32030

THREAD

"1324"

99000-32120

LOCK SUPER

LOCK

SUPER

• Magneto

rotor

nut

3-37

GENERAL

INFORMATION

1-4

Material

~

THREAD "1360" 99000-32020

LOCK

SUPER

&

THREAD 99000-32050

LOCK

"1342"

~ ~

~

~········.A

-

SUZUKI SILICONE GREASE 99000-25100

Part

• Disc

bolt

• Gearshift retainer screw

• Pawellifter

•

Cam

• Front

• Caliper axle

• Brakes

driven

fork

nut

and

cam

gear

bolt

damper rod

Page

7- 1

7- 2

7-31

and

bolt

guide screw 3-33

bolt

3-32

3-33 7-13

7-16

7- 5 7-34

1-

2-10

Part

1

Page

~

SUZUKI

99000-23110 (0.5L)

SUZUKI GOLDEN CRUISER 1200NA

(Non-Amine type)

99000-99032-1

BRAKE

~

~~~o.2.'-~

...

'···'<~

FLUID

ox

~

OIL

..

•

~

SUZUKI FORK 99000-99044-1

OIL#

OG

• Cooling solution

•

Front

fork

10

1-

17-17 7-22

2

1

1-5

GENERAL

INFORMATION

PRECAUTIONS

Observe

o Do

o

Be

CAUTION: Never reuse a circlip When slip After

o Tighten cylinder head and case bolts and

diameter, and

o Use special

o Use genuine parts and recommended oils.

the

following

not

run engine indoors

sure

to

replace packings, gaskets, circlips,

circlip

must

installing a

the

installing a circlip,

be installed.

circlip

over

tools

from

AND

items

after

new

circlip, care

the

inside

where

GENERAL INSTRUCTIONS

without

with

a circlip has been removed

shaft.

always

to

outside diagonally,

specified.

little

must

insure

fail

when

or no

be taken

that

nuts

disassembling and reassembling

ventilation.

0-rings

not

is

completely

beginning

to

and

cotter

from a shaft,

to

expand

seated in

with

the

specified

the

larger diameter and ending

pins

it

should be discarded and a

end gap larger

its

groove and securely

tightening

with

motorcycles.

new

ones.

than

torque.

required

fitted.

with

smaller

new

to

When

o

After

o

o Treat gasoline,

gasoline as cleaning solvent.

Warning, Caution and

WARNING

CAUTION..................

NOTE

more

the

...

;...................

than

reassembly, check parts

.................

2 persons perform

which

is

extremely

Note

are included in

The personal this

information These instructions point be

followed

This

provides

instructions

work

together,

for

tightness

flammable and

this

manual occasionally, describing

safety

to

clearer.

ofthe

could result in personal injury.

out

avoid damaging

special

information

pay

and operation.

highly

rider

or

special service procedures

the

REPLACEMENT PARTS

When replacement parts, or their equivalent. Genuine SUZUKI parts are high cally

you

replace

quality

for

SUZUKI vehicles.

parts

any

which

parts, use

are designed and

only

genuine SUZUKI

built

specifi-

attention

explosive,

bystanders

machine.

to

make

maintenance

to

with

may

the

safety

greatest care. Never use

be involved. Disregarding

or

of

the

following

precautions

easier

each other.

contents.

that

or

important

must

CAUTION:

of

Use to and damage.

replacement parts

genuine SUZUKI parts can lead

which

are

not

equivalent in

to

performance problems

quality

ASBESTOS INFORMATION

Note

the

following above WARNING LABEL or section

• Operate

which

if

possible

• Preferably use hand necessary,

with

· high speed equipped.

•

If

possible, dampen before

• Dampen

dust

and dispose

Any

domestic

apply,

but

be replaced

asbestos

which

by

Exhaust pipe gasket

when

contains

out

an

tools

are used,

and place

of

it

safely.

is likely

new

one

handling a

any

asbestos.

of

doors in a

tools

or

appropriate

cutting

it

in a properly closed receptacle

product

to

release fibres during use should

when

part

low

dust

they

to

which

worn.

supply

in

the

well

speed

extractor

should

or

part

parts

ventilated

tools

always

drilling.

the

above does

with

the

list

in

this

place.

equipped,

facility.

be so

not

if If

GENERAL

WARNING

CONTAINS

ASBESTOS

Breathing

duet

Ia

dang8f'OUI

tohnhh

Follow

Instruction•

INFORMATION

ubeatoa

safety

1-6

GENERAL

1-7

INFORMATION

SPECIFICAITONS

DIMENSIONS

Overall length Overall Overall height Wheelbase

Ground clearance....... 320

Seat

Dry mass .. .. .. .. .. .. .. .. .. 115

width.............

height...............

AND DRY

............

................

2 185

880 1 245 1 425

880

116

ENGINE

........................

Type

Intake

Number Bore Stroke

Piston displacement Corrected

compression ratio ......

Carburetor

Air

Starter system

Lubrication system .....

system

.........................

......................

cleaner

............

cylinders

of

................

...........

Two-stroke, cooled Crankcase valve

. . 1

.

66.0

57.0

.. . 195

8.5 MIKUNI TM30SS, Single Polyurethane foam element Primary kick SUZUKI

MASS

mm mm mm mm mm mm kg E-24, 28 kg

E-0

mm mm

3

cm

: 1

"CCI"

in)

(86.0 (34.6 in)

in)

(49.0

in)

(56.1 (12.6 in) (34.6 in)

lbs)

(253

lbs)

(256

04

2

,

water-

and reed

(2.598 in) (2.244 in)

cu.

11.9

(

...

in)

CHASSIS

Telescopic, coil spring,

Front suspension

Rear suspension

Steering Caster Trail Turning radius Front brake Rear brake Front tire size

Rear tire size .. .. .. .. .. .. . 110/90-18

Front Rear

angle

......................

.........................

................

stroke

fork

wheel travel

.......

........

......•....

...........

...............

............

........

.......

dampened

oil

Link type

system,

damping force

spring free way

43° 62° 117 mm (4.6 in)

2.3 m Disc Disc 80/100-21

270

gas/oil

(right 30'

.5

(7

mm (10.6 mm

ELECTRICAL

..............

Ignition Ignition timing

Spark plug

Battery

Fuse

type

................

.....................

.........................

...........

SUZUKI

B.T.D.C.

8°

r/min

000

2 NGK BR9ES or

W27ESR

NO

10.8

12V

HR

10 15A

suspension

damped,

adjustable,

adjustable

left)

&

ft)

P

51

P

61

in) in)

(10.6

below

kC

(COl)

(3

"PEl"

Ah)/

TRANSMISSION

Clutch

Transmission

Gearshift pattern

Primary reduction

Final reduction

Gear ratios,

Drive chain

......................

.............

........

.......

...........

........

Low

........

2nd

3rd ..........

.. .. .. .. . 1 .095 (23/21)

4th

.........

5th

........

Top

................

multi-plate

Wet

6-speed

1-down,

3.350

2.600

2.857 (40/14)

2.636 (29/11)

1.857 (26/14)

1.400

0.916

0.800 TAKASAGO RK520SO

106 links

constant

5-up (67/20) (39/15)

(21/15)

(22/24) (20/25)

type

...

mesh

E02, 04, 24

E-28

CAPACITIES

tank

Fuel

9.5 L (2.5/2.1

including

Engine Front

Transmission Cooling solution

These specifications are subject

without

...

E-02

...

E-04

...

E-24

...

E-28

reserve

reserve ..... 1.4 L

tank

oil

fork

notice.

For U.K. For France

Australia

For

Canada

For

.....

...........

.............

.........

oil

.........

(0.4/0.3 US/Imp

1.2 L (1.3/1.1 555 ml

452

950

900

...

ml

1.00/0.84 US/Imp

(

ml

(0.95/0.79 US/Imp

ml

US/Imp

US/Impqt)

E-24, 28 E-02, 04

change

to

gal) gal)

qt) qt)

PERIODIC

MAINTENANCE

AND

TUNE-UP PROCEDURES

~----------------CONTENTS----------------~

PERIODIC MAINTENANCE SCHEDULE

PERIODIC MAINTENANCE CHART

LUBRICATION POINTS

MAINTENANCE

BATTERY

CYLINDER NUTS, CYLINDER HEAD NUTS

EXHAUST

CYLINDER HEAD, CYLINDER SPARK PLUG

AIR

CLEANER TRANSMISSION COOLING SYSTEM CARBURETOR FUEL OIL

LINE

PUMP

PROCEDURES

....................................................................

PIPE

...................................................................

NUTS

..............................................................

OIL

.............................................................

.................................................

.........................................

..................................................

AND

....................................................

......................................................

...............................

.................................

MUFFLER

AND

..................

22222-

222222222-

1 1

2

3 3

3

4

5

6 6

7

8 8

CLUTCH

DRIVE CHAIN

BRAKES

TIRES

STEERING

FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR SUSPENSION

CHASSIS BOLTS

.....................................................................

..............................................................

.....................................................................

.........................................................................

...................................................................

.....................................................

AND

NUTS

........................................

2-

8

2-

9 2-10 2-13 2-14 2-14 2-14 2-15

PERIODIC

2-1

MAINTENANCE

AND

TUNE-UP

PROCEDURES

PERIODIC

The chart below lists the recommended intervals keep the motorcycle operating at

kilometers.

of

terms

MAINTENANCE SCHEDULE

all the required periodic

for

performance and economy. Traveling distances

peak

NOTE:

More frequent servicing

may

performed

be

on motorcycles

PERIODIC MAINTENANCE CHART

judged

This interval should odometer reading whichever

Battery Cylinder

pipe Cylinder head, cylinder and Spark plug

cleaner

Air

Transmission oil R

Radiator hoses

comes

nuts,

nuts

be

months,

or

first.

cylinder head

by

and

nuts

muffler

km 1

months

exhaust

that

000

2

-

T

-

I

are used

000

6

12

I I

T

c c

R

Clean

-

Replace

service

severe conditions.

under

12 000

24

T

R

every 3

R

I

every

work

are

18 000

36 48

T

c

R

km

000

-

4 years

necessary expressed

I

to

in

24 000

I

T

c

R

I

Coolant Carburetor

Fuel line

pump

Oil Clutch

Drive chain

Brakes

Brake hoses

Brake Tires Steering Front Rear suspension Chassis

fluid

fork

bolts

and

nuts

Replace every 2 years I I I I I

I I I

I

Clean

I I I

I

I I I

T

I

Replace

I I

I

and lubricate

Replace every 4 years

Replace every 2 years

I

I I I

T

I

every

4 years

I I

every

I

I I

T

1

I

I I I

000

I I

I

T

I I

I

km

I

I I I I

T

Inspection and adjust, clean, lubricate or replace as necessary

1:

Replace T: Tighten

C:

Clean

R:

LUBRICATION POINTS

Proper

cycle.

NOTE:

* Before lubricating

lubrication

Major

lubrication

is

important

each

for

points

part, clean

are

smooth

indicated

off

any

operation

below.

rusty spots and wipe

* Lubricate exposed parts which are subject to rust,

PERIODIC

and long life

with

motor

MAINTENANCE

of

each

off

any

grease,

oil

or

grease.

AND

TUNE-UP

working

oil,

PROCEDURES

parts

of

dirt

or

grime.

the

2·2

motor-

: Clutch lever

;:-c---

m : Side stand

~

: Clutch cable

~

: Drive chain

~:Motor

m:

Grease

m : Rear wheel

bearing

oil

m:

Kick starter lever

m:

Brake pedal shaft

~

:

Throttle

cable

m : Speedometer cable and

gear

box

PERIODIC

2-3

MAINTENANCE

AND

TUNE-UP

PROCEDURES

MAINTENANCE

This section describes the service procedures for each section

Periodic Maintenance.

of

PROCEDURES

BATTERY

months)

12

(

km

J1nspect

Remove

• Check

•

09900-25002

the

If

recharging.

Battery

Disconnect

• the

WARNING: When

CAUTION: Read

Every 6

the

voltage

battery.

disconnecting

ELECTRICAL SECTION''

II

the

000

frame cover.

left

battery

: Pocket

reading is

Above

:

battery

the

voltage

tester

below

12.0

8

battery

the

with

V

and

the

12.0

8:)

lead

for

I

pocket

V,

lead

wire,

the

tester.

battery

this

wires

8

servicing

needs

and remove

first.

wire

lead

battery.

CYLINDER NUTS, CYLINDER

NUTS

000

months)

AND

seat and

muffler.

first

nuts

the

nuts

23

:

NUTS

exhaust

:

(2

km

CYLINDER

fuel

tighten

and

the

to

shown.

-

(2.3

pipe

-

10 (1.0-

months)

tank.

(Refer

specified

N·m

27

7

2.

nuts

·m

N

16

1.6

kg-m,

to

kg-m,

Initial 1

(12

km

the the

head

torque

PIPE

the

torque

PIPE

EXHAUST

Tighten

000

6

CYLINDER NUTS

• Remove Remove

• First loosen

• cylinder numeriacal order as

Tightening

EXHAUST

Tighten

•

Tightening

HEAD

(Refer

to

the cylinder

the

NUTS

and Every

NUTS

to

3-2.)

page

torque

16.5

specified

7.0-

AND

3-2.)

page

and then

nuts

in ascending

lb-ft)

19.5

-

torque.

11.51b-ft)

PERIODIC

MAINTENANCE

AND

TUNE-UP

PROCEDURES

2-4

CYLINDER

Remove carbon Every 6

Carbon deposits in the combustion chamber

• head and ratio and may cause preignition Carbon deposited

• prevent the Remove cabon deposits

HEAD,

the piston

at

flow

CYLINDER

000

crown

the exhaust port

at

exhaust gas, reducing the

of

periodically.

AND

months)

12

(

km

will raise the compression

overheating.

or

SPARK PLUG

MUFFLER

the

of

cylinder

the

of

cylinder

will

output.

Inspect

000

6

Remove the carbon deposits the spark measuring When removing carbon deposits, appearance

deposits. The plug replace

1

months)

12

(

km

gap

plug

a thickness gauge.

with

the

of

color

suitable or not.

is

hotter

with

0.8

-

0.6

to

plug, noting the color

observed indicates whether the standard

the standard plug

If

one.

(2 months) and Replace Every

km

000

NGK

Standard

----

type

Hot

CAUTION:

thread size and reach when replacing the plug.

Confirm

the

BR9ES BASES

a wire

mm

sure

be

pin and adjust

or

0.03

(0.02

-

observe the

to

the carbon

of

to

is apt

ND

W27ESR W24ESR

get

in)

wet,

2-5

PERIODIC

MAINTENANCE

AIR CLEANER

AND

TUNE-UP

PROCEDURES

I Clean Every 3

If

the

air cleaner is clogged be increased an increase in Check and clean

• Remove

• Separate

element

• Fill a washing pan

ing

solvent.

and

wash

• Squeeze

by

pressing

twist

or

• Immerse

and squeeze wet

with

• Fit

the

cleaner

000

with

fuel

the

seat and

the

air cleaner case cover.

the

air cleaner

the

polyurethan

frame

Immerse

it

clean.

the

cleaning

it

between wring the

the

element in MOTOR OIL SAE #

the

oil.

element

km

with

dust,

intake resistance

a resultant decrease in

consumption.

element

left

in

the

frame

following

cover.

CD.

foam

element

®.

of

a proper size

the

solvent

the

element

oil

out

of

to

element in

with

out

of palms or

the

frame

of

it

will

element leaving

properly.

will

power

nonflammable clean-

the

both

develop tears.

output

manner.

®

cleaning

washed

hands:

30

or 1

and

from

solvent

element

do

OW/40,

it

slightly

the

not

CAUTION:

* Before and during the cleaning operation, inspect the element

for

tears. A

*

Be

sure

no incoming air piston rings and cylinder bore or

poorly

CAUTION: If

driving under dusty conditions, clean the air cleaner element

more frequently. The surest way use

the engine

Make

sure

Life

of

the engine depends largely on this component!

torn

element must be replaced.

to

position the element snugly and correctly,

will

fitted

element.

without

that

the air cleaner

bypass

the element

it.

Remember, rapid wear

is

often

caused

to

accelerate engine wear

or

to

use

a ruptured element.

is

in good condition

by

a defective

at

all times.

so

that

of

is

to

CORRECT

INCORRECT

TRANSMISSION OIL

PERIODIC

MAINTENANCE

AND

TUNE-UP

PROCEDURES

2-6

Replace (change) Every

After and quicken Replace dure

•

• Start

• Place

•

Drain plug

•

• Install

•

12

000

a long period

the

transmission

below.

Keep

ing

removing After

securely.

Add The transmission

Start at Turn check the

the

motorcycle

the engine

of

oil.

Shut

the

oil

the

draining

tightening

the

good

the

filler

up

the

engine and

idling speed.

off

the

oil level

hole,

add

Initial

km

(24

months)

of

use,

wear

of

oil periodically

upright.

to

warm up

off

the

pan

below

filler

cap

the

oil completely,

torque:

quality

engine and

the

SAE

will

hold

cap correctly.

screw

oil until

1

000

km

(2

months)

the

transmission oil will

sliding and interlocking surfaces.

following

the

oil,

this

will facilitate

engine.

the

engine and drain

CD

and drain

20-25

plug

fit

N·m

the

14.5-18.0

20W

/40

multi-grade

about

allow

wait

®.

If

it

950

ml

it

to

run

for

about one minute, and

the

oil

does

runs

out.

and

deteriorate

the

proce-

drain-

the

oil

®.

drain

(2.0-2.5

lb-ft)

of

several seconds

not

oil.

run

plug

kg-m,

motor

out

from

oil.

by

®

COOLING SYSTEM

Inspect Initial 1 12

000

km

Replace (change) Replace hoses Every 4 years

•

Loosen

•

Remove ly while

WARNING: Do

not

may

WARNING: Cooling in

contact eyes thoroughly ting

the

holding

open

be injured

solution

with

or

in

with

and

call

000

km

(2

(24

months)

coolant

screw

drain

the

contact

physician immediately.

and remove

plug

®

the

motorcycle

radiator cap

by

escaping

may

be

harmful

skin

or

eyes.

with

plenty

of

water.lf

the

months)

Every 2 years

and drain

when

hot

If

cooling solution

skin,

and Every

the

radiator cap

the

upright.

the

engine is

liquid

if

or

swallowed

it

swallowed,

@.

coolant

vapor.

should be flushed

thorough-

hot,

or

if

it

gets

induce

as

you

comes

into

vomit-

the

PERIODIC

2-7

• Flush the radiator Tighten the drain

•

the specified coolant

• Fill

MAINTENANCE

NOTE:

coolant

For section

the

• Fill

• Close

After

•

coolant

the

"F"

information,

4-2.)

page

reservoir

radiator

the

warming

level

of

if

fresh water.

with

securely.

plug

to

tank

cap securely.

reservoir

level

the

cooling

up and

the

TUNE-UP

AND

the radiator inlet hole.

to

up

"COOLING

the

is

to

"F"

down

tank

below

level

the

and add

"L".

refer

PROCEDURES

SYSTEM"

coolant.

with

the

check

coolant

engine,

the

to

Including

Reservoir tank

reservoir tank capacity:

capacity:

150

CARBURETOR

km

000

Inspect

000

6

Initial

km

ADJUSTING THROTTLE

Loosen

•

Adjust

•

adjuster@.

Throttle

After

•

cable

adjusting

IDLE R/MIN ADJUSTMENT

Adjust

•

NOTE: Make

•

this

Connect

the

Start

that

so

the

Turn original The engine

the

with

this

Set

highest

the

at

the

Turn specified

1

months)

(12

nut

lock

cable

the

play

the

throttle

the

adjustment

tachometer.

a engine and

engine

air

setting.

turning

screw

idles

screw

r/min

in a r/min.

throttle

engine

CABLE

CD.

play

0.5

® :

cable play,

cable paly.

when

turn at

in

®

increase

will

the

position

valve

r/min.

to

(Refer

of

idle

®

900

(0.16/0.13

ml

months)

(2

0.5

to

1.0

tighten

the engine is

throttle

the

r/min.

500

1

around

out

or

5-3.)

page

or

screw.

air

that

screw

stop

(0.95/0.79

ml

US/Imp

Every

and

mm

1.0

-

(0.02

mm

the

hot.

valve

/4

1

decrease in

allows

the

again and

US/Imp

qt)

turning

by

0.04

nut

lock

screw

stop

from

turn

accordance

engine

to

adjust

qt)

in)

CD.

®

the

idle

the

Engine

idle

CAUTION:

adjustment

This

readjust

so

r/min

oil

the

: 1

could

pump

400

affect

100

±

the

control

r/min

pump

oil

cable

control

play

cable play,

necessary.

if

PERIODIC

MAINTENANCE

AND

TUNE-UP

PROCEDURES

2-8

FUEL

Inspect 6 Replace Every

000

LINE

Initial

km

OIL PUMP

Inspect 6

000

The engine oil

of

oil control opening.

Check the

operation

•

Turn

•

Check lever

valve

•

If

the

•

After

Initial

km

fed

to

lever

oil pump in the for

the

whether

is

aligned

is positioned

the

marks are

adjuster

aligning

(

it

throttle

1

(

12

months)

4

1

12

months)

is fed is

regulated

which

throttle

@

the

000

km

(2

years

000

km

(2

by

the oil

by

is

controlled

following

valve full

grip

full

the

red mark

with

the index mark

as

above.

not

aligned, loosen

in

or

out

marks,

months)

pump

engine speed and

opening position.

open.

CD

to

align

tighten

and Every

to

the engine. The amount

by

the

amount

manner

on

the

to

®

when

lock marks. lock

the

oil

pump

of

throttle

confirm correct

oil

pump

nut®

nut@.

the

control

throttle

and

turn

CAUTION:

Oil

pump

adjustment.

cable

CLUTCH

Inspect 6

000

• Loosen

• Loosen the

with

15

Lever play

•

Tighten

•

If

out

side.

Initial

km

the

adjuster

mm.

the

the specified

the

adjustment

1

000

(12

months)

lock

nut

cable lock

® :

10

lock

play

must

be done

km

(2

months)

®

and

turn

nut

(j)

and adjust the

®

until play

-

15

nuts

®,

can

not

using the adjuster on the

mm

(j).

be

of

(0.4-

obtained

after

and Every

the adjuster

the

clutch

0.6

with

throttle

play

of

lever is

in)

adjuster, carry

clutch

®

fully

the

cable

1

lever

0

in.

-

2·9

PERIODIC

MAINTENANCE

DRIVE CHAIN

AND

TUNE-UP

PROCEDURES

Inspect Initial 1

6

000

km

Clean and Lubricate Every

Visually inspect malconditions. (Lift

the

under with

engine, and

the

transmission in NEUTRAL).

(

12

000

km

months)

the

drive chain

the

turn

rear wheel and place a

* Loose pins * Damaged rollers

* Dry or rusted links

* Kinked or binding links

If

any

defects

CHECKING

• Loosen

• Tense

are

the

exle

the

drive chain

found,

nut

CD.

fully

®.

•

Count between the

out

chain

21 pins on

the

two.

must

be replaced.

If

the

(2 months) and Every

1

000

km

for

the

rear wheel

below

listed possible

jack

or block

slowly

by

hand,

* Excessive wear

* Improper chain adjustment * Missing

the

drive chain

by

adjusting

chain and measure the distance

distance exceeds

0-ring

must

the

or seals

be replaced.

chain adjusters

following

limit,

Service Limit :

ADJUSTING

• Adjusting the chain

40

mm sprockets. The number on be

at

the same position wheels are correctly aligned. Place side stand

Drive chain slack :

•

After securely.

Tightening

adjusting

319.4 mm (12.57 in)

adjusters®

of

slack

for

at

the

accurate adjustment.

25 - 40 mm ( 1.0 - 1.6 in)

the

drive chain,

torque

:

55 -88

middle between engine and rear

both

to

ensure

N·m

(5.5 -8.8

until

the

chain has

cahin adjusters ®

that

the

front

the

motorcycle

tighten

kg-m,

40.0

the

-

and rear

axle

63.5

25

must

on

nut

lb-ft)

-

the

CD

25-40

mm

PERIODIC

MAINTENANCE

AND

TUNE-UP

PROCEDURES

2-10

CLEANING

•

Wash faster, the intervals must

CAUTION: Do

not

have

too more important, grease comes from the presence

After

• weight

CAUTION: Do

not

Such

oil

CAUTION: The standard drive chain recommends

used

for

AND

LUBRICATING

the chain

use

trichlene, gasoline

great a dissolving power

in the bush

washing

motor

use

any oil sold commercially

too

can

that

the replacement.

with

can

spoil the

to

pin clearance. Remember, high

and

drying

oil.

spoil the

the abovementioned standard drive chain

kerosene.

be

shortened.

or

any similar fluids:

"0"

of

grease

the

"0"

rings (or

is

TAKASAGO

If

the chain tends

for

this chain and, what

rings (or

in

that

chain, oil

seals)

clearance.

it

with

as

"drive

seals).

RK520SO. SUZUKI

to

rust

These

confining the

fluids

durability

a heavy-

chain

oil".

is

be

BRAKES

Inspect 6

000

Replace hoses Every 4 years Replace (change)

BRAKE FLUID LEVEL

• Keep straight.

• Check for lines

•

When brake

Specification

99000-2311

Initial 1

km

the

rear brake) and

on

the

fluid

000

(

12

months)

fluid

motorcycle

brake

level is

fluid

brake

below

that

meets

and

classification

0 : SUZUKI BRAKE FLUID

km

(2

Every 2 years

upright

level

lower

fluid

reservoirs.

the

months)

and place

by

observing

(both

front

lower

following

: DOT 4

and Every

the

and rear brake)

limit

line, replenish

specification.

handlebar

upper (only

limit

with

PERIODIC

2-11

WARNING:

The brake system based such brake

re-use

stored

WARNING:

Brake

immediately discolor

Check the brake

before riding.

brake

as

fluid

the brake

for

fluid,

MAINTENANCE

fluid.

silicone-based

taken from

fluid

periods.

long

leaks,

it

if

hoses

TUNE-UP

AND

motorcycle

this

of

different types

mix

or

use

not

Do

and petroleum-based. Do

unsealed

or

used

old,

from

over

left

interfere

will

painted surfaces.

cracks and

for

PROCEDURES

with

filled

is

containers. Never

servicing and

last

the

safe

with

joints

hose

glycol-

a

fluid

of

any

use

not

running and

leakage

for

BRAKE

Wearing condition

ing the marked on the replace

BRAKE LEVER PLAY

Adjust

•

Brake lever paly

•

BRAKE PEDAL

•

PADS

CD

line

limit

pad.

with

pads

the

brake

front

the

lock

Loosen Turn

Tighten

Loosen

brake Retighten proper position.

the

adjuster

the

lock

the

HEIGHT

lock

the

pedal 5 mm

the

lock

of

(front

nut

@

®

nut

brake

When

ones.

new

lever play

@.

in or

-

0

:

@.

@,

below

@

®

nut

pads

caliper)

the wear

(Refer

to

out

0.3

rotate

and

the

secure

to

can and

as

obtain

mm

top

checked

be

groove®

exceeds

page

to

follows.

the

0.01

-

(0

push

of

face

push rod ®

the

observ-

by

caliper)

(rear

limit

the

7-35.)

and

7-6

in)

play

to

locate

in

correct

rod® the footrest.

mark,

®.

the

Brake

REAR BRAKE LIGHT

Adjust on depressed.

pedal

just

height

the rear brake light

before a pressure is

5

@ :

SWITCH

switch,

mm

felt

(0.2

that

so

when

in)

light will

brake

brake pedal is

the

come

PERIODIC

MAINTENANCE

AND

TUNE-UP

PROCEDURES

2-12

BLEEDING AIR FROM

fluid

trapped in

Air

proportion

large

a cylinder and

brake caliper. The presence

the

of "sponginess" force. Considering exposes remounting normal

the

• Fill

•

condition,

following

up inspection brake). Attach free end Front brake : Bleed Squeeze and release succession, and squeeze it. Loosen

that

so remove

handlebar grip. Then,

the squeeze

the

until

tains

air

the

of

interferes

thus

the

of

the

machine and rider,

the

brake and restoring

the

manner:

master

the

window

Replace

a pipe

of

the

fluid bubbles.

cylinder reservoir

the

to

pipe

the

bleeder valve brake tension

lever,

fluid

and open the

flowing

THE BRAKE

circuit

pressure developed

the

with

brake

lever

danger

brake

(for

reservoir cap

the

of

fluid

front

caliper bleeder valve, and insert

a receptacle.

into

air

brake

the

runs

brake

the

into

FLUID CIRCUIT

a cushion

like

acts

braking performance

full

the

air is indicated

of

by

also

and

which

to

it

the

circuit

brake) and upper

to

the

from

lever several

lever

turning

by

the

into

lever

close

valve.

receptacle

such trapped air

essential

is

brake

be purged

upper end

the

to

prevent

bleeder valve.

without

fully

a quarter

it

receptacle:

causing

valve,

the

Repeat

to

the

by

of

lack

that,

system

line

entry

times

it

pump

this

longer

no

absorb master

by

braking

after

the

to

air in

of

the

of

(for rear

dirt.

of

the

in rapid

releasing

turn

a

of

will

this

touch

to

and

process

con-

NOTE:

reservoir as necessary while bleed-

Replenish the brake ing the brake

that

Make

reservoir.

• Close

•

Bleeder

Tightening

sure

bleeder valve,

the reservoir front

Rear brake : Differences

the

to

brake) and upper

master

valve

torque

fluid

system.

there is

upper end

the

cylinder

: 6 - 9

(0.6

always

is actuated

-

CAUTION:

with

brake

Handle with

the

paint, plastics, rubber materials,

fluid

some

disconnect

and

inspection

the

of

(for rear brake).

line

between

by

N·m

kg-m,

0.9

the

care:

fluid

and rear are

front

a pedal.

4.5

reacts

fluid

etc.

visible in the

Fill

pipe.

the

window

lb-ft)

6.5

-

chemically

the (for

that

PERIODIC

2-13

TIRES

MAINTENANCE

AND

TUNE-UP

PROCEDURES

000

Inspect

000

6

TIRE

Operating the decrease situation. the remaining depth cations.

Tire tread depth Service

Initial

km

TREAD

riding stability

Limit:

09900-20805:

TIRE PRESSURE

tire

the

If adversely

correct

the

tain

will

life

tire

FRONT

REAR

1

months)

12

(

CONDITION

motorcycle

highly recommended

is

It

(Front

3.0

Tire depth

pressure is

affected

tire

result. Cold

Solo

kPa

150

km

tire tread

of

and

(0.12

mm

too

tire

and

pressure

riding

kg/cm

1.50

months)

(2

with

consequently invite a dangerous

and

reaches

Rear)

in)

gauge

high or

increased. Therefore, main-

wear

for

inflation

2

psi kPa

22 22

and Every

excessively worn tires

replace the tire when

to

following

the

steering

low,

too

roadability

good

pressure is as

tire

Dual riding

kg/cm

150 175

1.50

1.75

specifi-

will

shorter

or

follows.

2

psi

22 25

will

be

CAUTION: The standard

and

front the standard may

SUZUKI Genuine Tire.

a

use

tire

110/90-18 61P

on this motorcycle

fitted

for

instability.

cause

rear. The

is

It

80/100-21

is

tire

a

of

use highly recommended

51P

other than

for

to

STEERING

PERIODIC

MAINTENANCE

AND

TUNE-UP

PROCEDURES

2-14

Inspect

000

6

Taper steering Steering handlebar and safe running. smooth poor Check supporting ground, near the ing bearing

Initial

km

roller

system

should

turning

stability.

that

with

axle and

1

months)

12

(

type bearing

for

be adjusted properly

handlebar and

of

there is no

machine so

the

wheel

pull

adjustment.

and

better

play

straight

forward.

(Refer

handling.

that

(2

km

000

FRONT FORK

months) and Every

(2

km

000

Inspect Initial

km ( 12 months)

000

6

the

outer

any

Inspect on Replace

1

forks

front

surface

defective

oil leakage,

for

the

of

parts,

months)

steel balls

Too

too

the

in

ahead, grasp

play

If

to

inner tubes.

necessary.

if

and Every

for

stiff

loose

front

the

is found, perform steer·

7-30.)

page

scoring and

applied

are

smooth

steering steering

assembly

fork

wheel

lower

on the

turning

prevents

cause

will

the

off

is

tubes

fork

scratches

of

by

REAR SUSPENSION

km

000

Inspect Initial

km ( 12 months)

000

6

Inspect there is no

the

1

shock

rear

play in

absorber

the

months) and Every

(2

oil leakage

for

swing

arm assembly.

and check

that

2-15

PERIODIC

MAINTENANCE

AND

TUNE-UP

PROCEDURES

CHASSIS

Tighten

000

6

The bolts and nuts listed below are to

the specified torque.

CD

Steering stem

®

Front

®

Front

@)

Front

® Steering stem head ®

Front

(j)

Front

®

Front

® Handlebar clamp ®

Front

(j])

Front

BOLTS

Initial 1 000

km

( 12 months)

fork

cap

fork

lower clamp

axle clamp

fork

cap

fork

lower clamp

axle clamp

fork

upper clamp

axle shaft

AND NUTS

km

(2

ITEM

head

nut

bolt bolt bolt

months) and Every

bolt

important

Convention a I front

fork

model

Inverted front

fork

model

safety parts.

N·m

50-80

15-30 18-28

9-

80-

30-40 20-30

15-25

18-28 22-35 50-80

They

11 100

must

be

retightened when necessary

kg-m

5.0-8.0

1.5-3.0

1.8-2.8

0.9-

8.0-

1.1

10.0

3.0 - 4.0

2.0-3.0

1.5-2.5

1.8-2.8

2.2-3.5

5.0-8.0

lb-ft

36.0-58.0

11.0-

13.0-20.0

6.5-8.0

58.0-72.5

21.5-29.0

14.5-21.5

11.0-

13.0-20.0

16.0-25.5

36.0-58.0

21.5

18.0

@

Front

brake master

@

Front

brake caliper

(jJ)

Brake

hose @Air @Disc

@Rear

®Rear ®Rear

bleeder valve

bolt

@Swingarm

shock absorber

(Upper & Lower)

@Rear

cushion lever cushion lever cushion rod

@ Rear axle

@Rear ®Rear

brake master brake rod lock

union

(Front

pivot

nut

cylinder

mounting

bolt

(Front

& Rear)

nut

mounting

nut nut

nut

cylinder

nut

bolt

(Front

& Rear)

(Front) (Center)

bolt

& Rear)

nut

5-8

18-28

20-25

6-9 18-28 55-88

48-72

7084-

8455-88

8-12 15-20

100 120

120

0.5-0.8

1.8-2.8

2.0-2.5

0.6-0.9

1.8-2.8

5.5-8.8

4.8-7.2

7.0-10.0

8.4-

12.0

8.4-

12.0

5.5-8.8

0.8-

1.2

1.5-2.0

3.5-6.0

13.0-20.0

14.5-

18.0

4.5-6.5

13.0-20.0

40.0-63.5

34.5-52.0

50.5

-72.5

60.5-87.0

40.0-63.5

6.0-8.5

11.0-

14.5

PERIODIC

MAINTENANCE

AND

TUNE-UP

PROCEDURES

2-16

ENGINE

~-----------------CONTENTS------------------~

ENGINE COMPONENTS REMOVABLE WITH

THE ENGINE IN PLACE

....................................................

3-

1

ENGINE REMOVAL

ENGINE REMOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 5

ENGINE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE COMPONENTS INSPECTION

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER

PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REED

BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRANKSHAFT.............................................................

CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRANK BALANCER

ENGINE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VALVE

AND

EXHAUST VALVE

...............................................................

REMOUNTING

.......................................................

SHAFT

AND

.............................

AND

................................

DRIVEN GEAR

SERVICING

..............

........

3- 2

3-

7

3-15 3-15 3-15 3-18 3-20 3-21 3-21 3-21

3-2

2

3-23 3-26 3-2

7

3-2

7

II

OIL

SEALS..................................................................

CRANKSHAFT.............................................................

CRANKSHAFT GEARSHIFT CRANKCASE CAM BALANCER

KICK STARTER

CLUTCH

MAGNETO

REED

OIL

PISTON RING CYLINDER

DRIVEN GEAR

.....................................................................

VALVE

PUMP

SHIM

CAM

...............................................................

SHAFT

..................................................................

...............................................................

....................................................

AND

SELECTION...................................

AND

CYLINDER HEAD

FORK

AND

.................................................

PISTON

........................................

GEARSHIFT

GEAR

.....................................

..........................................

..................................

SHAFT

................

· · · · · · ·

3-2

7

3-28 3-29 3-30

3-31 3-32

3-33

3-34

3-35 3-37 3-37

3-38 3-38 3-39

The

parts

Refer

to

listed

the

ENGINE LEFT SIDE

Gearshift

Engine Magneto Magneto Magneto

coil

Neutral

lever

....................

sprocket

cover rotor stator

....................................

indicator

...................

....................

.....................

and pick-up

switch

below

page listed in

....... 3-9

can be removed and reinstalled

3- 4 3- 4 3- 8 3- 8

3-

9

this

section

for

removal

without

instruction.

removing

the

engine

from

ENGINE CENTER ENGINE RIGHT SIDE

Carburetor Cylinder head Cylinder Piston

pump

Oil Intake pipe Reed valve

Exhaust valve

Thermostat

Water thermo-gauge ................

..........................

......................

..............................

................................

............................

..........................

..................... 3-15

.........................

3- 3 Kick 3- 7 Clutch 3-

7

3-

7 3- 8 3- 8 3- 8

4-

5 4-

9

starter

Clutch assembly Primary driven gear Crank balancer gear and shaft

starter

Kick Kick

starter Gearshift Gearshift cam driven gear

Water Primary drive gear Crank balancer drive gear

Oil

pump

Water

lever

cover

..................................

shaft idle gear

shaft

pump

drive gear

pump

........................

the

frame.

.................

.......................

..................

.............. 3-10

.................

............

....................

.....

drive gear

.........

...............

.....

.............

3- 7 3- 9 3-

9

3-10 3-1 0 3-1 0 3-11 3-11 3-12 3-12 3-12

3-14 4-

7

m

2

G)

-

2

m

0

s:

.,

0

2

m

2

-1

en

::rJ

m

s:

0

<

l>

aJ

r-

m

~

....

m

2

C'J

2

m

~

-

-1

J:

-1

J:

m m

2

G)

-

2

m

-

2

.,

r-

l>

0

m

ENGINE REMOVAL AND REMOUNTING

ENGINE

3-2

ENGINE

Before

engine

the removal is

• Drain transmission

• Drain

• Remove

• Remove Remove

• Turn

• the Remove

•

• Remove Loosen

•

Remove

•

@.

• Disconnect the water Disconnect the water

•

REMOVAL

engine

taking

the

fuel

the

suitable cleaner.

a

with sequentially explained

coolant.

the the the fuel

hose

the the

the

the first

(Refer

frame

®.

seat

radiator covers

lever

cock

@.

tank

fuel exhaust

clamp

muffler

out

(Refer

oil.

to

covers

to

@.

pipe

screw

hose hose

following

the

thoroughly

2-6.)

of

page

frame,

the

The procedure

in

page

to

2-6.)

CD.

@.

"OFF"

nuts

(j).

by removing the mounting

®

pipe

position, and disconnect

@.

by loosening the screw.

by removing the bolts.

C[j)

engine

of

steps.

clean

bolt

3-3

ENGINE

• Disconnect the

• Remove the carburetor

• Disconnect the interference

• Disconnect the spark plug lead

wire coupler

• Remove the oil pump cover

• Disconnect the

• Disconnect the tachometer cable

• Remove the clutch

• Remove the exhaust valve holder

• Remove the

• Loosen the exhaust valve inner cables by loosening the lock nuts

@and

• Remove the exhaust valve holder @

cables.

oil

hose

@.

oil

pump inner cable

release

bolt

@.

adjusters

CD.

by

loosening the clamp screws

hoses

@.

cap

@ and water thermo-gauge

by

removing the

(J)

and

®.

arm

@with

(j].

the clutch cable.

cap@.

with

@.

screws®.

throttle

the exhaust valve

cable@.

ENGINE

3-4

oil

hose

valve lever

Remove the exhaust

• Disconnect the

•

NOTE:

flow, connect the suitable cap to the

prevent

To

outlet.

Remove the gearshift

• Remove the engine sprocket

•

oil

lever

NOTE:

When firmly.

•

loosening the engine sprocket bolts,

Disconnect the magneto

magneto

Remove Remove the ignition Remove the engine mounting Remove the swingarm

the

lead

coil

NOTE:

to draw

careful

Be pletely suitable shaft

the frame.

of swingarm

not

from the

into

To

pivoting

side swingarm

right

left

the

keep the alignment

holes.

from

@

®and

lead

wire

mounting

shaft@.

pivot

the swingarm

out

side

spacer

CD,

oil

the

engine sprocket

the chain.

with

(J)

®.

wires

clamps

screws®.

(j])

bolts

pivoting

of

and spring

®

tank.

oil

cover®.

apply

rear brake

®.

brackets@.

and

pivot

hole from the

the frame holes and

shaft com-

hole. Insert the

left

®.

tank

side

Remove the engine

•

to

the

left

side.

ENGINE

3-5

ENGINE REMOUNTING

engine can be

The

NOTE:

The engine mounting nuts

been removed,

tighten them to the specified torque.

and

nuts

Tightening torque

ITEM

G),@,@

@

®

mounted

is

it

longer

no

N·m

28-34

55-88

20-30

are

of

in

the

reverse

order

self-lock type. Once the

any use. Be sure to use

at

of

kg-m

2.8-3.4

5.5-8.8

2.0-3.0

removal.

nut

lb-ft

20.0-24.5

40.0-63.5

14.5-21.5

has

new

Apply

• sprocket

99000-32110 Tightening

When

• to

THREAD

bolts

torque:

installing

prevent

:

the

LOCK SUPER

tighten

and

THREAD

-

10

(1.0

water

the

leakage.

water

the

to

them

LOCK

12

-

SUPER

N·m

kg-m,

1.2

hose pipe, use

"1322"

specified

"1322"

7.5

-

the

to

torque.

8.5

new

the

lb-ft)

0-ring

engine

®

When installing

•

protrusion

the

(J)

exhaust

the

of

valve

pully

to

holder

between

the

to

cylinder,

the

insert

springs@.

•

Apply tighten it.

THREAD

LOCK

SUPER

"1322"

to

the

bolt

CD

and

ENGINE

3-6

99000-32110:

• Align the mark the exhaust

NOTE:

When

aligning the marks, tighten the

•

Adjust turning

•

Tighten

NOTE:

Other

CAUTION: Make switch

• Tighten the exhaust pipe nuts

Tightening

(]):

®: ®:

bolt

1018-28

1.5

cable

sure

has

®

the

that

tuned

and

torque

16

-

2.5

THREAD

®on

valve

exhaust

adjuster.

lock

play

@

the

to

clamp

N·m N·m

N·m

LOCK SUPER

the

pulley

holder by adjusting the adjusters@,

cable play

nuts.

is

0

mm.

markes

screw

(1.0(1.8-

"ON"

(0.15

®,

®are

position.

®

to

1.6

2.8

-

0.25

"1322"

with

the

aligning

nuts®.

®

to

0.3

-

0.5

align,

(J),

the specified torque.

kg-m, kg-m,

kg-m,

after

first

muffler

7.0-

13.0-20.0

11.51b-ft)

1.0

the

-

mark®

®.

mm

by

ignition

mounting

lb-ft)

1.8

lb-ft)

on

TRANSMISSION OIL

•

Before

fied

(Refer

Transmission Oil change: 950 ml (1.00/0.84 US/Imp Overhaul

ADJUSTMENT

•

After necessary.

*

Throttle

*

Oil

*

Clutch

*

Drive chain

*

Air

*

Engine

*

Filling cooling

starting

amount

to

page

oil

:

1

000 ml

remounting

cable play

pump

bleeding

control

cable play

idle

the

engine, make sure

of

transmission oil

2-6.)

capacity

(1.1/0.9 US/Imp

the

engine,

..............................................

cable

slack

at

oil

r/min

.................................................

solution

........................................

................................................

pump

.......................................

.........................................

in

qt)

following

to

the

crankcase.

qt)

adjustments

pour

the

speci-

are

Page

2-7 2-8 2-8 2-9

5-7 2-7 2-7

3-7

ENGINE

ENGINE DISASSEMBLY

• Remove

• Loosen the cylinder the cylinder head.

• Remove the cylinder head.

• Disconnect the oil

the

kick

starter

head

hose

CD

lever.

nuts in the descending order on

by

loosening the clamps.

• Remove the cylinder

NOTE:

For

disassembling the exhaust

3-15.

•

Place

a clean circlip the piston pin circlip

from

rag

over the cylinder

dropping

by

removing the

valve

into

the crankcase and then, remove

with

long-nose pliers.

four

nuts.

related parts, refer

base

to

prevent piston pin

to

page

ENGINE

3-8

• Remove the piston pin

09910-34510 : Piston

• Remove the

oil

pump

and

with

puller

0-ring.

the special

CAUTION:

Do

not

use

the

removed

• Remove the intake pipe and reed valve.

0-ring.

tool.

• Remove the magneto cover.

• Remove the magneto

09930-40113 :

Rotor

rotor

holder

nut

with

the special

tool.

3-9

ENGINE

• Remove the magneto

09930-301 09930-30161

CAUTION:

Do

not

• Remove

hit

02

the

the the

: Sliding :

Attachment

rotor

stator neutral

rotor 0-ring,

rotor

with

the special tools.

shaft

"C"

with a hammer.

coil and

indicator

key

contact

pick-up

switch.

CD.

and spring.

coil.

CAUTION:

Do

not

use

the

removed

• Remove

the

clutch

NOTE:

For disassembling the

4-7.

• Remove tool.

0991

the

0-20115

clutch

:

Conrod

cover.

water

spring

holder

0-ring.

pump

bolts

parts,

refer

with

the

to

page

special

• Remove drive/driven

the

clutch

plates.

pressure plate, push piece and

ENGINE

3-10

• Flatten the lock washer, and remove the clutch nut

with

the special tool.

09920-5371

•

Remove

•

0 : Clutch sleeve hub holder.

the washer

the kick starter shaft

CD

and

primary driven

assemblies.

gear

assembly.

sleeve

hub

• Remove the circlip

kick starter idle

• Remove

0991

0-20115

• Remove

the

gear,

crank

: Conrod holder

crank

with a snap

washers

balancer

balancer driven gear.

ring pliers,

®and

nut

with

concaved

the

and

remove the

washer®.

special

tool.

3-11

ENGINE

Remove the washer

•

Remove the

•

Remove the gearshift shaft

• Remove the

• Remove the cam driven

•

balancer

lifter

pawl

®

key

CD,

with

shaft

®.

and cam guide.

gear®

balancer

and

plastic

a

removing the

by

weight®.

hammer.

bolt®.

NOTE:

When removing the cam driven gear

spring

and

®

(j),

pawl

shift

Remove the gearshift cam stopper

•

®.

not

do

®,

and cam stopper.

plate

loose the gear-

ENGINE

3-12

washer

Remove the

•

Remove the water pump drive

• removing the

09910-20115:

CAUTION:

has

nut

This

• Remove the

seal

the special tool.

with

nut

Conrod

left-hand threads.

balancer

holder

drive

and spacer

CD

gear

®.

and primary drive

gear

key.

and

gear

by

Remove the crankcase securing

•

retainers

• Remove the

two

@.

CAUTION: The removed screws

Remove the crankcase securing

•

should

®,

replaced

be

and screw.

bolts

then remove the bearing

and

ones.

new

with

@.

bolt

3-13

ENGINE

• Separate

09920-13120

• Remove forks

• Remove

the

@.

the

crankcase

with

: Crankcase separating

gearshift

countershaft

fork

shafts

and

the

special tool.

tool.

G), gearshift

driveshaft

cam®

together.

and

• Remove

the

09920-13120

• Remove ble

the

drift.

crankshaft

with

the

special tool.

: Crankshaft remover

(Crankcase separating tool)

respective oil seals and bearings

with

a suita-

starter guide and

Remove the

•

Remove the

• Remove the tachometer driven gear

•

gear.

kick

pump drive gear

oil

kick

CD

starter stopper.

the clutch cover.

from

sleeve

and driven

®

ENGINE

3-14

Remove the clutch

•

release

arm pinion.

3-15

ENGINE

ENGINE COMPONENTS INSPECTION

CYLINDER

Decarbon head.

NOTE:

servicing the thermostat

For

4-5

pages

CYLINDER Check tion

ance reading Service

09900-20803 If

exceeds emery paper (of about in a The gasketed surface order of

the

with

largest

the

lapping

to

reduced

HEAD

combustion chamber and

the

water thermo-gauge, refer

and

4-9.

and

HEAD

gasketed surface

a straightedge and thickness gauge, taking a

Limit

the

secure a

power

DISTORTION

several places.

at

(0.002

mm

0.05

:

: Thickness gauge

any portion

rework

must

joint.

tight

output

at

the

400)

#

and increased fuel

reading

limit,

manner.

the

of

surface

laid

smooth

be

leaky

A

in)

flat

clean

cylinder

of

by

on

and

joint

the

for

head

straightedge

the

rubbing

the

perfectly

can be

it

surface

the

consumption.

cylinder

distor-

against

AND

to

clear-

plate

in

flat cause

SERVICING

CYLINDER

Remove

•

Remove

• the

the

screw.

AND

exhaust

EXHAUST VALVE

cover.

valve

and spring by removing

arm

shaft,

valve

ENGINE

3-16

• Remove the exhaust valve and spring retainer the mounting

• Inspect the exhaust valve and cylinder sliding surface

nicks, scratches, wear or other

screws.

damage.

by

removing

for

• Remove

09921-20200 : Bearing remover 09930-30102 : Sliding shaft

the

oil seal

with

CAUTION:

The

removed

oil seal

should

CYLINDER DECARBON

Decarbon the exhaust

care

taking

notto

port

damage

and the upper part

the cylinder wall surface.

the

special

be replaced

tools.

with a new

of

the cylinder,

one.

3-17

ENGINE

CYLINDER BORE

The

wear

of

the

cylinder reading cylinder If

the rework machine Oversize pistons are available in mm

taken

gauge.

wear

thus

the

bore

or

replace

oversizes.

at

20

determined exceeds the limit indicated below,

to

mm

the

wall

is determined

from

the

top

oversize

with a new

two

Service Limit : 66.075 mm {2.6014 in) 09900-20508

After

reworking

the

edges emery nick

paper.

the

wall

: Cylinder gauge set

the

bore

to

of

ports To surface.

and

smooth

chamfer,

an oversize, be sure

the

use a scraper,

NOTE: Minor

similar off or

boring

surface

flaws

abnormalities can be

with

finegrain

otherwise

machine

emery

persist, the

to

on

the

paper.

cylinder

corrected

If

the

must

oversize.

from

diameter

of

the

cylinder

by

using a boring

one.

sizes:

0.25

mm

and

to

chamfer

chamfered edges

wall

by

flaws

be

taking

due

grinding

are deep grooves

care

to

seizure

the

reworked

with

0.5

with

not

flaws

with

a

to

or

a

REASSEMBLY

• Install the CAUTION:

When face the narrow side

• Install the exhaust

• Install the spring retainer

• Tighten the exhaust valve mounting

installing the

@

and tighten it.

of

the pin

spacers

side ® of

to

CD

and

pin®

spacers

the right hand

valve

CD·

and pin ®

the

spacer

to

the cylinder correctly.

@with

to

as

springs

the exhaust

to

the outside and wide

shown in the illustration.

screws

valves.

the exhaust

to

the exhaust valve

securely.

valves,

• Install the spring end

• Install to

Rotate the shaft

• groove

the exhaust valve shaft

groove@of

the

of

the arm.

shaft

90

arm®.

the

to

CD

the spring end

fit

and

®

shown in the

as

degree counterclockwise and

illustration.

fit

it

to

®

the

ENGINE

3-18

Apply

•

tighten

THREAD

it.

99000-32110

:

LOCK

THREAD

LOCK

PISTON

De-carbon the crown

• After in

smoothly. Carbon in groove

• stuck in the groove, and this engine power

A piston whose sliding surface

• due

• Shallow with

DECARBON

cleaning the grooves,

respective grooves

their

is

output.

overheating must

to

minor

grooves

emery paper

or

of

about

of

liable

be

SUPER

"1322"

SUPER

the piston and piston ring grooves.

the rings and rotate them

fit

be sure

to

cause

to

condition

badly

is

replaced.

can

scuff

400.

#

to

"1322"

that

the piston ring

lead

will

grooved

removed

be

they

reduced

to

or

grinding

by

move

get

to

scuffed

screw and

the

3-19

ENGINE

PISTON DIAMETER

Using a micrometer, measure the piston outside diameter

the place 12.5

If

the measurement

mm

from

is

less

the

skirt

than the

end

limit,

as

shown in Fig.

replace the piston.

at

Service 09900-20203:

Piston oversize : 0.25, 0.5

Limit:

65.910 Micrometer

mm

(2.5949 in)

(50-

mm

PISTON-CYLINDER CLEARANCE

As a result clearance exceeds the oversize piston,

Service

PISTON PIN

Using a caliper diameter.

If

reading exceeds the

a new one.

of

Limit:

the above measurement,

limit,

overhaul the cylinder and

or

replace

0.120

BORE

gauge,

both

cylinder and piston.

mm

I.D.

measure the piston pin bore inside

following

75 mm)

if

service

the piston

limit,

replace

to

cylinder

it

use

with

an

Service 09900-20605 : Dial calipers

PISTON

Using a micrometer, measure the piston outside diameter at three positions.

Service 09900-20205

Limit

Limit:

: 18.030

mm

O.D.

17.980

:Micrometer

mm

(0.7098 in)

(0.7079 in)

(0-

25 mm)

PISTON RING END GAP

Check gauge limit, The end squarely near the cylinder

each

ring

for

end gap, reading the

as

shown in Fig.

indicated below, replace

gap

of

each

into

the cylinder bore and held

bottom,

ring

If

the end

is

as

gap

is

it

with

new one.

to

be

measure

shown in Fig.

gap found

with

at

the least

with

to

the ring

a thickness

exceed the

fitted

worn

part

Service 09900-20803 : Thickness

Limit

(1st & 2nd) : 0.80

gauge

mm

(0.031 in)

PISTON RING

piston

the

As engine through piston Measure tension.

power

the

rings

the

enlarged

END GAP

FREE

ring wears,

output

end gaps

with

piston

ring free end gap

its

because

gap. Here

within

end gap increases reducing

using

of

spring

gas

of

lies

the

resultant

blowby

importance

limit.

check

to

the

ENGINE

3-20

: 1st :

Service

PISTON RING TO GROOVE CLEARANCE Fix side sliding

STD

1st : 2nd : 09900-20803

NOTE:

1st ring "R" to the piston.

Limit

piston ring in

the

clearance

surface

clearance

0.050

0.025

and

(1st)

0.070

-

0.060 mm (0.0008 -

-

2nd

"RN"

5.0 mm

4.1

2nd:

the

with

piston

of

mm

: Tichness gauge

differ

ring

(2nd)

(0.20 in) (0.16 in)

mm

piston ring groove, measure

to

while

top

thickness

and ring.

(0.0020 -

in the shape.

marked

gauge

0.0028 in)

0.0024 in)

side

Be

matching

to

sure

when

the

bring the

fitting

ring

the

them

Expander ring

1111

Top

2od

ring

c;og

OVERSIZE PISTON RING

of

types

following

The

They bear the

REED

Check the

0.2 is

VALVE

the dimension mm,

least 1

at

two following

Oversize

0.25 mm

0.5

clearnace

replace

mm.

mm

®

if

.

@

the reed

identification numbers.

the

oversize piston rings

Mark

valve

between

clearance

valve assembly.

reed

®

used.

are

and 2nd)

(1st

25

50

and its seat and

exceed

noted

is

The dimension

to

@

3-21

ENGINE

BEARINGS

Wash motor Turn smoothly. If is heard, a

the

oil before inspecting.

the

does

it

one.

new

bearing

inner ring and check

not

the

with

lightly,

turn

bearing is

OIL SEALS

Damage fuel-air replace damaged parts

to

mixture

oil. Inspect

or

the

of

lip

the

CRANKSHAFT

CRANKSHAFT Support rigged

the

to

RUNOUT

crankshaft

the

read

runout

see

to

may

for

"V"

shown.

solvent

and

blocks,

cleaning

quietly

defective

oil seal

there are any.

if

by

as

lubricate

and

inner ring

the

that

if

smoothly,

and

be

must

result in

damage and be sure

with

or

replaced

leakage

dial gauge

a

with

turns

noise

with

the

of

Play

to

Service Excessive crankshaft runout is often responsible

engine vibration.

09900-21303 09900-20701

09900-20606: Dial

CONDITION Turn of while no

CONROD Using a

Service 09900-20605

Limit

crankshaft

the

rotary

holding

rattle in

caliper

Limit

vibration shortens engine

Such

-block

V

:

gauge

with

big end.

the

BORE

mm

stand

(1/100

the

(0.9071

Magnetic

:

BIG BEARING

OF

motion

SMALL

in

crankshaft

the

big end.

the

END

gauge, measure the conrod

23.040

:

Dial calipers

:

(0.002

mm

0.05

:

in)

mm)

conrod

Move

rigidly

I.D.

in)

feel

to

the

be sure

to

the

rod up and

small

abnormal

for

life.

smoothness

down

there is

that

end diameter.

CLUTCH

DRIVEN PLATES

DRIVE

Clutch

lubricated driven plates last much longer. oil

These plates are expandable: when use gauge

AND

plates in service remain in

Because

oil.

with

subject

are

Their

in the clutch and also on the way the clutch

used

found

a caliper

worn

check thickness and claw

to

and surface plate

to

life depends largely on the

to

or

check

down

condition

oily

condition,

this

of

wearing action and therefore

little

meant

are

they

the respective

distorted

to

width

as

both

be

to

and a thickness

distortion.

they

drive and

quality

operated.

is

replaced

limit:

were

of

ENGINE

Checking

3-22

thickness

Service

Thickness : Claw width : 11.0 Distortion : 0.10

09900-20101 : 09900-20803 : Thickness

CLUTCH

Measure the free length

Limit

SPRING

mm

2.4

Vernier

(0.094 in)

(0.43 in)

mm

(0.004 in)

mm

FREE

calipers

gauge

LENGTH

of

each

coil spring calipers, and compare the elastic strength specified within

the

limit.

Replace all the springs

of

a vernier

with

each

of

any spring

is

the not

Checking

width

claw

distortion

Service

CLUTCH

Inspect

Limit:

RELEASE BEARING

clutch bearing

upon removal

should

reused Smooth

or

engagement and disengagement

much on the

mm

30.3

from

replaced.

be

condition

(1.19 in)

abnormality,

any

for

the clutch,

this bearing.

of

particularly

decide whether

to

the clutch depends

of

cracks, can

it

be

ENGINE

3·23

TRANSMISSION

transmission gears as

Disassemble

the

shown

in

illustration.

the

Driveshaft

CD

bearing

Driveshaft

®

Low

@

5th

@)

4th

®

3rd driven gear

®

Top driven gear

0

2nd driven gear

@

Driveshaft

®

Countershaft

®>

5th

®

3rd/4th

@

@Top

2nd drive gear

®

Countershaft

@

Countershaft right bearing

@

right

driven gear

left

drive gear

drive

drive gear

left

bearing

g~ar

bearing

ENGINE

3-24

GEARSHIFT FORK

Using a thickness gauge, check

its

groove This clearance portant action. Each

provided in its gear.

between the therefore,

If fied, replace

Shift

Service

Shift Standard No.

of

in

role

fork

and gear and,

fork

pushes

fork

liable

clearance checked is noted

the

the groove

to

fork

Limit

groove

fork

CLEARANCE

gear.

each

for

smoothness

the

has its prongs

In operation, there is sliding

gear axially.

the

cause

to

or

fork

clearance

mm

0.45

:

width

No.

&

1

the

of

when

the

its gear, or

(0.018

4.45

3 :

(0.175-

5.45

2 :

No.

(0.215-

thickness

fork

Shift

4.3

3 :

No.

&

Standard No.

1

(0.169

5.3

2 :

No.

(0.209

clearance in the

fork

shift

the

plays an im-

forks

shift

three

shifting-

and positiveness

the

into

fitted

a shifting action is initiated,

much

Too

meshed gears

exceed

to

both.

in)

mm

4.55

-

0.179

mm

5.55

-

0.219

mm

4.4

-

0.173

-

mm

5.4

-

0.212

-

of

annular groove

contact

a clearance is,

slip apart.

to

limit

the

in)

speci-

Vernier calipers

09900-20101

09900-20803

:

Thickness

:

gauge

REASSEMBLY

Assemble the countershaft and driveshaft,

disassembly.

of

attention

Pay

NOTE:

In reassembling the transmission,

the locations

sectional

mounting

CAUTION:

Never reuse a

*

shaft,

a circlip When

*

expand

the

over

installing

After

*

seated in

to

positions

and

given here will serve as a reference for correctly

view

the gears, washers

circlip.

removed

the

be

must

installing a

end

the

shaft.

groove

its

After circlip should be discarded and a

installed.

new

larger

gap

circlip,

a

and securely

following

the

points:

attention

washers

of

and

a circlip has been removed

circlip,

than

always

and

eire/ips.

must

care

required

insure

fitted.

the reverse order

in

be given

must

eire/ips. The cross

from

not

circlip

the

completely

to

that

be

it

taken

slip

is

to

new

to

ENGINE

3-25

When mounting the

• circlip.

the

of in the figure

Fit

with

the direction

attention

circlip,

to

it

the rounded side against the gear surface.

pay

the side where the

to

thrust

is

shown

as

crum

Sharp edge

ENGINE

3-26

2ND

MOUNTING

Press

•

Countershaft

106:~:~

THE

2nd drive gear

the

fit

length

(4.173:~:~~:

mm

®

NOTE: Before reassembling,

THREAD

with

gear

99000-32110

: THREAD

coat

LOCK

NOTE:

to smear

Take care

SUPER

not

"1322"

NOTE:

After

*

mounting the

gear spins

This procedure

*

smoothly

2nd

may

replacement is required.

CRANK BALANCER

(low

in)

GEAR

onto

2nd)

to

DRIVE

the internal face SUPER

LOCK

TOP

drive gear

"1322"

SUPER

drive gear, check

moving

by

be performed

SHAFT

AND DRIVEN

countershaft.

the

"1322"

with

it

twice

only

2nd

the

of and install it.

THREAD

that

LOCK

TOP

your fingers.

before

GEAR

drive

shaft

When

• to symmetrical shown

installing

the

Q),

pins

the

balancer driven gear

position, and

illustration.

the

in

align

springs

set

@,

the

®and

the

punched marks

inner race

CD

pins

to

@

®

the

as

balancer

Crank

CD

@Bearing, @Bearing,

Balancer

@)

®Washer

Balancer

®

Driven gear inner race

(j)

@Pin

Spring (4 pes)

®

@Retainer

L A

weight

driven gear

(2 pes)

shaft

3-27

ENGINE

ENGINE REASSEMBL

generally

Reassembly

disassembly,

demand

that

These ponents.

NOTE:

Apply

is

there

but

deserve

or

be

will

steps

engine oil to each running and sliding

reassembling.

BEARINGS

• Install the new bearings 09913-75520

09913-75810 09913-76010

09913-80112 : Bearing

: Bearing : Bearing : Bearing

performed in the

numbers

are

detailed explanation or emphasis.

taken up

the special tools.

with

installer installer installer installer

V

reverse

reassembling

of

respective parts and com-

for

part

order

steps

before

of

OIL SEALS

the

Apply

• 99000-25010:

NOTE:

grease

Replace the oil seal

prevent

oil leakage.

to

SUZUKI

seals.

oil

of

lip

SUPER GREASE

ones every disassembly to

new

with

"A"

CRANKSHAFT

ENGINE

Bearing, R

CD

®Shim ®Pin @Key

Crankshaft,

®

®Washer

Conrod

(J)

@Bearing ®Crank

Crankshaft,

@

®Bearing,

3-28

R

L

the

crankshaft.

the

53.0±0.1

:

(2.087

crankcase

the

0.004

±

mm

rebuilding

web

left

its

between

width

end into

width

right

web

to

the

when

to

pull

Dicide

• at

Crank

When mounting the crankshaft in the crankcase,

• sary

referring

webs

tools.

0-32812

0991

0-32820

0991 09911-1131

: Crankshaft installer : Crankshaft installer spacer : Crankshaft installer

0

attachment

CAUTION: Never

fit

crankshaft

the

into

crankcase

the

by

a plastic hammer.

Always accuracy

use the special tools, otherwise crankshaft alignment

affected.

be

will

to

in)

the

with

tapping

the

it

is

figure

neces-

special

with

it

53.0±0.1

mm

3-29

ENGINE

CRANKSHAFT SHIM SELECTION

•

Degrease

of

crankshaft right

•

Place

• Put the plasti-gauge (special tool) cut the shim,

the crankshaft right

side

bearing.

the removed shim on the right

as

shown in the illustration.

side

web, shim

side

and

crankshaft.

out

about 10 mm on

inner ring

Plasti-gauge

09900-22302

• Install

• Remove the bolts and separate the right and

with

the

09920-13120

• Mesure the scale.

STD

Thrust

: Plastigauge

right crankcase and

specail

tool.

: Crankcase separating

width

clearance :

of

compressed plasti-gauge

0.01 -0.07

tighten

tool

mm

it

(0.0004 -0.0028

•

If

the clearance

size

of

shim.

•

After crankcase.

• Recheck the clearance proper clearance is obtained.

List

selecting

of

shim

Part number

09170-25341-160 1.60 mm 09170-25341-165 1.65 mm 09170-25341-170 09170-25341-175 09170-25341-180 09170-25341-185 09170-25341-190

09170-25341-195 09170-25341-200 09170-25341-205 09170-25341-210 2.10 mm 09170-25341-215 2.15 mm 09170-25341-220 09170-25341-225 2.25 mm 09170-25341-230

is

the

of

not

shim

within

proper size

specification, select the proper

with

the above procedure until

of

shim, place

Shim thickness

1.70 mm

1.75 mm

1.80 mm

1.85 mm

1.90 mm

1.95 mm

2.00 mm

2.05 mm

2.20 mm

2.30 mm

with

left

with

in)

the

bolts.

crankcase

envelop

it

on

the

ENGINE

3-30

GEARSHIFT CAM AND

FORK

CD

Pawl

lifter

® Cam driven gear

@Pawl @Pawl ®Pin ®Spring

No.1 No.2

0 Cam guide

® Gearshift cam plate

® Gearshift

@ Gearshift

® Fork

@ Cam stopper

@Cam

@ Neutral

@

Switch

@

0-ring

@

Switch

@ Gearshift

@)Fork @)Spacer

® Gearshift

@ Gearshift

shaft

switch

contact

body

shaft

fork fork

No.1

fork

No.2

shaft shaft

No.1 No.3

No.2

spring

return spring

•

After

shift

fitting

grooves,

the gearshift forks

fit

the gearshift

cam

NOTE:

Three kinds

reassemble

and

configuration.

of

gearshift forks

each

other

CD

very closely

Carefully examine the photograph

and

For

directions.

5th

driven gear (No. 1)

Top

driven

3rd/4th

gear

drive

(No. 3)

gear

(No. 2)

tions

CD

® For

CD,

® and ®

on the crankcase.

, ®

and

in

external appearance

for

correct installing posi-

into

® are

the gear-

used.

They

3-31

ENGINE

CRANKCASE

When reassembling

• Fit

the

•

Apply

surfaces

dowel

SUZUKI BOND No. 121 5

of

pins

the

crankcase pay

CD,

new

0-ring

crankcase as

attention

to

following.

® and selected shim ®.

uniformly

shown

in

to

the

illustration.

mating

99000-31110:

• Assemble the

@ and screw ®

SUZUKI BOND No. 1215

Left

crankcase

cases

after few minutes and tighten the bolts

to

the specified torque.

Apply SUZUKI

Bond No. 1215

Tightening torque

@ :

9-

13 N-m

(0.9-

1.3 kg-m,

6.5-9.5

lb-ft)

® : 6 - 10 N·m (0.6 - 1.0 kg-m, 4.5 - 7.0 lb-ft)

• Tighten the Tightening torque : 9 -

• Install the bearing CAUTION:

Always

use

bolt ® to

the specified torque.

13 N·m

(0.9 - 1.3 kg-m, 6.5 - 9.5 lb-ft)

(J)

and tighten the retainer screws@.

new screws@.

After

• check

a

If

•

tapping the driveshaft

by

hammer.

• Install

the

Fit

•

and screws

the crankcase

driveshaft and countershaft rotate

if

resistance

large

the new

key®

0-ring

and pin

bolts

felt

is

CD

@,

to

the

to

install

rotation,

countershaft

or

balancer

the

have

smoothly.

to

try

drive

balancer

tightened,

been

free the shafts

a plastic

with

gear.

drive gear.

ENGINE

3-32

Tighten

•

torque

0991

Tightening

NOTE:

This

CAM

Apply

• stopper

the

with

115

0-20

has

nut

DRIVEN

THREAD

@,

torque

99000-32030

Tightening

• Install

CAUTION: When installing the bearing.

torque:

oil

the

water

the

:

pump

special

Conrod

60

:

(6.0

left-hand

GEAR

LOCK SUPER

and tighten

THREAD

:

15(1.5-

®

seat

the

drive

tool.

holder

80

-

8.0

-

threads.

AND

to

it

LOCK

N-m

23

kg-m,

2.3

spacer®.

and

face the

®,

the

to

nut

gear

N·m

-

kg-m,

43.5

GEARSHIFT

the gearshift arm

"1303"

flat

to

lb-ft)

surface

"1303"

the specified torque.

SUPER

11.0-16.5

specified

lb-ft)

58.0

SHAFT

seat

the

of

to

•

Apply

bolt®

THREAD

and stopper arm

99000-32050

LOCK

THREAD

:

"1342"

bolt®,

LOCK

the retainer screw

to

and tighten them.

"1342"

(]),

3-33

When

• The

ENGINE

installing

large shoulder

the

gearshift

must face

®

pawls

to

cam driven gear.

the

into

outside as shown.

the

cam guide

• Install

• Apply tighten them.

• Apply

99000-32050

•

• Install gear driven gear as shown

the

THREAD LOCK

THREAD

@ , and tighten it.

: THREAD

Fit a spring

photo.

on

to

gearshift shaft. Match

the

gearshift shaft with

the

and pawel

CD

"1342"

LOCK

the

''1342"

LOCK "1342"

gearshift shaft correctly as shown

photo.

in

lifter®.

the

to

the

to

the

center

the

screws and nuts, and

cam driven gear

center

teeth

on

of

the

in

bolt

the

cam

BALANCER SHAFT AND GEAR

balancer

@and

key

the

Fit

•

@.

install

the

weight®

and washer

•

When punched marks

•

Tighten

special

0991

installing the balancer driven

tool.

0-20

CD.

the

balancer

115

: Conrod holder

nut

to

the

specified

gear,

align the three

torque

with

the

ENGINE

3-34

Tightening torque :

45-55 (4.5-5.5

KICK STARTER SHAFT

•

When

installing

the

kick

starter,

®.

• Install the the return spring

kick

starter shaft assembly and rotate the

to

the hole

N·m

kg-m,

of

32.5-40.0

align

the crankcase.

the

lb-ft)

punched

end®

marks

of

3-35

ENGINE

CLUTCH

CD

Clutch spring

® Pressure

plate

@ Drive

@ Driven @

® Clutch

(j) Release

@ Driven

® Washer

@ Lock

(j])

@ Washer .

@

plate

plat~

Thrust

bearmg k

rel_e~senrac

PlniO

plate

(Th:

1.9

mm)

seat

washer

Clutch sleeve

Primary

dnven

No.1

No.

hub

ear

g

(Th:

2

assembly

1.4

mm)

•

Fit

the tongue

sleeve

hub.

. n

•

Tlghte

. h

Wit

Tightemng

the

. torque · k m

09920-5371

CD

of

the washer

clutch

specla

0 . Clutch sleeve

.

. I

tool.

•

sleeve

40-60

(4.0-6.0

to

hub

nut

N·m

g- ,

hub holder

he

t

to

29.

groove

the

specified

0-43.5

of

the clutch

torque

lb-ft)

ENGINE

3-36

• Install the clutch plate as

shown

• Install the drive plate and driven plate No. 1 one by one.

• Insert plate.

Tighten

• tool.

in

the illustration.

the

clutch

the

clutch

release rack and bearing

spring

seat

bolts

CD

and

driven plate No. 2 ®

diagonally

into

with

the

pressure

special

CD

I

jilt-®

~~

09910-20115 : Conrod holder

•

Fit

the new 0-ring @

• Install the oil pump drive CAUTION:

Use

a new gasket

• Engage at

gear Make ly.

To

and

tighten

the

sure

install

to

teeth

clutch

that

the

and

gear

prevent

of

cover

the

cover,

bolts.

oil

clutch release rack

side, and replace

rack and pinion gears engage

tap

dowel

with

leakage.

lightly

pins@.

shaft.

with

the

plastic

those

clutch

of

pinion

cover.

positive-

hummer,

ENGINE

3-37

MAGNETO

Degrease

• the magneto

the key

Fit

•

the tapered

rotor.

CD.

portion

the crankshaft and

of

also

• Insert

• Install

• Install switch.

Align

•

rotor

Apply

•

tighten

neutral

the

the new

the magneto stator, pick-up coil

the key groove

the crankshaft.

to

THREAD

to

it

indicator switch spring

0-ring

the specified

@.

with

LOCK

SUPER

torque

the key and

"1324"

with

the

®and

and

install

the

to

special

contact

neutral

indicator

the magneto

rotor

tool.

nut

®.

and

99000-32120

: THREAD

Tightening torque :

09930-40113

Before

reed

the matter

VALVE

REED

•

: Rotor holder

installing the

valve carefully,

stuck between reed

®

LOCK SUPER

75-85

.5-8.5

(7

reed

making sure there

N·m

kg-m,

valve

"1324"

is

valve

lb-ft)

not

stopper.

54.0-61.5

the crankcase, examine

to

and reed

foreign

OIL

PUMP

• Install the new

•

When tion

installing the

®.

0-ring

oil

CD.

pump,

align the

groove®

with

protru-

ENGINE

3-38

PISTON

•

Mount

ring and

NOTE:

Top and

Be

sure

to

the piston.

•

Each ring in locating

• Install conrod.

•

Before SUZUKI CCI Oil small end bearings.

•

The arrow mark on the piston crown points

exhaust

RING

the

top

2nd

to

bring the marked side

pin.

the

installing

port

AND

piston rings in

ring.

rings have

place should be so positioned

bearing

or

side.

PISTON

letter

@

and

the

piston

two-stroke

the

two

to

order

uR"

to

thrust

the

oil

to

of

marked.

top when

conrod,

the

expander ring, 2nd

fitting

as

washers

be sure

conrad big end and

to

the cylinder

to

@

hug

to

them

the

apply

CORRECT

I

INCORRECT

I

•

The circlip should be the

mating

groove portion

ends

of

the

mounted

circlip

piston.

in such a position

do

not

coincide

®

with

that

the

ENGINE

3-39

Before inserting the piston in the

• two-stroke

or

Oil

SUZUKI the piston and piston ring grooves.

Fit

•

• Install

CCI

dowel

two

the

the new gasket

pins.

CD.

cylinder,

to

oil

apply

to

sure

be

the outer surface

of

CYLINDER

Tighten

•

specified

Tightening

• Connect the

clamps.

• Install

the

torque.

torque

the new

AND

cylinder

:

hose

oil

cylinder

CYLINDER

the

in

nut

N·m

27

-

23 (2.3-

2.7

cylinder

the

to

gasket properly

head

HEAD

criss-cross

kg-m,

16.5

and

manner

19.5

-

the

fix

position.

to

lb-ft)

hose

the

with

CAUTION: When marked

installing

• Install

®

the copper washers

side

the

to

cylinder

top

the

head gasket,

shown in

as

®.

sure

be

photograph.

the

to

bring

"UP"

Tighten the

• ascending

Tightening

NOTE:

CD

nuts

Cap

Apply

• and

THREAD

tighten

cylinder

numerical

torque

position

LOCK

it.

to

nuts

head

order on the cylinder

N·m

27

-

23

:

7 kg-m,

2.

-

(2.3

shown in the phtograph.

as

is

SUPER

"1322"

the specified torque in

head.

lb-ft)

19.5

-

16.5

bolt

the kick

to

lever

ENGINE

3-40

99000-32110

:THREAD

LOCK SUPER

"1322"

COOLING

~----------------CONTENTS'----------------~

SYSTEM

COOLING SYSTEM COOLING SOLUTION RADIATOR

THERMOSTAT.................................................................

W A

TER

WATER THERMO-GAUGE..................................................

AND

PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

..........................................................

.......................................................

RESERVOIR TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1 4-2

4-2 4-5 4-6 4-9

II

COOLING

4-1

SYSTEM

COOLING SYSTEM

DESCRIPTION

in forced

coolant

type

by

made

cooled

The engine head, and through the radiators. For the water pump, a high-capacity

tube-and

are heat dissipation.

is

fin

set

aluminum material,

recirculation through jackets formed in the

characterized

which

is

centrifugal

lightness

by

pump

cylinder

The radiators

used.

is

in weight and good

and

The thermostat

of

through

coolant

the

most

flow

the

to

condition.

heat

of

over the in the pellet.

Referring lates regulated

As

is established.

the

wax pellet type,

of

is coolant

following

the

temperature

At

through the radiators. The

route

about

released

is

illustration,

comprising

to

rises

coolant

65°C

of

to

the

Radiator

complete

thermostat

the

pump,

atmosphere

engine, by-pass

and

50°C

temperature,

with

valve

the

through

the

as

valve

a

actuated

is

the

is in

holes

thermostat

the

temperature-dependent

means by

closed

valve

radiator core.

of

the temperature-sensive

condition,

thermostat

the

of

unseats,

becomes

the

was

water

that

so

and radiator in

normal

completely

coolant

control

contained

recircu-

the

flow

open and

Water

pump

COOLING SOLUTION

manufacture, the

of

time

the

At

distilled

solution

50

a 50

tection, temperatures above

-31°C

55%

:

50

coolant.

If

NOTE:

The characteristics

know

to

CAUTION: Do

Do

This

and

motorcycle

the

(-24°

60% according

or

the

put

not

mix

not

will

F), this

protection

in more than

different

of

mixture

50

: protect

-31°C

to

is

mixing

to

different

of

you

brands

will

cooling

the

(-24°

exposed

be

ratio

the Fig. 2.

anti-freezes vary. Read the label

will

60% anti-freeze

anti-freeze.

of

is

freezing

from

increased

50%.

than

heat pro-

below

up

system

to

sould

or

system

excellent

temperatures

be

less

cooling

water and anti-freeze/summer

provide

F).

have.

with

filled

at

to

c

·c;

a.

c

"'

·c;

a:l

Fig. 1

(oC)

tF)

150

302

140

284 266

130

248 120 230

110

212 100

Coolant

(oF)

32

c

·c;

·22

a.

c

"'

·40 ·40

...

.,

~

u..

·58

·76

·94

14

·4

r--

=

0 1 0

tc)

0

·10

·20

·30

·50

·60

-70

COOLING

k--

--

,...-

-

~

-

~

-

density-boiling

"

-

30

20

Density(%)

1'\

f\

\

40

\

SYSTEM

1--""1

f..-

,.....

.-

--

f.-

......-

~

50 60

curve

point

I

1/

J

•

..

•

4-2

~

.5

j

~

0.9

c.

~

0.5

j

0~

RADIATOR

AND

RESERVOIR TANK

Fig. 2

Coolant

60

40

20

Density(%)

density-freezing

100

80

point

curve

COOLING

4-3

SYSTEM

RADIATOR REMOVAL

and

to fuel louvers.

coolant. (Refer

Drain

• Remove the

•

• Remove the radiator

seat

2-6.)

page

tank. (Refer

to

page

3-2.)

• Disconnect the radiator

Remove

•

RESERVOIR

Remove

• Remove

•

the radiators.

TANK REMOVAL

tank.

fuel

the

reservoir

the

hoses

(Refer

tank.

and

to

reservoir

page 3-2.)

hose.

INSPECTION

Before removing

following

the

1. Test as

the

follows:

two

cooling system

radiator and draining

the

items.

tightness

for

coolant,

a radiator tester

with

inspect

COOLING

SYSTEM

4-4

Remove the radiator cap, and connect the tester

2

filter.

if sure there

Give a pressure

the system

should fall

leaking

a

is

holds

during this 1

the entire system and

2. Test the radiator radiator tester in the

shown, and

tester,

as

the tester. Make sure

2

if it

and

of

is

that

0.15 cap the

kg/cm

capable

is

cap

about 1 kg/cm

of

this pressure

in the system;

point

replace

for

cap

following

build up pressure

the pressure

that

with

that,

pressure

found

not

for

0-second interval,

leaking

the

relieving pressure

manner:

the tester

least 10

at

for

satisfy eigher

to

(14.2 psi) and

seconds.

10

such

In

component

Fit

slowly

build-up

held at a

the

seconds.

requirements.

0.15

air is

dented

or

blade

found

pressure :

2

kg/cm

stuck

,

to

recommended

can be repaired

a

of

in cracked

12.8

fins

the

small

2.1 psi)

±

must

this

for

by

screwdriver.

condition

Radiator

15

±

90

3. Road

of

Use Fins

them

ing Any

4. must

valve

cap

(0.90

kPa

trashes

or

dirt

compressed

down

bent

with

replaced.

be

hose

water

release

±

the

to

see

pres-

the

If

it

case,

a

by

means

that

inspect

part.

or

using the

the

to

cap

by operating

0.9

at

stops standstill, the

Replace

two

these

of

removed.

be

cleaning.

straighten-

flattened

or

±

Radiator

cap

RADIATOR HOSE

leakage

Inspect section radiator

any

If hose Any corrected

for

from

and

hose.

leakage

should

leakages

by

the

from

replaced.

be

from

proper

INSTALLATION

to

radiator

The removal radiator, be sure information.

is

procedure and refer

to

radiator

the

from

radiator hose

radiator hose are detected,

the

connecting

the

hose

itself

(joint)

tightening.

reverse

the

to

in

page

refer

8-13.

to

be installed

coolant:

add

connecting

fork

and

section

order installing

After

2-7

page

kinks

radiator

the

should

refilling

for

(joint)

the

in

be

the

of

the

COOLING

4-5

SYSTEM

THERMOSTAT

REMOVAL

• Drain Disconnect

•

Remove

•

• Remove

coolant.

the

(Refer

spark

the

thermostat

thermostat.

to

plug

page

cap.

cover.

2-6.)

INSPECTION

thermostat

Inspect

Test following

•

• Immerse as thermostat

thermometer.

• the

should be

the

thermostat

the

manner.

a string between

Pass

the

shown

pan on a

Read

ature

stove

thermometer

the

bottom

level

in is in suspension. Heat

at

anywhere

at

flange,

thermostat

illustration.

the

and observe

pan. This reading,

the

of

which

the

pellet

the

between

for

bench

as

the

in

the

when

just

thermostat

signs

shown in the

water

Note

rising

48.5

of

control

for

contained in

that

water

the

temperature

thermostat

the

which

valve

°C

and 51.5

cracking.

action, in

illustration.

the

immersed

the

placing

by

drops

the

is

begins

to

°C.

the

pan,

the the

on

to

temper-

open,

Thermostat

Thermometer

Thermostat

48.5-

Keep on heating

•

beyond

valve opening

51.5°C

65°C (149°

(119.3

the

temperature

-124.7°F)

water

F).

to

raise

:

temperature

its

to

and

COOLING

SYSTEM

4-6

water

when

Just

• should

Thermostat

thermostat

• A ments

the

lifted

have

:

lift

valve

failing

(start-to-open

replaced.

WATER PUMP

reaches

least

at

by

Over 3.0

65°C (149°

at

to

mm

satisfy

temperature

65°C,

3.0 (0.12

F)

either

and valve

the

mm.

in)

of

thermostat

require-

two

the

must

lift)

valve

be

Tightening

Item

®

torque

N·m

11-14

CD

®

@

@ @

®

(j)

kg-m

1.1-1.4

Circlip Water pump driven

pump

Water Mechanical

Impeller 0-ring 0-ring

lb-ft

8.0-10.0

shaft

seal

gear

REMOVAL

Drain transmission

• Drain

•

• Remove Disconnect

•

• Remove

Remove

•

AND

coolant.

first

the

kick

the

clutch

the

clutch

the

DISASSEMBL

(Refer

oil.

page

(Refer

to

muffler.

tachometer

starter

lever. release cover. (Refer

(Refer

V

page

to

2-6.)

page

to

cable.

arm. (Refer

(Refer

to

page

2-6.)

page

to

3-2.)

page

to

page

3-9.)

3-3.)

3-7.)

3-3.)

COOLING

4-7

SYSTEM

Remove

•

Remove

•

Remove the

• and

CD

with

cover.

water

a

pump

water

the

impeller

the

circlip, and remove the water pump driven

pin®.

pump

plier.

gear

Remove

•

Remove the oil

• CAUTION:

The removed

a new one.

with

the

water

oil

pump

and mechanical

seal

mechanical

and

seal

shaft

with

seal.

seal

plastic

a

should

hummer.

replaced

be

INSPECTION

Rotate the water pump shaft

rotating smoothly.

noise occurs

Replace the water pump shaft

or

REASSEMBLY

Reassemble and

removal

of

Apply

• mechanical

99000-31140:

and

SUZUKI

seal

SUZUKI

remount disassembly.

BOND NO. 12078

and

the

install

BOND

hand inspect

by

there

if

water

it.

No.

anything

is

pump

to

12078

any abnormal

if

unusual.

reverse order

the

in

the outer surface

of

COOLING

SYSTEM

4-8

seal

CD

oil

be installed toward the water

must

• Install

NOTE:

seal lip

Oil

the new

gear.

When installing the ring,

• facing toward the impeller.

gasket

• Use a installing

and

Tighten

• with

new

the

bolthead.

the

water

a

gasket, face

impeller

pump

a suitable

with

must

it

for

®

the

mounting plier.

installed

be

impeller iron side

to

bolt

size

center

to

the

sleeve.

pump

with

bolt.

spring

the

specified

driven

mark®

its

When

washer

torque

Tightening

the

• Fill

torque

specified

: 7 - 9

-

(0.7

coolant.

N-m

0.9

(Refer

kg-m,

to

5.0

page

6.5

-

2-7.)

lb-ft)

4-9

COOLING

SYSTEM

WATER THERMO-GAUGE

REMOVAL

•

Drain coolant.

•

Remove the water thermo-gauge after disconnecting the

wire.

INSPECTION

Test the water thermo-gauge at the bench value

changes,

run

as

follows:

meter and stove, heat the thermometer water thermo-gauge whose ohmic

proportion indicated in the

place

(Refer

as

specified,

Connect the water thermo-gauge it oil

placed

to

page

2-6.)

with

temperature. The test

in

oil

contained in a pan, which

to

raise

its temperature

in the

pan

table

and

value

must

also does

be

replaced.

to

see

to

is

slowly,

the ohmmeter. A

not

change

lead

if

its ohmic

is

to

be

the

ohmplaced reading the

on a

in the

09900-25002 : Pocket tester

If

the resistance noted

in resistance

Water thermo-gauge specification

value, water thermo-gauge must

Water temp.

50

(122)

115

(239)

For inspecting the water temperature meter, refer

°C

to

(°F)

show

infinity

or

too

be

Standard resistance

Approx. Approx.

REASSEMBLY

•

Apply the water thermo-gauge and

99000-31110:

• Fill CAUTION:

Take special care when cause

SUZUKI BOND

SUZUKI

the specified coolant.

damage

if

it

gets

BOND

handling

a sharp impact.

NO.

install

(Refer

1215

to

it

to

No. 1215

to

apge

the

water thermo-gauge may

the thread

the

cylinder

2-7.)

much difference

replaced.

(0)

226 26

to

page

6-8.

portion

head.

of

Tightening

torque:

6-

(0.6

10 N-m

- 1.0

kg-m, 4.5 - 7.0 lb-ft)

FUEL

~----------------CONTENTS----------------~

AND

LUBRICATION

SYSTEM

FUEL

CARBURETOR...................................................................

OIL PUMP

COCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

CARBURETOR SETTING TABLE REMOVAL

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NEEDLE VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FLOAT REASSEMBLY

AIR

BLEEDING...............................................................

CHECKING OIL PUMP

AND

HEIGHT

........................•...............................................

DISASSEMBLY

ADJUSTMENT

AND

REMOUNTING

....................................................

....................................

.......................................

........................................

..................................

5-2

~..

5-3

5-4 5-5

5-6 5-6

5-6

5-7

5-7 5-7

5·1

FUEL

LUBRICATION

AND

SYSTEM

FUEL

COCK

REMOVAL

lever

cock

fuel

the

Turn

• the

to

must

from

"RES"

be

taken.

fuel hose

the Place a clean oil pan under

•

fuel cock lever

Remove

•

WARNING: Gasoline Extreme

the fuel cock assembly.

very explosive.

is care

CLEANING

tends

tank

fuel

the

from

Oust

has been neglected

filter

when the Remove

WARNING:

the

of

flow

the

Gasket must

fuel.

dust

replaced

be

from

the

with

"OFF"

to

fuel cock.

fuel

the

position

filter

a new one

and

build

to

using compressed air.

position and disconnect

assembly,

cock

drain fuel.

filter,

the

in

up

a long period, inhibits

for

prevent fuel

to

turn

which,

leakage.

Gasket

CARBURETOR

AND

FUEL

®

i

~

u

fl-.oo

\1

'

LUBRICATION

SYSTEM

5-2

1.0. NO. LOCATION

®

0-ring

CD

Throttle

@

E-ring

@

needle

@Jet

Throttle

@

vent

Air

®

Throttle

(J)

screw

@Air ®Needle @Pilot

®Main

Needle valve

@

@Float @Plunger @Lever

jet

valve

hose

valve

jet

spring

stop

screw

5-3

FUEL

AND

LUBRICATION

SYSTEM

CARBURETOR SETTING TABLE

Carburetor type

Bore

size

1.0. No. Idler/min. F I oat height

Main jet Main air

jet

Jet needle

Needle jet Cut-away Pilot jet By-pass

Pilot

outlet

Air

screw

ITEM

(M.J.)

(M.A.J.)

(J.N.) (N.J.)

(C.A.)

(P.J.)

(B.P.)

(P.O.)

(A.S.)

Canada,

France

MIKUNI

30mm

0802

400±

1

12.9

(0.51 ± 0.04 in)

# 170

0.6mm

60HY36-3rd

0.9mm

0.6mm

2%

turns back +-

SPECIFICATION

and

TM30SS

100

r/min

± 1.0 mm

N-8

4.0

# 35

U.K. Australia

+-

0803

+-

+++++-

+++-

Starter

jet Power jet Valve

seat

Throttle cable play

(G.S.)

(P.W.J.)

(V.S.)

# 35 #80

2.5 mm

0.5-1.0

mm

(0.02 - 0.04 in)

+++-

+-

REMOVAL AND DISASSEMBLY

seat and

page

the

clamp screws and remove the carburetor. (Refer

3-3.)

carburetor

the

Remove

• Loosen the

• to

• Remove

tle valve assembly.

fuel

top

tank.

(Refer

end cap and remove

to

page

3-2.)

the

throt-

FUEL

LUBRICATION

AND

SYSTEM

5-4

Disconnect

•

Remove

•

the

float

throttle

chamber.

cable.

Remove

•

the

float

assembly.

5-5

FUEL

AND

LUBRICATION

SYSTEM

• Remove the

• Remove

•

Remove

the

the starter lever

float

main

pin,

jet,

float

and needle valve.

needle

and

jet

starter plunger.

and

pilot

jet.

INSPECTION

Check

* * Pilot * Needle

* Float * Needle valve mesh * Gasket

Main

the

jet

following

air bleeding hole holes

items

for

any damage

* * Pilot

Throttle

outlet

or

clogging.

valve

and bypass

FUEL

LUBRICATION

AND

SYSTEM

5-6

NEEDLE

foreign matter

If needle,

flow.

limits, similar trouble

sticks, the

float

the

worn

is

valve

a

with

FLOAT HEIGHT

check the

To

ing the

float

just in contact

is

Bend

value.

Float 09900-20101

VALVE

gasoline

the

and

seat

the

If

gasoline

chamber and

shown in the

as

Clean

seat.

compressed air.

float

arm pin

float

arm kept free,

with

the tongue

height : 12.9

CD

: Vernier

is

will

the

ADJUSTMENT

as

±

INSPECTION

and the

caught between the valve

continue

needle

will not float

illustration, replace

fuel

height, invert the carburetor body,

that

so

measure

needle valve

necessary

mm (0.51

1.0 calipers

flowing and

worn beyond the

are

occur.

flow

parts

the pin

Conversely,

the

into

with

passage

the height ®

of

will

with

bring the height

to

0.04

±

float

gasoline.

the mixing chamber

not

calipers.

a

in)

seat

to

it

cause

permissible the

if

chamber. Clean

the needle

If

together

it

With the

off.

slip

float

while

®to

over-

needle

with

hold-

arm

this

INCORRECT CORRECT

NOTE:

When measuring float height, be sure to remove the gasket.

REASSEMBLY AND

remount

Reassemble

removal

of

After

• are necessary.

Throttle

*

Engine

*

and

disassembly.

and

remounting

cable

idle

play

r/min

REMOUNTING

carburetor

the

carburetor,

the

.........................

............................

the

in

following

Refer Refer

reverse order

adjustments

page

to

page 2-7.

to

2-7.

5-7

FUEL

AND

LUBRICATION

SYSTEM

OIL PUMP

AIR BLEEDING

Whenever the

oil pipe servicing, be

sure

in place before returning

• Remove

• To bleed Loosen the

that good and hard.

CHECKING OIL PUMP

Use the special tool, uring interval.

• Have and

• Run

• Holding engine lever up inner cable operation, the reading taken on the device should

4.7

evidence is noted

from

the

oil

tank

or

if

the

oil

pump

to

carry

out

an air bleeding operation

the

carburetor. (Refer

the

air, hold

screw

the

trapped air has all been bled,

the

amount

the

tool

connect

the

engine

to

the

mi.

CD

to

of

oil

filled

it

to

the

at

speed

fully

and

let the pump draw

has

the

machine in standstill condition.

to

let

out

check

the

pump

with

SUZUKI CCI

suction

2

000

r/min.

at the

open position by pulling up the oil pump

of

some air tlaving leaked

in a machine

to

be removed

with

machine

the air and after making sure

the

pump

same

to

page

tighten

for

draws

side

during

of

the

or

2 000 r/min.,

for

2 minutes. For this

the

3-3.)

capacity

CCI

brought

for

servicing,

the oil pump

user.

the

by

the

specified

SUPER

pump.

move

be

into

in

for

screw

meas-

OIL

the

3.8 -

09900-21602 Oil

pump

NOTE:

Adjust checking

discharge rate (Full open) :

both

oil

: CCI oil gauge

3.8 - 4.7 ml

throttle pump. (Refer

and

for

2 minutes at 2 000

oil

pump

to

pages

control

2-7

cable

and 2-8).

r/min

play

after

ELECTRICAL

~-----------------CONTENTS'------------------~

SYSTEM

IGNITION SYSTEM

DISCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 1

CHARGING SYSTEM

DISCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 4

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-

EXHAUST VALVE ACTUATOR

WATER TEMPERATURE METER

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

OIL LEVEL GAUGE

LAMPS

COMBINATION

REMOVAL

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

..........................................................................

........................... ' .......................................

..........................................................

.......................................................

.........................................

.......................................

..........................................................

METER....................................................

6- 1 6-

1

6- 4

5

6- 7 6- 8

6- 8

6-

9

6-10

SWITCHES.....................................................................

BATTERY

.......................................................................

6-11

6-12

ELECTRICAL

6-1

SYSTEM

IGNITION SYSTEM

-Y

Engine stop switch

.-------<J~o----....,

~

~---R/B--+---~~~~~~-+

COl/Actuator

control

Except

unit

-.+--.8/R--+--,

Pick-up coil

-+----t

R

81/

__._______.

R/ G

8/W

~

,.

Battery

i

stand

switch

I

~Side

J,

for

\1

W/8

Ignition coil

Actuator

Canada

'

g1

gz

DESCRIPTION

~

engine

has

It

the currents

one ignition

into

"lg1"

if

induced in the

is

only

can

in neutral

is

r/min.

rotor

formed, and

equipped

in gear, the side stand

TS200R

The fluctuations. ing on the engine

When the magneto

charges the capacitor

pick-up coil,

the converted "SCR" a high voltage

This motorcycle The engine

Transmission

The transmission

INSPECTION

MAGNETO COIL

seat

Remove

• Measure

•

lowing

the

table

resistance

with

equipped

is

"ignition

an

"C';

started

be

and

pocket

a

rotates,

via diode

are

signal.

with

if:

or

fuel

between

ignition

a new

with

timing

electric current

an

"D1

generated,

This

the electric energy stored in the capacitor

as

ignition

interlock

tank.

(Refer the

tester.

type

control

On

".

they

sent

is

signal

secondary

switches

fully

is

page

to

wires

lead

circuit"

is

the

flow

to

coil"lgz

for

up.

system. This new system

which accurately controls

generated in the power source coils,

hand, when the protrusion on the

other

ignition

the

to

"SCR"

"SCR",

ignition

3-2.)

the

in

the

",and

fol-

a sprak.

circuit.

timing

becomes

further

ignition

control

ON, the

is

"C"

rotor

and

timing

depend-

passes

are

they

"C"

~

reduces

timing

and this current

circuit,

circuit

discharged instantly,

09900-25002

: Pocket tester

resistance

Magneto

Pick-up Power

coil

source

coil

Charging coil

IGNITION COIL

Remove

• Remove

•

the the

R/G-

180-280

8/R

50-80

Y-Y

0.1

seat and ignition

-

fuel

coil.

81/R

R/8

1.0

n

(x

n

tank.

(x

10

(x

100

range)

n

range)

n

1

(Refer

n

to

range)

page

3-2.)

ELECTRICAL

WIRE COLOR

with

Red

:

R/G

with

Blue

:

BI/R

Black

B/R :

with

Red

R/B :

:Yellow

Y

Green tracer

Red

with

Black

tracer

tracer tracer

SYSTEM

6-2

Checking

ignition

the

Test

connection

Test

needle Spark

sparking

performance

09900-281

Checking Ignition

coil resistance

with

06

with

electro

distance

Electro

:

pocket

tester

sparking

for

coil

is as indicated. Make sure

is

(STD)

tester

Primary (Terminal-Ground) :

cap-Ground) :

Secondary 09900-25002

COl/ACTUATOR

Remove

• Remove

•

(Plug

: Pocket

CONTROL

seat.

the

COl/Actuator

the

tester

at

8

:

0.1

UNIT

performance.

8

least

(0.3

mm

1.0

-

13

control

mm.

in)

Q

20

unit.

kQ

that

the

three-

ELECTRICAL

6-3

Measure

ing table

SYSTEM

resistance between the lead wires in

the

with

the

pocket

tester.

the

follow-

tester

EB

Probe

of

---------

Probe

EB

B/R R/B

00

00 00 00

EB

0

00

of

-----

Probe

of

10-60

-----

10-60

R/B

0

p

Gr

: Pocket

BI/R

R/G

30-150

-----

09900-25002

Ignition circuit

For

0

(])

+-'

....

.0

(])

0

+-'

....

C/)

---------

(])

a.

+-'

CDc

0

-

(])

.00

0+-'

.... ....

a.

CD~

For Exhaust valve actuator circuit

0

-

(])

.co

0+-'

.... ....

a.

CD~

B/R

..

-----

(])

+-'

B/Y

+-'

W/BI

-----

..

B/W

(])

+-'

Unit: tester to: BI/R R/G

5-25

DO

======-----

Unit:

to:

tester

B/Y

DO

1-6

200-1000

~

-----

Unit:

to:

tester

B/W

7-30

p

35-140

1-6

60-250

------

30-130

60-250

-----

Unit:

W/BI

DO

00

Gr

1-6

kn

:Black :Green

: :Pink :White :

: Black : Black

: Blue

/BI:

COLOR

Orange

Yellow

Red Red White

WIRE

B Gr

0

p

w

y

B/R B/W B/Y : Black BI/R R/B : R/G : W

with with with

Red

with

Black tracer

with

Green tracer

with

tracer

Red

White

Yellow

Blue tracer

tracer

EB

0

-

..

(])

.co

0+-'

.... ....

0.(])

+-'

CD~

CAUTION:

capacitors, zener diodes,

As resistance values SUZUKI

w

---------

y

B

will

pocket

tester

Probe

--------

of

w

5-25

1-5

deffer

is used.

5-25

-----------

are used insid

etc.

when

an

y

3-15

ohmmeter

to:

tester

B

1.5-7 6-30

=====------

the

unit,

this

than

other

CHARGING SYSTEM

DESCRIPTION

The

circuit tor/rectifier The

AC it

charges

of

the

unit

current

the

charging

and battery.

generated

battery.

system

from

is

AC

generator

indicated

in

figure,

is

rectified

which

by

rectifier

is

composed

and is

ELECTRICAL

of

an

AC

turned

into

SYSTEM

generator,

DC

current,

6-4

regula-

then

Function While voltage

battery

the

of

Regulator

engine

of

regulator,

directly.

r/min

the

Lighting

.---------------,

....

·:;

~

"13

0

....

c

0

u

L----------------~

is

low

and

the

regulator

generated

does

not

voltage

function,

of

AC

generator

incidentally

-~-m

the

generated

~

:

I

/

is

G)

:::

Cll

~

lower

than

current

c

<(

0

...J

the

switch

adjusted

charges

the

.-------------

I

I I

I

n

I

___..

--,

....

·:;

~

"13

0

....

c I

0 I

u I

t

-·-

~

I

>

....

G)

....

Cll

m

I

..,__

I.J

I

L----------------~

/

Lighting

c

<(

0

...J

switch

6-5

ELECTRICAL

SYSTEM

When voltage generated by the then tive, hence When result, operation

battery.

the

engine speed increases

battery

a signal from

voltage (voltage between ® and

the

voltage does

the

battery

the

generated voltage will

of

voltage falls,

the

regulator,

the

and

the

generator.

circuit will flow

not

charge

the

start

the

battery

.---------------,

~

I

the

load decreases,

The

battery

to

the

battery

signal

to

charge

voltage will be maintained

will

®)

the

SCR. When

the

reaches

but

SCR will be

the

continue

the

returns

battery

to

value

the

SCR goes

to

out

once again. Due

charge voltage will increase

be charged

set

of

the

generator.

off, causing

constant,

...

':J

~

·o

-e

...

c:

0

u

by

the

generated voltage until

the

control circuit

"ON",©-

to

preventing overcharging

~

I

I a:l

the

~

Q)

t::

IU

@will

SCR

to

repetition

Lighting

-·-

due

to

the

in

the

regulator,

become conduc-

go

"OFF".

of

switch

0

<(

0

....1

the

As

above

of

the

a

INSPECTION

CHARGING OUTPUT CHECK

• Remove

•

Start

lighting switch

• Using the

under 13.0V load performance and regulator/rectifier.

NOTE:

When

the

left frame cover.

the

engine and keep it running

the

battery

turned

pocket tester, measure

EB

terminal and 8 terminal.

or

ON

(High position).

over 15.5V, check

making this test, be sure that the battery

charged condition.

STD charging

09900-25002 : Pocket tester

output:

13.0-

15.5V

at 5 000

the

(DC)

r/min with

DC

voltage between

If

the

tester reads

AC

generator no-

is

at 5 000

r/min

in

,

the

fully-

ELECTRICAL

SYSTEM

6-6

GENERATOR

AC

Remove the

•

• Disconnect the AC

• Start the engine and keep Measure the

•

the pocket tester.

with

the tester

If

STD No-load performance : More than 33 V

09900-25002

GENERATOR STATOR COIL

AC

pocket

Using lead Also

the

wires

check

of

NO-LOAD PERFORMANCE

and fuel

seat

AC voltage

under 33

reads

: Pocket tester

tester, stator.

the

that

tank. (Refer

generator

stator

lead

running at 5 000

it

between the three

the

V,

r/min

check

core is

wire

AC

continuity

the

insulated.

to

coupler.

generator

page

yellow

(AC)

3-2.)

r/min.

faulty.

is

5

at

between

lead

000

wires

the

resistance :

STD 09900-25002

NOTE:

0.1

: Pocket tester

n

1.0

-

When making this test, it is generator.

REGULATOR/RECTIFIER

fuel

and

seat

• Remove Disconnect

•

the

lead

wires.

necessary to remove the

not

page

tank.

(Refer

to

AC

3-2.)

6-7

ELECTRICAL

Using

the

pocket between is

incorrect, replace

09900-25002 : Pocket tester

0

...

CD

...

Ul

CD

...

....

0

CD

.c

0

...

a..

CD

WIRE COLOR

Y:

R: B/W : Black

the

Y1 Y2

30-

----

Y3

30-

R

20-

1 - 6

B/W

Yellow Red

SYSTEM

tester (x 1

lead wires

y,

150 150 100

with

in

the

regulator/rectifier.

® Probe of

Y2

30-

150

30-

150

-------

20-

100

1 - 6 1 - 6

White

tracer

kn

range); measure

the

following table.

tester

Y3

30-

150

30-

150

20-

100

----

the

If

the

Unit :

to:

1 - 6 1 1

2-

----

Approx.

R

-6

10

resistance

reading

kO

B/W

20-

100

20-

100

20-

100

10-

60

----

R

r;_B/W

CAUTION:

As

SCR

and diodes are used inside

the

resistance values will differ when

SUZUKL

pocket

tester

is

used.

this

regulator/rectifier

an

ohmmeter

EXHAUST VALVE ACTUATOR

• Remove Using

wires

If

the

Actuator

W-

B : Y - B : 0 P - Gr : 4.5 -

the

pocket

in

the

following table.

reading

is

coil resistance

3.2-7.2

7.2

seat and fuel

tester, measure

incorrect, replace

kn

(x

30

n (x

(x

kn 10

kn

tank.

range)

n range)

(Refer

the

to

page 3-2.)

resistance between

actuator.

other

the

unit,

than

lead

WIRE COLOR

B : Black Gr: Gray

P

:Pink

W:

White

Y:

Yellow

w

v-fb

.-P

B

G<

WATER TEMPERATURE METER

INSPECTION

water

the

of

spring is installed

coil

the

As

temperature

position

test

To

be used. The

may is operating

the

out

To perform this test, disconnect the B/G temperature meter from the water thermo-gauge. Connect a jumper wire between B/G wires coming harness the water temperature meter

II

wi

test positions.

Connect a 226-ohm resistor between the B/G

water thermo-gauge

thermo-gauge

when the specified voltage

pointer indicates the

26 ohms.

to

replace

the water temperature meter

meter,

when

water

the

but

range.

engine ground. With the ignition switch turned on,

and

check the accuracy

is

If

the

ignition

temperature

first,

not

will

and

normal

"H"

either one

on the

needle

switch

simplest

and indicate

should

of

the ground

its pointer indicates the

if

applied

is

position when the resistor

or

needle

is forced

is turned

meter

meters accuracy through-

the

indicate

the meter in the

both indications

with

shaft

back

OFF.

two

will

test

lead

from

lead

the circuit

to

a new one.

original

the

to

the

if

the water

of

The

and

"H"

wire

position

"C"

and

changed

is abnormal,

checks

meter

second

"C''

the

of

its

if

different

tell

wire

the main wiring

"H".

lead

wire. The water

are

ELECTRICAL

~ ~

SYSTEM

6·8

WATER TEMPERATURE METER

POSITION

CD

®

TEMP

50°C

115°C

OIL LEVEL GAUGE

Remove

•

Check

lead

B/W

ohm

1

-

surface

the

or

the

oil level

wires.

when

replace

seat and

switch

tester

the

If

switch

th~

the

oil level

for

ring is in

unit.

gauge.

continuity

not

does

bottom,

RESISTANCE

2260

260

between

value

show

the

file

the

81/W

of

contact

and

0

ELECTRICAL

6-9

LAMPS

HEADLIGHT

SYSTEM

TAIL/BRAKE

LIGHT

For

France

LICENSE

For the others

LIGHT

TURN

SIGNAL LIGHT

COMBINATION METER

REMOVAL

(Refer

to

page

7-2

7)

ELECTRICAL

SYSTEM

6·10

INSPECTION

pocket

Using If

09900-25002

NOTE:

the

continuity

the

measured is incorrect,

: Pocket

When making this

Canada

For

8

T

e>m

II

I

N

iiiO

I I

>-~

II

tester, check

tester

not

it is

test,

SP

TA

....

(.!)

I

continuity

the

replace

between

the

lead

respective parts.

wires

in

following

the

necessary to remove the combination meter.

For the others

Temp. meter

F

N

8

SP

8

Ill

(.!)

..._ ..._

lD lD

I

~

i

Oiii

I

>-~

I

....

(.!)

I

TA

diagram.

Temp. meter

(.!)

..._ lD

lD

I I

8

....

iil

I

: Speedometer

SP T A: Tachometer

Neutral

:

beam

signal

indicator

8 : High

T : Turn

N

light

indicator

indicator light

light

Speedometer

SP:

Tachometer

TA:

8 : High F : Turn

: Neutral

N

light

indicator

beam

signal/oil level indicator

indicator light

light

6-11

ELECTRI~AL

SWITCHES

SYSTEM

Inspect each ring

to

respective 09900-25002

the

switch

chart.

switch

: Pocket

for continuity

If

any

abnormality

assemblies

tester

with

new

IGNITION SWITCH

LIGHTING SWITCH

~r

p

OFF

s

ON

0 Gr

0 0

-o

'-"

DIMMER SWITCH

~r

p

HI

LO

w

0

y

0

TURN SIGNAL LIGHT SWITCH

p

~

R

L

B Lbl

0

-o

the pocket tester refer-

is

found,

ones.

replace

the

FRONT BRAKE LIGHT SWITCH

n

~

OFF

ON

REAR

p

~

OFF

Y/W

ON

SIDE

-o

Y/W

-o

Lg

~or

n

(Upright

OFF

(Down position)

NOTE:

When inspecting the side-stand switch, connect the

EB

probe

probe to G lead

-o

NEUTRAL

~r

p

Neutral

position

0

W/B

0

BRAKE LIGHT SWITCH

0

W/B

0

STAND

ON

position)

of

SWITCH

G

pocket tester to B!W lead wire and 8

wire.

INDICATOR

Bl

SWITCH

Ground

0

-o

-Q

B/W

-o

ENGINE

~r

p

OFF

ON

WIRE COLOR B

Bl Br G Gr

Lbl

STOP SWITCH

:Black :Blue :Brown :Green :Gray

:Light

,

blue

B/Y

0

: Light

Lg

:Orange

0

:Red

R

:White

w

y

:Yellow

B/BI :Black

B/W

-o

green

with

Blue tracer

HORN BUTTON

~or

p

OFF

ON(Push)

B/W : Black B/Y

:Black

W/B :White

Y

IW:

Yellow

B/BI

0

with with

with

B/W

-o

White tracer

Yellow tracer Black tracer

White tracer

ELECTRICAL

SYSTEM

6-12

BATTERY

SPECIFICATIONS

Type

designation Capacity Standard

INITIAL CHARGING

Filling

• Remove lyte

• Remove

electrolyte

the

aluminum tape

filler holes.

the

caps

S.G.

®.

YT4L-BS

12V,

10.8kC

1.320

CD

at

sealing

or

20°C

the

battery

FT4L-BS

(3

Ah)/10HR

(68°F)

electro-

Upper cover breather

Cathpde plates

Filter

Filler holes

NOTE:

*

After

cap

* Do

trolyte

• Insert battery's electrolyte filler holes, holding the container firmly Electrolyte

so of

•

Make

container, and leave in

20

filling

® as

not

that the

minutes.

the

electrolyte

the

seald caps

remove

container.

the

it

does

fluid

sure air bubbles are

or

nozzles

not

to

spill.

pierce

completely,

of

battery-filler

the

sealed areas @

of

the

electrolyte

fall. Take precaution

coming

this

position

container

up

for

use

the

holes.

not

each

about

removed

of

the

into

to

allow

electroyte

more

elec-

the

any •containers

than

Air

bubbles

Insert

in

filler holes

75

~

o,

;.

/

•

0

~

..:.."

R5

0

..

0

~

.~

o.

'0

~

\

. :

.0

~

..

0

.

~

1

•

0

~~

~

IJL..

1ro

I

Suzuki TS200R Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

GROUP INDEX

ENGINE