Suzuki UH150K5 Service Manual

Catalog Title:

UH150K5 (UH150K5 P19)

Block No. Block Title.

FIG1 GASKET SET

Ref No

Part No

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Description

1 1 2 3 4 5 6 7 8 9 10 11 11 12 13 14 15 16

11403-49810 11403-49811 11141-21FA0 11173-49F00 11241-21F00 11482-49F00 11483-21F00 12837-19B10 14181-37D10 16524-20E00 09168-06023 09168-08008 09168-08016 09168-14002 09280-00029 09280-22001 09280-32006 09280-54001

Gasket Set Gasket Set

• . Gasket, Cylinder Head

• . Gasket, Cylinder Head Cover

• . Gasket, Cylinder

• . Gasket, Clutch Cover

• . Gasket, Magneto Cover

• . Gasket, Tensioner Adjuster

• . Gasket, Exhaust Pipe

• . Gasket, Oil Strainer Cap

• . Gasket (5.8x13x1.2)

• . Gasket (8.2x14x1)

• . Gasket (13.8x18.8x0.4)

• . O Ring (d:2.4, Id:161)

• . O Ring (d:2.4, Id:21.8)

• . O Ring (d:2.4, Id:31.7)

• . O Ring (d:2.4, Id:52.6)

Catalog Title:

UH150K5 (UH150K5 P19)

Block No. Block Title.

FIG2 CYLINDER HEAD COVER

Ref No

1 2 3 4 5

Part No

11171-49F00 11173-49F00 09106-07015 09161-11008 09106-07017

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Description

Cover, Cylinder Head Gasket, Cylinder Head Cover Bolt (7x18.5) Washer Bolt (7x31)

Catalog Title:

UH150K5 (UH150K5 P19)

Block No. Block Title.

FIG3 CYLINDER HEAD

Ref No

1 2 3 4 5 6 7 8 9 10 11 12 13 14 14 14 14 14 14 15 16 17 18 19 20 21 22

Part No

11100-49F00 09103-06026 09103-06165 09103-06064 09206-08001 11115-14D71 11141-21FA0 09103-10276 09103-10281 01421-06253 08316-10063 09160-10082 04211-13189 09482-00456 09482-00457 09482-00516 09482-00515 09482-00458 09482-00459 13110-49F01 09280-32006 01550-06163 09402-46208 17661-49F00 17670-08D30 01547-06203 34850-21E00

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Description

Head Assy, Cylinder

• . Bolt (6x39)

• . Bolt (6x45)

• . Bolt (6x60)

• . Pin (6.2x8x11) Guide, Valve (os:0.3) Gasket, Cylinder Head Bolt (10x175) Bolt (10x145) Stud Bolt Nut Gasket (10.5x19x2) Pin Spark Plug (ngk, Cr8e) Spark Plug (denso, U24esr-n) Spark Plug (ngk, Cr7e) Spark Plug (denso, U22esr-n) Spark Plug (ngk, Cr9e) Spark Plug (denso, U27esr-n) Pipe, Intake O Ring (d:2.4, Id:31.7) Bolt Clamp Cover, Thermostat Thermostat, Water Bolt Gauge Assy, Water Temperature

Catalog Title:

UH150K5 (UH150K5 P19)

Block No. Block Title.

FIG4 CYLINDER

Ref No

1 2 3 4 5

Part No

11210-21FA0-0F0 11241-21F00 01421-06253 08316-10063 04211-13189

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Description

Cylinder Gasket, Cylinder Stud Bolt Nut Pin

Catalog Title:

UH150K5 (UH150K5 P19)

Block No. Block Title.

FIG5 CRANKCASE

Ref No

1 2 3 4 5 6 7 8 9 10 11 12 12a 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

Part No

11310-21830 09319-12060 11320-49810 09319-12060 09319-10032 07120-08853 07120-08653 07120-08753 01547-06353 01547-06553 04211-11169 11323-06F11 09125-06086 09247-14026 09168-14002 01550-08123 09168-08016 01550-08123 09103C12058J00 08310-00125 09247-12006 09168-12002 11390-21F00 09280-04004 09106-06075 11430-21830 01550-08303 04211-11169 09280-00029 11186-49F00

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Description

Crankcase Set, Rh

• . Bush Crankcase Set, Lh

• . Bush

• . Bush Bolt Bolt Bolt Bolt Bolt Pin, Crankcase Plate, Gear Box Screw Plug, Oil Drain (14x12) Gasket (13.8x18.8x0.4) Bolt Gasket (8.2x14x1) Bolt Bolt (12x215) Nut Plug (12x10) Gasket (12.1x16.2x3.7) Jet, Piston Cooling O Ring (d:1.2,id:4.0) Bolt (6x12) Cover Set, Gear Box Bolt Pin O Ring Separator, Oil Breather

Catalog Title:

UH150K5 (UH150K5 P19)

Block No. Block Title.

FIG6 CRANKCASE COVER

Ref No

1 1a 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Part No

11340-49811 09180-06310 11482-49F00 01547-06253 11380-21F00 11388-49F10 11389-14F00 01547-06253 01547-06603 08322-01063 11351-49F00 11483-21F00 01547-06353 01547-06453 04211-09149 11971-14F00 09280-17003 09248-14005 09168-14002 09248-16012 09168-16002

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Description

Cover, Clutch

• . Spacer Gasket, Clutch Cover Bolt Duct, Belt Cooling Filter, Belt Cooling Holder, Belt Cooling Filter Bolt Bolt Washer Cover, Magneto Gasket, Magneto Cover Bolt Bolt Pin Gauge, Oil Level O Ring (d:3.1, Id:16.8) Plug Gasket (13.8x18.8x0.4) Plug (16x8) Gasket (16x22x2)

Catalog Title:

UH150K5 (UH150K5 P19)

Block No. Block Title.

FIG7 CRANKSHAFT

Ref No

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Part No

12200-49F50 12161-21F00-0B0 12210-05F00 09263-30048-0B0 12221-49F50 12260-49F50 12664-24B01 09181-35024 09262-12001 09262-35038 09282-12009 09283-34011 08331-41286 12111-21F50-0F0 12140-21F50 12151-43400 09381-16001 12100-21F60-050

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Description

Crankshaft Assy

• . Connecting Rod

• . Pin, Crank

• . Bearing (30x38x17)

• . Crankshaft, Rh

• . Crankshaft, Lh Nut Shim, Crankshaft Rh Bearing, Rh (12x28x8) Bearing (35x72x17) Oil Seal, Rh (12x21x7) Oil Seal, Lh (34x52x6) Circlip Piston Ring Set, Piston Pin, Piston Snap Ring Piston Set (os:0.5)

Catalog Title:

UH150K5 (UH150K5 P19)

Block No. Block Title.

FIG8 STARTER CLUTCH

Ref No

1 2 3 4 5 6 7 8

Part No

12611-49F00 09206-12002 07130-06163 12600-21821 12633-05300 09261-10003 09440-03007 12649-20E02

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Description

Gear, Starter Idle Pin (7x12x50.5) Bolt Clutch Set, Starter

• . Piece, Starter Clutch Roller

• . Roller

• . Spring Shim, Starter Clutch Hub

Catalog Title:

UH150K5 (UH150K5 P19)

Block No. Block Title.

FIG9 CAM SHAFT/VALVE

Ref No

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Part No

12710-21F60 12741-04B01 09261-05005 07120-06103 09390-22002 12840-49F00 12842-17C50 12843-27A00 12850-49F00 12842-17C50 12843-27A00 12861-21F50 09164-12018 12911-21F00 12912-21F00 12920-06B00 12931-27A20 12932-27A00 12933-81400 09289-05011

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Description

Shaft, Cam Sprocket, Cam Shaft (nt:34) Roller Bolt C Ring Arm, Valve Rocker,intake

• . Screw, Tappet Adjusting

• . Nut, Tappet Adjusting Arm, Valve Rocker,exhaust

• . Screw, Tappet Adjusting

• . Nut, Tappet Adjusting Shaft, Valve Rocker Arm Washer, Valve Rocker Arm Shaft Valve, Intake Valve, Exhaust Spring Set, Valve Retainer, Valve Spring Cotter, Valve Seat, Valve Spring Oil Seal

Catalog Title:

UH150K5 (UH150K5 P19)

Block No. Block Title.

FIG10 CAM CHAIN

Ref No

1 2 3 4 5 6 7 8 9 10 11 12

Part No

12760-04B00 12771-21F00 12811-21F00 12812-32410 09168-08016 12830-02A00 12832-02A00 12833-02A00 12834-02A00 12837-19B10 07130-06203 09168-06023

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Description

Chain, Cam Shaft Drive Guide, Cam Chain Tensioner, Cam Chain Bolt, Cam Chain Tensioner Gasket (8.2x14x1) Adjuster Assy, Tensioner

• . O Ring

• . Spring

• . Plug, Adjuster Gasket, Tensioner Adjuster Bolt Gasket, Tensioner Adjuster Bol

Catalog Title:

UH150K5 (UH150K5 P19)

Block No. Block Title.

FIG11 CARBURETOR

Ref No

1 1a 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 44 44 45 45 46 47

Part No

13200-49FA0 13500-20EK0 13383-49FA0 13382-14F00-X00 13503-49F00 13502-20EK0 13601-11F00-X00 13341-34F50 13342-49FA0 09491-22026 09492-35027 13279-49FA0 13271-14F00-X00 13291-26E00-X00 13295-26E00-X00 13370-26E00-X00 13375-26E00-X00 13250-14F00-X00 13254-26E00-X00 13602-43E00-X00 13258-14F00-X00 02112-04127-X00 13247-11F00 13491-20EK0 13494-14F00-X00 13497-14F00-X00 13488-14F00-X00 02112-04107-X00 13499-14F00-X00 13565-49F01 02142-05087-X00 02142-05147-X00 13267-26E10-X00 13271-26E10-X00 13430-49F00 13428-06F30-X00 02112-14087-X00 13433-06F30-X00 13683-14F00-X00 13684-49F00 09401-05402-X00 13674-49F00 13683-49F01 13685-49F00 13650-49F00 13650-20E00 13650-49F10 13655-16F00 13655-25E00 09407-14407 D9436-01425

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Description

Carburetor Assy

• . Diaphragm Assy

• . Needle, Jet (n425-cna00)

• . Seat

• . Spring

• . Cover, Diaphragm

• . Screw

• . Jet, Needle (n426-36630)

• . Holder Needle Jet

• . Main Jet (#112)

• . Pilot Jet (n424-51b35)

• . Adjust Screw

• . Spring

• . Washer

• . O Ring

• . Valve Assy, Needle

• . Clip

• . Float

• . Pin, Float

• . Screw

• . Packing

• . Screw

• . Screw, Drain

• . Diaphragm Assy

• . Spring

• . U Ring

• . Cover

• . Screw

• . Cap

• . Plate

• . Screw

• . Spring

• . Element Assy, Thermo

• . Plate

• . Screw

• . Cover

• . Hose

• . Pipe

• . Clip

• . Filter

• . Pipe

• . Joint Heater Assy, Carburetor (35w) Heater Assy, Carburetor (25w) Heater Set, Carburetor Switch, Carb Heater Thermo Switch, Carb Heater Thermo Clamp, Carb Starter Air Clamp, Carb Overflow Hose (l:1

Catalog Title:

UH150K5 (UH150K5 P19)

Block No. Block Title.

FIG12 AIR CLEANER

Ref No

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Part No

13720-49F00 13780-49F00 13810-49F00 13746-49F00 13741-49F00 13092-09E00 03141-05165 13854-47D50 D9500-0159P 13853-49F00 D9500-0159P 13739-49F00 D9500-0196P D9500-0159P 13880-49F00 D8391-12504 D8391-12324 13891-49F00 13912-20E00 D1557-06255 13737-49F00 13710-49F00 13761-49F00 13838-49F00 D2116-05105 02142-05105

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Description

Case Comp, Cleaner Filter Comp, Air Cleaner Trap Comp, Flame Gasket, Air Clnr Cap, Air Cleaner Tube, Drain Screw Plug Clip Tube, Breather Clip Tube Chamber Clip Clip Tube Assy, Outlet Clamp Clamp Tube, Inlet Collar Bolt Cushion Box No. 1 Chamber, Air Cleaner Plate, Chamber Collar Bolt Screw

Catalog Title:

UH150K5 (UH150K5 P19)

Block No. Block Title.

FIG13 MUFFLER

Ref No

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part No

14181-37D10 01421-08163 D8319-60085 14180-49F00 14185-49F00 D7107-05125 14310-49F01-E02 D1507-08355 14773-49F00 09320-12035 14780-49F00 09139-06091 D8322-91068 09180C06306J000 09320C08051J000 09160C08032JE0N D8321-01085

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Description

Gasket, Exhaust Pipe Bolt, Stud Nut, Exhaust Pipe Cover, Exhaust Pipe Clamp, Exhaust Pipe Bolt, Clamp Body, Muffler Bolt, Muffler Support Spacer, Muffler Support Cushion, Muffler Support Cover, Muffler Screw (6x12) Washer Spacer (6.5x9x5) Cushion Washer Washer

Catalog Title:

UH150K5 (UH150K5 P19)

Block No. Block Title.

FIG14 OIL PUMP

Ref No

1 2 3 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Part No

16400-49F00 01547-06253 16422-49F00 16331-14F00 09181-10158 08331-31106 09261-04009 16310-14F00 16520-09402 16524-20E00 16523-20E00 01547-06253 16512-47E00 09280-54001 09440-18002 16510-05240 09280-13004 01547-06163 01547-06653

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Description

Pump Assy, Engine Oil Bolt Cover, Oil Pump Sprocket, Oil Pump Driven Shim Circlip Pin (4x15.8) Chain Assy, Oil Pump Drive Strainer, Engine Oil Gasket, Oil Strainer Cap Cap, Oil Strainer Bolt Cap, Oil Filter O Ring (d:2.4, Id:52.6) Spring Filter, Engine Oil O Ring (d:1.9, Id:13) Bolt Bolt

Catalog Title:

UH150K5 (UH150K5 P19)

Block No. Block Title.

FIG15 FUEL PUMP

Ref No

1 2 3 4 5 6 7 8 9 10 11 12 13

Part No

15100-49F00 D1507-06205 D8322-01065 15801-07E00 D9510-0115P 09440C13027J000 09355C50105J660 09407-07E00 09404C06433JEE3 09440C13027J000 09440C13017J000 09355C50105J040 09367C06008J000

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Description

Pump Assy, Fuel Bolt (6x20) Washer Hose, Fuel Clip Spring (l:470) Hose (5x10x660) Clamp, Vacuum Hose Clamp Spring, Vacuum Hose (l:470) Spring, Vacuum Hose (l:200) Hose, Vacuum No.2 Joint, Vacuum Hose 3way

Catalog Title:

UH150K5 (UH150K5 P19)

Block No. Block Title.

FIG16 WATER PUMP

Ref No

1 2 3 4 5 6 7 8 9 10 11 12

Part No

17400-21F11 17491-21F00 02112-06163 17418-14F00 17470-02F00 09283-10004 09262-10014 08332-11086 17435-33400 09280-22001 01547-06353 01547-06553

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Description

Pump Assy, Water

• . Impeller

• . Screw

• . O Ring

• . Mechanical Seal

• . Oil Seal

• . Bearing

• . E Ring

• . O Ring O Ring (d:2.4,id:21.8) Bolt Bolt

Catalog Title:

UH150K5 (UH150K5 P19)

Block No. Block Title.

FIG17 RADIATOR

Ref No

1 2 2a 3 4 5 6 7 8 9 10 11 12

Part No

17710-49F00 D1507-06255 D8322-91065 09180C06310J000 16628C27A00J000 09320C10501J000 17680-45D00 17689-50F00 17800-49F00 09689-E0002 09689-E0003 17761-49F00 09409-06322-5PK

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Description

Radiator Assy, Water Bolt (6x25) Washer Spacer (6.5x10x10) Cushion, Radiator Lower Cushion Switch, Radiator Fan

• . O Ring Fan Assy, Radiator Screw, Radiator Fan Washer Duct, Radiator Clip

Catalog Title:

UH150K5 (UH150K5 P19)

Block No. Block Title.

FIG18 RADIATOR HOSE

Ref No

1 2 3 4 5 6 7 8 9 9a 10 11 12 13 14 15

Part No

17730-49F00 17851-49F00 17852-49F00 17855-07E00 17791-49F00 D2116-06165 17911-49F00 17932C12C00J000 D1507-06125 D8322-01065 D8391-12164 17981C12C00J000 17981-07E00 D9510-0104P 17859-07E00 17858-49F00

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Description

Cap, Radiator Hose, Radiator Inlet Hose, Radiator Outlet Hose, Conduction Conduction, Radiator Screw Tank, Reservoir Cap, Reservoir Tank Screw Washer Clamp Hose, Reservoir Tank Overflow Hose, Reservoir Tank Inlet Clip Plate, Water Hose Clamp Clamp, Radiator Hose

Catalog Title:

UH150K5 (UH150K5 P19)

Block No. Block Title.

FIG19 2ND AIR

Ref No

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Part No

18450-06G00 18461-49F00 18510-49F00 18516C35F00J000 18517C35F00J000 18611-49F00 18612-49F00 D7107-06165 D8322-01065 09355C35755J100 18711-49F00 D9500-0177P D9500-0168P 18531-49F00 01550-06203 D9436-01425

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Description

Valve Assy, 2nd Air Reed Hose, 2nd Air Valve Valve Assy, Air Cut Cushion, 2nd Air Valve Cushion, 2nd Air Valve Rr Bracket, 2nd Air Valve Upper Bracket, 2nd Air Valve Lower Bolt, 2nd Air Valve Washer Hose, 2nd Air Valve Vacuum Hose, 2nd Air Cleaner Clip, 2nd Air Cleaner Hose Clip, 2nd Air Cleaner Hose Cap, 2nd Air Reed Valve Bolt, 2nd Air Cover Clamp

Catalog Title:

UH150K5 (UH150K5 P19)

Block No. Block Title.

FIG20 TRANSMISSION (1)

Ref No

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Part No

21110-21F01 21120-21F01 21122-21F00 21125-21F00 21431-21F50 21481-14F00 21650-21F30 02142-04103 21210-21F30 21214-35E00 21240-21F10 21243-21F30 21248-16F00 21249-06F00 21471-03A61 09262-12018 08331-41246 27601-21F11 09140-16001 09164-16005 09280-41005 09284-34002

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Description

Face, Fixed Drive Face, Movable Drive Cover, Movable Drive Face Spacer, Movable Drive Plate, Movable Drive Damper, Movable Drive Plate Roller, Movable Drive Screw, Movable Drive Face, Fixed Driven Bearing, Fixed Driven Rh Face, Movable Driven Spring, Movable Driven Pin, Movable Driven Spacer, Movable Driven Pin Sheet, Movable Driven Bearing, Fixed Drive Lh (12x24 Circlip, Fixed Driven V Belt Nut, Fixed Drive Face Washer, Fixed Drive Face O Ring (d:15,id:39.7) Seal (34x39x3)

Catalog Title:

UH150K5 (UH150K5 P19)

Block No. Block Title.

FIG21 TRANSMISSION (2)

Ref No

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Part No

21220-20E01 21501-20E31 09140-28004 09159-10110 24131-21F02 24151-21F12 24381-21F01 09262-15031 09262-12023 09263-16032 08211-16301 09283-25097 08331-31206 09262-25126 24741-20A00 09126-06014 24141-21F60 24371-21F10 64841-28E00 08110-62030 09262-22027 08331-31226 24751-07900 02122-06163

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Description

Housing, Clutch Clutch Assy, Shoe Nut, Shoe Clutch Nut, Clutch Housing Shaft, Drive (nt:16) Shaft, Idle (nt:15) Gear, Idle Driven (nt:45) Bearing, Drive Shaft Rh (15x35 Bearing, Idle Shaft Rh (12x32x Bearing, Idle Shaft Lh (16x24x Washer, Idle Shaft Lh Seal, Drive Shaft Oil (25x37x6 Circlip, Idler Driven Bearing, Drive Shaft Lh (20x47 Retainer, Drive Shaft Screw (6x16) Shaft, Rear Axle Gear, Final Driven (nt:64) Seal, Axle Shaft Oil Bearing, Axle Shaft Lh Bearing, Axle Shaft Rh (22x50x Circlip, Final Driven Gear Retainer, Axle Shaft Bearing Screw, Bearing Retainer

Catalog Title:

UH150K5 (UH150K5 P19)

Block No. Block Title.

FIG22 STARTING MOTOR

Ref No

1 2 3 4 5 6 7 8 9 10 11 12 13

Part No

31100-14F01 31150-08F00 31153-49210 31175-14F00 31264-32C10 31281-08F00 31156-38300 31361-32C10 31361-38300 09280-24003 01550-06203 D1507-05085 D8321-01055

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Description

Motor Assy, Starting

• . Bracket

•• .. O Ring

• . Frame Assy, Commutator End

• . O Ring

• . Bolt

• . O Ring

• . Plate, Lock

• . Shim

• . O Ring (d:3,id:24.5) Bolt Screw (5x8) Washer

Catalog Title:

UH150K5 (UH150K5 P19)

Block No. Block Title.

FIG23 MAGNET0

Ref No

1 2 3 4 5 6

Part No

32101-21F00 32102-21F00 09159-14015 02112-05103 02112-05303 08341-31039

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Description

Stator Assy Rotor Assy Nut, Magneto Rotor Screw, Sensor Screw, Magneto Stator Key, Magneto