Suzuki GSX 11OOF, Service Manual

Page 1: ...SUZUKI SERVICE MANUAL 99500 39080 03E 5 L _ ULLKI HOIOR co LTD I RI TED 1 J I I O OREN ti 7 ...

Page 2: ... IMPORTANT All street legal Suzuki motorcycles with engine displacement of 50cc or greater are subject to Environmental Protection Agency emission regula tions These regulations set specific standards for exhaust emission output levels as well as particu lar servicing requirements This manual includes specific information required to properly inspect and service the GSX 1 1OOF in accordance with a...

Page 3: ... OF GSX1100F l SERIAL NUMBER LOCATION 1 1 I FUEL AND OIL RECOMMENDA TlON 1 1 I BREAK IN PROCEDURES 1 2 I CYLINDER IDENTIFICA TlON 1 2 SPECIAL MA TERIALS 1 3 PRECAUTIONS AND GENERAL INSTRUCTIONS 1 5 SPECIFICA TIONS 1 6 _ _ _ l ...

Page 4: ...pare parts FUEL AND OIL RECOMMENDATION FUEL Use only unleaded or low lead type gasoline of at least 85 95 pump octane M method or 89 octane or higher rated by the Research Method ENGINE OIL SUZUKI recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil which is rated SE or SF under the API American Petroleum Institute classification system The vis cosity rating is SAE 10W 40 If an SAE 10W 4...

Page 5: ...d and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to BREAK IN before subjecting the engine to maximum stresses The future performance and reliability of the engine depends on the care and restraint exercise during its early life The general rules are as follows Keep to these break in engine speed limits Intial 800 km 500 miles Below 4...

Page 6: ...al 7 8 7 47 7 34 SUZUKI SUPER GREASE A Wheel bearing Shock absorber dust seal 7 25 99000 25030 Steering stem bearing 3 26 Valve stem 3 35 Conrod big end bearing 3 44 Countershaft and driveshaft 3 50 Crankshaft journal 3 60 Camshaft journal 6 13 Starter motor armature end 6 5 Generator damper 7 49 SUZUKI MOLY PASTE 99000 25140 Clutch lever push rod 1 f f 1 3 50 Crankcase mating surface Signal gener...

Page 7: ... mounting bolt 3 48 I Front fork damper rod bolt Countershaft bearing retain 3 51 er screw 3 51 lifter screw Gearshift cam guide pawl Starter motor mounting bolt 3 56 6 6 THREAD LOCK 1342 Generator bearing retainer screw 99000 32050 l Clutch Brakes SUZUKI BRAKE FLUID J 99000 23110 t j ROlf FORK OIL 11 SUZUKI FORK OIL 10 I 99000 99044 10G C a rb u r e to r s e t p I a te s c re w 4 10 r I I I THREA...

Page 8: ...ing torque D Use special tools where specified D Use genuine parts and recommended oils D When 2 or more persons work together pay attention to the safety of each other D After the reassembly check parts for tightness and operation D Treat gasoline which is extremely flammable and highly explosive with greatest care Never use gasoline as cleaning solvent Warning Caution and Note are included in th...

Page 9: ...CC l lumber of cylinders 4 Bore 78 0 mm 3 07 in Stroke 59 0 mm 2 32 in Piston displacement 1127cm3 68 8 cu in Carburetor MIKUNI BST34SS four Air cleaner Polyester fiber element Starter system Electric Lubrication system Wet sump TRANSMISSION Clutch Wet multi plate type Transmission 5 speed constant mesh Gearshift pattern 1 down 4 up Primary reduction 1 522 67 44 Final reduction 3 466 52 15 Gear ra...

Page 10: ...re size 150 80V 16 V250 Front fork stroke 140mm 5 5in Rear wheel travel 125mm 4 9in ELECTRICAL Ignition type Fully Transistorized Ignition timing 13 B T D C below 1500 r min and 32 B T D C above 2 375 r min Spark plug N G K JR9B or J9B Battery 12V 50 4 kC 14Ah IOHR Generator Three phase A C Generator Fuse 10 10 10 10 10A Circuit breaker 30A CAPACITIES Fuel tank 21 0 L 5 5 US gal 19 5 L 5 2 US gal ...

Page 11: ...I 2 2 I MAINTENANCE AND TUNE UP PROCEDURES 2 3 BA TTERY 2 3 CYLINDER HEAD NUTS EXHAUST PIPE DOL TS 2 4 AIR CLEANER 2 4 VAL VE CLEARANCE 2 5 SPARK PLUGS 2 7 ENGINE OIL AND OIL FIL TER 2 8 FUEL LINE 2 9 CARBURETOR 2 9 CLUTCH 2 9 DRIVE CHAIN 2 11 BRAKES 2 12 TIRES 2 14 STEERING 2 15 FRONT FORKS 2 16 REAR SUSPENSION 2 16 CHASSIS DOL TS AND NUTS 2 17 J ...

Page 12: ... peak performance and to maintain proper emission levels Mileages are expressed in terms of kilometer miles and time for your convenience PERIODIC MAINTENANCE CHART em Innttee rvaall km 1000 6000 12000 18000 24000 miles 600 4000 7500 11000 15000 t Item months 2 12 24 36 48 1 _ _ k_C_ _ _U_ag_r _n_c_e I V_S __ I __ _ _ Il I It III R 1 Fuel line Fuel line and vapor hose California version only Engin...

Page 13: ...e Major lubrication points are indicated below Q Oil ill Grease Q Clutch lever holder Q Throttle cable and brake lever holder I 9 Brake pedal pivot and brake rod link I Q Drive chain ill Side stand pivot NOTE Before lubricating each part clean off any rusty spots and wipe off any grease oil dirt or grime Lubricate exposed parts which are subject to rust with oil or grease ...

Page 14: ...evel line o For checking specific gravity use a hydrometer to determine the charged condition 09900 28403 Hydrometer Standard specific gravity 1 28 at 20 C 68 F An S G reading of 1 22 at 20 C or under means that the battery needs recharging Remove the battery from the ma chine and charge it with a battery charger CAUTION Never charge a battery while still in the machine as damage may result to the...

Page 15: ...alue below Cylinder head bolt 7 11 N m 0 7 1 1 kg m 5 0 8 0 Ib ft Cylinder head nut 7 11 N m 0 7 1 1 kg m 5 0 8 0 Ib ft When installing the cylinder head cover apply SUZUKI Bond No 1207B to the head cover groove and cam end caps Refer to page 3 64 Tighten the head cover bolts to the specified torque Tightening torque 13 15 N m 1 3 1 5kg m 9 5 11 0 Ib ft EXHAUST PIPE Tighten the exhaust pipe clamp ...

Page 16: ...re frequently The surest way to accelerate engine wear is to use the engine without the element or to use a ruptured element Make sure that the air cleaner is in good condition at all times Life the engine depends largely on this component VALVE CLEARANCE Inspect Initially at 1000 km 600 miles 2 months and Every 6000 km 4000 miles 12 months thereafter Remove the seat frame covers and fuel tank Rem...

Page 17: ...shafts Ex and In to the positions shown In this condition read the valve clearance at the valves In and Ex of NO 1 cylinder Ex of No 2 and In of l lo 3 I I I I I _____ l _ _ J Use a thickness gauge between the adjusting screw and the valve stem end If the clearance is off the specification bring it into the specified range by using the special tool 09900 20803 Thickness guage 09917 14910 Valve adj...

Page 18: ...e electrodes are extremely worn or burnt replace the plug Also replace the plug if it has a broken insulator damaged thread etc NGK JR9B as listed in the table should be used as the standard plug However the heat range of the plug should be selected to meet the requirements of speed actual load fuel etc If the plugs need be replaced it is recommended that ones having a heat range closest to the st...

Page 19: ...To properly tighten the filter use the spacial tool Never tighten the filter by hand Fit the drain plug CD securely and add fresh oil through the oil filler The engine will hold about 4 5 L 4 8 US qt of oil Use an API classification of SE or SF oil with SAE 10W 40 viscosity Start up the engine and allow it to run for several seconds at idling speed Turn off the engine and wait about one minute the...

Page 20: ...ottle cable play with the following procedure Loosen the lock nut and turn the adjuster in or out until the specified play is obtained Tighten the lock nut while holding the adjuster Throttle cable play 0 5 1 0mm 0 02 0 04in WARNING After the adjustment is completed check that handlebar rnovemen t does not raise the engine idle speed and that the throttle grip returns smoothly and automatically CL...

Page 21: ...le Squeeze and release the clutch lever several times in rapid succession and squeeze the lever fully without releasing it Loosen the bleeder valve by turning it a quarter of a turn so that the fluid runs into the receptacle this will remove the tension of the clutch lever causing it to touch the handlebar grip Then close the valve pump and sqeeze the lever and open the valve Repeat this process u...

Page 22: ...llowing limit the chain must be replaced Service Limit 319 4mm 12 6in ADJUSTING Loosen the chain adjusting bolts 4 until the chain has 20 25 I11Ill 08 10 in of slack at the middle between engine and rear sprockets The mark on both chain adjusters must be at the same position on the scnle to ensure that the front and rear wheels are correctly aligned Place on side stand for accurate adjustment Afte...

Page 23: ...ines on the brake fluid reservoirs When the level is below the lower limit line replenish with brake fluid that meets the following specification Specification and Classification DOT4 WARNING The brake system of this motorcycle is filled with a glycol based brake fluid Do not use or mix different types of fluid such as silicone based and petroleum based Do not use any brake fluid taken from old us...

Page 24: ... squeezed or the brake pedal is depressed AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the brake caliper The presence of air is indicated by spongi ness of the brake lever and also by lack of braking force Considering th...

Page 25: ...ill rernove the tension of the brake lever causing it to touch the handlebar grip Then close the valve pump and squeeze the lever and open the valve Repeat this process until the fluid flowing into the receptacle no longer contains air bubbles NOTE Replenish the brake fluid reservoir as necessary while bleeding the brake system Make sure that there is always some fluid visible in the reservoir Clo...

Page 26: ...standard tire fitted on this motorcycle is 120 80 V16 V250 for front METZELER ME33 and 150 80 V16 V250 for rear METZELER ME99A The use of tires other than those specified may cause instability It is highly recommended to use a SUZUKI Genuine Tire STEERING Inspect Initially at 1000 km 600 miles 2 months andl rEvery 6000 km 4000 miles 12 months thereafter J I Taper roller type bearings are used on t...

Page 27: ...he front forks for oil leakage scoring or scratches on the outer surface of the inner tubes Replace any defective parts if necessary Refer to page 7 16 REAR SUSPENSION Inspect Initially at 1000 km 600 miles 2 months and Every 12000 km 7500 miles 24 months thereafter Inspect the rear shock absorber for oil lakage and check that there is no play in the swingarm assembly ...

Page 28: ...0 18 0 t e ou gb lt 1 2 _ I 5t r Front brake master cylinder mounting bolt 8 12 I 0 8 1 2 i 6 0 8 5 ____t iO Front brake caliper mounting bolt 25 40 l 2 5 4 0 18 0 29 0 I f__ i i Front brake caliper housing bolt 18 23 I 1 8 2 3 13 0 16 5 I Brake clutch ho e unio bolt I 2o 25 i 25 1 14 5 18 0 f Air bleeder valve 6 9 I 0 6 0 9 4 5 6 5 t _ __ _ _ _ Front and rear disc bolt 15 25 1 5 2 5 11 0 18 0 I f...

Page 29: ...PERIODIC MAINTENANCE AND TUNE UP PROCEDURES 2 18 ...

Page 30: ... AND SERViCiNG CYLINDER HEAD VALVE CAMSHAFT CAM CHAIN TENSIONER CyLINDER PiSTON PISTON RING CRANKCASE CRANKSHAFT CLUTCH OIL PUMP TRANSMISSION GEARS ENGINE REASSEMBL Y CRANKCASE CLUTCH SIGNAL GENERA TOR STARTER CLUTCH PISTON AND RING CyLINDER CAMSHAFT 3 3 2 3 3 3 10 3 20 3 20 IJ 3 21 3 27 3 29 3 30 3 31 3 31 3 36 3 38 3 40 3 41 3 42 3 47 3 50 3 53 3 54 3 55 3 56 3 58 3 6 I ...

Page 31: ... compression pressure between any two cylinders is more than 200 kPa 2 kg cm 2 28 psi All compression pressure are below 1100 kPa 11 kg cm 2 156 psi standard even when they measure than 900 kPa 9 kg cm 2 128 psi COMPRESSION TEST PROCEDURE NOTE Before testing the engine for compression pressure make sure that the cylinder head nuts and bolt are tightened to the specified torque values and valves ar...

Page 32: ...Starter clutch 3 15 Starter idle gear 3 15 ENGINE CENTER See page Exhaust pipe muffler 3 5 Oil cooler 3 6 Oil hose 3 10 Oil filter 3 10 Oil pan 3 16 Sump filter 3 17 Carburetors 3 4 Throttle cable 3 4 Cam chain tensioner 3 10 Cylinder head cover 3 10 Camshafts 3 11 Starter motor 3 12 Generator 3 12 ENGINE RIGHT SIDE See page Signal generator cover 3 10 Signal generator 3 13 Oil pressure switch 3 5...

Page 33: ...ower fairing Disconnect the battery 81ead wire from the battery terminal Remove the fuel tank mounting bolts CD Lift the fuel tank and then disconnect the two fuel hoses 0 and vacuum hose CD from the fuel cock NOTE Do not lose the fuel hose clips Disconnect the fuel level gauge sending unit lead wires and remove the fuel tank Remove the left and right air cleaner case mounting screws 0 Loosen each...

Page 34: ...le 0 Disconnect the various lead wires Battery 0 lead wire coupler 0 Generator lead wires coupler Neutral indicator switch lead wire coupler Signal generator lead wires coupler Oil pressure indicator switch lead wire Starter motor lead wire Side stand switch lead wires coupler Disconnect the spark plug caps out of each spark plug ...

Page 35: ...move the muffler mounting bolts left and right Remove the left and right exhaust pipe muffler Place an oil pan under the engine and remove the oil drain plug to drain out engine oil Place an oil pan under the engine and remove the two oil cooler hoses by removing the union bolts Tightening torque Union bolt 25 30 N m 2 5 3 0 kg m 18 0 21 5 Ib ft ...

Page 36: ...to prevent clutch piston retainer damage Flatten the engine sprocket nut lock washer by using chisel Remove the engine sprocket nut while depressing the brake pedal Loosen the axle shaft pinch bolts right and left and pullout the cotter pin and loosen the axle nut Loosen the drive chain adjusting lock nuts right and left and push the rear wheel forward Disengage the drive chain and engine sprocket...

Page 37: ...ine jack Remove the engine mounting bolts nuts and spacer at the engine reM side Remove the frame down tube mounting bolts and nuts right and left Gradually lower the engine assembly along with the frame IIIf down tubes NOTE After removing the engine assembly from the frame remove r the frame down tubes from the engine ...

Page 38: ...ing torque 55 mm 22 in 50 60 N m 50 6 0 kg m 43 5 Iblt If 1 f60 I I 7 1 in I 70 80 Nm 140 m l 56 b ft 5 5 In _ Down tUb ounting bolt 25 38 N m 2 5 3 8 kg m 18 0 27 5 Ib ft NOTE The engine mounting nuts are self locking Once the nut has been removed it is no long er of any use Be sure to use new nuts and tighten them to the specified torque Right side Left side Point 27 mm 1 1 in Point 1 I Bush Bus...

Page 39: ...API classifica tion SF into the engine Several minutes after starting and stopping engine check that the oil level remains between the marks of oil inspection window OIL CHANGE 4300 ml 4 5 3 8 US Imp qtj OIL AND FILTER CHANGE 4500 ml 4 8 4 0 US Imp qtj OVERHAUL 5500 ml 5 8 4 8 US Imp qtj Tighten the engine sprocket cover bolts sequentially in the ascending order of numbers After remounting the eng...

Page 40: ...es by removing the bolts Remove the cylinder head cover by removing the bolts 09914 25811 6 mm T type hexagon wrench Remove the signal generator cover by removing the bolts 09911 73730 5 mm T type hexagon wrench Remove the spring holder bolt and spring and then remove the cam chain tensioner by removing the bolts 09911 73730 5 mm T type hexagon wrench Remove the cam chain idler by removing the bol...

Page 41: ...d exhaust Pullout the cam chain guide The cylinder head becomes free for removal when its one 6 mm bolt and twelve 10 mm nuts are removed 09911 74510 Long socket 14 mm 09914 24510 T handle NOTE When loosening the cylinder head nuts break each nut loosen a little at a time in a descending orderaccording to the numbers cast on a cylinder head Remove the right and left oil pipes 2 Remove the cylinder...

Page 42: ...n removing or handling the cylinder block This precaution applies to the cylinder head also Scribe the cylinder No on the head of the respective pistons Place a cloth benei lth the piston so as not to drop the parts in the crankcase and remove the circlip CD with long nose pliers Draw out the piston pin Place each piston pin in the same piston as that it was removed from Remove the starter motor b...

Page 43: ...th a conrad stopper remove the clutch spring set bolts in a criss cross manner 2 3 lo 09910 20116 Conrod stopper 1 After removal of pressure plate remove the thrust washer 1 bearing 0 and clutch push piece 0 and draw out the clutch push rods CD and L Flatten the clutch sleeve hub nut lock washer by using chisel Firmly secure clutch sleeve hub to remove mounting nut with a clutch sleeve hub holder ...

Page 44: ...emove the primary driven gear assembly with the genera tor oil pump drive gears Remove the thrust washer 0 Remove the clip and washer from the gearshift shaft Draw out the gearshift shaft CD and then remove the cam driven gear 0 by removing the screws 0 09900 09003 Impact driver set NOTE When removing the cam driven gear do not lose gear shifting pawl CD pin and spring 0 ...

Page 45: ...ter idle gear and its shaft Loosen the starter clutch mounting bolt by using the special tool 09920 34810 Starter clutch holder NOTE When removing the starter clutch assembly from the crank shaft do not remove the starter clutch mounting bolt after loosening the bolt The starter clutch mounting bolt is used in conjunction with the special tool Remove the starter clutch assembly from the crankshaft...

Page 46: ...oving the screws NOTE Do not lose the O ring 1 switch contact and its spring 0 Remove the countershaft bearing retainer by removing the two screws Remove the plug 1 on the upper crankcase Remove the upper crankcase securing bolts and nut 09911 73730 5 mm T type hexagon wrench Remove the oil pan by removing the bolts 09911 73730 5 mm T type hexagon wrench ...

Page 47: ... at the portion 0 Before removing the crankshaft tightening bolts remove the main oil gallery plug When installing the main oil gallery plug replace the O ring with new one and tighten it to the specified torque 09914 25811 6 mm T type hexagon wrench 09900 00401 L type hexagon wrench set Tightening torque Main oil gallery plug 35 45 N m 3 5 4 5 kg m 25 5 32 5 Ib ft Make sure that all bolts are rem...

Page 48: ...e Remove the O rings and 0 NOTE Bear in mind that the crankshaft thrust bearings are located between shaft and case Remove the countershaft assembly and driveshaft assem bly NOTE Do not lose the C rings and bearing pins 0 Hold the gearshift forks by hand to draw out the gearshift fork shaft from the lower crankcase ...

Page 49: ...by removing the circlip 0 09900 06107 Snap ring pliers NOTE When replacing the gearshift cam stopper bolt 4 apply a small quantity of THREAD LOCK 1342 to the bolt Rotate the bearing by hand to inspect for abnormal noise and smooth rotation Replace the bearing if there is any thing unusual Remove the oil pump by removing the mounting bolts 09900 00401 L type hexagon wrench set Remove the O rings an...

Page 50: ...t out Tighten the set bolt i and plug to the specified torque Removal of valves completes ordinary disassembling work If valve guides have to be removed for replacement after inspecting related parts carry out the steps shown in valve guide servicing Tightening torque Set bolt i 8 12 N m 0 8 1 2 kg m 6 0 8 5 Ib ft Plug 25 30 N m 2 5 3 0 kg m 18 0 21 5 Ib ft Using special tools compress the valve s...

Page 51: ...d face and measure the valve head radial runout If it measures more than the limit replace the valve Service Limit 0 03 mm 0 001 in VALVE FACE WEAR Visually inspect each valve for wear of its seating face Replace any valve with an abnormally worn face The thickness CD decreases as the wear of the face advances Measure the thickness and if the thickness is found to have been reduced to the limit re...

Page 52: ...ssemblies Only oversized valve guides are available as replacement parts Part No 11116 06870 Re finish the valve guide holes in cylinder head with the reamer and handle 09916 34580 Valve guide reamer 09916 34541 Reamer handle Fit a ring to each valve guide Be sure to use new rings and valve guides Rings and valve guides removed in disassembly must be discarded Oil the stem hole too of each valve g...

Page 53: ...re machined to two different angles The seat contact surface is cut 45 and the area above the contact surface closest to the combustion chamber is cut to 15 _ f I Exhaust side 1 J 116 or 122 1 J 116 or 122 N 116 or 121 I N 120 or 121 Inta ke side Valve seat cutter N 116 120 121 and 122 Solid pilot N 100 5 0 NOTE The valve seat contact area must be inspected after each cut Insert the solid pilot wi...

Page 54: ... should have a velvety smooth finish and not a highly polished or shiny finish This will provide a soft surface for the final seating of the valve which will occur during the first few seconds of engine operation Clean and assemble the head and valve components Fill the intake and exhaust ports with gasoline to check for leaks If any leaks occur inspect the valve seat and face for burrs or other t...

Page 55: ...unt for the chattering noise coming from the valve mechanism Check the valve springs for proper strength by measuring their free lengths and also by the force required to compress them If the spring length is less than the service limit or if the force required to compress the spring does not fall within the range specified replace both the inner and outer springs as a set CAUTION Replace both the...

Page 56: ...not to confuse the lower seat with the spring retainer 0 For Intake side For Exhaust side Insert the valves with their stems coated with high quality molybdenum disulfide lubricant SUZUKI MOLY PASTE all around and along the full stem length without any break CAUTION When inserting each valve take care not to damage the lip of the stem seal 99000 25140 SUZUKI Moly Paste I Install the valve springs ...

Page 57: ... and journals if the engine has been noted as giving abnormal noise or vibration or lack power output Any of these conditions may be caused by camshafts worn down or distorted to the service limit The exhaust camshaft can be distinguished from that of the intake by the embossed letters EX for exhaust as against letters IN for intake Similarly the right end can be distinguished by the notch from th...

Page 58: ...o their original positions page 3 62 Tighten the camshaft holder bolts evenly and diagonally to the specified torque Tightening torque 8 12 N m 0 8 1 2 kg m 6 0 8 5 Ib ft NOTE Do not rotate the camshafts with plastigauge inplace Remove the camshaft holders and read the width of com pressed plastigauge with envelope scale This measurement should be taken at the widest part If the camshaft journal o...

Page 59: ...ow marks 1 and 2 on EXHAUST sprocket located as shown in refer ence to the notch CD in the camshaft right end REASSEMBLY Apply THREAD LOCK SUPER 1303 to the threads of cam sprocket bolts and tighten them to the following torque value 99000 32030 Thread lock super 1303 Tightening torque 24 26 N m 2 4 2 6 kg m 17 5 19 0 Ib ft CAM CHAIN TENSIOI lER The cam chain tensioner is maintained at the proper ...

Page 60: ...threads of bolt 99000 32020 Thread lock super 13338 CYLINDER DISTORTION Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge taking a clearance reading at several places as indicated If the largest reading at any position of the straightedge exceeds the limit replace the cylinder of the measurements exceeds the limit overhaul the cylinder and replace th...

Page 61: ...llowing limit overhaul the cylinder and use an oversize piston or replace both cylinder and piston Service Limit 0 12 mm 0 0047 in Piston oversize 0 5 1 0 mm L _ PISTON RING GROOVE CLEARANCE Using a thickness gauge measure the side clearances of the 1st and 2nd rings If any of the clearances exceeds the limit replace both piston and piston rings 09900 20803 Thickness gauge Pinston ring groove clea...

Page 62: ...ISTON PIN AND PIN BORE Using a small bore gauge measure the piston pin bore inside diameter and using a micrometer measure the piston pin outside diameter If the difference between these two measure ments is more than the limits replace both piston and piston pin Piston pin bore I D Service Limit 20 030 mm 0 7886 in RING END GAP Before installing piston rings measure the free end gap of each ring ...

Page 63: ...de clearance by using a thickness gauge If the clearance exceeds the limit replace con rod or crankshaft Service Limit 0 3 mm 0 01 in 09900 20803 Thickness gauge Standard Big end width 20 95 21 00 mm 0 825 0 827 in Standard Crank pin width 21 10 21 15 mm 0 831 0 833 in 09900 20205 Micrometer 0 25 mm 09900 20605 Dial calipers _ _ 11 _ CONROD CRANK PIN BEARING SELECTION Loosen the bearing cap nuts a...

Page 64: ...iminate one end from the other namely front and rear NOTE Never rotate the crankshaft or conrod when a piece of Plastigauge is in the clearance Remove the caps and measure the width of compressed plastigauge with envelope scale This measurement should be taken at the widest part Crank pin bearing oil clearance Standard 0 032 0 056 mm 0 0013 0 0022 in Service Limit 0 080 mm 0 0031 in If oil clearan...

Page 65: ... No _ _ _ _ Green 12164 06BOO OAO _ _ __ Black 12164 06BOO OBO Brown 12164 06 BOO OCO Yellow 12164 06BOO 000 _ _ I J Color code Thickness 1 480 1 484 mm 0 0583 0 0584 in 1 484 1 488 mm 0 0584 0 0586 in 1 488 1 492 mm 0 0586 0 0587 in 1 492 1 496 mm 0 0587 0 0589 in CAUTION Bearing should be replace as a set BEARING ASSEMBLY When fitting the bearings to the bearing cap and conrad be sure to fix the...

Page 66: ...the oil hole and do not rotate the shaft when plastigauge is in place Mate the lower crankcase with the upper crankcase and tighten the crankshaft tightening bolts with specified torque value in the indicated order Tightening torque Initial Tightening Final Tightening I r t Ic 13N m 120 24N m 8 mm bolt 1 3 kg m 2 0 2 4 kg m 9 5 Ib ft I 14 5 17 5 Ib ft Remove the lower crankcase and measure the wid...

Page 67: ...n table Crankshaft 0 0 0 Code A B C Crankcase A Green Black Brown 1 0 CD B Black Brown Yellow Crankcase 1 0 specification Code 1 0 specification A 39 000 1 5354 39 008 mm 1 5357 in B 39 008 1 5357 39 016 mm 1 5361 in Crankshaft journal 0 0 specification Code 0 0 specification r A 35 992 36 000 mm 1 4170 1 4173 in B 35 984 35 992 mm 1 4167 1 4170 in C 35 976 35 984 mm 1 4164 1 4167 in 09900 20202 M...

Page 68: ...rance crankcase use on the a NOTE Push the crankshaft to the starter clutch side so that there is no clearance on the right side thrust bearing Thurst clearance Standard 0 04 0 08 mm 0 002 0 003 in If the thrust clearance exceeds the standard range adjust the thrust clearance by the following procedures Remove the right side thrust bearing and measure its thickness with a micrometer If the thickne...

Page 69: ... 2 2 4 4 m m 0 04 0 08 mm 0 002 0 003 in _JO 0 _ 98 0992 __ 12228 48BOO 000 252 254 mm r Red 0 0961 2 46 0 0969 in 2 48 mm f J0099 0 1_000 inL_ 12228 48BOO OCO 0 0969 0 0976 in 2 54 256 mm Brown 2 48 2 50 mm ___ 0_ o 0 _ c _OO _in_ _ _ 13 _8_BO_0_ 0_B_0_ 0 0976 0 0984 in 2 56 257 mm Pink I 2 50 2 52 mm 0 04 007 mm 0 1008 01012 in 12228 48BOO OAO 1 0 0984 0 0992 in 0 002 0003 in Color cord After se...

Page 70: ...on 09900 20102 Vernier calipers 09900 20803 Thickness gauge Standard 2 52 2 68 mm ness No 1 No 2 Drive plate thick 0 100 0 106 in Driven plate distortion I Checking thickness Service Limit 2 22 mm 0 087 in 0 10 mm 0 004 in Checking distortion CLUTCH SPRING FREE LENGTH I Measure the free length of each coil spring with vernier calipers and compare the elastic strength of each with the specified lim...

Page 71: ...he piston by using air gun CAUTION Do not use high pressure air to prevent piston damage INSPECTION Inspect the clutch cylinder bore wall for nicks scratches or other damage Inspect the oil seal for damage and wear Inspect the piston surface for any scratches or other damage REASSEMBLY Reassemble the clutch cylinder in the reverse order of disas sembly and by taking the following steps CAUTION Was...

Page 72: ...i 7 Low driven gear 2 1 ear r0 4th driven 9 0 ear r0 3rd driven 9 V ear Top driven 9 8 ear 2nd driven 9 Driveshaft drive gear rshaft Low f7 Counte v gear 4th drive 8 ear I 3rd drive 9 9 ear Top drive 9 ear 2nd drive 9 __ 0 1 _ _ ...

Page 73: ...rs and 2nd drive gear 0 toward the Top drive gear 4 Remove the 2nd drive gear circlip and then remove the 2nd drive gear 0 Top drive gear and 3rd drive gear 0 8 Remove the 4th drive gear by removing the circlip 1 09900 06107 Snap ring pliers DRIVESHAFT DISASSEMBLY Each driven gear on the driveshaft is easily removed by using 9 snap ring pliers 09900 06107 Snap ring pliers I The order of disassembl...

Page 74: ...p must be installed When installing a new circlip care must be taken not to expand the end gap larger than required to slip the circlip over the shaft After installing a circlip always insure that it is com pletely seated in its groove and securely fitted NOTE In reassembling the transmission attention must be given to the locations and positions of washers and circlips The cross sectional view gi...

Page 75: ...e sure to align the three grooves of the lock washer 0 with the three tabs of the lock washer 0 Before installing the spacer 0 fit a new O ring onto the driveshaft Apply grease to the oil seal lip and install it onto the drives haft 99000 25030 SUZUKI super grease A 6 ...

Page 76: ...I ENGINE 3 46 TRANSM ISSION e 8 Q O cC CG J 8 8 ...

Page 77: ...he limit speci fied replace the fork or its gear or both 09900 20803 Thickness gauge 09900 20102 Vernier calipers Checking clearance L Shift fork groove width I Standard No 1 No 2 No 3 5 00 5 10 mm 0 197 0 201 in Checking groove width Shift fork thickness Standard No 1 No 2 No 3 4 80 4 90 mm 0 189 0 193 in Checking thickness ENGINE REASSEMBLY The engine is reassembled by carrying out the steps of ...

Page 78: ...rks to the crankcase in the correct positions and directions CD For 4th driven gear o For 3rd driven gear For Top driven gear Fit the O rings CD and 0 and dowel pins to the correct positions as shown in the Figs CAUTION Replace the O rings with new ones to prevent oil leakage Install the oil pump to the lower crankcase with three bolts and tighten them to the specified torque NOTE Apply a small qu...

Page 79: ...gear which is engaged to the neutral position NOTE Before fitting the crankshaft journal bearings check the nozzles CD fitted on the upper crankcase for clogging CD Nozzle 4 pes For upper case When fitting the crankshaft journal bearings to the upper and lower crankcases be sure to fix the stopper part first and press the other end Refer to page 3 38 CAUTION Do not touch the bearing surfaces with ...

Page 80: ...on surfaces thinly to form an even layer and assemble the cases within few minutes Take extreme care not to apply any bond No 12078 to the bearing surfaces Apply to distorted surface as it forms a comparatively thick film Fit up the right oil pipe with No 1 bolt Fit up the copper washers to the No 9 and No 11 bolts Locate the two allen bolts at position and ten 8 mm bolts Tighten the crankshaft ti...

Page 81: ...il pan bolts to the specified torque Tightening torque 12 16 N m 1 2 1 6 kg m 8 5 11 5 Ib ft NOTE Fit a new gasket to the correct position as shown CAUTION Use a new gasket to prevent oil leakage Tighten the engine oil drain plug to the specified torque Refer to page 8 22 Install the countershaft bearing retainer with two screws NOTE Apply a small quantity of THREAD LOCK 1342 to the two screws 990...

Page 82: ...CD and fix the gearshift shaft with the clip Install the washer CD pin oil pump driven gear and washer 1 Fix the oil pump driven gear with the circlip 09900 06107 Snap ring pliers Install the thrust washer CD onto the countershaft NOTE Flat surface of washer is positioned outside Install the genrator oil pump drive gears onto the primary driven gear ...

Page 83: ...utch drive plate and driven plate one by one into the sleeve hub in the prescribed order drive plate first NOTE Two kinds of drive plate and are used they resemble each other in external appearance and configuration But drive plates and can be distinguished by the painted white Install the clutch push rod 1 clutch push piece 0 bearing and thrust washer 0 into the countershaft Then fit the pressure...

Page 84: ...Bond No 1207B to its thread lightly 99104 31140 SUZUKI Bond No 1207B Install the signal generator stator with three screws Connect the oil pressure switch lead wire to the oil pressure switch terminal Make sure to fit the slot CD on the back surface of the signal generator rotor over the locating pin at the end of crankshaft NOTE Bond No 1207B should be applied to the groove of the signal generato...

Page 85: ...ure to locate the spring switch contact and O ring Degrease the tapered portion of the starter clutch and also the crankshaft Use nonflammable cleanig solvent to wipe off the oily or greasy matter to make these surfaces com pletely dry NOTE Apply a small quantity of THREAD LOCK SUPER 1303 to the starter clutch mounting bolt 99000 32030 Thread lock super 1303 Tighten the starter clutch mounting bol...

Page 86: ...y as shown in the Fig CAUTION Use a new gasket to prevent oil leakage Install the generator with three bolts Tightening torque 21 29 N m 2 1 2 9 kg m 15 0 21 0 Ib ft NOTE Apply SUZUKI super grease A to the generator O ring 99000 25030 SUZUKI super grease A Install the starter motor with two bolts NOTE Apply SUZUKI super grease A to the starter motor O ring Apply a small quantity of THREAD LOCK 134...

Page 87: ... each either way 1 _ _ 6 _ Position the gaps of the three rings as shown Before EX inserting each piston into the cylinder check that the gaps are so located 2nd ring Lower side ra iI Top ring IN Spacer NOTE Check the oil jets D fitted on the crankcase for clogging NOTE When reinstalling the cylinder stud bolt apply SUZUKI Bond No 1207B lightly to its thread Tightening torque 13 16 N m 1 3 1 6 kg ...

Page 88: ...ston Place the dowel pins and new cylinder gasket on the crankcase NOTE Be sure to identify the top surface by UP mark CD on the cylinder gasket as shown in the Fig Install piston ring holders in the indicated manner Some light resistance must be overcome to lower the cylinder block With No 2 and l lo 3 pistons in place install NO 1 and No 4 pistons and insert them into the cylinder 09916 74521 Ho...

Page 89: ...uper grease AU II I I CAUTION Replace the O rings 1 with new one to prevent oil leakage I t L J Place the cylinder head on the cylinder I A f l Cylinder head nuts and washers must be fitted in the correct I i positions as shown in the illustration Copper washer with cap nut 8 pes I oo Copper washer with normal nut 4 pes i I I I I _ i I _ 1 Tighten the twelve 10 mm nuts to the specification with a ...

Page 90: ... dry spot Apply engine oil to the camshaft journal holders 99000 25140 SUZU KI Moly paste The exhaust camshaft can be distinguished from that of the intake by the embossed letters EX for exhaust as against IN EX letters IN for intake Similarly the right end can be distinguished by the notch CD at the right end With T mark accurately lined up with the timing mark hold the camshaft steady and lightl...

Page 91: ...rrow marked 2 and ending with the 22nd roller pin Engage the cam chain with intake sprocket locating the 22nd pin at the above the arrow marked 3 on the intake sprocket NOTE The cam chain is now riding on all three sprockets Be careful not to disturb the crankshaft until the ten camshaft journal holders cam chain idler and cam chain tensioner are secured 22nd pin 1st pin J ...

Page 92: ...r to push shafts down evenly NOTE Damage to head or camshaft journal holder thrust surfaces may result if the camshaft journal holders are not drawn down evenly Tighten the camshaft journal holder bolts to the specified torque Tightening torque 8 12 N m 0 8 1 2 kg m 6 0 8 5 Ib ft CAUTION The camshaft journal holder bolts are made of special material and much superior in strength compared with othe...

Page 93: ...ensioner to the cylinder block with two bolts and tighten them to the specified torque Tightening torque 6 8 N m 0 6 0 8 kg m 4 5 6 0 Ib ft Insert the spring into the cam chain tensioner and tighten the spring holder bolt CD to the specified torque Tightening torque 30 45 N m 3 0 4 5 kg m 21 5 32 5 Ib ft CAUTION After installing the cam chain tensioner check to be sure that the tensioner work prop...

Page 94: ...r apply SUZUKI Bond No 1207B to the grooves of the head cover Apply SUZUKI Bond No 1207B to the four cam end caps of the gasket and shown in the Fig 99104 31140 SUZUKI Bond No 1207B Place the cylinder head cover on the cylinder head Fit up the four gaskets to each head cover union bolt Seat the eight gaskets to each exact position CAUTION Replace the gaskets with new ones to prevent oil leakage Af...

Page 95: ... 6 0 8 5 Ib ft CAUTION Replace the O rings 0 and with new ones to prevent oil leakage NOTE When rep acing the intake pipes identify the four different intake pipes according to each 0 code 13110 0680 for No 1 13120 0680 for No 2 13130 0680 for No 3 13140 0680 for No 4 II CAUTION Use a new O ring to prevent sucking air from the joint ...

Page 96: ... 4 SLOW SYSTEM 4 5 MAIN SySTEM 4 6 STARTER SYSTEM 4 7 FLOA T SySTEM 4 7 FUEL SySTEM 4 8 REMOVAL 4 9 DISASSEMBL Y 4 9 INSPECTION 4 9 NEEDLE VALVE INSPECTION 4 9 FLOA T HEIGHT ADJUSTMENT 4 9 REASSEMBLY AND REMOUNTING 4 10 BALANCING CARBURETORS 4 11 LUBRICATION SySTEM 4 13 OIL PRESSURE 4 13 OIL FIL TER 4 13 OIL SUMP FILTER 4 14 RELIEF VALVE 4 14 OIL COOLER 4 15 ENGINE LUBRICATION SYSTEM CHART 4 16 EN...

Page 97: ...EL COCK REMOVAL Remove the fuel cock assembly by removing the two bolts WARNING Gasoline is very explosive Extreme care must be taken Gasket must be replaced with a new one to prevent fuel leakage FUEL GAUGE REMOVAL Remove the fuel level gauge assembly by removing the four screws and five bolts WARNING Gasoline is very explosive Extreme care must be taken Gasket must be replaced with a new one to ...

Page 98: ...um hose Carbo set upper plate Fuel hose connector Air vent connector Washer iJ Starter shaft Jet needle Throttle lever Piston valve Vacuum inspection screw Needle jet Throttle stop screw Pilot air jet Carbo set lower plate Oil seal Spring E ring Spring seat Main jet E ring Pilot jet Retainer screw Needle valve Float arm pin Float Pilot screw a ring Drain screw 1 ...

Page 99: ... 0 6 mm Jet needle J N 5DL 11 5DL 16 Needle jet f Pilot jet N J P J P 2 32 5 p o f2 5 By pass 1 Pilot outlet B P P O 0 8 0 8 0 8 mm 0 8 mm Valve seat V S 2 8 mm Starter jet G S 42 5 Pilot screw _ _ Throttle valve P S ThV PRE SET 125 130 Pilot air jet Throttle cable play PAJ 0 5 135 1 0 mm 0 02 0 04 in 155 E 33 California model E 03 Other state models 1 0 NO LOCATION Each carburetor has 1 0 Number ...

Page 100: ...ownstream side of the venturi Vacuum is admitted into the diaphragm chamber through an orifice provided in the piston Rising vacuum overcomes the spring force causing the piston to rise to increase the said area and thus prevent the air velocity from increasing Thus air velocity in the venturi passage is kept relatively constant for improved fuel atomization and for securing and optimum ratio of f...

Page 101: ... jet where it mixes with air coming in through pilot air jet This mixture rich with fuel then goes up through pilot pipe to pilot screw A part of the mixture is discharged into the main bore out of bypass ports The remainder is then metered by pilot screw and sprayed out into the main bore through pilot outlet r Pilot air jet Pilot screw Pilot Jet J Air J Fuel Air mixture I Fuel I i I ...

Page 102: ...ted through main air jet to form an emulsion The emulsified fuel then passes through the clearance between needle jet and jet needle and is discharged into the venturi in which it meets main air stream being drawn by the engine Mixture proportioning is accomplished in needle jet the clearance through which the emulsified fuel must flow is large or small depending ultimately on throttle position Th...

Page 103: ...mixture for starting is produced when the mixture is sprayed out through starter outlet into the main bore FLOAT SYSTEM Floats and needle valve are associated with the same mechanism so that as the floats move up and down the needle valve too moves likewise When fuel level is up in float chamber floats are up and needle valve remains pushed up against valve seat Under this condition no fuel enters...

Page 104: ...sure works on the diaphram of fuel cock through passageway provided in the carburetor main bore and vacuum pipe and diaphragm builds up a negative pressure which is higher than the spring pressure Fuel valve is forced to open due to diaphragm operation and thus allows fuel to flow into carburetor float chamber FUEL TANK FUEL HOSE CARBURETOR FUEL ...

Page 105: ...ontinue flowing and cause it to overflow If the seat and needle are worn beyond the permissi ble limits similar trouble will occur Conversely if the needle sticks the gasoline will not flow into the float chamber Clean the float chamber and float parts with gasoline If the needle is worn as shown in the illustration replace it together with a valve seat Clean the fuel passage of the mixing chamber...

Page 106: ...pply thread lock cement to the upper and lower plates screws 99000 32040 Thread lock cement Align the starter shaft securing screw CD with dent mark on the starter shaft and grease sliding portions Set each throttle valve in such a way that its top end meets the foremost by pass This is accomplished by turning the throttle stop screw and throttle valve balance screws After all work is completed mo...

Page 107: ... 1 No 4 carb 09913 13190 Adaptor For No 2 No 3 carb Start up the engine and run it in idling condition for warming up Stop the warmed up engine Remove the vacuum inlet screw CD for No 1 or 1 l0 4 cylinder and install adaptor with O ring NOTE When removing the vacuum inlet screws be careful not to drop them Connect one of the four rubber hoses of the balancer gauge to this adaptor and start up the ...

Page 108: ...s Start up the engine and keep it running at 1750 r min A correctly adjusted carburetor has the steel balls in the Nos 1 through 4 tubes at the same level as shown If the steel balls are not in correct positions adjust the throttle valve balance screws correctly After adjusting l tighten its lock nut securely 09913 14911 Throttle valve adjust wrench NOTE When adjusting the throttle valve balance s...

Page 109: ... pressure specification Above 300 kPa 3 0 kg cm2 Below 600 kPa 6 0 kg cm2 at 3000 r min Oil temp at 60 C 140 F 09915 74510 Oil pressure gauge 09915 77330 Meter for high pressure 09915 74540 Adaptor NOTE Engine oil must be warmed up to 60 C 140 F when checking the oil pressure If the oil pressure is lower or higher than the specifications several causes may be considered Low oil pressure is usually...

Page 110: ...iner is free from any sign of rupture and wash the strainer clean periodically When installing oil sump filter be sure to face the arrow mark on its oil guide to the front CAUTION Replace the oil pan gasket and O ring with new ones to prevent oil leakage RELIEF VALVE Check the hole of the relief valve for clogging ...

Page 111: ...he oil cooler When the relative pressure of the entrance and exit is greater than 6 0 kg cm2 the relief valve operates bringing oil directly from the oil pump to the oil filter High Engine Oil Temperature When engine oil temperature is high oil viscosi ty is low and relative pressure drops below 6 0 kg cm2 600 kPa In this case the relief valve does not operate this allows the oil to be cooled by f...

Page 112: ...STON CYLINDER 111 YlINDER HEi l YlINDER H AD I WALL t r J STUD BOLTS I II STUD BOLTS I NOZZLE I NOZZLE i ljOZZUJ NOZZLE STARTER CLUTCH CONROD I EXHAUST SIDE INTAKE SIDE 1 r t m BUSHING r BIG ENDSI t t I I L I I I I RANKSHAFT JOURNALS I I R l OIL JETS I L SUB GALLERY I MAI N GALL RY I t I t l lOlL PRESSURE SWITCH I OIL JET J OIL JET rRJ I COUNTERSHAFT l jR IV ES H AF T RELIEF VALVE rn LEFT SIDE RIG...

Page 113: ...4 17 FUEL AND LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM ...

Page 114: ...l FUEL AND LUBRICATION SYSTEM 4 18 CYLINDER HEAD COOLING SYSTEM CHART I STUD BOLT h r _ST U_DB_O_LT_I I rIPE It 1 1 t I t CYLINDER HEAD COVER t I HOSES OIL PUMP OIL SUMP FILTER I I OIL PAN ...

Page 115: ...4 19 FUEL AND LUBRICATION SYSTEM CYLINDER HEAD COOLING SYSTEM ...

Page 116: ... EMISSION CONTROL INFORMATION CONTENTS EMISSION CONTROL CARBURETOR COMPONENTS 5 1 EVAPORATIVE EMISSION CONTROL SySTEM 5 2 CANISTER HOSE ROUTING 5 3 AIR SUCTION SySTEM 5 4 AIR SUCTION HOSE ROUTING 5 5 ...

Page 117: ...t Genuine Suzuki Parts be utilized whenever possible for the best possible performance and durability Conventional Figures Used I on Standard Tolerance Jet I 1234567890 Components 1 i l i Emission Type Figures Used I On Close Tolerance Jet I I 2 5 5 7 a o Components The carburetor specification for the emission controlled GSX 11 OOF are as follows Carburetor Main Needle I Jet Pilot Pilot B 0 1 e O...

Page 118: ...NFORMATION 5 2 EVAPORATIVE EMISSION CONTROL SYSTEM Only for California model r Fuel hose Fuel tank Surge hose Roll over valve I Vacuum hose __________ Air vent hose l way valve Purge hose Canister FUEL HC VAPOR FRESH AIR ...

Page 119: ...Painted line in red To NO 1 Carbo NO 2 Carb IN HOSE from fuel tank to canister I 1 way valve To fuel tank To No 4 Carbo To No 3 Battery Carbo Purge hose _ Surge hose painted line in red _ J To No 1 Carbo NO 2 Carbo To canister From canister I I Purge hose OUT HOSE from canister to carburetors I I Ilcarburetor i Purge hose Clamp Roll over VIEW OF LEFT valve I L __ _ ...

Page 120: ...INFORMATION 5 4 AIR SUCTION SYSTEM Only for California model Vacuum hose j II IL _ To No 3 No 4 air suction reed valve Air switching valve J From 2nd air cleaner No 1 No 2 air suction reed valve FRESH AIR I EXHAUST GAS ...

Page 121: ...ead pipe Air switching valve U f Air suction reed valve Cylinder 0 Exhaust port t r Vacuum ___ hose To No 3 cylinder No 4 cylinder To No 1 cylinder No 2 cylinder 5 5 EMISSION CONTROL INFORMATION AIR SUCTION HOSE ROUTING Only for California model i To fuel cock I 3 way To carburetor joint Vacuum hose t Air suction hose NO 3 ...

Page 122: ...ECTRICAL SYSTEM CONTENTS CHARGING SYSTEM 6 1 IGNITION SySTEM 6 8 STARTER SySTEM 6 11 COMBINATION METER 6 15 FUEL LEVEL METER GAUGE 6 17 DIGITAL CLOCK 6 18 LAMPS 6 18 SWiTCHES 6 20 RELAy 6 22 BATTERy 6 23 ...

Page 123: ... slip rings to the rotor coil mounted on the rotor The stator windings are assembled on the inside of a laminated core that forms part of the generator housing A rectifier bridge connected to the stator windings contains six diodes and electrically changes the stator A C voltages to a D C voltage which appears at the generator output terminal B IG c CO u o I IC regulator I ______ __j I B Fuse Stat...

Page 124: ...ove the engine sprocket cover Refer to page 3 6 Remove the generator Refer to page 3 12 Use a vise and proper pieces of woods to hold the generator driven gear as shown in the illustration and remove the generator driven gear nut CAUTION Do not hold the damper housing with a vise or damage or breakage of damper housing will result After removing the generator driven gear remove the damper housing ...

Page 125: ...r bearings by hand to inspect for abnormal noise and smooth rotation Replace the bearing if there is anything unusual Remove the bearings by using the bearing puller CAUTION The removed bearing should be replaced L_ STATOR COIL CONTINUITY CHECK Using the pocket tester check the continuity between the lead wires of the stator If there is no continuity replace the stator Also check that the stator c...

Page 126: ... with a clean dry cloth SLIP RING 0 0 Standard 14 4 mm 0 57 in Service Limit 14 0 mm 0 55 in CARBON BRUSH If the brushes are worn down charging performance decreas es Measure the length of the brushes replacing them when they are too short or chipping Service Limit 4 5 mm 0 18 in RECTIFIER Check the continuity between terminals and ground Put one tester lead to terminal 8 and the other lead to gro...

Page 127: ...check Second check Under the above condition set the variable DC power source to the 14 5 V if the bulb goes out IC regulator is in good condition If the bulb remains lit replace the IC regulator F Switch Pocket tester Tester range DC25V Variable DC power source E IC regulator F Rotor coil terminal IG Ignition terminal E Ground GENERATOR DRIVEN GEAR DAMPER Inspect the dampers for wear and damage I...

Page 128: ... NOTE Before reinstalling the slip ring side bearing to the generator end housing turn the expander ring and align the expander ring lug with the center of the chamfer of the bearing outer race Fit the three O rings to the bearing retainer screws Apply a sma II qua ntity of Th read Lock 1 342 to the bea ri ng retainer screws 99000 32050 Thread Lock 1342 I I 0 Hand press 1 X I Rotor n n L i 5 1 n B...

Page 129: ...DamPer housing 0 Damp 0 1 seal I o I g 3 pcs O rln I O ring housing I 7 Generator I Washer Gear side Q Bearing I retainer Bearing iJ Rotor over No 2 Bearing SliP ring side Bearing cover No 1 Bearing nd houslIlg 1 Generator e 5 f r Recti I older frame 11 Brush Ie regUlato nd cover r c Generator 19 I ...

Page 130: ...ition coil secondary windings and produce the spark between spark plug gaps Ignition cut off circuit is incorporated in the ignitor unit to prevent over running engine If engine r min reaches 10 900 r min this circuit cuts off the ignition primi lry current for all spark plugs CAUTION Engine can run over 10 900 r min without load even if the ignition cut off circuit is effective and it may cause e...

Page 131: ...er A SUZUKI pocket tester or an ohm meter may be used instead of the electro tester In either case the ignition coli is to be checked for continuity in both primary and secondary windings Exact ohmic readings are not necessary but if the windings are in sound condition their continuity will be noted with these approximate ohmic values 09900 25002 Pocket tester Ignition coil resistance Primary tap ...

Page 132: ...lug in the table be selected Remove the plugs and inspect the insulators Proper heat range would be indicated if all insulators were light brown in color If they are baked white they should be replaced by a cold type NGK JR OB Recommended spark plug I Standa d J Cold type u_j L NGK JR9B JR OB NOTE R type spark plug is installed for some specifications R type spark plug has a resister located at th...

Page 133: ... to close which connects the starter motor to the battery The motor draws about 80 amperes to start the engine II I Starter interlock sWitch Clutch switch Starter relay Starter button Engine stop sWitch Circuit breaker Ignition switch I I I I I I Battery I I STARTER MOTOR REMOVAL AND DISASSEMBLY Remuve the engine sprocket cover and generator Refer to pages 3 6 and 12 Disconnect me starter motor le...

Page 134: ... brushes replacing them when they are too short or chipping Service Limit 6 mm 0 2 in COMMUTATOR If the commutator surface is dirty starting performance decreases Polish the commutator with 400 or similar fine emery paper when it is dirty After polishing it wipe the commutator with a clean dry cloth Measure the commutator under cut D Service Limit 0 2 mm 0 008 in I CD O ring o Housing end Gear sid...

Page 135: ...grounded replace the armature Continuous use of a defective armature will cause the starter motor to suddenly fail 09900 25002 Pocket tester OIL SEAL Check the seal lip for damage or oil leakage If any damage is found replace it STARTER MOTOR REASSEMBLY a RING CAUTION Replace the a rings with new ones to prevent oil leakage and moisture BRUSH HOLDER Align the groove of brush holder with the lug on...

Page 136: ...lead wire of the starter motor at starter relay l Turn on the ignition switch inspect the continuity between the terminals positive and negative when squeezing the clutch lever and pushing the starter button If the starter relay is in sound condition continuity is found 09900 25002 Pocket tester I _ l l I _ _ _ Disconnect the lead wires from the starter relay Check the coil for open ground and ohm...

Page 137: ...ECTRICAL SYSTEM ION METER COMBINAT ISASSEMBLY REMOVAL AND upper fairings the lower an Remove headlight Remove the mb nat on meteL as follows Remove the co mbination meter D IS assem bl e the co I I I I I I L_ ...

Page 138: ...s incorrect replace the respective parts 09900 25002 Pocket tester NOTE When making this test it is not necessary to remove the combinaTion meter 1 I BI NEUTRAL i3 Gr ILLUMI ED CLOCK Gr ILLUMI EB B Y TACHO EB Y HIGH BEAM ED NEUTRAl O G TACHO OIL CLOCK I FUEL ED B W GROUND J r A _ _ _ 1 I I I G Y OIL 8 I B W GHOUND Lg TUHN R ED YIB FUEL EB B TURN L EB ...

Page 139: ...t a 11 O ohm resistor between the YIB lead wire of the fuel gauge and the ground lead wire The fuel meter is normal if its pointer indicates the E empty position when the specified voltage is applied to the circuit and if its pointer indicates the F full position when the resistor is changed to 3 ohms If either one or both indications are abnormal replace the fuel meter with a new one ___________ ...

Page 140: ...oses the function replace the battery as follows Remove the lower and upper fairings Remove the headlight Remove the combination meter Remove the clock by removing two screws Remove the cover by removing eight screws Replace the two batteries with new ones NOTE The stamped ffi mark on the battery is positioned outside LAMPS HEADLIGHT ...

Page 141: ...6 19 ELECTRICAL SYSTEM TAIL BRAKE LIGHT i 1 I I J TURN SIGNAL LIGHT CAUTION Do not overtighten the lens fitting screws ...

Page 142: ... START SWITCH _ I O BI I O W I YIG t 1 li 6 i _ J START I II i 0 i 0 Push I FRONT BRAKE SWITCH I _____________ O G I ____l_ W B _ ON i I Squeeze lever i f L I 0 1 0 I OFF I i I i NEUTRAL INDICATOR SWITCH 1 I BI Ground j r oN O i O e t_ra_1po 1 OFF I I DIMMER SWITCH w J Y Y 1 _ __ I L o t o 1 LO I 0 0 HORN SWITCH 1 _ _ _ _ _ _ _ _ __ _tI G _ _ B_ W_ I _ _ oN s4 C _t o CLUTCH SWITCH 1 _ _ i y G I y ...

Page 143: ...oil inspection window O W YIG O G WINDOW SCREEN SWITCH BI I WIG i 0 1 W R G Y f 0 J 0 UP I t W B i O BI f J 1 R W DOWN I 0 0 I 0 WIG W R Gray Brown White Yellow Yellow with White tracer Black Light blue Light green Green Black with White tracer Orange with White tracer Yellow with Green tracer Orange with Green tracer Blue Green with Yellow tracer White with Black tracer Orange with Blue tracer Re...

Page 144: ... replace it with a new one 09900 25002 Pocket tester L 4 WIND SHIELD MOTOR RELAY The wind shield motor relay is located on the fairing brace of right side INSPECTION First Check the insulation between terminals CD and 0 CD and 0 with pocket tester Second Apply 12 volts to and 0 terminals EEl to and 8 to 0 and check the continuity between CD and 0 terminals Third Apply 12 volts to and 0 terminals E...

Page 145: ...nufacture Confirmation for date of manufacture Date of manufacture is indicated by a three part number 0 as shown in the photograph each indicating month date and year Near the end of charging period adjust the specific gravity of electrolyte to value specified After charging adjust the electro lyte level to the MAX LEVEL with DISTILLED WATER SERVICING Visually IIlspect the surface of the battery ...

Page 146: ...attery SERVICE LIFE Lead oxide is applied to the pole plates of the battery which will come off gradually during the service When the bottom of the battery case becomes full of the sediment the battery cannot be used any more If the battery is not charged for a long time lead sulfate is generated on the surface of the pole plates and will deteriorate the performance sulfation Replace the battery w...

Page 147: ...IS CONTENTS FAIRING 7 1 WiND SHIELD 7 3 FRONT WHEEL 7 6 FRONT BRAKE 7 10 FRONT FORK 7 16 STEERING 7 22 REAR BRAKE 7 26 REAR WHEEL 7 31 TIRE AND WHEEL 7 36 REAR SUSPENSiON 7 41 CLUTCH MASTER CyLiNDER 7 49 L _ ...

Page 148: ...que 0 4 kg m 1 5 _ _ _ 0 2 _ _ Panel _ _ REMOVAL F dng ew 2 4 N m 30 Ib ft T I I U Per fairing G P 9 CD Lower falr d_Shield brace Fairing wI I oPanel L H the seat Remove I ft and Remove the e ht frame c removln g the rig overs by screws ...

Page 149: ...ng assembly by removing the screws 09900 00401 L type hexagon wrench set Remove the upper fairing assembly by removing the screws 09900 00401 L type hexagon wrench set REINSTALLATION Reinstall the fairing in the reverse order of removal ...

Page 150: ...Wind shield slider Driveshaft right end holder i Driveshaft Wind shield bracket R H Wind shield bracket L H 8 Motor _ _ _ _ _ _ REMOVAL AND DISASSEMBLY Remove the upper and lower fairings Page 7 1 7 2 Remove the wind shield assembly along with the fairing brace by removing the fairing brace mounting bolts ...

Page 151: ...ove the motor assembly by removing the bolts Remove the left and right wind shield brackets by removing the bolts Remove the driveshaft right end holder by removing the bolts and remove the driveshaft Remove the left and right wind shield slider guides Remove the left and right wind shield brackets from the wind shield slider by removing the bolts ...

Page 152: ...ield assembly check the wind shield for smooth operation by using the 12V battery and jumper wires NOTE Put one jumper wire to EB terminal and other jumper wire to 8 terminal then swap the two jumper wires When checking the wind shield motor relay refer to page 6 22 WIRING DIAGRAM R W Ignition switch R W 0 I VV G a WIR 0 0 UP Of F DOWN 0 K W R ex Circllit breaker SCREEN SWITCH ex Baltery I R Y I B...

Page 153: ...block under the exhaust pipe Loosen the axle pinch bolt Remove the cotter pin Remove the axle nut Remove both brake calipers by removing the mounting bolts Remove the axle shaft and front wheel NOTE Do not operare the brake lever while dismounting the brake calipers CAUTION Hang the brake caliper from the motorcycle frame by using the string etc taking care not to bend the brake hose ...

Page 154: ... shaft for runout and replace it if the runout exceeds the limit 09900 20606 Dial gauge 1 100 09900 20701 Magnetic stand Not available in U S Service Limit 0 25 mm 0 010 in l WHEEL Make sure that the wheel runout checked as shown does not exceed the service limit An excessive runout is usually due to worn or loose wheel bearings and can be reduced by replacing the bearings If bearing replacement f...

Page 155: ...assemble and remount the front wheel in the reverse order of removal and disassembly Pay attention to the following points WHEEL BEARING Apply grease to the bearings before installing 99000 25030 SUZUKI super grease A Install the wheel bearings as follows by using the special ________ J tool NOTE First install the left wheel bearing then install the right wheel bearing The sealed cover on the bear...

Page 156: ... attach the speedometer gearbox to the wheel hub When tightening the front axle check to be sure that the speedome ter gearbox is in the position so that the speedometer cable does not bend sharply AXLE SHAFT Tighten the axle nut and axle pinch nut to the specified torque Tightening torque Axle nut 55 88 N m 5 5 8 8 kg m 40 0 63 5 Ib ft Axle pinch nut 15 25 N m 1 5 2 5 kg m 11 0 18 0 Ib ftl BRAKE ...

Page 157: ... _ _ l 20 25 2 0 2 5 I 14 5 180 f T l I H J r j 8 c l i BRAKE PAD REPLACEMEI lT Remove the dust seal cover Remove the clips pins and springs Remove the pads CAUTION Do not operate the brake lever while dismounting the pads Replace the brake pad as a set otherwise braking performance will be adversely affected ...

Page 158: ...e Remove the caliper mounting bolts and remove the caliper NOTE Slightly loosen the caltjJer housing bolts to facilitate later disassembly before removing the caliper mounting bolts 09900 00410 Hexagon wrench set Remove the pads Page 7 10 Separate the caliper halves by removing the caliper housing bolts Remove the O ring NOTE Once separate the caliper halves replace the O ring with a new one Place...

Page 159: ...y Pay attention to the following points CAUTION Wash the caliper components with fresh brake fluid before reassembly Never use cleaning solvent or gasoline to wash them Apply brake fluid to the caliper bore and piston to be inserted into the bore CALIPER BOLTS Tighten the bolts to the specified torque Item N m kg m I Ib ft 1 Brake hose union 20 25 2 0 2 5 14 5 18 0 _aliPer mount ing bolt _ _ rr2 O...

Page 160: ... With the disc mounted on the wheel check the disc for face runout with a dial gauge as shown 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand Not available in U S Service l imit 0 30 mm 0 01 in MASTER CYLINDER REMOVAL AND DISASSEMBLY Remove the front brake light switch Place a rag underneath the union bolt on the master cylinder to catch the spilled drops of brake fluid Unscrew the unio...

Page 161: ... Remove the dust seal boot Remove the circlip with the snap ring pliers 09900 06108 Snap ring pliers Remove the spring primary cup piston secondary cup out of the master cylinder MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other damage Inspect the piston surface for any scratches or other damage Inspect the primary cup secondary cup and dust seal boot for wear ...

Page 162: ...h them Apply brake fluid to the cylinder bore and all the internal parts to be inserted into the bore When remounting the master cylinder on the handlebar align the master cylinder holder mating surface C j with punched mark CD on the handlebar and tighten the upper clamp bolt first as shown Tightening torque 8 12 N m 0 8 1 2 kg m 6 0 8 5 Ib ft CAUTION Bleed air after reassembling master cylinder ...

Page 163: ... m 15 25 1 5 25 15 25 15 2 5 6 9 0 6 09 Ib ft 11 0 18 0 1 0 180 45 6 5 REMOVAL AND DISASSEMBLY Remove the upper and lower fairings Page 7 1 7 2 Remove the brake calipers left and right Page 7 6 Remove the front wheel page 7 6 Remove the front fender by removing screws ...

Page 164: ...ront fork cap NOTE To remove the stopper ring it will be necessary to push the front fork cap inwards to remove the spring pressure from the stopper ring Remove the spacer spring seat and spring out of the inner tube Invert the fork and stroke it several times to let out fork oil Hold the fork inverted for a few minutes to drain oil Remove the dust seal and oil seal stopper ring IIiii 1 I I i I I ...

Page 165: ...inner tube out of the outer tube CAUTION The outer tube and inner tube ANTI FRICTION metals must be replaced along with the oil seal and dust seal 1 Oil seal 3 Oil seal retainer J Anti friction metal outer Anti friction metal Inner Remove the inner and outer anti friction metals INSPECTION FORK SPRING Measure the fork spring free length If it is shorter than the service limit replace it with a new...

Page 166: ...UBE METAL Hold the inner tube vertically and clean the metal groove Clean the metal inner and outer surfaces and install it to the metal groove of the inner tube as shown CAUTION Use special care to prevent damage to the Teflon coated surface of the Anti friction metal when mounting it DAMPER ROO BOLT App y Thread Lock 1342 to the damper rod bolt and tighten it to the specified torque 99000 32050 ...

Page 167: ...opper ring 0 Install the dust seal 0 CD Anti friction metal Oil seal retainer 3 Oil seal CD Oil seal stopper ring Dust seal FORK OIL Use front fork oil whose viscosity rating meets specifications below Fork oil type Fork oil 10 Fork oil capacity 478 ml 16 2 US OZ each leg 5 4 3 2 Hold the front fork vertical and adjust the fork oil level with the special tool NOTE When adjusting oil level remove t...

Page 168: ... the upper surface of the inner tube at 3 mm depth from the upper surface of the steering stem upper bracket NOTE Before installing the front fork stabilizer move the front fork up and down 4 or 5 times TIGHTENING TORQUE Item N m I kg m Front fork upper clamp bolt I I 20 30 2 0 3 0 Front fork lower clamp bolt 15 25 1 5 2 5 0 1 In Steering stem bracket Font fork Inner tube Ib ft _ _ 14 5 21 5 11 0 ...

Page 169: ...I CHASSIS 7 22 STEERING r I I ...

Page 170: ... the four screws Remove the left and right handlebars by removing their mounting bolts Disconnect the ignition switch lead wires coupler Remove the steering stem upper bracket by removing the stem head bolt and stem clamp bolt Remove the brake hose joint off the steering stem lower bracket by removing the bolt Remove the steering stem nut by using the special tool then remove the steering stem low...

Page 171: ... wear and brinelling Bearing wear or damage Abnormal noise of bearing Distortion of steering stem Inspect the play of steering dampers by hand while it is in the steering stem upper bracket If play can be found replace the dampers REASSEMBLY AND REMOUNTING Reassemble and remount the steering stem in the reverse order of removal and disassembly Pay attention to the following points OUTER RACES Pres...

Page 172: ...imes to the left and right so that the taper roller bearing will be seated properly L _ _ Turn back the stem nut by 1 4 1 2 turn NOTE This adjustment will vary from motorcycle to motorcycle Tightening torque NOTE Hold the front fork leg move it back and forth and make sure that the steer ing is not loose L_ Steering stem head bolt I 35 55 1I J m 3 5 5 5 kg m 25 5 40 0 Ib ft Steering stem clamp bol...

Page 173: ...0 9 145 6 5 18 23 1 8 2 3 i O 1l3 5 ___ L __ _ 25 40 25 4 0 18 0 29 0 BRAKE PAD REPLACEMENT Remove the dust seal cover Remove the clips pins and springs Remove the pads CAUTION Do not operate the brake pedal while dismounting the pads Replace the brake pad as a set otherwise braking performance will be adversely affected ...

Page 174: ...d remove the caliper NOTE Slightly loosen the caliper housing bolts to facilitate later disassembly before removing the caliper mounting bolts 09900 00410 Hexagon wrench set Remove the pads Page 7 26 Remove the caliper housing bolts and separate the caliper halves Page 7 11 Remove the O ring Page 7 11 NOTE Once separate the caliper halves replace the O ring with a new one Remove the dust seal and ...

Page 175: ..._8 1 3 0 16 Caliper mounting bolt 25 40 I 2 5 4 0 18 0 29_0 I MASTER CYLINDER REMOVAL AND DISASSEMBLY Remove the right frame cover Place a rag underneath the union bolt on the master cylinder to catch spilled drops of brake fluid_ Unscrew the union bolt and disconnect the brake hose off the master cylinder CAUTION Immediately and completely wipe off any brake fluid con tacting any parts of the mot...

Page 176: ...ng pliers Remove the spring primary cup piston secondary cup out of the master cylinder Remove the reservoir tank hose connector by removing the screw CAUTION The removed O ring should be replaced with new one MASTER CYLINDER II ISPECTION Inspect the cylinder bore wall for any scratches or other damage Inspect the piston surface for any scratches or other damage Inspect the cup set and each rubber...

Page 177: ...d all the internal parts to be inserted into the bore CAUTION Bleed air after reassembling master cylinder Refer to page 2 15 Adjust the rear brake light switch and brake pedal height after installation Refer to page 2 14 REAR BRAKE PEDAL When reinstalling the brake pedal align the punched mark on the brake pedal shaft with the slit of the brake pedal TIGHTENING TORQUE Tighten the bolts to the spe...

Page 178: ...i gh ht 8ningtor ue_ kg rn Nrn___ i 3 94 27 I 15 2 5 r 5 2 I 48 72 L 4 8 7 2_________ Ib ft_ 0 680 _ 9 _ 11 0_ 8 0 __ 0 35 0 _ 52 nr M IV l j I I II 1 1 d IPAC18 7 27 1 t f II bake i i I l I n 1 IPrn ove the r I j I liql 1 j I l t r ...

Page 179: ...alHJ while they dIe in the wheel and sprocket drurn Rotate the 1I111er race by halld to inspect for abnormal nOise dnd smooth I otdtldn Replace th bearing if there is anything LJIIIJ lldl _ I I Remove the dampers out of the wheel hub Remove the axle shaft and disengage the drive chain from the rear sprocket Remove the rear wheel Remove the rear sprocket dlong with Its mounting drum Off the wheel h...

Page 180: ...Service Limit 0 25 mm 0 010 in l I WHEEL Make sure that the wheel runout checked as shown does not exceed the service limit An excessive runout is usually due to worn or loose wheel bearings and can be reduced by replacing the bearings If bearing replacement fails to reduce the runout replace the wheel Service Limit Axial and Radial 2 0 mm 0 08 in L SPROCKET l Inspect the sprocket teeth for wear I...

Page 181: ... Pay attention to the following points WHEEL BEARING Apply grease to the bearings before installing 99000 25030 SUZUKI super grease A Install the wheel bearings by using the special tools 09941 34513 Bearing installer set NOTE First install the right wheel bearing then install the left wheel bearing The sealed cover on the bearing is positioned outside _ _ _ _ R swin9 ar ...

Page 182: ...specified torque Tightening torque 48 72 N m 4 8 7 2 kg m 35 0 52 0 Ib ft BRAKE DISC Make sure that the brake disc is clean and free of any greasy nlattf r Apply Thread Lock 1360 to the disc bolts and tighten them the specified torque 99000 32130 Thread Lock 1360 Tightening torque 15 25 N m 1 5 2 5 kg m 11 0 18 0 Ib ft TIGHTENING TORQUE _ r It8111 N m kg m Ib ft _ _ _ _ 1 94 127 __ L6 _9 0_ I BrdK...

Page 183: ... tire removal the following tools are required _ _ a J J 3 4 1 8 Tire changer stand Operation arm 5 6 7 Tire lever Center shaft Bead pushing roller Rlnl guide roller Bead breaker Rim protector Core remover Air pressure gauge Tire lubricant 11 9 Remove the valve core from the valve stern and deflate the tire completely NOTE Mark tire with chalk to note the position CD of the tire on the rim and rot...

Page 184: ... and dismount the bead from the rim Turn the wheel dismount the other bead from the rim Install the rim guide roller B Install the rim protector and raise the tire bead with the tire lever 0 Set the tire lever against the operation arm and rotate the lever around the rim Repeat this procedure to remove the other bead from the rim over and I I _ _ _ _ L J 1 I i I I _____ J 1 I 7 I L J 1 __ I L ...

Page 185: ... or split at the side wall Tread depth less than 1 6mm 0 06 in in the front tire and less than 2 0 mm 0 08 in in the rear tire Ply separation Tread separation Tread wear is extraordinarily deformed or distributed around the tire Scratches at the bead Cord is cut Damage from skidding flat spots Abnormality in the inner liner REPAIR NOTE When repairing a flat tire follow the repair instructions and ...

Page 186: ... ITING Apply a special tire lubricant or neutral soapy liquid to the tire bead CAUTION Never apply grease oil or gasoline l When installing the tire make certain that the directional arrow faces the direction of wheel rotation and align the balancing dot of the tire with the valve stern as shown Set the bead pushing roller i Rotate operation arm around the rim to mount the bead completely Do the b...

Page 187: ...on the tire side walls It must be equidistant from the wheel rim all the way around If the distance between the rim line and wheel rim vaires this indicates that the bead is not properly seated If this is so deflate the tire completely and unseat the bead for the both sides Coat the bead with lubricant any try again After tire is properly seated to the wheel rim adjust the pressure to the recommen...

Page 188: ...7 41 CHASSIS REAR SUSPENSION SWINGARM Jr i 1 Tightening torque Item N m kg m Ib ft I 0 22 33 2 2 3 3 16 0 24 0 55 88 5 5 8 8 40 0 63 5 L _ _ _ ...

Page 189: ... CHASSIS 7 42 SHOCK ABSORBER AND CUSHION LEVER 1 Tightening torque Item I N m m Ib ft 40 60 4 0 6 0 29 0 43 5 70 100 10 0 50 5 725 ...

Page 190: ...garm Remove the spring pre load adjuster mounting bolts I Remove the shock absorber upper end bolt and nut Remove the left side muffler by removing its connection bolts and mounting bolts Remove the cushion lever mounting bolt and nut Remove the swingarm pivot shaft and nut Remove the shock absorber and cushion lever rod along with the swingarm ...

Page 191: ...t the shock absorber body and hose joints for damage and oil leakage If any defects are found replace the shock absorber assembly with new one t 4 CUSHION LEVER ROD Inspect the respective cushion lever and rod bearings by hand while they are in the cushion lever and rod Rotate each bearing spacer to inspect for abnormal noise and smooth rotation Replace the bearing if there is anything unusual Ins...

Page 192: ...bearings by hand while they are in the swingarm Rotate the bearing spacer to inspect for abnormal noise and smooth rotation Replace the bearing if there is anything unusual Inspect the dust seals If they are found to be damaged replace them with new ones Remove the dust seals and spacers Remove the swingarm pivot bearings with the special tools 09923 74510 Bearing puller 09930 30102 Sliding shaft ...

Page 193: ...ension in the reverse order of disassembly and removal Pay attention to the following points CUSHION LEVER ROD Apply grease to the bearings and dust seals 99000 25030 SUZUKI super grease A Install the respective cushion lever and rod bearings with proper socket wrench Refer to page 7 47 for details NOTE When installing the bearing the stamped mark on the bearing is positioned outside SWINGARM Appl...

Page 194: ...0 6 0 kg m torque Swingarm r Cushion lever rod rf l j li A B T h 70 100 Nm Ig tenlng 70 _ 100 kg m torque I 50 5 72 5 Ib ft Tightening 70 100 N m torque i 70 10 0 kg m 505 72 5 Ib ft Point 01 0 Shock absorber Apply SUZUKI Super grease A to each bearing and dust seal lip I 70 100Nm Tightening i 7 0 100 kg m torque i 505 72 5Ib ft ...

Page 195: ...lity of this motorcycle makes proper suspension setting and balance very important Use the following table to adjust the rear suspension SETTING TABLE r _ Damping force STD 2 4 Factory setting Dual riding 3 4 Solo riding I added weight Spring pre Io 2 5 3 5 5 3 5 5 30kg 66 1 Ibs 3 4 Dual riding added weight 4 4 4 5 30kg 66 1 Ibs _ _ tIf p Position 1 provides the softest damping force Position 4 pr...

Page 196: ...Unscrew the union bolt and disconnect the clutch hose from the master cylinder CAUTiON Completely wipe off any brake fluid adhering to any parts of motorcycle The fluid reacts chemically with paint plastics rubber materials etc and will damage them severely Remove the clutch master cylinder by removing its clamp bolts DISASSEMBLY AND REASSEMBLY Disassemble and reassemble the clutch master cylinder...

Page 197: ... SERVICING INFORMATION CONTENTS _ WIRING DIAGRAM 8 8 TROUBLESHOOTING 8 1 1 WIRE CABLE AND HOSE ROUTING 8 10 SPECIAL TOOLS 8 19 TIGHTENING TORQUE 8 22 I SERVICE DATA 8 25 L ...

Page 198: ...uel cock Replace 4 Clogged fuel hose or fuel filter Clean or replace 1 Clean Engine stalls easily 1 Fouled spark plugs Replace 1 2 Defective signal generator or ignitor unit 3 Clogged fuel hose Clean 4 Clogged jets in carburetors Clean I i 5 Valve clearance out of adjustment Adjust N isy i xcessivevalve chatter 1 Valve clearance too large I djUst 2 Weakened or broken valve springs Replace 1 I 3 Wo...

Page 199: ...ft is rubbing or sticky I Repair 3 Distorted or worn gearshift forks Replace Transmission jump f I 1 Worn shifting gears on driveshaft or countershaft a c e j out of gear 2 Distorted or worn gearshift forks I Replace 3 Weakened stopper spring on gearshift stopper ePlace 4 Worn gearshift pawl Replace Engine idles poorly 1 Valve clearance out of adjustment Adjust 2 Poor seating of valves Replace 3 D...

Page 200: ...ce Drain out excess oil Clean I I Add oil Replace or clean Adjust Retighten or replace I I Change Symptom and possible causes Remedy Complaint _ _ _ _ _ Trouble with starting 1 Starter jet is clogged I Clean 2 Starter pipe is clogged I Clean I Air leaking from a joint between starter body and Check starter body and I 3 carburetor carburetor for tightness adjust and replace gasket I 4 Air leaking f...

Page 201: ... generator coils I Replace 3 Shorted or panctured regulator and rectifier Replace 4 Brushes not seating properly on slip ring in rotor tepair o place l Generator does 1 Lead wires tend to get shorted or open circuited or I Repair or retighten charge but charging loosely connected at terminals I rate is below the 2 Grounded or open circuited stator coils of generator 11 Replace specification Genera...

Page 202: ...em 3 A short circuit condition exists within the battery due to excessive accumula Replace the battery tion of sediments caused by the high electrolyte S G 4 Electrolyte S G is too low Recharge the battery fully and adjust elec 5 Contaminated electrolyte trolyte S G Replace the electrolyte recharge the bat 6 Battery is too old tery and then adjust S G Replace the battery Reversed battery The batte...

Page 203: ...eplace Refill Front suspension too stiff 1 Fork oi I too viscous 2 Too much fork oil 3 Incorrect air pressure in front fork Replace Drain excess oil Adjust Noisy front suspension 1 Not enough fork oil 2 Loose nuts on suspension Refill Retighten Wobbly rear wheel 1 Distorted wheel rim 2 Worn down rear wheel bearings or swingarm bearings 3 Defective or incorrect tire 4 Worn swingarm and rear cushion...

Page 204: ...itting 3 Damaged wheel bearing I Replace 4 Loose front wheel axle or rear wheel axle Tighten to specified I torque I I 5 Worn pads Replace 6 Foreign material in brake fluid Replace brake fluid 7 Clogged return port of master cylinder I Disassemble and clean E x c e s si v e b r ke I t I ra rYlinde _ I 1 Air In hydraulic system lever stroke I 2 Insufficient brake fluid Replenish fluid to speci I I ...

Page 205: ...ack with Red tracer Black with White tracer Black with Yellow tracer Blue with Black tracer Green with Yellow tracer Orange with Black tracer Orange with Blue tracer Orange with Green tracer Orange with Light green tracer Orange with Red tracer OIW OIY RIW RIY WIB WIG WIR YIB YIG YIW BV r h B RNS GNA Lg LJ J lQ f h 8W l jJ BW w jJEw3 B BW TAil 8RA E liGHT 1 AHRT Tr AN SIG Al Orange with White trac...

Page 206: ...er Orange with White tracer Orange with Yellow tracer Red with White tracer Red with Yellow tracer White with Black tracer White with Green tracer White with Red tracer Yellow with Black tracer Yellow with Green tracer Yellow with White tracer OIW OIY RIW RIY WIB WIG WIR YIB YIG YIW co cD en IT s 2 C 2 Tl o s x o 2 i1o WIRE COLOR B Black BI Blue Br Brown G Green Gr Gray Lbl Light blue Lg Light gre...

Page 207: ... relay Clamp BaUery8Jead Starter motor lead Turn signal relay Ignitor Battery Battery 8 terminal I Side stand relay _ Wiring harness Clamp Ignition coil Clamp Ciamp U I III I Clamp To RH Turn signal Headlight j w I li w coupler Side stand switch Fuse box n 1m ri Main wiring harness ...

Page 208: ...le Cankcase breather hose Clutch hose Wind shield bracket Fairing brace Front fork LH Cable guide CABLE ROUTING CALIFORNIA MODEL ONLY Front Steering head Air suction reed valve hoses Throttle cable Starter cable Front fork RH Ignition switch Clamp RH NOTE Pass the starter cable through the clamp LH in the same manner of the throttle cable Throttle calbe ...

Page 209: ... SERVICING INFORMATION 8 12 FRONT BRAKE HOSE ROUTING Q l 15 ro u ij Q l E o 0 Q l Q l Cl f I o 0 q Q l Q l j t ro o 0 or oz Q l t c ro c 20 cD Li or ...

Page 210: ...er cylinder stopper tighten the union bolt Rear brake hose Rear brake master cylinder o Clamp J Reservoir _ tank hose Pass the rear brake hose through the brake hose guide attached on the swingarm l 0 l D 0 l m I 0 en m 0 0 C f Z G en I Tl lJ 2 C 2 0 lJ s l 0 2 ...

Page 211: ...SERVICING INFORMATION 8 14 CLUTCH HOSE ROUTING a E ell U 1 ...

Page 212: ...ATION FUEL HOSE VACUUM HOSE ROUTING No 1 Carbo No 2 Carbo Crankcase breather hose Fuel hose RH I Fuel cock I Fuel hose LH Crankcase breather hose Fuel cock Fuel hose LH Vacuum hose No 1 Carbo No 2 Carbo No 3 Carbo __ Frame ...

Page 213: ...SERVICING INFORMATION 8 16 FUEL TANK HOSE ROUTING ...

Page 214: ... fuel drain hose Breather cover 0 I i I m en D I T I c I n 0 z en C1 m Z en 1 1 c D s 0 l C 0 I z 2 G Clamp Air cleaner water drain hose Fuellevel gauge water fuel drain hose Fuel tank water drain hose I I I I I I I 1 Shock absorber Air cleaner water drain hose Fuel tank water drain Battery breather hose ...

Page 215: ...SERVICING INFORMATION 8 18 BATTERY BREATHER HOSE ROUTING Battery breather hose Fuel level gauge water fuel Fuel tank water drain hose drain hose ...

Page 216: ...ers t t _ 09900 20701 Magnetic stand 09900 25002 Pocket tester dlIS 0 00 900 0 00 000 Impact driver set _ 1 erniercaliper_s e L I f o rC 09900 20508 09900 20605 Cylinder bore gauge set pers 1 c529 09900 20805 I 09900 21304 1 _b_IO_C_k_ 1_0_0_m_m l I 09900 28403 0991020116 Hydrometer Conrod holder ii1 iid 0c c w 09900 0 0 0 0000 0 _M_i_c_ro_m_e_ter 2_5_ _5_0_m_m _I _i_cr_o_m_eter 75 100 mml 09900 2...

Page 217: ...7r amer _ i J fter attac lidPi_lo_t I_N_ 1_0_0_ _5_ _0_ _ _N_ 1_1_S _N _ _2_0_o_r_N_ _2_ _N _1_2_2 i_R_e_a_m_e_r_h_a_n_d_le___ 15_O_mm z I i 0991634580 I 09916 44310 Valve guide reamer I Valve guide remover 09916 74521 09916 74540 I 09916 84510 Piston holder handle Piston holder e_z_e_r_s J2 O S r11 I t ler I I c I I 09924 84511 09917 14910 0992034810 09920 53722 09923 73210 I Bearing installer se...

Page 218: ...er f 09941 84510 Bearing remover 09941 44510 09941 34513 Swingarm bearing I 09941 50110 09941 74910 Steering race insta lI_e_r_ l_re_m_o_v_e_r l _B_ea_r_in g re_m_o_ve_r _St_e_e_ri_n g_b_e_a_r_in g in_s_ta_lI_e_r Not available in U S A 09943 74111 Fork oil level gauge ...

Page 219: ...45 3 0 4 5 21 5 32 5 Cam chain idler mounting bolt 8 12 0 8 1 2 6 0 8 5 Conrad bearing cap nut 49 53 4 9 5 3 35 5 38 5 Starter clutch mounting bolt 143 157 14 3 15 7 103 5 113 5 Signal generator bolt 25 35 2 5 3 5 18 0 25 5 Crankcase bolt 6 mm 9 13 0 9 1 3 6 5 9 5 8 mm 20 24 2 0 2 4 14 5 17 5 Oil pump mounting bolt 8 12 0 8 1 2 6 0 8 5 Oil drain plug 20 25 2 0 2 5 14 5 18 0 Oil pan bolt 12 16 1 2 ...

Page 220: ...lt 35 _ 55 __ 40 I _H_a_n __ d_le_b_a_r_m_o_u_n_t_in_g_b_o_lt __ 2_5_ _3_5 5 2 5 _ _ 5_ Clutch master cylinder mounting bolt 8 12 0 8 1 2 I 6 0 8 5 1 1 Front brake master cylinder mounting bolt 1 8 12 0 8 1 2 6 0_ __8 Brake clutch air bleeder I 6 9 0 6 0 9 4 5 6 5 I i Brake clutch hose union bolt 20 25 2 0 2 5 14 5 18 0 Front brake caliper mounting bolt 25 40 i 2 5 4 0 rl m nt brake caliper housin...

Page 221: ...ed bolt mm N m I kg m ib tt N m i kg m 1 j b ft 1 t i 1 1 O 6 jll 4 7 0 4 0 7 3 0 5 0 8 12 0 8 1 2 6 0 8 5 f f 1 t 8 10 16 11 0 1 6 7 0 11 5 18 28 1 8 2 8 13 0 20 0 j 1 1 10 t 22 35 2 2 3 5 16 0 25 5 40 60 4 0 6 43 5__ I _ _ _ 35 55 3 5 5 5 25 5 40 0 70 100 7 0 10 0 50 5 72 5 1 14 50 80 5 0 8 0 36 0 58 0 16 80 130 18 130 190 IT J f 1 Conventional Bolt 4 Marked Bolt 7 Marked Bolt ...

Page 222: ... EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve stem end length IN EX 2 5 0 10 Valve seat width IN EX 0 9 1 1 0 035 0 043 Valve head radial runout IN EX 0 03 0 001 Valve spring free length IN EX INNER 35 0 1 38 OUTER 37 8 1 49 Valve spring tension IN EX 5 3 6 5 kg INNER 11 7 14 3Ibs at length 28 mm 1 1 in 13 1 15 1 kg OUTER 28 9 33 3 Ibs at length 31 5 mm 1 2 in CAMSHAFT CYLINDER HEAD Uni...

Page 223: ...g cm 2 Compression pressure difference I 156 _ 2__ H I I 2 kg cm 2 28 pSI Piston to cylinder clearance 0 050 0 060 0 120 I 0 0020 0 0024 0 0047 I c t Cylinder bore I 78 000 78 015 78 080 r I L3 0709 3 07 15 3 0 O_ _ t 1 ___ ____1 Piston diam I 77 945 77 960 77880 3 0687 3 0693 1 _________________ Measure at 15 mm 0 6 in from the sl ir e _3 _ _ _ _ Cylinder distortion r 0 20 i 0 008 t 1 Piston ring...

Page 224: ...haft journal oil clearance 0 020 0 044 0 080 I I ______________________________l J_ _00C _ _ 00 __L t _ g_o_ l Crankshaft journal 0 0 I 35 976 36_000 i 1 1 4164 1 4173 I L i Crankshaft thrust clearance I 0 04 0 08 I 0 002 0 003 l c nk h ftt h t b i g nc i T g g 1 1 I 2 44 2 46 I i R ght side 0 096 0 097 I t 1 Crankshaft runout 0 05 0 002 OIL PUMP ITEM STANDARD i LIMIT l t Oil pump reduction ratio ...

Page 225: ... 21_ O L_ L o_52 _0 0 __ 1 Shift fork groove width No 1 NO 5 0 5 1 1 10 3 0 197 0 201 I Shift fork thickness rNo 1 NO 2 4 8 4 9 1 1 I o 3 0 189 0 183 I or iv e c h ai n Type OAI DO 01053 2ZLV 1 I 1 r I Li nks I 1 18 lin ks I I 1 1 3 19 4 I 20 pitch length I 1 26 D r i v e c h a i n s a c k If 20 25 I I 0 8 1 0 I CARBURETOR SPECIFICATION ITEM __ l _ _ _ _ 1 _ _ _ _ _ I California model only r Carbu...

Page 226: ...lug L_Typ_e_i_ K JR9B_ _ 9B_ I G I 0 6 0 7 I c I_ __ 0 024 0 028 1 _rl yer a_nce t Over 8JO 3 _tm L_______ _ Signal coil resistance i Tester range Approx 135 2000 I ____ r T __ __ lOOn Ignition coil resistance I EB tap 8 tap I Tester range I Pnmary i Approx 3 5n 10 I I Plug cap Plug cap I Tester range S d econ ary I Approx 25 45 kn X 1 kO I ____r_ Generator 1 S J _ nng O D _ LL OJO N D Brush lengt...

Page 227: ...0 Brake disc thickness 5 0 0 2 4 0 Front 0 197 0 008 0 15 _ 6 7 0 2 6 0 Rear 0 24 0 264 0 008 1 Brake disc runout 0 30 0 012 Master cylinder bore 14 000 14 043 0 5511 0 5529 12 700 12 743 0 5000 0 5017 rt _ Master cylinder piston diam 13 957 13 984 Front 0 5495 0 5506 12 657 12 684 Rear I 0 4983 0 4994 1 Front Brake caliper cylinder bore 38 180 38 256 Rear 1 5031 1 5061 I Brake caliper piston diam...

Page 228: ... PSI FRONT 1250f2M136 REAR 1290 2 90 I 42 I FUEL OIL ITEM SPECIFICATION I LIMIT Use only unleaded or low lead type ga s o in e I Fuel type of at least 85 95 pump octane _ M meth I od or 89 OCTane or higher rated by the I Research Method _ 1 f Fuel tank capacity 21 0 L k 5 5 US gal 19 5 L I Ca I if o rn ia m o d 5 2 US gal only Engine oil type 1 SAE 10W 40 API SE or SF FiI 1 4300 ml 1 Change 4 5 US...

Page 229: ......

Page 230: ...Ir Prepared by SUZUKI MOTOR CO LTD Technical Department Motorcycle Service Division 1st Ed October 1987 Part No 99500 39080 03E Printed in Japan 230 i ...