119 PDF

EN125-2A
SERVICE MANUAL
99500H06100-01E
Prepared by
JIANG MEN DACHANGJIANG GROUP CO., LTD.

Customer Service Department
1st Ed. Aug, 2003
Part No.:99500H06100-01E
Printed in China
FOREWORD
The SUZUKI EN125-2A was designed to offer superior performance through light weight
design and four stroke power. The new EN125-2A represents another major advance by
Suzuki in four stroke motorcycles.
This service manual has been produced primarily for experienced mechanics whose job is
to inspect, repair and service Suzuki Motorcycles. Apprentice mechanics and "do it
yourself " mechanics will also find this manual to be an extremely useful guide.
Model EN125-2A manufactured to standard specifications is the main subject matter of

this manual. However, the EN125-2A machines distributed in your country might differ in
minor respects from the standard-specification EN125-2A and, if they do, it is because
some minor modifications (which are of no consequence in most cases as far as servicing
is concerned) had to be made to comply with the statutory requirements of your country.
This manual contains up-to-date information at the time of its issue. Latermade
modifications and changes will be explained to each SUZUKI distributor in respective
markets, to whom you are requested to make query about updated information, if any.
SUZUKI MOTOR CORPORATION

JIANG MEN DACHANGJIANG GROUP CO., LTD.
GROUP INDEX
GENERAL INFORMATION 1
PERIODIC MAINTENANCE AND
BREAK-IN PROCEDURES 2
ENGINE 3
FUEL AND LUBRICATION SYSTEM 4
CHASSIS 5
ELECTRICAL SYSTEM 6
SERVICING INFORMATION 7
GENERAL INFORMATION
CONTENTS
WARNING/CAUTION/NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1
FUEL AND OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . 1-2
BREAK-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
SPECIAL FEATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
SPECIAL MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-1 G E N E R A L I N F O R M AT I O N
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the
words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted
by these signal words.
WARNING:
Personal safety of the rider is involved, and disregard of the information could result in injury.
CAUTION:
For the protection of the motorcycle, the instruction or rule must be strictly adhered to.
NOTE:
Advice calculated to facilitate the repair of the motorcycle is given under this heading.
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential
hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARNINGS and
CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are unsure about
how to perform a particular service operation, ask a more experienced mechanic for advice.
GENERAL PRECAUTION
WARNING:
Proper service and repair procedures are important for the safety of the service mechanic and the safety
and reliability of the motorcycle.
When more than 2 persons perform work in cooperation, pay attention to the safety of each other.
When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors.
When working with toxic or flammable materials, make sure that area you work in is well-ventilated and that
you follow all of the material manufacturer s instrucations.
Never use gasoline as a cleaning solvent.
To avoid getting burned, do not touch the engine, engine oil, oil cooler and exhaust system until they have
cooled.
Afer servicing the fuel, oil, exhaust or brake systems, check all lines and fittings related to the system for
leaks.
CAUTION:
If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent.
When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be
reinstalled in the proper order and orientation.
Be sure to use special tools when instructed.
Make sure that all parts used in reassembly are clean. Lubricate them when specified.
Use the specified lubricant, bond or sealant.
When removing the battery, disconnect the negative cable first and then the positive cable.
When reconnecting the battery, connect the positive cable first and then the negative cable,and replace the
terminal cover on the positive terminal.
When performing service to electrical parts, if the service procedures not require use of batery power,
disconnect the negative cable the battery.
When tightening the cylinder head and case bolts and nuts, tighten the larger sizes first.
Always tighten the bolts and nuts diagonally from the inside working out and to the specified tightening
torque.
Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking nuts, cotter pins,
circlips and certian other parts as specified, be sure to replace them with new ones. Also, before installing
these new parts, be sure to remove any left over material from the mating surfaces.
Never reuse a circlip. When installing a new circilp, take care not to expand the end gap larger than
required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated
in its groove and securely fitted.
Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is
smeared with them.
After reassembling, check parts for tightness and proper operation.
To protect the environment, do not unlawfully dispose of used motor oil, engine coolant and other
fluids: batteries tires.
To protect Earth's natural resources, properly of uesd motorcycle and parts.
G E N E R A L I N F O R M AT I O N 1-2
SERIAL NUMBER LOCATIONS

ENGINE OIL
The frame serial number Ù is stamped on the Be sure that the engine-oil you use comes under
API classification of SF or SG and that its
steering head pipe. The engine serial number
viscosity rating is SAE 10W-40. If SAE 10W-40
is located on the crankcase.
motor oil is not available, select the oil viscosity
These numbers are required especially for
according to the following chart:
registering the machine and ordering spare parts.
SAE
40
30
20W/50
10W/50
10W/30
1 20W
10W
C -20 -10 0 10 20 30 40
Temp.
F -4 14 32 50 68 86 104
BRAKE FLUID
Specification
DOT3, DOT4
and Classification
FRONT FORK OIL

2
FORK OIL 10
BREAK-IN PROCEDURE
During manufacture only the best possible materials
are used and all machined parts are finished to a
very high standard but it is still necessary to allow
the moving parts to "BREAK-IN" before subjecting
the engine to maximum stresses. The future
performance and reliability of the engine depends
on the care and restraint exercised during its
FUEL AND OIL early life. The general rules are as follows:
RECOMMENDATIONS
Keep to these break-in en gine speed limits:
FUEL
Use gasoline with an octane number of 90 - 97 or Initial 800 km Below 4,500 r/min
higher (Research Method), preferably unleaded Up to 1,600 km Below 5,500 r/min
Over 1,600 km Below 10,000 r/min
NOTE:
Unleaded and low-lead gasoline will extend Upon reaching an odometer reading of 1,600 km
spark plug life. you can subject the motorcycle to full throttle
operation.
However, do not exceed 10,000 r/min at any
time.
Do not maintain constant engine speed for an
extended time period during any portion of the
break-in. Try to vary the throttle position.
SPECIAL FEATURE
TRANSISTORIZED IGNITION SYSTEM WITH ELECTRONIC ADVANCE
DESCRIPTION
On the Model EN125-2A, the timing advance characteristics of the ignition timing have been changed
from the previously-employed mechanical timing advance system incorporating a centrifugal advance
governor to an electronic timing advance system.
The introduction of this new electronic timing advance system minimizes fluctuations in the ignition
timing and also has improved the timing advance performance during high-speed operations.
The ignitor has the following functions:
(1)Revolution advance angle control
Controls ignition timing in response to engine r/min.(See Fig.1,)
(2)Closing angle control
When engine speed is low, reduces the conducting period (closing angle) of the transistor (Tr) so
that power consumption is reduced; when engine speed is high, increases the conducting period
(closing angle) to prevent voltage drop of the ignition coil. (See Figure 2 and 3.)
Closing angle (Degree)

Advance angle (Degree)
O
30 200
O O
16.9 3 /7000rpm
100 O
20
2 4 6 8 10
10
19.0O 2.8O/4500rpm Engine r/min (x 1000 r/min)
Fig.2
BTDC
Electric current (A)
O
13 BASE 0
1.0
0 1 2 3 4 5 6 7 8 9 10 11
Engine r/min (x 1000 r/min)
0.5
Fig.1
2 4 6 8 10
Engine r/min (x 1000 r/min)
Fig.3
Ignition switch
Signal generator Ignitor unit Ig 2

Ig 1
Ignition coil Battery

(A) ( C)
(B)
(Tr)
Spark plug
Pick-up coil
Signal rolor
G E N E R A L I N F O R M AT I O N 1-4
SPECIAL MATERIALS
The materials listed below are needed for maintenance work on the EN125-2A and should be kept on hand
for ready use. These items supplement such standard materials as cleaning fluids, lubricants, emery cloth
and the like. How to use them and where to use them are described in the text of this manual.
Material Part Page Material Part Page
Cam sprocket bolts 3-27

Oil seals 3-47
2nd drive gear 3-44
Wheel bearing 5-3 Starter clutch allen bolt 3-53
5-31 Gear position sw. bolts 3-55
Brake cam 5-32
Steering stem 5-16
Dust seal cover and 5-36

spacer
THREAD LOCK SUPER
SUZUKI Speedometer gear box 2-2 "1303B"
5-3
SUPER GREASE"A" 99000-32030
Wheel mounting drum 5-31
99000-25010
Front fork damper rod 5-10
Brake piston holder 5-22 bolts
Piston pin 3-24

Valve stem 3-25
Camshaft journal 3-28 THREAD LOCK CEMENT
Rocker arm shaft 3-28 99000-32040
Countershaft bearing 3-44

retainer screws
Gearshift cam guide 3-48
SUZUKI MOLY PASTE
and pawl screws
99000-25140
Engine oil pump moun- 3-49
ting screws
Front fork damper rod 5-10
bolt Pick up coil screws 6-2
Starter motor securing 6-11
screws
THREAD LOCK "1342"

99000-32050
SUZUKI BOND No.4

Magneto rotor nut 3-53
99000-31030
Cylinder head cover 2-4

3-29
Mating surfaces of left 3-47
and right crankcase
THREAD LOCK SUPER

SUZUKI BOND No.1215 "1305"
99000-31110 99000-32100
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1945mm
Overall width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 735mm
Overall height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1070mm
Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1265mm
Ground clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160mm
Seat height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750mm
Dry mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122kg
ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four-stroke, air-cooled, OHC
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.0mm
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.8mm
Piston displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124cm 3
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2:1
Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIKUNI BS26SS, single
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Polyurethane foam 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.470(59/17)
Final reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.214(45/14)
Gear ratios, Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.000(33/11)
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.857(26/14)
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.368(26/19)
4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.143(24/21)
Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.957(22/23)
Drive chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KMC 428H 118 Links
G E N E R A L I N F O R M AT I O N 1 - 6
ELECTRICAL
Ignition type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transistorized
lgnition timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 O B.T.D.C. below 1 950 r/mim
32 O B.T.D.C. between 4 000-5 000 r/min
O
29.9 B.T.D.C. between 6 000-7500 r/min
O
34.1 B.T.D.C. above 9 000 r/min
Spark plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK CR8E, NIPPON DENSO U24ESR-N
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 28.8kc(7Ah) 10h
Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A, 15A
Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 35W/35W
Tail/Brake light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 5W/21W
Turn signal light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 21W
Turn signal indicator light . . . . . . . . . . . . . . . . . . . . . . . . . 12V 2W 2
Neutral indicator light . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 2W
Speedometer light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 3W
Tachometer light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 3W
Fuel capacity light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 3W
High beam indicator light . . . . . . . . . . . . . . . . . . . . . . . . . 12V 2W
Position lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 5W
Gear position indicator . . . . . . . . . . . . . . . . . . . . . . . . . 12V 2W
CHASSIS
Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Telescopic, coil spring, oil dampened
Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swing arm, oil dampened
spring 5-way adjustable
Steering angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 O (right and left)
Caster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 O30
Trail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90mm
Turning radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1m
Front brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disc
Rear brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal expanding
Front tire size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80/100-18 4PR Tubeless
Rear tire size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90/90-18 4PR Tubeless
CAPACITIES
Fuel tank including reserve . . . . . . . . . . . . . . . . . . . . . . . 14 L
reserve . . . . . . . . . . . . . . . . . . . . . . . 2.0 L
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100 ml
Front fork oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 ml
*The specifications subject to change without notice.

PERIODIC MAINTENANCE AND
TUNE-UP PROCEDURES
CONTENTS
PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . 2-1

MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
CYLINDER HEAD NUTS, CYLINDER NUTS, EXHAUST PIPE
BOLTS AND NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
AIR CLEANER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
FUEL HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
ENGINE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
OIL SUMP FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
FRONT FORK OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
CHASSIS AND ENGINE BOLTS AND NUTS . . . . . . . . . . . . . . . 2-17
2-1 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES
PERIODIC MAINTENANCE SCHEDULE

The chart below lists the recommended intervals for all the required periodic service work necessary to
keep the motorcycle operating at peak performance and economy.
NOTE:
More frequent servicing may be performed on motorcycles that are used under extreme severe
conditions.
PERIODIC MAINTERNANCE CHART

ENGINE
Interval Km Initial 1 000 km Every 4 000 km Every 8 000 km
Page
ltem Months 5 20 40
Battery Inspect Inspect - 2-3
Cylinder head nuts, cylinder nuts,
Inspect Inspect - 2-4
exhaust pipe bolts and nut
Air cleaner element Clean every 3 000 km 2-5
Valve clearance Inspect Inspect - 2-6
Compression pressure Inspect Inspect 2-7
-
Spark plug Inspect Inspect 2-7
Replace
Inspect Inspect
Fuel hose -
Replace every 4 years 2-8
Fuel filter Clean -
Clean 2-8
Engine oil Change Change
- 2-8
Engine oil filter Replace Replace
- 2-9
Oil pressure - Inspect
- 2-9
Oil sump filter - -
Clean 2-9
Carburetor Inspect Inspect
- 2 - 10
Clutch Inspect Inspect
- 2 - 10
CHASSIS
Interval Km Initial 1 000 km Every 4 000 km Every 8 000 km
Page
ltem Months 5 20 40
Drive chain Inspect and clean every 1 000 km 2 - 11
Brakes Inspect Inspect - 2 - 12
Inspect Inspect -
Brake hose 2 - 12
Replace every 4 years
Brake fluid Change every 2 years 2 - 12
Tires Inspect Inspect - 2 - 15
Steering Inspect Inspect - 2 - 16
Front fork oil Change - Change 2 - 16
Chassis bolts and nuts Inspect Inspect - 2 - 17
PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-2
PERIODIC LUBRICATION CHART

The maintenance schedule, which follows, is based on this philosophy. It is timed by odometer indication,
and is calculated to achieve the ultimate goal of motorcycle maintenance in the most economical manner.
Interval Km Initial and Every 6 000 km Every 12 000 km

ltem Months 6 12
Throttle cable Engine oil -
Throttle grip - Grease
Clutch cable Engine oil -
Speedometer cable - Grease
Speedometer gear box - Grease
Tachometer cable - Grease
Drive chain Engine oil every 1 000 km
Brake pedal Grease or engine oil -
Brake cam shaft - Grease
Steering stem bearings
Grease every 2 years or 20 000 km
Swing arm bearings
WARNING:
Be careful not to apply too much grease to the brake cam shafts. If grease gets on the linings,
brake slippage will result.
Lubricate exposed parts which are subject to rust, with either motor oil or grease whenever the motorcycle
has been operated under wet or rainy conditions.
Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.
MAINTENANCE PROCEDURES
This section describes the service procedures for
each section of Periodic Maintenance.
BATTERY
Inspect initial 1 000 km and Every 4 000 km
The battery must be removed to check the

electrolyte level and specific gravity.
Remove the right frame cover.
Remove battery lead at the battery terminal.
Remove battery lead.
Remove battery from the frame.
Check electrolyte for level and specific gravity. 2
Add distilled water, as necessary, to keep the 1
surface of the electrolyte above the LOWER
LEVEL line but not above the UPPER LEVEL
line .
For checking specific gravity, use a hydrometer to

determine the charged condition.
Hydrometer 09900-28403
Standard specific
1.28 at 20 OC
gravity
An S.G. reading of 1.22 (at 20 OC ) or under means

that the battery needs recharging off the machine:
take it off and charge it from a recharger.
Charging the battery in place can lead to failure of
the regulator/rectifier.
To install the battery, reverse the procedure

described above.
WARNING: Battery
When installing the battery lead wires, fix the
lead first and lead last.
Breather pipe
Make sure that the breather pipe is tightly

secured and undamaged, and is routed as
shown in the figure.
CYLINDER HEAD NUTS, CYLINDER

1
NUTS, EXHAUST PIPE BOLTS AND
NUT
CYLINDER HEAD NUTS

Remove the seat and fuel tank
(Refer to page 3-2) .
Remove the right and left caps of the cylinder
head cover after remove the tachometer cable
( Refer to page 3-5 ).
Remove the cylinder head cover
(Refer to page 3-8) .
Tighten the four 10mm nuts and two 6-mm 2
nuts to the specified torque with a torque
wrench, when engine is cold.
25 -35 N m
10 mm
Tightening (2.5 -3 .5 kg m)
torque 7 - 11 N m
6 mm
(0.7 - 1.1 kg m) 3
When installing cylinder head cover, apply

SUZUKI BOND No.1215 to the mating surface
of cylinder head (Refer to page 3-29).
4
SUZUKI BOND No.1215 99000-31110
CYLINDER NUTS
Tighten the two 6 mm nuts to the specified
torque.
7 - 11 N m
Tightening torque
(0.7 - 1.1 kg m)
EXHAUST PIPE BOLTS AND MUFFLER 5

CLAMP BOLT
Tighten the exhaust pipe bolts and muffler
clamp bolt to the specified torque.
Tightening torque
Exhaust pipe
9 - 12 N m
bolts and muffler
(0.9 - 1.2 kg m)
clamp bolt
AIR CLEANER ELEMENT
Clean Every 3 000 km
If the air cleaner is clogged with dust, intake

resistance will be increased with a resultant
decrease in power output and an increase in fuel
consumption.
Check and clean the element in the following
manner.
Remove the left frame cover.

Remove the screws and take out the air cleaner
element assembly.
Separate the polyurethane foam element from
the element frame.
NOTE:
When installing the air cleaner case cover,
place the "UP" mark upward.
Element
Fill a washing pan of a proper size with 2
nonflammable cleaning solvent. Immerse the 1
element in the cleaning solvent and wash it clean.
Squeeze the cleaning solvent out of the washed
element by pressing it between the palms of
both hands.
Immerse the element in motor oil, and squeeze Non-flammable
Cleaning
the oil out of the element leaving it slightly wet Solvent
with oil.
4 3
NOTE:
Do not twist or wring the element because it
will tear or the individual cells of the element
will be damaged.
Motor oil
CAUTION:
Inspect the element carefully for rips, torn
seams, etc. If any damage is noted, replace
the element.
VALVE CLEARANCE 1
1
Excessive valve clearance results in valve noise 2

and insufficient valve clearance results in valve
damage and reduced power. At the distances
3
indicated above, check and adjust the clearance
to the following specification.
The procedure for adjusting the valve clearance

is as follows:
Remove the seat and fuel tank.
Remove the tachometer cable.
Remove the left cap of the cylinder head cover.
Remove the right cap of the cylinder head cover.
Remove spark plug, valve inspection caps ,
and valve timing inspection plug .
Remove the magneto cover cap and rotate
the magneto rotor with the 14 mm box wrench to
set the piston at (TDC) of the compression
stroke.
(Rotate the rotor until the "l " line on the rotor is
aligned with the center of hole on the crankcase.)
Insert the thickness gauge to the valve stem
end and the adjusting screw on the rocker arm.
Thickness gauge 09900-20803
Valve clearance specifications
IN. 0.04 - 0.07 mm

EX. 0.13 - 0.18 mm
If clearance is off the specification, bring it into

the specified range by using the special tool.
Tappet adjust driver 09917-13210
Reinstall spark plug, valve inspection caps,

cylinder hand cover caps, tachometer cable, valve
timing inspection plug and magneto cover cap.
NOTE:
Valve clearance is be checked when the
engine is cold.
Both the intake and exhaust valves must be
checked and adjusted when the piston is at
Top-Dead-Center (TDC) of the compression
stroke.
COMPRESSION PRESSURE
Inspect initial 1 000 km Every 4 000 km
Refer to page 3-1.
SPARK PLUG
Replace Every 8 000 km
Remove the carbon deposits with a wire or pin and

adjust the spark plug gap to 0.7-0.8 mm,
measuring with a thickness gauge.
When removing carbon deposits, be sure to
observe the appearance of the plug, noting the
color of the carbon deposits. The color observed
indicates whether the standard plug is suitable or
not. If the standard plug is apt to get wet, a hotter
plug should be used. If the standard plug is apt to
overheat (porcelain is whitish in appearance),
replace with a colder one.
NOTE:
"R" type spark plug fitted under some of
specifications and it means that the resistor
is located at the center electrode to prevent 0.7 mm-0.8 mm
radio noise.
NGK CR7E
Hot type
NIPPON DENSO U22ESR-N
NGK CR8E
Standard
NGK CR9E
Cold type
FUEL HOSE
Replace every four years.
Inspect the fuel hose and connections for damage

and fuel leakage.
If any defects are found, the fuel hose must be
replaced.
FUEL FILTER
Clean initial 1 000 km and Every 8 000 km
If the fuel filter is dirty with sediment, fuel will not

flow smoothly and loss in engine power may result.
Clean the filter with non-flammable cleaning
solvent.
ENGINE OIL
Change initial 1 000 km and Every 4 000 km 2

1
The oil should be changed with the engine hot.

The procedure is as follows:
Support the motorcycle by center stand.
Drain the oil by removing the drain plug and
1
filler cap .
Fit the drain plug securely and add fresh oil
through the filler. The engine will hold about
1100 ml of oil.
Use 10W/40 viscosity of oil under API
classification of SF or SG.
Start up the engine and allow it to run for
several seconds at idling speed.
Shut down the engine and wait about one 3
minute. Then check the oil level in the oil level
window . The motorcycle must be in a level,
upright position for accurate measurement. If
the level is below the "L " mark, add oil until the
ENGINE OIL FILTER
Replace initial 1 000 km and Every 4 000 km
Replace the oil filter in the following manner:

Drain engine oil by removing the drain plug.
Remove the three screws securing the filter cap.
Take off the cap, and pull out the filter.
Replace the filter with a new one.

Before installing on the filter, check to be sure
that the O-ring is properly installed. 1
Before putting on the filter cap, check to be sure
that the filter spring and the O-ring are
installed correctly.
Replace the filter cap and tighten the screws
securely.
Pour in engine oil and check the level.
NOTE:
Pour about 1,150 ml of engine oil into the
engine only when changing oil and replacing
oil filter at the same time.
When performing engine overhaul, the
amount of oil to be replenished is 1,350 ml.
CAUTION:
When reassembling the oil filter, make sure 2 3
to check the oil filter installed as shown in
illustration. If the filter is installed improperly,
serious engine damage may result.
OIL PRESSURE
Inspect Every 4 000 km
Refer to page 3-1.
OIL SUMP FILTER
Clean Every 8 000 km
Clean the sump filter screen to remove any foreign

matter that may be collected there. Inspect the
screen to insure that it is free of any sign of damage.
CARBURETOR
IDLING ADJUSTMENT
NOTE:
Make this adjustment when the engine is hot.
Start up the engine and set its speed at 1

anywhere between 1 300 and 1 500 r/min by
turning throttle stop screw .
Engine idle speed 1400 100r/min
A
THROTTLE CABLE PLAY 3
There should be 0.5-1.0 mm play A on the throttle
cable .To adjust the throttle cable play. 2
Tug on the throttle cable to check the amount of
play.
Loosen the two lock nuts and turn the adjuster
in or out until the specified play is obtained.
Secure the lock nuts while holding the adjuster
Throttle cable play A 0.5 - 1.0 mm
CLUTCH
Clutch play should be 4 mm as measured at the

clutch lever holder before the clutch begins to 2
disengage. If the play in the clutch is incorrect, 1 4mm
adjust it in the following way:
Loosen the lock nut and screw the adjuster
on the clutch lever holder all the way in.
Loosen clutch cable adjuster lock nut .
Turn the clutch cable adjuster in or out to
acquire the specified play.
Tighten lock nut while holding the adjuster in 3
4
The clutch cable should be lubricated with a light

weight oil whenever it is adjusted.
DRIVE CHAIN
Inspect and Clean Every 1 000 km
DRIVE CHAIN
Visually inspect the drive chain for the below listed
possible malconditions. (Lift the rear wheel by
placing the center stand, and turn the rear wheel
slowly by hand when the transmission in NEUTRAL.)
Inspect for:
1. Loose pins
2. Damaged rollers
3. Rusted links
4. Twisted or seized links
5. Excessive wear
If any defects are found, the drive chain must be 5
4 3
replaced.
1
Wash the chain with kerosene. If the chain
tends to rust faster, the interval must be
shortened.
After washing and drying the chain, lubricate it
2
with chain lube or gear oil SAE #90.
Check the drive chain for wear and adjust the

chain tension as follows:
Loosen axle nut Ù after pulling out cotter pin
and loosen the lock nut .
Adjust the drive chain carefully by tightening
the adjuster .
CHAIN SAG 10-20mm

Loosen the adjuster until the chain has 10 - 20
mm of sag at the middle between engine and
rear sprockets.
The mark on both chain adjusters must be at
the same position on the scale to ensure that
the front and rear wheels are correctly aligned.
After adjusting the drive chain, tighten the lock
nut and the axle nut Ù securely and lock with
123 19 20 21
CHAIN WEAR
Count out 21 pins on the chain and measure the
distance between. If the distance exceeds
259.4 mm, the chain must be replaced.
Service Limit
Drive chain
259.4 mm
20 pitch length
BRAKERS
Inspect initial 1 000 km and every 4 000 km
UPPER
Replace brake hose every 4 years.
Change brake fluid every 2 years.
LOWER
FRONT BRAKE
Brake fluid level
Support the motorcycle body on the center
stand, and place the handlebars straight.
Check the brake fluid level by observing the
lower limit line on the brake fluid reservoir.
When the level is below the lower limit line,
replenish with brake fluid that meets the
following specification.
Specification
DOT3, DOT4
and Classification
SUZUKI BRAKE FLUID 99000-23021
CAUTION:
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 fluid
for refilling the system, otherwise serious
damage will be caused. Do not use any
brake fluid taken from old or used or
unsealed containers. Never re-use the brake
fluid left over from the last servicing and
stored for long periods.
WARNING:
Brake fluid, if it leaks, will interfere with safe
running and immediately discolor painted
surfaces.
Check the brake hose for cracks and hose
joint for leakage before riding.
Brake pads
Inspect wear situation of brake pads.
Replace the pads with new ones as necessary
(Refer to page 6-20).
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
caliper brake. The presence of air is indicated by
"sponginess" of the brake lever and also by lack of
braking force. Considering the danger to which
such trapped air exposes the machine and rider, it
is essential that, after remounting the brake and
restoring the brake system to the normal condition,
the brake fluid circuit be purged of air in the
following manner:
Fill up the master cylinder reservoir to the
"HIGH"level line .Replace the reservoir cap to
prevent entry of dirt.
Attach a pipe to the caliper bleeder valve, and
insert the free end of the pipe into a receptacle.
Bleeder valve 7 9N m
tightening torque 0.7 0.9 kg m)
Squeeze and release the brake lever several

times in rapid succession, and squeeze the
lever fully without releasing it. Loosen the
bleeder valve by turning it a quarter of a turn so
that the brake fluid runs into the receptacle; this
will remove the tension of the brake lever
causing it to touch the handlebar grip. Then,
close the valve, pump and squeeze the lever,
and open the valve. Repeat this process until
the fluid flowing into the receptacle no longer
contains air bubbles.
NOTE:
Replenish the brake fluid reservoir as
necessary while bleeding the brake system.
Make sure that there is always some fluid
visible in the reservoir.
Close the bleeder valve, and disconnect the pipe.

Fill the reservoir to the "HIGH" level line.
CAUTION:
Handle the brake fluid with care: the fluid
reacts chemically with paint, plastics,
rubber materials, etc.
REAR BRAKE
Bring the brake pedal to a position about 10 mm
(behind the frame). This is effected by turning the
brake pedal stopper Ù after remove the two
screws and take off the right cover. Be sure to
tighten the lock nut securely after setting the bolt.
H
Rear brake height H 10 mm
After adjusting the rear brake height, adjust the

brake pedal travel. First set the pedal at a position
for comfortable riding by turning the brake pedal
stopper Ù , and then adjust the free travel to 20 -
30 mm.
If adjustment is necessary, turn the rear brake
adjuster to obtain the specific play. 1
Brake pedal travel 20 - 30 mm
3
2
Brake lining wear limit

This motorcycle is equipped with brake lining wear
limit indicator on rear brake. As shown in the
illustration at right, at the condition of normal
lining wear, an extended line from the index mark
on the brake camshaft should be within the range
embossed on the brake panel with the brake on. To
check wear of the brake lining, follow the steps
below.
Fist check if the brake system is properly
adjusted. The extension line of the index mark is within the range.
While operating the brake, check to see that the
extension line from the index mark is within the
range on the brake panel.
If the index mark is outside the range as shown
in the illustration at right, the brake shoe assy
should be replaced to ensure safe operation.
The extension line of the index mark is outside of the range.
TIRES
TIRE
Inspect the tires for wear and damage; and check
the tire tread depth as shown. Replace a badly
worn or damaged tire. A tire with its tread worn
down to the limit (in terms of tread depth) must be
replaced.
TIRE TREAD DEPTH SERVICE LIMIT

Front 1.6 mm
Rear 1.6 mm
Check the tire pressure, and examine the valve for

evidence of air leakage.
TIRE PRESSURE
Normal riding
Cold inflation
Sold riding Dual riding
tire pressure
2 2
kPa kg/cm kPa kg/cm
Front 175 1.75 175 1.75
Rear 200 2.00 225 2.25
STEERING
C C
A
Steering stem bearings be adjusted properly for
smooth turning of the handlebars and safe running.
Steering which is too stiff prevents smooth
movement of handlebars.
Steering which is too loose will cause vibration
and damage to the steering bearings. Check to B
see that there is no play in the front fork attachment.
If the play is found, perform steering bearing

adjustment as described in page 6-16 of this manual.
Tightening torque
ITEM
A Handlebars clamp bolts 12 - 20 1.2 - 2.0
B Steering stem head bolts 35 - 55 3.5 - 5.5
Front fork upper

C clamp bolt 20 - 30 2.0 - 3.0
D
Front fork lower
D clamp bolt 25 - 35 2.5 - 3.5
FRONT FORK OIL
Change Every 8 000 km
Remove the front fork (See page 6-4) .

Let out the fork oil (See page 6-8) .
Pour specified amount of oil from the top of the
inner tube.
Specified amount
139 ml
(each tube)
Specification Fork oil #10
Tightening torque
ITEM
Fork top cap 15 - 30 1.5 - 3.0
Front fork upper clamp bolt 20 - 30 2.0 - 3.0
Front fork lower clamp bolt 25 - 35 2.5 - 3.5
CHASSIS AND ENGINE MOUNTING BOLTS AND NUTS
The nuts and bolts listed are important parts, and they must be in good condition for safety.
They must be retightened, as necessary, to the specified torque with a torque wrench.
Tightening torque
ITEM
Front axle nut 36 - 52 3.6 - 5.2
Caliper mounting bolt 25 - 40 2.5 - 4.0
Brake hose union bolt 25 - 35 2.5 - 3.5
Master cylinder bolt 5-8 0.5 - 0.8
Swing arm pivot nut 50 - 80 5.0 - 8.0
Rear shock absorber fitting nut 20 - 30 2.0 - 3.0
Rear axle nut 50 - 80 5.0 - 8.0
Rear torque link bolt 10 - 15 1.0 - 1.5
Rear brake cam lever bolt 5-8 0.5 - 0.8
A A 37 - 45 3.7 - 4.5
Engine mounting bolt
B B 28 - 34 2.8 - 3.4
3
1
4
6 6
9 7
B
8
A
B
ENGINE
CONTENTS
COMPRESSION PRESSURE AND OIL PRESSURE . . . . . . . . . . . 3-1

ENGINE REMOVAL AND REMOUNTING . . . . . . . . . . . . . . . . . . . . . 3-2 3
UPPER END COMPONENTS DISASSEMBLY . . . . . . . . . . . . . . . . . 3-7
UPPER END COMPONENTS INSPECTION
AND SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
UPPER END COMPONENTS REASSEMBLY . . . . . . . . . . . . . . . . . 3-23
LOWER END COMPONENTS DISASSEMBLY . . . . . . . . . . . . . . . . 3-30
LOWER END COMPONENTS INSPECTION
AND SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
LOWER END COMPONENTS REASSEMBLY . . . . . . . . . . . . . . . . . 3-42
3-1 ENGINE
COMPRESSION PRESSURE AND OIL PRESSURE

COMPRESSION PRESSURE
NOTE:
1
* Before testing the engine for compression
pressure, make sure that the cylinder head
nuts and bolts are tightened to specified 2
torque values and valves are properly
adjusted.
* Have the engine warmed up by idling
before testing it.
Ù1 Compression gauge 09915-64510

2 Adapter 09915-63310 OIL PRESSURE
Install the oil pressure gauge in the position
Remove spark plug. shown in the illustration.
Fit the compression gauge Ù and adapter to Warm up the engine as follows.
the plug hole, taking care to make the connection Summer approx. 10 min. at 2 000 r/min.
absolutely tight. Winter approx. 20 min. at 2 000 r/min.
Twist the throttle grip into wide-open position. After the warming up operation, increase the
Crank the engine several times with the starter engine speed to 3 000 r/min, and read the oil
motor, and read the highest gauge indication as pressure gauge
the compression of the cylinder.
Oil pressure
Compression pressure
3 Oil pressure gauge 09915-74510
Standard Limit
2
Above 0.1 kg/cm
10 - 14 kg/cm 2
8 kg/cm 2
Below 0.3 kg/cm 2 at 3 000 r/min.
A low compression pressure may indicate any of

the following malfunctions:
Excessively worn cylinder wall.
Worn piston or piston rings.
Piston rings stuck in the grooves.
Poor seating contact of valves.
Defective cylinder head gasket.
3
When the compression pressure noted is down to
or below the limit indicated above, the engine
must be disassembled, inspected and repaired as
required.
If the pressure is too low, it means that the oil
pump is internally worn or otherwise defective
and the complete oil pump unit needs to be
replaced.
ENGINE 3-2
ENGING REMOVAL AND REMOUNTING

ENGING REMOVAL
Before taking the engine out of the frame,
thoroughly clean the engine with a suitable
cleaner.
The procedure of engine removal is sequentially
explained in the following steps.
Take off the right and left frame covers.
Disconnect the and lead wires of battery.
CAUTION:
First, disconnect the lead wire.
Turn the fuel cock lever "OFF" position.

Take off the fuel hose.
Remove the seat by using the key.
Take off the fuel tank by removing the mounting

bolts and discounnect the coupler of fuel
capacity sensor.
3-3 ENGINE
Take off the clutch cable by removing the clutch

lever bolt and adjuster lock nut.
Take off the breather pipe.
Disconnect the couplers of generator and gear

position indicator.
Loosen the throttle cable adj u ster lock nuts,

and take off the throttle cable.
Remove the carburetor by unscrewing the

clamp screws.
ENGINE 3-4
Remove gear shift lever.

Take off the engine sprocket cover.
Take off the drive chain by removing the clip.

Direction of travel
Disconnect the ground wire from the crankcase.
Disconnect the lead wire of starter motor.

Take off the spark plug cap.
3-5 ENGINE
Remove the tachometer cable.

Take off the left and right caps of the cylinder
head cover.
Remove the exhaust pipe nuts and muffler

mounting bolt, then take off the muffler.
Remove engine mounting bolts, swing arm pivot

nut, footrest bar bolts and brackets.
Use both hands, and lift the engine from the
frame.
NOTE:
The engine must be taken out from the right
side.
CAUTION:
Be careful not to draw out the swing arm
pivot shaft completely from the left side
swing arm pivot hole. Insert the shaft or rod
into the right side pivot hole from the right
side of the frame to keep the alignment of the
frame holes and swing arm pivot holes.
ENGINE 3-6
ENGINE REMOUNTING After remounting the engine, following adjust-

ments are necessary.
The engine can be mounted in the reverse order of
removal. * Throttle cable play (Page: 2 -10 )
Temporarily fasten the engine mounting bracket * Clutch cable (Page: 2 - 10)
before inserting the engine mounting bolts. * Drive chain (Page: 2 - 11)
* Idling speed (Page: 2 - 10)
NOTE:
The engine mounting nuts are self-lock nuts.
Once the nut has been removed, it is no
longer of any use. Be sure to use new nuts
and tighten them to the specified torque.
Tightening torque for engine mounting bolts

M8L50
37 - 45 N m
L: (80 mm)
(3.7 - 4.5 kg m)
M8L80
28 - 34 N m M8
The Others
(2.8 - 3.4 kg m) 2.8-3.4kg.m
Tightening the exhaust pipe nuts and muffler

M8L88
mounting bolt to specified torque.
M8
3.7-4.5kg.m
Exhaust 9 - 12 N m M8
2.8-3.4kg.m
pipe bolts (0.9 - 1.2 kg m)
Pour 1.35 L of engine oil SAE10W/40 graded SF

or SG into the engine after overhauling engine.
Start up the engine and allow it run for several
seconds at idle speed. About one minute after
stopping engine, check oil level.
If the level is below the "L " mark, add oil with the
level reaches the "F" mark.
Notch Mark
Installing position for clutch release arm
Align the release arm slit surface with the notch
mark on the release cam shaft. Slit
3-7 ENGINE
UPPER END COMPONENTS DISASSEMBLY

CYLINDER HEAD COVER
AND CYLINDER HEAD
NOTE:
* If top end repair only is being performed,
it is not necessary to remove the engine
from the frame.
* As already noted, seat, fuel tank, frame
covers etc. must be removed.
Drain engine oil.
Remove magneto cover cap and inspection

plug.
Remove cam chain tensioner.
Remove valve inspection caps and spark plug.

ENGINE 3-8
Bring the piston to top dead center.
NOTE:
When removing cylinder head cover, piston
must be at top dead center on compression
stroke.
First, remove the tachometer sleeve securing

6
screw, and then pull out the tachometer driven 8
Do not
gear shaft with sleeve. remove 9 4
Next, loosen the cylinder head cover bolts in the 1
10
order indicated in the illustration and remove 3
bracket comps of cylinder head cap.
Detach the cylinder head cover. 5 7 2
NOTE:
When removing cylinder head cover, do not
remove conically recessed top bolts.
Detach the camshaft end cap.

Flatten camshaft sprocket lock washer.
Remove camshaft sprocket bolts and detach
the camshaft.
NOTE:
The cam chain tensioner bolt Ù is to be
removed only when disassembling the engine.
CAUTION:
Do not drop camshaft drive chain, pin and
sprocket into crankcase. 1
Loosen the six cylinder head nuts diagonally,

then detach the cylinder head.
NOTE:
If it is difficult to remove the cylinder head,
gently pry it off while tapping the finless
portion of the cylinder head with a plastic
hammer. Be careful not to break the fins.
3-9 ENGINE
Remove cylinder base nuts and cylinder.
CAUTION:
If tapping with plastic hammer is necessary.
do not break the fins.
Remove rocker arm shaft set bolts.
Pull out the rocker arm shafts with pliers.

ENGINE 3-10
Compress the valve spring by using the special

tool.
Valve lifter 09916-14510
Take off the valve cotters from valve stem.
Tweezers 09916-84510
Take out the valve spring retainer, inner spring

and outer spring.
Pull out the valve from the other side.
Remove oil seal, using long-nose pliers.

Take out the spring seat.
CAUTION:
Removed oil seal should be replaced with a
new one.
3-11 ENGINE
Remove valve guide by using the special tool.
Valve guide remover 09916-44910
CAUTION:
Only oversize valve guide is available as a
spare part.
Place a clean rag over the cylinder base to

prevent piston pin circlip from dropping into
crankcase and then, remove the piston pin
circlip with long-nose pliers.
Remove piston pin.
Piston pin puller 09910-34510

ENGINE 3-12
UPPER END COMPONENTS INSPECTION AND SERVICING

CYLINDER HEAD COVER
DISTORTION
After removing sealant (SUZUKI BOND No.1215)
from the fitting surface of the cylinder head cover,
place the cylinder head cover on a surface plate
and check for distortion with a thickness gauge.
Check points are shown in Fig.
Service limit 0.05 mm
If the distortion exceeds the limit, replace the

cylinder head cover and cylinder head.
ROCKER ARM SHAFT O.D.

Measure diameter of rocker arm shaft.
Micrometer
09900-20205
(0 25 mm)
Standard 11.966 11.984 mm
ROCKER ARM I.D.

When checking the valve rocker arm, the inside
diameter of the valve rocker arm and wear of the
camshaft contacting surface should be checked.
Standard 12.000 12.018 mm
CAMSHAFT
The camshaft should be checked for runout and
also for wear of cams and journals if the engine
has been noted to produce abnormal noise or
vibration or a lack of output power. Any of these
malconditions could be caused by a worn
camshaft.
3-13 ENGINE
CAMSHAFT CAM WEAR

Worn-down cams are often the cause of mistimed
valve operation resulting in reduced output power.
The limit of cam wear is specified for both intake
and exhaust cams in terms of cam height H ,
which is to be measured with a micrometer.
Replace camshafts if found it worn down to the
limit.
Micrometer
09900-20202
(25 50 mm)
Cam height
Height H service limit
Intake cam 33.350 mm
Exhaust cam 33.000 mm
CAMSHAFT JOURNAL WEAR

Measure the outside diameter of camshaft journal.
Replace either the cylinder head set or the cam
shaft if the O.D. is incorrect.
Micrometer
09900-20205
(0 25 mm)
Camshaft journal
21.959 21.980 mm
O.D.standard
CAMSHAFT RUNOUT
Measure the runout with a dial gauge. Replace the
camshaft if the runout exceeds the limit.
Magnetic stand 09900-20701

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

ENGINE 3-14
CYLINDER HEAD DISTORTION

Decarbon combustion chamber.
Check the gasketed surface of the cylinder head
for distortion with a straightedge and thickness
gauge, taking a clearance reading at several
places as indicated. If the largest reading at any
position of the straightedge exceeds the limit,
replace the cylinder head.
VALVE FACE WEAR

Measure the thickness T and, if the thickness is
found to have been reduced to the limit, replace
the valve.
NOTE:
Visually inspect each valve for wear of its
seating face. Replace any valve with an
abnormally worn face.
VALVE STEM RUNOUT

Support the valve with "V" blocks, as shown, and
check its runout with a dial gauge. The valve must
be replaced if the runout exceeds the limit.

Dial gauge (1/100 mm) 09900-20606
V-block (100 mm) 09900-21304
VALVE HEAD RADIAL RUNOUT

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

3-15 ENGINE
VALVE STEM WEAR

If the valve stem is worn down to the limit, when
measured with a micrometer, replace the valve.
Micrometer
09900-20205
(0 25 mm )
Valve stem O.D.

Standard
IN. 4.975-4.990 mm
EX. 4.955-4.970 mm
Inspect valve stem end face for pitting and wear.
CAUTION:
* This remedy is permissible where the
length will not be reduced to less than 2
mm. If this length becomes shorter than 2
mm, then the valve must be replaced.
* After installing the valve whose stem end
has been ground off as above, check that
the face of valve stem end is above the
cotter .
VALVE GUIDE INSTALLATION

Re-finish the valve guide holes in cylinder head
with a 10.8 mm reamer and handle.
10.8 mm reamer 09916-34580

Handle 09916-34542
Fit a ring to each valve guide. Be sure to use

new rings and valve guides. Use of rings and
valve guides removed in disassembly must be
avoided.
ENGINE 3-16
Oil the stem hole, in each valve guide and drive

the guide into the guide hole using the valve
guide installer.
Valve guide installer 09916-44310
After fitting all valve guides, re-finish their

guiding bores with a 5.0 mm reamer. Be sure to
clean and oil the guides after reaming.
5.0 mm reamer 09916-34570

Reamer Handle 09916-34542
Install valve spring lower seat . Be careful not

to confuse the lower seat with the spring
retainer .
Lubricate valve stem seal with oil, and press-fit

the seal into position with a finger tip.
CAUTION:
Do not reuse the oil seals.
3-17 ENGINE
VALVE SEAT WIDTH

Coat the valve seat with prussian blue uniformly.
Fit the valve and tap the coated seat with the
valve face in a rotating manner, in order to
obtain a clear impression of the seating contact.
In this operation, use the valve lapper to hold
the valve head.
The ring-like dye impression left on the valve

face must be continuous without any break. In
addition, the width of the dye ring, which is the
visualized seat "width", must be within the
specification.
Valve seat width

STD. W 0.9 1.1 mm
If either requirement is not met, correct the seat by

servicing it as follows.
VALVE SEAT SERVICING

The valve seats for both intake and exhaust valves
are machined to four different angles. (The seat INTAKE EXHAUST
O O O
contact surface is cut 45 ). 60 45
O
30 O 15
O
INTAKE SINDE EXHAUST SINDE 45
45 O N-122 or N-116 45 O N-122 or N-116
Valve seat Valve seat
O O
30 N-126 15 N-121 or N-120
O
60 N-111
Vale seat cutter (N-121) 09916-20610

Solid pilot (N-100-5.0) 09916-24311
Vale seat cutter set 09916-21110
NOTE:
The valve seat contact area must be inspected
after each cut.
ENGINE 3-18
1. Insert with a slight rotation, the solid pilot that

gives a snug fit. The shoulder on the pilot
should be about 10 mm from the valve guide.
O
2. Using the 45 cutter, descale and cleanup the
seat with one or two turns.
3. Inspect the seat by the previous seat width
measurement procedure. If the seat is pitted or
burned, additional seat conditioning with the
O
45 cutter is required.
CAUTION:
Cut the minimum amount necessary from the
seat to prevent the possibility of the valve
stem becoming too close to the rocker arm
for correct valve contact angle.
If the contact area is too high or too wide, use the

O O O
15 cutter (for exhaust side) and 30 /60 cutters
(for intake side) to lower and narrow the contact
area.
If the contact area is too low or too narrow, use the
45 O cutter to raise and widen the contact area.
4. After the desired seat position and width is

O
achieved, use the 45 cutter very lightly to clean
up any burrs caused by the previous cutting
operations.
CAUTION:
DO NOT use lapping compound after the
final cut is made. The finished valve seat
should have a velvety smooth finish and not
a highly polished or shiny finish. This will
provide a soft surface for the final seating of
the valve which will occur during the first few
seconds of engine operation.
5. Clean and assemble the head and valve

components. Fill the intake and exhaust ports
with gasoline to check for leaks. If any leaks
occur, inspect the valve seat and face for burrs
or other things that could prevent the valve from
sealing.
WARNING:
Always use extreme caution when handling
gasoline.
NOTE:
Be sure to adjust the valve clearance after
reassembling the engine.
3-19 ENGINE
VALVE SPRINGS
Check the springs for strength by measuring their
free lengths and also the force required to
compress them. If the limit indicated below is
exceeded by the free length reading or if the
measured force does not fall within the range
specified, replace with a new spring as a set .
Valve spring free length

Spring Service limit
INNER 31.2 mm
OUTER 33.6 mm
3.77-4.43 kg
Valve spring tension 26.78 mm

Spring Standard
INNER 3.77 4.43 kg/26.78 mm
OUTER 8.86 10.4 kg/29.78 mm
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.
CYLINDER BORE
Measure the cylinder bore diameter at six places.
If any one of the measurements exceeds the limit,
replace the cylinder.
Cylinder gauge set 09900-20508

ENGINE 3-20
PISTON DIAMETER
Using a micrometer, measure the piston outside
diameter at the place 10 mm from the skirt end as
shown in Fig. If the measurement is less than the
limit, replace the piston.
Micrometer
(50 75 mm) 09900-20203
NOTE:
Using a soft-metal scraper, decarbon the
crown of the piston. Clean the ring grooves
similarly.
PISTON-CYLINDER CLEARANCE
As a result of the above measurement, if the
piston to cylinder clearance exceeds the limit
shown in the table below, rep l ace both the cylinder
a n d piston.
PISTON RING-GROOVE CLEARANCE

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

Piston ring Service limit
1st 0.180 mm
2nd 0.150 mm
3-21 ENGINE
Piston ring groove width Piston ring thickness

Piston ring Service limit Piston ring Service limit
1st 1.01 1.03 mm 1st 0.97-0.99 mm
2nd 1.01 1.03 mm 2nd 0.97-0.99 mm
Oil 2.01 2.03 mm
PISTON RING FREE END GAP AND

PISTON RING END GAP
Before installing piston rings, measure the free
end gap of each ring using vernier calipers.
Next, fit the ring in the cylinder, and measure each
ring end gap using a thickness gauge.
If any ring has an excess end gap, replace the ring.
Piston ring free end gap
Vernier calipers 09900-20101
1st R 5.6 mm
2nd R 4.8 mm
Piston ring end gap
1st and 2nd 0.50 mm

ENGINE 3-22
PISTON PIN AND PIN BORE

Using a caliper gauge, measure the piston pin
bore inside diameter, and using a micrometer
measure the piston pin outside diameter. If the
difference between these two measurements is
more than the limits, replace both piston and
piston pin.
Micrometer
09900-20205
(0 25 mm)
Piston pin O.D.
Piston pin bore
CONROD SMALL END I.D.

Using a caliper gauge, measure the conrod small
end inside diameter.
If the conrod small end bore inside diameter

exceeds the limit, replace conrod.
3-23 ENGINE
UPPER END COMPONENTS REASSEMBLY

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

Top ring and 2nd ring differ in the shape of ring
face and the face of top ring is chrome-plated
whereas that of 2nd ring is not. The color of 2nd
ring appears darker than that of the top one.
Top and 2nd rings have the letter " R" marked on
the top. Be sure to bring the marked side to the top
when fitting them to the piston.
Position the gaps of the three rings as shown.

Before inserting piston into the cylinder, check
that the gaps are so located.
ENGINE 3-24
PISTON
The following are reminders for piston installation:
Rub a small quantity of SUZUKI MOLY PASTE
onto the piston pin.
Place a clean rag over the cylinder base to
prevent piston pin circlip from dropping into
crankcase, and then fit the piston pin circlip with
long-nose pliers.
SUZUKI MOLY PASTE 99000-25140
CAUTION:
Use a new piston pin circlip to prevent circlip
failure which will occur with a bent one.
When fitting the piston, turn hole on the piston

head to exhaust side.
CYLINDER
Before mounting the cylinder, oil the big end and
small end of the conrod and also the sliding
surface of the piston.
Fit dowel pins to crankcase and then fit gasket.
CAUTION:
To prevent oil leakage, do not use the old
gasket again, always use new one.
Hold each piston ring with the piston rings

properly spaced and insert them into the cylinder.
Check to insure that the piston rings are
properly inserted into the cylinder.
NOTE:
When mounting the cylinder, after attaching
camshaft drive chain , keep the camshaft
drive chain taut. The camshaft drive chain
must not be caught between cam drive chain
sprocket and crankcase when crankshaft is
rotated.
NOTE:
There is a holder for the bottom end of the
cam chain guide cast in the crankcase. Be
sure that the guide is inserted properly or
binding of the cam chain and guide may
result.
3-25 ENGINE
VALVE AND SPRING

Insert the valves, with their stems coated with
SUZUKI MOLY PASTE all around and along the
full stem length without any break.
Similarly oil the lip of the stem seal.
CAUTION:
When inserting each valve, take care not to
damage the lip of the stem seal.
Install valve springs, making sure that the

close-pitch end of each spring goes in first to
rest on the head. The coil pitch of both the inner
and outer springs vary: the pitch decreases
from top to bottom, as shown in the illustration.
Fit valve spring retainer, compress spring with a

valve lifter and insert cotters.
ENGINE 3-26
CYLINDER HEAD
Fit dowel pins to cylinder head and then,
attach new gasket to cylinder head.
CAUTION:
Use a new cylinder head gasket to prevent oil
leakage. Do not use the old gasket.
Copper washers and cap nuts are used to

secure the cylinder head.
With the head snugly seated on the cylinder,

secure it by tightening the nuts diagonally.
Tighten each nut to the torque value specified
below:
Cylinder head nuts tightening torque

25 N m
8 mm Diam (2.5 .5 kg m)
7 11 N m
6 mm Diam (0.7 1.1 kg m)
After tightening the cylinder head nuts to the

specified torque, tighten the cylinder base nuts
to the specified torque.
Cylinder base 7 11 N m
nuts tightening
torque (0.7 1.1 kg m)
3-27 ENGINE
CAMSHAFT
Align the mark on magneto rotor with the index
mark on the crankcase keeping the camshaft
drive chain pulled upward.
CAUTION:
If crankshaft is turned without drawing the
camshaft drive chain upward. the chain will
be caught between crankcase and cam chain
drive sprocket.
NOTE:
Apply grease on the cam sprocket locating
pin and install the pin into the camshaft.
Engage the chain on the cam sprocket with the

locating pin hole at just past top position.
NOTE:
Do not rotate magneto rotor while doing this.
When the sprocket is not positioned
correctly, turn the sprocket. When installing
the camshaft into the cam sprocket, pay
attention not to dislodge the locating pin or it
may fall into the crankcase.
Align the marks on the camshaft so it is parallel

with the surface of the cylinder head.
Fit lock washer so that it is covering the locating
pin.
Apply THREAD LOCK SUPER "1303B" to the
bolts and tighten the cam sprocket.
THREAD LOCK SUPER

99000-32030
"1303B"
10 13 N m
Tightening torque
(1.0 1.3 kg m)
ENGINE 3-28
Bend up he washer tongue positively to lock the

bolts.
Apply SUZUKI MOLY PASTE to the camshaft

journal and place camshaft on cylinder head.
VALVE ROCKER ARM AND SHAFT

Apply SUZUKI MOLY PASTE to the rocker arms
and shafts.
Place the spring and the wave washer and arm
in the exhaust side.
Place the wave washer and arm in the inlet side.
After inserting the shafts, tighten the set bolts.
CAUTION:
* Use a new O-ring on the rocker arm shafts
to prevent oil leakage.
* Use a new gasket on the set bolts to
prevent oil leakage.
3-29 ENGINE
CYLINDER HEAD COVER

Thoroughly wipe off oil from the fitting surfaces
of cylinder head.
Fit the two dowel pins to the cylinder head side.
Uniformly apply SUZUKI BOND No.1215 to the
cylinder head surface. Dowel Pin
SUZUKI BOND
99000-31110
No.1215
NOTE:
Do not apply SUZUKI BOND No.1215 to the
camshaft end cap.
Fit a gasket to head cover bolt correctly as

shown in Fig.
CAUTION:
Use only new gasket. To prevent oil leakage.
NOTE:
When tightening the cylinder head cover
bolts, position must be at top dead center on
compression stroke.
Lightly tighten the cylinder head cover bolts

diagonally and then, if everything is satisfactory,
tighten securely with a torque wrench to the
specified torque.
Tightening 9 10 N m
torque (0.9 1.0 kg m)
Apply engine oil to the tachometer driven gear

shaft and then, insert together with sleeve and
tighten the set screw.
CAM DRIVE CHAIN TENSIONER

Install cam drive chain tensioner following the
procedure below.
Remove the lock bolt , and spring .
Fully insert push rod into the chain tensioner
by lift the pawl.
Mount the chain tensioner on the cylinder.
Install and tighten the lock nut and spring into
the chain tension.
VALVE CLEARANCE
After tightening the head cover bolts, check and
adjust the valve clearance. Refer to page 2-6
for procedures.
ENGINE 3-30
LOWER END COMPONENTS DISASSEMBLY

MAGNETO ROTOR
Remove magneto cover bolts and detach
magneto cover.
Loosen and remove the starter motor mounting

bolts.
Take off the starter motor.
Remove the starter idle gear.
Remove magneto rotor nut.
Rotor holder 09930-44511
NOTE:
Do not allow camshaft drive chain to be
caught between crankcase and camshaft
drive sprocket.
3-31 ENGINE
Remove magneto rotor and key.
Rotor remover
09930-30180
attachment
Slide shaft 09930-30102
Remove starter clutch gear.
Remove cam drive chain.
Remove roller , spring and push piece

from starter clutch.
Clamp the rotor with a vise taking care not to

damage it and remove the three allen bolts
using th 5 mm "T" type hexagon wrench.
"T" type hexagon

019911-73730
wrench (5 mm)
ENGINE 3-32
CLUTCH
Remove clutch cover bolts and oil filter cap
bolts, and detach clutch cover by tapping with a
plastic hammer.
Remove clutch spring mounting bolts

diagonally while holding the primary driven gear,
and remove clutch pressure plate.
Conrod holder 09910-20116
After removal of clutch drive and driven plates,

flatten the lock washer and remove the clutch
sleeve hub nut by using the special tool.
Clutch sleeve hub

09920-53710
holder
Take off the sleeve hub with the primary driven

gear assy.
3-33 ENGINE
OIL PUMP DRIVE GEAR, DRIVEN GEAR

AND PRIMARY DRIVE GEAR
Flatten the lock washer, then remove the nut,
lock washer and oil pump drive gear.
CAUTION:
This is a left-hand thread nut.
Remove oil pump driven gear, then remove

primary drive gear and key.
OIL PUMP
Remove oil pump mounting screws and take off
oil pump body.
GEAR SHIFTER
To remove cam driven gear, first remove gear
shifting shaft, and loosen pawl lifter and cam
guide screws with a impact driver.
NOTE:
When removing cam driven gear, do not lose
gear shifting pawl , pin and spring .
ENGINE 3-34
DRIVE SHAFT RETAINER

Remove the drive shaft retainer circlip by using
snap ring pliers.
Snap ring pliers 09900-06107
GEAR POSITION SWITCH

Remove gear position switch.
NOTE:
When removing gear position switch, do not
lose contact and spring.
ENGINE SPROCKET
Flatten the lock washer, then remove the
sprocket nut by using the special tool.
Rotor and
09930-40113
sprocket holder
CRANKCASE
Remove sump filter cap and neutral cam
stopper.
3-35 ENGINE
Remove sump filter.
Remove crankcase securing bolts.
Separate the crankcase into 2 parts, right and

left with crankcase separating tool.
Crankcase
09920-13120
separating tool
Fit the crankcase separating tool, so that the

tool plate is parallel with the end face of the
crankcase.
CAUTION:
The crankshaft and transmission
components must remain in the left
crankcase half. This is necessary because
the gear shifting cam stopper is mounted on
the left crankcase half and will be damaged if
the transmission components remain in the
right half.
ENGINE 3-36
TRANSMISSION
Remove gear shifting cam stopper spring.
Draw out gear shifting fork shafts and take off

forks.
Remove clusters of gears and gear shifting cam.
CRANKSHAFT
Remove crankshaft by using crankshaft rem o ver.
Crankshaft remover 09920-13120

3-37 ENGINE
OIL SEAL AND BEARING

Remove retainers, oil seals and bearings.
Oil seal remover 09913-50121
Bearing puller 09923-73210
09940-53311
09924-84510
Bearing installer
09913-75820
09913-80112
ENGINE 3-38
LOWER END COMPONENTS INSPECTION AND SERVICING
CONROD DEFLECTION AND CONROD

BIG END SIDE CLEARANCE
Wear on the big end of the conrod can be
estimated by checking the movement of the small
end of the rod. This method can also check the
extent of wear on the parts of the conrod's big end.
Push the big end of the conrod to one side and

measure its side clearance with a thickness gauge.
Standard Service limit
0.10 0.45 mm 1.00 mm
Where the limit is exceeded, replace crankshaft

assembly or reduce the deflection and the side
clearance to within the limit by replacing the worn
parts conrod, big end bearing, crankpin and
thrust washers, etc. (Refer to the SERVICE DATA)
CRANKSHAFT RUNOUT
Support the crankshaft with "V" blocks as shown,
with the two end journals resting on the blocks.
Position the dial gauge, as shown, and rotate the
crankshaft slowly to read the runout.
Correct or replace the crankshaft if the runout is
greater than the limit.

3-39 ENGINE
CLUTCH DRIVE PLATE

Measure the thickness and claw width of each
drive plate with vernier calipers. Replace drive
plates found to have worn down to the limit.
Item Standard Limit

Thickness 2.9 3.1 mm 2.6 mm
Claw width 11.8 12.0 mm 11.0 mm
CLUTCH DRIVEN PLATE

Measure each driven plate for distortion with a
thickness gauge. Replace driven plates which
exceed the limit.
CLUTCH SPRING FREE LENGTH

Measure the free length of each coil spring with a
vernier calipers, and determine the elastic
strength of each. If any one of springs is not within
the limit, replace all the springs at a time.

ENGINE 3-40
CLUTCH RELEASE BEARING

Inspect the release bearing for any abnormality,
particularly cracks, to decide whether it can be
reused or should be replaced.
Smooth engagement and disengagement of the
clutch depends much on the condition of this
bearing.
SHIFTING FORK AND GEAR

Using a thickness gauge, check the shifting fork
clearance in the groove of its gear. If the clearance
limit is exceeded by any of the three gears,
determine whether the gear or the gear shifting
fork should be replaced by measuring the
thickness and groove width.
Item Standard Limit

Shifting fork
to groove 0.10 0.30 mm 0.50 mm
clearance
Shifting fork groove width

No.1
& 5.0 5.1 mm
Standard No.2
No.3 5.5 5.6 mm
Shifting fork thickness

No.1
& 4.8 4.9 mm
Standard No.2
No.3 5.3 5.4 mm

3-41 ENGINE
PRIMARY DRIVEN GEAR

1
Primary dr i ven gear is composed as shown.
2
3
ÙPrimary driven gear Rivet
4
Damper Clutch housing 5
Plate
If the internal damper wears, play is generated
between gear and housing, causing abnormal
noise. If the play is extreme, replace the primary
driven gear assembly with a new one.
CAM CHAIN 20-PITCH LENGTH

Pull the chain tight to remove any slack, then 123 19 20 21
using vernier calipers, measure the 20-pitch (21
pins) length of cam chain. If it measures more than
the limits, replace the cam chain.
CRANKCASE BEARING
Inspect the play of crankcase bearing inner race Play
by hand while fixing it in the case.
Play
Rotate the inner race by hand to inspect for an
abnormal noise and a smooth rotation. Replace
the bearing if there is something unusual.
STARTER CLUTCH BEARING

I n s p e c t t h e b e a r i n g f o r a n y a b n o r m a l i t y,
particularly cracks, to decide whether it can be
reused or should be replaced.
ENGINE 3-42
LOWER END COMPONENTS REASSEMBLY
CRANKSHAFT
Decide the width between the webs referring to When mounting the crankshaft in the crankcase,
the figure below when rebuilding the crankshaft. it is necessary to pull its left end into the
crankcase.
STD
53.0 0.1 mm Crankshaft installer 09910-32812
width between webs
53.0 0.1 mm
3-43 ENGINE
CAUTION:
Never fit the crankshaft into the crankcase
by striking it with a plastic hammer.
Always use the special tool, otherwise
crankshaft alignment accuracy will be affected.
TRANSMISSION
CAUTION:
* Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded and a
new circlip 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 completely seated in its groove and securely
fitted.
ENGINE 3-44
Washers and circlips thickness

A A 1.2 mm (0.05 in) D 0.5 mm(0.02 in)
B 1.0 mm (0.04 in)
C 1.0 mm(0.04 in)
C A A D D A B B
NOTE:
When reassembling the bearing retainer, apply a small quantity of THREAD LOCK "1342" to the
threaded parts of the bearing retainer screws.
In reassembling the transmission, attention must be given to the locations and positions of
washers and circlips. The cross sectional view given here will serve as a reference for correctly
mounting the gears, washers and circlips.
COUNTERSHAFT
Mounting 2nd drive gear
Press-fit 2nd drive gear onto the counter shaft.
Before reassembling, coat the internal face of
the 2nd drive gear with THREAD LOCK SUPER
"1303B " and install it so that the length A as
shown in Fig.
THREAD LOCK A
99000-32030
SUPER "1303B"
THREAD LOCK
99000-32050
1342
NOTE:
* This procedure may be performed only
Countershaft
twice before shaft replacement is required.
length 88.0~88.2 mm
(Low to 2nd) A
3-45 ENGINE
GEAR SHIFTING CAM AND FORK
Fit the gear shifting cam on the crankcase.

Position the cam as shown in Fig. so that the
gear shifting fork can be installed easily.
ENGINE 3-46
NOTE:
Two kinds of gear shifting forks, Ù and are
used. They resemble each other very closely in
external appearance and configuration.
Carefully examine the illustration for correct
installing positions and directions. 1 2
After cam stopper and gear shifting forks have

been fitted, hook cam stopper spring onto the
crankcase.
3-47 ENGINE
CRANKCASE
When reassembling the crankcase pay attention
to the following.
Coat SUZUKI SUPER GREASE "A" to the lip of
oil seals.
Remove sealant material on the fitting surfaces
of right and left halves of crankcase and thor-
oughly remove oil stains.
Fit dowel pins on the left half.
Apply engine oil to the big end of the crankshaft
conrod and all parts of the transmission gears.
Apply SUZUKI BOND No.1215 (99000-31110)
uniformly to the fitting surface of the left half of
the crankcase, and after waiting a few minutes,
fit the right half on the left half.
SUZUKI SUPER
99000-25010
GREASE "A"
SUZUKI BOND
99000-31110
No.1215
After the crankcase bolts have been tightened,

check if driveshaft and countershaft rotate
smoothly.
If a large resistance is felt to rotation, try to free

the shafts by tapping the driveshaft or
countershaft with a plastic hammer as shown in
Fig.
ENGINE 3-48
GEAR SHIFTING CAM DRIVEN GEAR

When installing the gear shifting pawls into the
cam driven gear. The large shoulder A must face
to the outside as shown. A
A
Next, install cam guide and pawl lifter, Apply a

small quantity of THREAD LOCK "1342" to the
threaded parts of the securing screws.
THREAD LOCK
99000-32050
"1342"
GEAR SHIFTING SHAFT

Install the gear shifting shaft. Match the center
teeth of the gear on the shifting shaft with the
center teeth on the shifting driven gear as
shown.
NOTE:
After the cam driven gear, cam guide, gear Top
shifting shaft and neutral cam stopper have 4th

been fitted, confirm that gear change is 3rd
normal while turning the countershaft and
2nd
driveshaft. If gear change is not obtained, it
means that assembly of gears or installation N
of gear shifting fork is incorrect. If this is the
case, disassemble and trace the mistake. Low
PRIMARY DRIVE GEAR AND OIL PUMP

Fit key in the key slot on the crankshaft, and
install the primary drive gear.
3-49 ENGINE
Before mounting the oil pump, apply engine oil

to the sliding surfaces of the case, outer rotor,
inner rotor and shaft.
Apply a small quantity of THREAD LOCK
"1342" to the threaded parts of oil pump
mounting screws.
THREAD LOCK
99000-32050
"1342"
Tighten the oil pump mounting screws.
NOTE:
After mounting the oil pump in the crankcase,
rotate the pump gear by hand to see if it
turns smoothly.
After checking the oil pump, install the oil pump

drive gear, lock washer and nut, tighten it with a
torque wrench to the specified torque and bend
up the washer.
NOTE:
This is a left-hand thread nut. Bend up
40 - 60 N m
Tightening torque
(4.0 - 6.0 kg m)
DRIVE SHAFT RETAINER

Install the washer and circlip.

ENGINE 3-50
CLUTCH
1.5 mm
2.0 mm
Install the clutch camshaft by positi o ning the

face to right side.
Install the oil seal by using the 17 mm socket.
Tighten the oil seal retainer screw.

3-51 ENGINE
Assemble the clutch, in the reverse order of

disassembly. Pay attention to the following points.
When inserting spacer on countershaft, apply a
small quantity of engine oil to both inside and
outside of the spacer.
Tighten clutch sleeve hub nut using the special
tool to the specified torque;
Clutch sleeve hub

09920-53710
holder
Tightening 30 - 50 N m
torque (3.0 - 5.0 kg m)
Be sure to lock the nut by firmly bending the

tongue of the washer.
Install drive plates and driven plates to the

sleeve hub.
Insert push rod in the countershaft.
Cam side Push Piece

side
Longer Shorter
Tighten clutch spring bolts diagonally.

ENGINE 3-52
Clutch release screw adjustment

Loosen the lock nut, and turn in the release
screw to feel high resistance.
From that position, turn out the release screw
1/4 - 1/2 turn, and tighten the lock nut.
1/4
When reassembling the clutch cover, fit a

gasket to correctly position as shown in Fig.
CAUTION:
Do not use the old gasket to prevent oil
leakage.
OIL SUMP FILTER

Wash the sump filter with cleaning solvent, and
then blow compressed air through it to dry off
solvent.
After mounting the sump filter, fit the cap and
tighten it.
Front mark
CAM DRIVE CHAIN

Engage the chain on the sprocket.
3-53 ENGINE
STARTER CLUTCH
Apply THREAD LOCK SUPER "1303B" to allen

bolts and tighten with specified torque.
THREAD LOCK
99000-32030
SUPER "1303B"
"T" type hexagon

wrench (5 mm) 09911-73730
15 - 20 N m
Tightening torque
(1.5 - 2.0 kg m)
MAGNETO ROTOR
Fit key in the key slot on the crankshaft.
Install the magneto rotor.
Apply a small quantity of THREAD LOCK
SUPER "1305" to the threaded parts of
crankshaft.
Tighten magneto rotor nut to the specified
torque.
THREAD LOCK
99000-32100
SUPER "1305"
Rotor holder 09930-44511
30 - 40 N m
Tightening torque
(3.0 - 4.0 kg m)
ENGINE 3-54
STARTER IDLE GEAR AND MOTOR

Install the starter idle gear.
Install the starter motor.
DRIVESHAFT OIL SEAL AND

Oil seal
ENGINE SPROCKET
CAUTION:
O-ring
* Always replace the driveshaft oil seal with
a new one every disassembly to prevent
oil leakage. Also grease the oil seal lip. On
installation, refer to Fig. for correct
position and direction.
* Replace "O" ring with a new one every
disassembly.
NOTE:
After reassembling the LOWER END COM-
PONENTS, install the O-ring and spacer.
3-55 ENGINE
Tighten the engine sprocket nut to the specified

torque and bend up the washer.
Rotor and
Sprocket holder 09930-40113
80 - 100 N m
Tightening torque
(8.0 - 10.0 kg m)
GEAR POSITION SWITCH

Apply THREAD LOCK SUPER "1303B" to gear
position switch bolts.
THREAD LOCK
99000-32030
SUPER "1303B"
Install gear position switch.

FUEL AND LUBRICATION SYSTEM
CONTENTS
FUEL COCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-1 FUEL AND LUBRICATION SYSTEM
FUEL COCK
CLEANING
Rust from the fuel tank tends to build up in the
filter, which, when the filter has been neglected
for a long period, inhibits the flow of fuel.
Remove the rust from the filter using compressed
air.
DISASSEMBLY
Turn fuel cock to "OFF" position and discon-
nect fuel line from the fue l cock.
Place a clean oil pan under the fuel cock Gasket

assembly, turn fuel cock to "ON" position and
drain the fuel.
Unscrew the fuel cock securing bolts, and take
off the fuel cock assembly.
WARNING: WARNING:
Gasoline is very explosive. Extreme care Gasket must be replaced with a new one to
must be used. prevent leakage.
FUEL AND LUBRICATION SYSTEM 4-2
CARBURETOR
CARBURETOR CONSTRUCTION
C
A
Unit: mm
ITEM SPECIFICATION ITEM SPECIFICATION
Carburetor type MIKUNI BS26SS Jet needle (J,N,) B 4DH41-2nd
Bore size 26 Needle jet (N.J.) C P-0 (390)
I.D.No. 26-183 Pilot jet (P.J.) D £ 12.5
Idle r/min. 1450 50 r/min Starter jet (G.S) £ 37.5
Flat height 29 0.5 Pilot screw (P.S.) PRE-SET (2,5/8 turn out)
Main jet (M.J.) A £ 110 Pilot air jet (P.A.J.) E 1.25
Main air jet (M.A.J.) 0.6 Throttle cable play 0.5-1.0
REMOVAL AND DISASSEMBLY

Take off the carburetor (Refer to page 3-2and 3) .
Remove the carburetor top cover by unscrewing
the cover screws.
Remove the throttle valve and spring.
Remove the float chamber body by unscrewing

the two screws.
Loosen the fitting screw and remove the float.

Remove the needle valve retainer and needle

valve.
Remove the main jet.
Remove the needle jet.
Remove the pilot jet.
Remove the main air jet.
NEEDLE VALVE INSPECTION

If foreign matter is caught between the valve seat
and the needle, the gasoline will continue flowing
and cause it to overflow. If the seat and needle are
worn beyond the permissible limits, similar trouble
will occur. Conversely, if the needle sticks, the
gasoline will not flow into the float chamber. Clean
the float chamber and float parts with gasoline. If
the needle is worn as shown in the illustration,
replace it together with a valve seat. Clean the fuel
passage of the mixing chamber with compressed
air.
REASSEMBLY
Reassemble the carburetor by reversing the 1
sequence of disassembling steps.
NOTE:
Place tongue of diaphragm to carburetor
body properly.
REMOUNTING
Remount the carburetor by reversing the
sequence of removal steps, and following A
2
adjustments and inspection are necessary after
remounting the carburetor.
1
Throttle cable play adjustment

Throttle cable should be adjusted to have correct
play A 0.5 - 1.0 mm.
Loosen the lock nuts .
Slide the adjuster to obtain the correct play
0.5 - 1.0 mm.
Idling adjustment
(Refer to page 2-10)
LUBRICATION SYSTEM
CAMSHAFT JOURNAL CONROD SMALL END

AND CAM FACE
ROCKER ARM CAM CHAIM CYLINDER WALL

SHAFT
CONROD BIG
END BEARING
CLUTCH
RELEASE CAM
CONTERSHAFT
DRIVESHAFT BEARING OIL FILTER
BEARING
COUNTERSHAFT
DRIVESHAFT AND GEARS
OIL PUMP
AND GEARS
PRIMARY DRIVEN
GEAR SPACER
SUMP FILTER
CLUTCH PLATES
OIL PAN
CHASSIS
CONTENTS
FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 5
STEERING STEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
REAR WHEEL AND REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
REAR SWING ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
5-1 CHASSIS
FRONT WHEEL
Tightening torque
Item N m kg m
A 36 52 3.6 5.2
B 15 25 1.5 2.5

Support the machine by center stand and jack
or block.
Pull out the cotter pin and remove the axle

nut .
Draw out the axle shaft and take off the wheel.
NOTE:
Do not operate the front brake lever while
dismounting the front wheel.
CHASSIS 5-2
Using the appropriate drift, drive out the wheel

bearings.
Unlock the washers and remove the four bolts.

Separate the disc plate from the wheel.
CAUTION:
Do not reuse the lock washers.
INSPECTION
WHEEL BEARING Play
Inspect the play of wheel bearings inner race by

Play
hand while fixing it in the wheel hub.
Rotate the inner race by hand to inspect whether
abnormal noise occurs or rotating smoothly.
Replace the bearing if there is something unusual.
AXLE SHAFT
Using the special tools, check the axle shaft for
runout and replace it if the runout exceeds the limit.
Dial gauge(1/100) 09900-20606

V-block(100mm) 09900-21304
TIRE
(See page 2-15)
5-3 CHASSIS
REASSEMBLY
Reassemble and remount the front wheel and
front brake in the reverse order of disassembly
and removal, and also carry out the following steps:
BRAKE DISC
Make sure that the brake disc is clean and free
of any greasy matter, After securing it in place
by tightening its bolts, be sure to lock with
specified torque.
15 25 N m
Tightening torque
(1.5 2.5 kg m)
NOTE:
Always use new lock washers.
Bend the washer to the bolts.
WHEEL BEARING
Apply grease to the bearings before installing.
SUZUKI SUPER
99000-25010
GREASE "A"
Install the wheel bearings by using the special

tool.
Bearing installer 09913-75820
SPEEDOMETER GEAR BOX

Before installing the speedometer gear box
grease it and align groove on the wheel hub
with two drive pawls on the speedometer
drive gear box.
SUZUKI SUPER
99000-25010
GREASE "A"
When tightening the front axle, check to be sure

that the speedometer gear box is in the position
shown.
CHASSIS 5-4
FRONT FORK
Tightening torque
Item N m kg m
A 15 30 1.5 3.0
B 20 26 2.0 2.6

Remove the front wheel (See page 5-1).
Remove the two bolts and dismount the front
caliper.
5-5 CHASSIS
Remove the four bolts and take off the front

fender.
Remove the two screws and take off the head-

light.
Disconnect the couplers and lead wires.

Remove the lead wires from the headlight
housing.
Remove the two bolts and take off the head-

light housing.
CHASSIS 5-6
Disconnect the couples of handle switch and

gear position switch (Refer to page 3-4) .
Remove the tachometer cable and the

speedometer cable.
Remove the two bolts and take off the
combination meter assembly.
Disconnect the clutch inner cable from the

clutch lever.
Remove the brake hose clamp bolt.

Take off the throttle cable by removing the right
handle switch assy.
Remove the handlebars clamp bolts after take

off the caps.
5-7 CHASSIS
Loosen the front fork upper clamp bolts.

Remove the stem head bolt.
Remove the head of steering stem.
NOTE:
Slightly loosen the front fork cap bolts to
facilitate later disassembly.
Remove the brackets of headlamp right and left.
Remove the cover of steering stem after

remove the flashers right and left.
Loosen the front fork lower clamp bolts.
NOTE:
Slightly loosen the front fork cap bolts to
facilitate later disassembly.
Pull down right and left front forks.

CHASSIS 5-8
Remove the cap bolt and draw out the fork

spring.
Invert the fork and stroke it several times to

remove the oil.
Hold the fork inverted for a few minutes.
Remove damper rod bolt by using the special

tools and 8mm hexagon wrench.
"T" handle 09940-34520

Attachment "D" 09940-34561
Remove the oil lock piece and damper rod with

reboumd spring.
Separate the inner tube from the outer tube.
5-9 CHASSIS
Remove the stopper ring.
Remove the oil seal by using the special tool.
CAUTION
The oil seal removed should be replaced with
a new one.
INSPECTION
DAMPER ROD RING
Inspect the damper rod ring for wear and damage.
INNER TUBE AND OUTER TUBE

Inspect the inner tube and outer tube sliding
surfaces for any scuffing or flaws.
CHASSIS 5-10
FORK SPRING
Measure the fork spring free length. If it is shorter
than the service limit, replace it.
Service limit 485 mm
REASSEMBLY
Reassemble and remount the front fork in the
reverse order of disassembly and removal, and
also carry out the following steps:
DAMPER ROD BOLT

Apply SUZUKI BOND No.4 and THREAD LOCK
CEMENT to the damper rod bolt and tighten the
bolt by using the 8 mm hexagon wrench and
special tools.
SUZUKI BOND
99100-31110
NO.4
THREAD LOCK
99000-32040
CEMENT
"T" handle 09940-34520
Attachment "D" 09940-34561
20 26 N m
Tightening torque
(2.0 2.6 kg m)
OIL SEAL
Install the oil seal to the outer tube by using the
special tool as shown.
Fork oil seal

09940-50112
installer
FORK OIL
For the fork oil, be sure to use a front fork oil
whose viscosity rating meets specifications
below.
Fork oil type FORK OIL #10
Capacity ( each leg )
Hold the front fork vertical and adjust thefork oil

level with the special tool.
NOTE:
When adjusting oil level, remove the fork
spring and compress the inner tube fully.
Forl oil level gauge
Oil level
FORK SPRING Upside
When installing the front fork spring, the close

pitch end should position upside.
REMOUNTING
When installing the front fork assembly, align
the top of inner tube to the upper surface
of the steering stem head.
Tighten the upper and lower clamp bolt to

the specified torque.
Tightening
torque
Tighten the stem head bolt to the specified

torque.
Tightening
torque
Tightening torque
Item

Remove the front wheel ( See page 5-1).
Remove the front fork (See page 5-4 ).
Remove the steering stem nut and draw out

steering stem.
NOTE:
Hold the steering stem by hand to prevent
from falling.
Remove the upper and lower steel balls.
Upper 22pcs
Number of balls
Lower 18pcs
Remove the outer race fitted on the steering

stem. This be done with a chisel.
Draw out the two inner races fitted to the top

and bottom ends of the head pipe.
INSPECTION
Inspect and check the remove parts for the
following abnormalities.
Handlebars distortion.
Handlebars clamp wear.
Race wear and brinelling.
Worn or damaged steel balls.
Distortion of steering stem.
REASSEMBLY
Reassemble and remount the steering stem in the
reverse order of disa sse mbly and removal, and
INNER RACES
Press in the upper and lower inner races using the
special tool.
Steering race
installer
OUTER RACE
Press in the outer race by using the special
tool.
Steering bearing
installer
STEEL BALL
Apply grease to the upper and lower inner races
when installing the steel balls.
SUZUKI SUPER 99000-25010

GREASE A
Upper 22pcs
Number of
balls
Lower 18pcs
STEERING STEM NUT

Tighten the steering stem nut to 40-50N m by
using the special tool
Steering nut
09940-14911
socket wrench
Turn the steering stem right ang left, lock-to-lock,

five or six time to seat the ball bearings.
Turn back the stem nut by 1/4-1/2 turn.
NOTE:
This adjustment will vary from motorcycle to
motorcycle.
Tighten the steering stem head bolt, the upper
and lower clamp bolts to the special torque
(Refer to page 6-12).
Tightening
turque
Tightening turque
CAUTION:
After performing the adjustment and instal-
ling the steering stem upper head, rock
the front wheel assembly forward and back-
ward to ensure that there is no play and that
the procedure was accomplished correctly.
Finally check to be sure that the steering
stem moves freely from left to right with its
own weight. If play or stiffness is noticeable,
readjust the steering stem nut.
HANDLEBARS
Set the handlebars to match its punched mark
to the mating face of the holder.
Secure the each handlebars clamp in such a way

that the clearances A ahwad of and behind the
handlebars should be equalized.
20-30 N m
Tightening turque (2.0-3.0 kg m)
CHASSIS 5-18
FRONT BRAKE
Tightening turque
Item N m kg m
A 5 8 0.5 0.8
B 7 9 0.7 0.9
C 25 2.5 .0
BRAKE PAD REPLACEMENT
Lossen the tow pins of caliper .
Remove the caliper mounting bolts and take
off the caliper.
CAUTION:
Do not operate the brake level while dismo-
unting the caliper.
Push the piston and piston holder all the way to

the caliper when removing the brake pads.
Remove the bracket.

Pull out the pins.
Remove the brake pads and replace them.
CAUTION:
Replace the brake pad with a set, otherwise
braking performance will be adversely
affected.
Reassemble the brake pads and the caliper in

the reverse orders.
Tighten the caliper mounting bolts to the
specified torque.
N m
Tightening torque
(2.5 .0 kg m)
NOTE:
Push in the piston and piston holder all the
way to the caliper when remounting the
caliper.
CHASSIS 5-20
CALIPER
Disconnect the brake hose from the caliper by
remove the bolt and catch the brake fluid in a
suitable receptacle (Refer to page 2-13).
Loosen the two pins of caliper.
Remove the caliper mounting bolts and take
off the caliper.
CAUTION:
Never re-use the brake fluid left over from
the last servcing and stored for long periods.
CAUTION:
Do not operate the brake lever while
dismounting the caliper.
Remove the bracket.

Pull out the pins.
Remove the brake pads.
Place a rag over the piston to prevent popping

up. Force out the piston by using air gun.
CAUTION :
Do not use high pressure air to prevent
piston damage.
Remove the piston, piston boot and piston seal.

5-21 CHASSIS
INSPECTION
CALIPER CYLINDER
Inspect the cylinder bore wall for nick, scratch or other
damage.
PISTON
Inspect the piston surface for any scratches or
damage.
RUBBER PARTS
Inspect the each rubber part for damage and wear.
BRAKE DISC
Measure the disc thickness by using the
micrometer.
Micrometer (0~25 mm)
Service limit
CHASSIS 5-22
With the disc mounted on the wheel check the

disc for face runout with a dial gauge, as shown.
Dial gauge (1/100mm) 09900-20606
Service limit 0.3mm
REASSEMBLY
Reassemble and remount the caliper in the reverse
orders of disassembly and removal, and also carry
out the following steps:
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 all
internal parts before inserting into the bore.
Apply SUZUKI SUPER GREASE to the piston

holder.
SUZUKI SUPER 99000-25100

GREASE
Tightening torque
Item
Union bolt
Caliper mounting bolt
WARNING:
Bleed air from the brake fluid circuit after
reassembling the caliper (See page 2-13).
5-23 CHASSIS
MASTER CYLINDER
Place a cloth underneath the union bolt on the
master cylinder to catch spilled drops of brake
fluid. Unscrew the union bolt and disconnect the
brake hose from the master cylinder joint.
CAUTION:
Immediately and completely wipe off any
brake fluid contacting any part of the
motorcycle. The fluid reacts chemically with
paint, plastics, rubber materials, etc. And
will damage them severely.
Remove two clamp bolts and take off the master

cylinder.
Remove two fitting screws, and remove the cap

and diaphragm.
Drain brake fluid.
Remove the dust seal boot.

Remove the circlip by using the special tool.
Remove the piston, primary cup and spring.

CHASSIS 5-24
INSPECTION
Inspect the master cylinder bore for any
scraches or other damage.
Inspect the piston surface for scratches or other

damage.
Inspect the primary cup, secondary cup and
dust seal boot for wear or damage.
REASSEMBLY
Reassemble and remount the master cylinder in
the reverse orders of disassembly and removal,
and also carry out the following steps.
CAUTION:
Wash the master cylinder components with
fresh brake fluid before reassembly.
Never use cleaning solvent or gasoline to
wash them.
Apply brake fluid to the cylinder bore and all
internal parts before inserting into the bore.
When remounting the master cylinder on the

handlebars, first tighten the clamp bolt for
upside as shown.
WARNING:
Bleed air from the brake fluid circuit after
reassembling master cylinder (See page 2-13).
5-25 CHASSIS
REAR WHEEL AND REAR BRAKE
Tightening torque
Item N m kg m
A 50 80 5.0 8.0
B 5 8 0.5 0.8
C 18 28 1.8 2.8
REMOVAL
Support the machine by the center stand.
Remove the rear brake adjuster nut and
disconnect the brake rod.
Pull off the cotter pin and remove the torque link
nut and bolt.
CHASSIS 5-26
Pull off the cotter pin and remove the rear axle
nut.
Loosen the chain adjuster lock nut and adjuster
bolt, right and left.
Draw out the axle shaft and take off the chain
from rear sprocket.
Take off the rear wheel and separate the brake
panel from the wheel.
DISASSEMBLY
REAR WHEEL
Flatten the washers and remove the four nuts.
Separate the rear sprocket and mounting drum
from the wheel.
Remove the oil seal by using the special tool.

5-27 CHASSIS
Remove the bearing and retainer from the

mounting drum.
Remove the cushion from the wheel.
Remove the right and left side wheel bearings.
NOTE:
Removing the left side bearing first makes
the job easier.
CHASSIS 5-28
REAR BRAKE
Take off the brake shoes.
Remove the cam lever nut and bolt.
Pull off the brake cam, washer, O-ring and cam

lever.
5-29 CHASSIS
INSPECTION
WHEEL BEARING Play
Inspection the wheel bearings for play by hand.
Rotate the inner race by hand to inspect whether Play
abnormal noise occurs and it rotates smoothly.

Replace the bearing if there are any defects.
AXLE SHAFT
Using the special tools, check the axle shaft for
Dial gauge (1/100) 09900-20606

V-block (100mm) 09900-21304
TIRE (See page 2-15)

CHASSIS 5-30
SPROCKET
Inspect the sprocket teeth for wear. If they are
worn as illustrated, replace the sprocket and drive
chain.
REAR BRAKE DRUM

Measure the brake drum I.D. to determine the
extent of wear and, if the limit is exceeded by the
wear noted, replace the drum. The value of this
limit is indicated inside the drum.
BRAKE SHOE
Check the brake shoes and decide whether it
should be replaced or not from the thickness of the
brake shoe linings.
CAUTION:
Replace the brake shoes as a set, otherwise
affected.
CUSHION
Inspect the cushion for wear and damage.
5-31 CHASSIS
REASSEMBLY
Reassemble and remount the rear wheel and rear
brake in the reverse order of disassembly and
removal, and also carry out the following steps:
WHEEL BEARING
Apply grease to the bearings before installing.
SUZUKI SUPER
99000-25010
GREASE "A"
Install the wheel bearings by using the special

tool.
NOTE:
First install the wheel bearing for right side.
MOUNTING DRUM
Insert the bearing by using the special tool.
Apply grease to the mounting drum as shown.
SUZUKI SUPER
99000-25010
GREASE "A"
CHASSIS 5-32
SPROCKET
After tightening the four nuts to specification,
bend the lock washers.
18 - 28 N m
Tightening torque
(1.8 - 2.8 kg m)
BRAKE CAM
Apply grease to the brake cam.
SUZUKI SUPER
99000-25010
GREASE "A"
WARNING:
Be careful not to apply too much grease to
the brake cam. If grease gets on the lining,
brake slippage will result.
BRAKE CAM LEVER

Install the brake cam lever and tighten the cam
lever nut with specified torque.
5-8 N m
Tightening torque
(0.5 - 0.8 kg m)
5-33 CHASSIS
REAR SWING ARM
Tightening torque
Item Nm kg m
A 50 - 80 5 .0 - 8 .0
B 10 - 15 1.0 - 1.5

Remove the rear wheel (See page 5-25).
Remove the rear shock absorber units and take
off the shock absorber units.
CHASSIS 5-34
Remove the two screws and take off the chain

case.
Remove the swing arm pivot nut and draw out

the shaft.
Remove the swing arm.
Pull off the cotter pin and remove the nut and
bolt.
Remove the torque link.
Remove the chain buffer

Remove the dust seal covers and draw out the
spacers.
5-35 CHASSIS
Draw out the bushings by using the special

tools.
Bearing puller 09923-73210
Rotor remover
09930-30102
slide shaft
INSPECTION
BUSHING
Inspect the bushing for wear and damage.
SWING ARM PIVOT SHAFT

Using a dial gauge, check the pivot shaft for
Dial gauge (1/100) 09900-20606

V-block (100mm) 09900-21304

CHASSIS 5-36
REASSEMBLY
Reassemble and remount the swing arm in the
reverse order of disassembly and removal, and
SWING ARM BUSHINGS

Force-fit the bushings into the swing arm by using
the special tool.
Bearing installer set 09924-84510
SPACER AND DUST SEAL COVER

Apply grease to the spacer and dust seal cover
when installing.
SUZUKI SUPER
99000-25010
GREASE "A"
ELECTRICAL SYSTEM
CONTENTS
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 6
STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
COMBINATION METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6-1 ELECTRICAL SYSTEM
IGNITION SYSTEM
DESCRIPTION
In the full-transistorized ignition system, the electrical energy on the pick-up coil generated by the
magneto rotor tip flows to the transistor/ignition timing control circuit. This energy is released in a single
surge at the specified ignition timing point, and current flows through the primary side of the ignition coil. A
high voltage current is induced in secondary windings of the ignition coil resulting in strong spark between
the spark plug gap.
MAGNETO IGNITOR
Ignition switch
O/W O/W O R
O/W
Pick-up coil Engine kill switch

L
Spark plug
W
Ignition coil
Magneto G Battery
B/W
Ignitor
WIRE COLOR
L : Blue B/W : Black with White tracer
G : Green O/W : Orange with White tracer
O : Orange
R : Red
W : White IGNITION COIL AND SPARK PLUG
ELECTRICAL SYSTEM 6-2
INSPECTION
PICK-UP
Using the pocket tester(RX1 range), measure
the resistance between the lead wires in the
following table .
Pocket tester 09900-25002
_
Pick-up coil L G
_
resistance Approx.120 200
WIRE COLOR
Charging coil Y_Y
resistance Approx.0.5 _ 2.0 L : Blue
G : Green
Y : Yellow
NOTE:
When mounting the stator on the magneto
cover, apply a small quantity of THREAD
LOCK "1342" to the threaded parts of screws.
THREAD LOCK
99000-32050
"1342"
IGNITOR
Using the pocket tester (Rx1 range), measure
the resistance between the terminals in the 4
following table.

1 2 3
Unit:k
Probe of tester
Probe of tester
Approx. Approx.
3.6 5.0
Approx. Approx.
3.0 2.0
Approx. Approx.
5.0 2.0
IGNITION COIL
Check the ignition coil with electro tester.
Test the ignition coil for sparking performance.
Test connection is as indicated. Make sure that
the three-needle sparking distance is at least 8
mm.
Electro tester 09900-28106
STD
Spark performance 8 mm
Check the ignition coil with pocket tester.
Ignition coil resistance

O/W - W
Primary
Approx.3.5 -4. 5
Plug cap - O/ W
Secondary
Approx.16-30k
SPARK PLUG
Clean the plug with a wire brush and pin. Use the
pin to remove carbon, taking care not to damage
the porcelain.
Check the gap with a thickness gauge.
Spark plug gap 0.6 - 0.7mm
0.7-0.8 mm
IGNITOR UNIT
Remove the spark plug from the cylinder. Install
the plug cap and place the spark plug on the
cylinder head.
Remove the seat and disconnect the lead wire
from the pick-up coil.
Turn the ignition switch ON.
The ignitor unit is in good condition if the follow-
ing is observed.
Connect probe of SUZUKI Pocket Tester (x1
range) with Green lead wire on the ignitor side and
probe with Blue lead wire.
Next connect probe with Blue lead wire on the
ignitor side and probe with Green lead wire .
The moment the tester probes are connected, the
spark plug sparks.
NOTE:
This checking presupposes that the ignition
coil used for checking is a good one.
CHARGING SYSTEM
DESCRIPTION
The circuit of the charging system is indicated in figure ,which is composed of an AC generator,
regulator/rectifier unit and battery.
The AC current generated from AC generator is converted by rectifier and is turned into DC current, then it
charges the battery.
Ig. switch
LOAD
SCR SCR SCR Battery
Control
unit
A.C. Generator
Function of Regulator
While the engine r/min is low and the generated voltage of AC generator is lower than the adjusted voltage
of regulator, the regulator does not function, incidentally the generated current charges the battery
directly.
Ig. switch
LOAD
SCR SCR SCR Battery

Control
unit
A.C. Generator
When the engine r/min becomes higher, the generated voltage of AC generator also becomes higher and
the voltage between points A and B of regulator becomes high according, and when it reaches the
adjusted voltage of control unit, control unit becomes "ON" condition consequently. On the "ON" condition
of control unit, signal will be sent to the SCR (Thyristor) gate probe and SCR will become"ON" condition.
Then the SCR becomes conductive to the direction from point A to point C .Namely at the state of this,
the current generated from the AC generator gets through SCR without charging the battery and returns to
AC generator again. At the end of this state, since the AC current generated from AC generator flows into
the point B ,reverse current tends to flow to SCR ,then the circuit of SCR turns to OFF mode and begins to
charge the battery again. Thus these repetitions maintain charging voltage to the battery constant and
protect it from overcharging.
Ig. switch
LOAD
SCR SCR SCR Battery
Control
unit
A.C. Generator
C B
INSPECTION
CHARGING OUTPUT CHECK
Start the engine and keep it running at 5 000r/min.
Using the pocket tester, measure the DC voltage
between the battery terminal and .
If the tester reads under 13.5V or over 16.0V,
check the AC generator no-load performance and
regulator/rectifier.
NOTE:
When making this test, be sure that the
battery is full-charged condition.
STD charging output IG. switch
13.5V - 16.0V at 5 000r/min

Regulator
Rectifier
Battery DCV
AC GENERATOR NO-LOAD PERFORMANCE

Disconnect the three lead wires from the AC
generator terminal.
Start the engine and keep it running at 5 000r/min.
Using the pocket tester, measure the AC voltage
between the three lead wires.
If the tester reads under 70V, the AC generator is
faulty.
STD No-load performance

More than 70V (AC) at 5 000r/min
REGULATOR/RECTIFIER
Using the pocket tester (X1 tange), measure the
resistance between the lead wires in the following
table.
If the resistance checked is incorrect, replace the
regulator/rectifier.
Unit:
Probe of tester
R B B B B/W
Probe of tester
R OFF OFF OFF OFF

B 7-8 OFF OFF OFF
B 7-8 OFF OFF OFF
B 7-8 OFF OFF OFF
B/W 35-55 7-8 7-8 7-8
STARTER SYSTEM
DESCRIPTION
The starter system is shown in the diagram below: namely, the starter motor, relay, engine kill switch, IG
switch, starter button and battery. Depressing the starter button (on the right handlebar switch box)
energizes the relay, causing the contact points to close which connects the starter motor to the battery.
The motor draws about 80 amperes to start the engine.
Starter relay
S. Button Ig. switch ON
Fuse
Engine kill switch
RUN
Starter motor
STARTER MOTOR REMOVAL AND DISASSEMBLY

Remove the starter motor (See page 3-30).
Disassemble the starter motor as follows.
STARTER MOTOR INSPECTION

CARBON BRUSHES
When the brushes are worn, the motor will be
unable to produce sufficient torque, and the
engine will be difficult to turn over. To prevent this,
periodically, inspect the length of the brushes,
replacing them when they are too short or chipping.
COMMUTATOR
If the commutator surface is dirty, starting per-
formance decreases. Polish the commutator with
SEGMENT
#400 or similar fine emery paper when it is dirty.
After polishing it, wipe the commutator with a
clean dry cloth.
MICA
ARMATURE COIL
Using a pocket tester, check the coil for open and
ground by placing probe pins on each commutator
segment and rotor core (to test for ground) and on
any two segments at various places (to test for
open), with the brushes lifted off the commutator
surface.
If the coil is found to be open-circuited or ground-
ed, replace the armature. Continuous use of a
d efe ctive armature will cause the starter motor to
suddenly fail.

STARTER MOTOR REASSEMBLY

BRUSH HOLDER AND HOUSING END
When fixing brush holder to starter motor case,
align the protrusion Ù of the starter motor case
with the notch of the brush holder. 2 1
When installing housing end, fix the protrusion
of the starter motor case to the notch on the
housing end.
SECURING SCREWS
Apply THREAD LOCK "1342" to starter motor
securing screws.
THREAD LOCK
99000-32050
"1342"
STARTER RELAY INSPECTION

Disconnect lead wire of the starter motor at starter
relay.
Turn on the ignition switch, inspect the continuity
between the terminals, positive and negative,
when pushing the starter button.
If the starter relay is in sound condition, continuity
is found.
Check the coil for "open", "ground" and ohmic

resistance. The coil is in good condition if the
resistance is as follows.
STD resistance Approx.3 - 4

COMBINATION METER
Remove the combination meter (See page 5-5) .
Disassemble the combination meter.
INSPECTION
Using the pocket tester, check the continuity be-
tween lead wires in following diagram.
If the continuity measured is incorrect, replace the SP F.C. TA
FUEL
respective part.
N 1 2 3 4 5
NOTE:
Br/R
W/Y
R/B
B/W
G/L
Y/L
Y/B
Lg
Gr
O
B
Y
L
When making this test, it is not necessary to

remove the combination meter.
LIGHTS
HEADLIGHT TURN SIGNAL LIGHT
TAIL/BRAKE LIGHT
SWITCHES
Inspect each switch for continuity with the pocket
tester referring to the chart. If it is found any
abnormality, replace the respective switch as-
sembly with new one.
IGNITION SWITCH
R O
OFF
ON
LIGHTING SWITCH Ù
Gr O Y/W
1
ENGINE KILL SWITCH
3
O O/W
STARTER SWITCH
O/W Y/G
OFF
4
FRONT BRAKE LIGHT SWITCH

O W/B
OFF
ON
DIMMER SWITCH Ù
Y/W Y W
1
TURN SIGNAL LIGHT SWITCH
B Sb Lg 2
HORN SWITCH
G B/W
OFF
REAR BRAKE LIGHT SWITCH

O W/B
OFF
ON
GEAR POSITION INDICATOR LIGHT SWITCH

Ground L W/Y R/B G/L Y/L Br/R
Neutral
Low
2nd
3rd
4th
Top
WIRE COLOR
B ........... Black B/W .......... Black with White tracer
Br .......... Brown Br/R ......... Brown with Red tracer
G ........... Green G/L ........... Green with Blue tracer
Gr ......... Gray O/W ......... Orange with White tracer
L ........... Blue R/B .......... Red with Black tracer
Lg ......... Light green W/B .......... White with Black tracer
O ........... Orange W/Y .......... White with Yellow tracer
R .......... Red Y/B .......... Yellow with Black tracer
P ........... Pink Y/G........... Yellow with Green tracer
Sb ......... Light blue Y/L ........... Yellow with Blue tracer
W .......... White Y/W .......... Yellow with White tracer
Y .......... Yellow
BATTERY
SPECIFICATIONS Batter y
Type designation GM7Z-A

Breather
Capacity 28.8kc(7Ah)/10HR pipe
O
1.28 at 20 C
Standard electrolyte S.G.
(68 OF)
In fitting the battery to the motorcycle, connect the
breather tube to the battery vent.
INITIAL CHARGING
Filling electrolyte
Remove short sealed tube before filling electrolyte.
Fill battery with electrolyte (dilute sulfuric acid
solution with acid concentration of 35.0% by
O
weight, having a specific gravity of 1.28 at 20 C
O
(68 F) up to indicated UPPER LEVEL. Filling A
O
electrolyte should be always cooled below 30 C
O
(86 F) before filling into battery. Leave battery
standing for half an hour after filling. Add
additional electrolyte if necessary.
Charge battery with current as described in the
A Sealed tube
tables shown below.
Maximum
charging current 0.7 A
1
Charging time
The charging time for a new battery is determined
by the number of months that have elapsed since
the date of manufacture.
Confirmation for date of manufacture

Date of manufacture is indicated by a three-part
number Ù , as follows. The first number indicating
year, the second and the third indicating month.
Near the end of charging period, adjust the Over

Months after manufacturing 6 - 12
specific gravity of electrolyte to value specified. 12
After charging, adjust the electrolyte level to the Necessary charging hours 5 8
UPPER LEVEL with DISTILLED WATER.
Servicing
Visually inspect the surface of the battery
container. If any signs of cracking or electrolyte
leakage from the sides of the battery have
occurred, replace the battery with a new one.
If the battery terminals are found to be coated with
rust or an acidic white powdery substance, then
this can be cleaned away with sandpaper.
Check the electrolyte level and add distilled water,

as necessary, to raise the electrolyte to each cell's
UPPER LEVEL.
Check the battery for proper charge by taking an
electrolyte S.G. Reading. If the reading is 1.22 or
O O
less, as corrected to 20 C(68 F), it means that the
battery is still in a run-down condition and needs
recharging.
NOTE:
First, remove the lead wire.
BASED ON S.G. READING 1.30
RECHARGING OPERATION 1.29
Specific gravity
1.28
O O
To correct an S.G. reading 20 C (68 F), use 1.27 Normal
following table. 1.26
1.25
Recharge
1.24
To read the S.G. on the hydrometer , bring the 1.23
electrolyte in the hydrometer to eye level and read 1.22 Recharge of Replace
1.21
C 0 5 10 15 20 25 30 35 40
the graduations on the float scale bordering on the
F 32 41 50 59 68 77 86 95 104
meniscus (curved-up portion of electrolyte surface),
Temperature
as shown in figure.
O
Check the reading (as corrected to 20 C) with
chart to determine the recharging time in hours by
constant-current charging at a charging rate of 0.8
amperes (which is a tenth of the capacity of the
present battery).
Be careful not to permit the electrolyte tempera-

ture to exceed 45 OC (113 OF ), at any time, during
the recharging operation. Interrupt the operation,
as necessary, to let the electrolyte cool down.
Recharge the battery to the specification.
Hydrometer 09900-28403
Electrolyte O O
specific gravity 1.28 at 20 C (68 F)
CAUTION: Hydrometer
Constant-voltage charging, otherwise called
"quick" charging, is not recommendable for
it could shorten the life of the battery.
Specific gravity at 20OC

1.28
1.24
1.20
1.16
1.12
1.08
2 4 6 8 10 12 14 16 18
Charging time(hour)
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 with
new one in such a case.
When a battery is left for a long term without using,

it is apt to be subject to sulfation. When the
motorcycle is not used for more than 1 month
(especially during the winter season), recharge
the battery once a month at least.
WARNING:
* Before charging a battery, remove the seal
cap from each cell.
* Keep fire and sparks away from a battery
being charged.
* When removing a battery from the
motorcycle, be sure to remove the ter-
minal first.
SERVICING INFORMATION
CONTENTS
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 7
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
WIRE AND CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
7-1 S E R V I C I N G I N F O R M AT I O N
TROUBLESHOOTING
ENGINE
Complaint Symptom and possible causes Remedy
Engine will not start Compression too low

or is hard to start. 1. Valve clearance out of adjustment Adjust.
2. Worn valve guides or poor seating of valves. Repair or replace.
3. Valves mistiming. Adjust.
4. Piston rings excessively worn. Replace.
5. Worn-down cylinder bore. Replace or rebore.
6. Poor seating of spark plug. Retighten.
7. Starter motor cranks but too slowly. Consult "electrical complaints"
Plug not sparking

1. Fouled spark plug. Clean or replace.
2. Wet spark plug. Clean and dry.
3. Defective pick up coil. Replace.
4. Defective ignitor unit. Replace.
5. Defective ignition coil. Replace.
6. Open or short circuit in high-tension cord. Replace.
No fuel reaching the carburetor

1. Clogged hole in the fuel tank cap. Clean.
2. Clogged or defective fuel cock. Clean or replace.
3. Defective carburetor float valve. Replace.
4. Clogged fuel pipe. Clean or replace.
5. Clogged fuel filter. Clean or replace.
1. Fouled spark plug. Clean.
Engine stalls easily.
2. Defective pick up coil. Replace.
3. Defective ignitor unit. Replace.
4. Clogged fuel pipe. Clean.
5. Clogged jets in carburetor. Clean.
6. Valve clearance out of adjustment. Adjust.
7. Clogged fuel filter. Clean or replace.
Noisy enigne. Excessive valve chatter

1. Valve clearance too large. Adjust.
2. Weakened of broken valve springs. Replace.
3. Worn down rocker arm or rocker arm shaft. Replace.
Noise appears to come from piston

1. Piston or cylinder worn down. Replace.
2. Combustion chamber fouled with carbon. Clean.
3. Piston pin or piston pin bore worn. Replace.
4. Piston rings or ring groove worn. Replace.
Noise seems to come from clutch

1. Worn splines of countershaft or hub. Replace.
2. Worn teeth of clutch plates. Replace.
3. Distorted clutch plates, driven and drive. Replace.
4. Clutch damper weakened. Replace.
Noise seems to come from crankshaft

1. Worn of burnt bearings. Replace.
2. Bjg-end bearings worn and burnt. Replace.
3. Thrust clearance too large. Replace.
S E R V I C I N G I N F O R M AT I O N 7-2
Noisy engine. Noise seems to come from transmission

1. Gears worn of rubbing. Replace.
2. Badly worn splines. Replace.
3. Primary gears worn or rubbing. Replace.
4. Badly worn bearings. Replace.
Slipping clutch. 1. Clutch control out of adjustment or loss of play. Adjust.

2. Weakened clutch springs. Replace.
3. Worn or distorted pressure plate. Replace.
4. Distorted clutch plates, driven and drive. Replace.
Dragging clutch. 1.Clutch control out of adjustment or too much play. Adjust.
2.Some clutch springs weakened while others are not. Replace.
3.Distorted pressure plate or clutch plates. Replace.
Transmission will not 1.Broken gearshift cam. Replace.

shift. 2.Distorted gearshift forks. Replace.
3.Worn gearshift pawl. Replace.
Transmission will not 1.Broken return spring on shift shaft. Replace.

shift back. 2.Shift shafts are rubbing or sticky. Repair.
3.Distrorted or worn gearshift forks. Replace.
Transmission jumps out 1.Worn shifting gears on driveshaft or countershaft. Replace.

of gear. 2.Distorted or worn gearshift forks. Replace.
3.Weakened stopper pawl spring on gearshift cam. Replace.
4.Worn gearshift pawl. Replace.
Engine idles poorly. 1.Valve clearance out of adjustment. Adjust.

2.Poor seating of valves. Replace.
3.Defective valve guides. Replace.
4.Worn rocker arm or arm shaft. Replace
5.Defective pick up coil. Replace.
6.Defective ignitor uint. Replace.
7.Spark plug gap too wide. Adjust or replace.
8.Defective ignition coil resulting in weal sparking. replace.
9.Clogged jets. Clean.
Engine runs poorly in 1.Valve springs weakened. Replace.

high speed range. 2.Valve timing out of adjustment. Adjust.
3.Worn cams or rocker arms. Replace.
4.Spark plug gap too narrow. Repair.
5.Defective ignition coil. Replace.
6.Clogged air cleaner element. Clean.
7.Clogged fuel pipe, resulting in inadequate fuel supply to carburetor, Clean and prime.
8.Defective pick up coil or ignitor unit. Replace.
Dirty or heavy exhaust 1.Too much engine oil in the engine. Check with inspection window,
smoke. drain out excess oil.
2.Worn piston rings or cylinder. Replace.
3.Worn valve guides. Replace.
4.Cylinder wall scored or scuffed. Replace.
5.Worn valves stems. Replace.
6.Defective stem seals. Replace.
7.Worn side rails. Replace.
Engine lacks power. 1. Loss of valve clearance. Adjust.

2. Weakened valve springs. Replace.
3. Valve timing out of adjustment. Adjust.
4. Worn piston ring or cylinder. Replace.
5. Poor seating of valves. Repair.
6. Fouled spark plug. Clean or replace.
7. Worn rocker arms or its shafts. Replace.
8. Sprak plug gap incorrect. Adjust or replace.
9. Clogged jets in carburetor. Clean.
10. Clogged air cleaner element. Clean.
11. Too much engine oil. Drain out excess oil.
12. Suck air intake pipe. Retighten or replace.
Engine overheats. 1. Heavy carbon deposit on piston crown. Clean.

2. Not enough oil in the engine. Add oil.
3. Defective oil pump or clogged oil circuit. Repair or clean.
4. Air leak from intake pipe. Retighten or replace.
5. Use of incorrect engine oil. Change.
CARBURETOR
Trouble with starting. 1.Starter jet is clogged. Clean.

2.Starter pipe is clogged. Clean.
3. Air leaking from a joint between starter body and carburetor. Check starter body and carburetor
for tightness, adjust and replace
gasket.
4.Starter plunger is not operating properly. Check and adjust.
Idling or low-speed 1. Pilot jet, pilot air jet are clogged or loose. Check and clean.
trouble. 2. Pilot outlet or bypass is clogged. Check and clean.
3. Starter plunger is not fully closed. Check and adjust.
Medium or high-speed
1. Main jet or main air jet is clogged. Check and clean.
trouble.
2. Needle jet is clogged. Check and clean.
3. Throttle valve is not operating properly. Check throttle valve for operation.
4. Filter is clogged. Check and clean.
Overflow and fuel 1. Needle valve is worn or damaged. Replace.

level fluctuations. 2. Spring in needle valve is broken. Replace.
3. Float is not working properly. Check and adjust.
4. Foreign matter has adhered to needle valve. Clean.
ELECTRICAL
No sparking or poor 1. Defective ignition coil. Replace.

sparking. 2. Defective spark plug. Replace.
3. Defective pick up coil or ignitor unit. Replace.
Spark plug soon become 1. Mixture too rich. Adjust carburetor.

fouled with carbon. 2. Idling speed set too high. Adjust carburetor.
3. Incorrect gasoline. Change.
4. Dirty element in air cleaner. Clean.
5. Spark plug too cold. Replace by hot type plug.
Spark plug become 1.Worn piston rings. Replace.

fouled too soon. 2.Pistons or cylinder worn. Replace.
3.Excessive clearance of valve stems in valve guides. Replace.
4.Worn stem oil seals. Replace.
Spark plug electordes 1.Spark plug too hot. Replace by cold type plug.
overheat or burn. 2.The engine overheats. Tune up.
3.Defective pick up coil or ignitor unit. Adjust.
4.Spark plug loose. Retighten.
5.Mixture too lean. Adjust carburetor.
Generator does not

1.Open or short in lead wires, or loose lead connections. Repair or replace or retighten.
charge.
2.Shorted, grounded or open generator coils. Replace.
3.Shorted or panctured regulator/rectifler. Replace.
Generator charges,but
1.Lead wires tend to get shorted or open-circuited or loosely connected Repair or retighten.
charging rate is below
at terminals.
the specification.
2.Grounded or open-circuited stator coils of generator. Replace.
3.Defective regulator/rectifier. Replace.
4.Not enough electrolyte in the battery. Add distilled water between the
level lines.
5.Defective cell plates in the battery. Replace the battery.
Generator overcharges.
1.Internal short-circuit in the battery. Replace the battery.
2.Resistor element in the regulator/rectifier damaged or defective. Replace.
3.Regulator/rectifier poorly grounded. Clean and tighten ground
connection.
Unstable charging. 1.Lead wire insulation frayed due to vibration, resulting in intermittent Repair or replace.
shorting.
2.Generator internally shorted. Replace.
3.Defective regulator/rectifier. Replace.
Starter button is not

1.Batttery run down. Recharge or replace.
effective.
2.Defective switch contacts. Replace.
3.Brusnes not seating properly on commutator in starter motor. Repair or replace.
4.Defective starter relay. Replace.
BATTERY
"Sulfation", acidic white 1. Not enough electrolyte. Add distilled water, if the battery has not been damaged
powdery substance or and "sulfation" has not advanced too far, and recharge.
spots on surfaces of cell 2.Battery caes is cracked. Replace the battery.
plates. 3.Battery has been left in a run-down condition for Replace the battery.
a long time.
4.Contaminated electrolyte (Foreign matter has If "sulfation" has not advanced too far, try to restore the
enters the battery and become mixed with the battery by replacing the electrolyte, recharging it fully
electrolyte.) with the battery detached from the motorcycle and then
adjusting electrolyte S.G.
Battery runs down 1. The charging method is not correct. Check the generator, regulator/rectifier and circuit
quickly connections, and make necessary adjustments to
obtain specified charging operation.
2. Cell plates have lost much of their active material Replace the battery, and correct the charging system.
as result of over-charging.
3. A short-circuit condition exists within the battery Replace the battery.
due to excessive accumulation of sediments
caused by the high electrolyte S.G.
4. Electrolyte S.G. is too low. Recharge the battery fully and adjust electrolyte S.G.
5. Contaminated electrolyte. Replace the electrolyte, recharge thebattery and the
adjust S.G.
6. Battery is too old. Replace the battery.
Reversed battery polarity. The battery has been connected the wrong way Replace the battery and be sure to connect the
round in the system, so that it is being charged in battery properly.
the reverse direction.
Battery "Sulfation" 1. Changing rate too low or too high. Replace the battery.
(When not in use, batteries should be recharged
at least once a month to avoid sulfation.)
2. Battery electrolyte excessive or insufficient, or its Keep the electrolyte up to the prescribed level, or
specific gravity too high or too low. adjust the S.G. by consulting the battery maker's
directions.
3. The battery left unused for too long in cold Replace the battery, if badly sulfated.
climate.
Battery discharges too 1. Dirty container tap and sides. Clean.

rapidly 2. Impurities in the electrolyte or electrolyte S.G. is Change the electrolyte by consulting the battery
too high. maker's directions.
CHASSIS
Steering feels too heavy 1. Steering stem nut overtightened. Adjust.

or stiff. 2. Worn bearing or race in steering stem. Replace.
3. Distorted steering stem. Replace.
4. Not enough pressure in tires. Adjust.
Steering oscillation. 1. Loss of balance between right and left front suspensions. Replace.
2. Distorted front fork. Repair or replace.
3. Distorted front axle or crooked tire. Replace.
Wobbly front wheel. 1.Distorted wheel rim. Replace.

2.Warn-down front wheel bearings. Replace.
3.Defective or incorrect tire. Replace.
4.Loose nut on axle. Retighten.
Front suspension too 1. Weakened springs. Replace.

soft. 2. Not enough fork oil. Refill.
Front suspension too 1. For oil too viscous. Replace.

stiff. 2. Too much fork oil. Remove excess oil.
Noisy front suspension. 1. Not enough fork oil. Refill.

2. Loose nuts on suspension. Retighten.
Wobbly rear wheel. 1. Distorted wheel rim. Remedy

2. Worn-down rear wheel bearings. Replace.
3. Defective or incorrect tire. Replace.
4. Loose nut on axle. Retighten.
5. Worn swing arm bushings. Replace.
6. Loosen nuts on the rear shock. Retighten.
Rear suspension too 1. Weakened springs. Replace.

soft. 2. Rear suspension adjuster improperly set. Adjust.
Rear suspension too 1. Rear suspension adjuster improperly set. Adjust.

stiff. 2. Warn swing arm bushings. Replace.
Noisy rear suspension. 1. Loose nuts on suspension. Retighten.

2. Worn swing arm bushings. Replace.
BRAKES
Poor braking. 1. Not enough brake fluid in the reservoir. Refill to level mark.
2. Air trapped in brae fluid circuit. Bleed air out.
3. Pads worn down. Replace.
4. Top much play on brake lever or pedal. Adjust.
5. Linings worn down. Replace.
Insufficient brake power. 1. Leakage of brake fluid from hydraulic system. Repair or replace.
2. Worn pads. Replace.
3. Oil adhesion on engaging surface of pads. Clean disc and park
4. Worn disc. Replace
5. Air in hydraulic system. Bleed air
Brake squeaking. 1.Carbon adhesion on pad surface. Repair surface with sandpaper.
2.Tilted pad. Modify pad fitting.
3.Damaged wheel bearing. Replace.
4.Loose front-wheel axle or rear-wheel axle. Tighten to specified torque.
5.Worn pads. Replace.
6.Foreign material in brake fluid. Replace brake fluid.
7.Clogged return port of matter cylinder Disassemble and clean master
cylinder.
Excessive brake lever 1.Air in hydraulic system. Bleed air.

stoke. 2.Warn brake lever cam. Replace brake lever.
3.Insufficient brake fluid. Replenish fluid to specified lever;
bleed air.
4.Improper quality of brake fluid. Replace with correct fluid.
Leakage of brake fluid. 1.Insufficlent tightening of connection joints. Tighten to specified torque.
2.Cracked hose. Replace.
3.Worn piston and/or cup. Replace piston and/or cup.
SPECIAL TOOLS
ITEM PART NO. PART NAME
1 09900-06107 Snap ring pliers (opening type)
2 09900-06108 Snap ring pliers (closing type)
3 09900-09003 Impact driver set
4 09900-20101 Vernier calipers (150 mm)
09900-20202 Micrometer (25 - 50 mm)
5 09900-20203 Micrometer (50 - 75 mm)
09900-20205 Micrometer (0 - 25 mm)
6 09900-20508 Cylinder gauge set
7 09900-20606 Dial gauge (1/100)
8 09900-20701 Magnetic stand
9 09900-20803 Thickness gauge
10 09900-21304 V-block
11 09900-25002 Pocket tester
12 09900-28106 Electro tester
13 09900-28403 Hydrometer
14 09910-20116 Conrod holder
15 09910-32812 Crankshaft installer
16 09910-34510 Piston pin puller
17 09911-73730 "T" type hexagon wrench (5 mm)
18 09913-50121 Oil seal remover
19 09913-75820 Bearing installer
21 09915-63310 Compression pressure adapter
22 09915-64510 Compression gauge
23 09915-74510 Oil pressure gauge
24 09916-14510 Valve spring compressor
25 09916-21110 Valve seat cutter set
26 09916-24311 Solid pilot (N-100-5.0)
27 09916-24610 Valve seat cutter 15 O (N-121)
09916-20620 Valve seat cutter 45 O (N-122)
28
09916-20630 Valve seat cutter 30 O (N-126)
29 09916-34542 Reamer handle
30 09916-34570 5.0mm reamer
31 09916-34580 10.8 mm reamer
32 09916-44310 Valve guide installer
33 09916-84510 Tweezers
34 09917-13210 Tappet adjust driver
35 09920-13120 Crankcase separating tool/crankshaft remover
36 09920-53710 Clutch sleeve hub holder
37 09923-73210 Bearing puller
38 09924-84510 Bearing installer set
39 09930-30102 Rotor remover slide shaft
40 09930-30180 Attachment
41 09930-40113 Rotor and sprocket holder
ITEM PART NO. PART NAME

42 09930-44511 Rotor holder
43 09940-14911 Steering stem nut socket wrench
44 09940-34520 "T"handle
45 09940-34561 Attachment "D"
46 09940-50112 Fork oil seal installer
48 09941-34513 Steering race installer
49 09943-74111 Fork oil level gauge
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 27
28 29 30
31 32 33
34 35 36
37 38 39
40 41 42
43 44 45
46 47 48
49
TIGHTENING TORQUE
ENGINE
ITEM kg¤ m N¤ m
Cylinder head cover bolt 0.9 - 1.0 9 - 10
Camshaft sprocket bolt 1.0 - 1.3 10 - 13
Cylinder head nut 8 mm Diam 2.5 - 3.5 25 -35
Cylinder head nut 6 mm Diam 0.7 - 1.1 7 - 11
Cylinder base nut 6 mm Diam 0.7 - 1.1 7 - 11
Magneto rotor nut
3.0 - 4.0 30 - 40
Primary drive gear/oil pump drive gear nut
4.0 - 6.0 40 - 60
Clutch sleeve hub nut
3.0 - 5.0 30 - 50
Engine oil drain plug
1.8 - 2.0 18 - 20
Engine sprocket nut
8.0 - 10.0 80 - 100
Engine mounting bolt 8 mm Diam
( A 80 mm length) 3.7 - 4.5 37 - 45
Engine mounting bolt 8 mm Diam
( B the others) 2.8 - 3.4 28 - 34
Exhaust pipe clamp nut
Muffler clamp bolt 0.9 - 1.2 9 - 12
Starter clutch bolt 0.9 - 1.2 9 - 12

1.5 - 2.0 15 - 20
CHASSIS
ITEM kg¤ m N¤ m
Front axle nut 3.6 - 5.2 36 - 52
Front fork damper rod bolt 2.0 - 2.6 20 - 26
Front fork lower clamp bolt 2.5 - 3.5 25 - 35
Front fork upper clamp bolt 2.0 - 3.0 20 - 30
Steering stem head bolt 3.5 - 5.5 35 - 55
Handlebars clamp bolt
1.2 - 2.0 12 - 20
Front brake maser cylinder mounting bolt
0.5 - 0.8 5-8
Front brake caliper mounting bolt
2.5 - 4.0 25 - 40
Front brake hose union bolt
2.5 - 3.5 25 - 35
Front brake bleeder valve
0.7 - 0.9 7-9
Front brake disc bolt
1.5 - 2.5 15 - 25
Swing arm pivot nut
5.0 - 8.0 50 - 80
Front footrest bolt
Rear torque link nut (Front and Rear) 3.6 - 5.2 36 - 52
Rear shock absorber fitting nut (upper and lower) 1.0 - 1.5 10 - 15
Rear axle nut 2.0 - 3.0 20 - 30

Rear sprocket nut 5.0 - 8.0 50 - 80
Rear brake cam lever bolt 1.8 - 2.8 18 - 28
Front fork cap bolt 0.5 - 0.8 5-8
1.5 - 3.0 15 - 30
TIGHTENING TORQUE CHART

For other bolt and nuts who's torque is not listed, refer to this chart:
Bolt Diameter Conventional or "4" marked bolt "7" marked bolt

(mm) kg¤ m N¤ m kg¤ m N¤ m
4 0.1 - 0.2 1.0 - 2.0 0.15 - 0.3 1.5 - 3.0
5 0.2 - 0.4 2.0 - 4.0 0.3 - 0.6 3.0 - 6.0
6 0.4 - 0.7 4.0 - 7.0 0.8 - 1.2 8.0 - 12.0
8 1.0 - 1.6 10.0 - 16.0 1.8 - 2.8 18.0 - 28.0
10
2.2 - 3.5 22.0 - 35.0 4.0 - 6.0 40.0 - 60.0
12
3.5 - 5.5 35.0 - 55.0 7.0 - 10.0 70.0 - 100.0
14
5.0 - 8.0 50.0 - 80.0 11.0 - 16.0 110.0 - 160.0
16
8.0 - 13.0 80.0 - 130.0 17.0 - 25.0 170.0 - 250.0
18
13.0 - 19.0 130.0 - 190.0 20.0 - 28.0 200.0 - 280.0
Conventional bolt "4" marked bolt "7" marked bolt

SERVICE DATA
VALVE + GUIDE Unit: mm
ITEM STANDARD LIMIT
IN. 25.5 -
Valve diam
EX. 22.5 -
Valve clearance IN. 0.04 - 0.07 -

(when cold)
EX. 0.13 - 0.18 -
Valve guide I.D. IN.& EX 5.000 - 5.012
-
IN. 4.975 - 4.990
Valve stem O.D. -
EX. 4.955 - 4.970
-
Valve stem runout IN.& EX -
0.05
Valve head thickness IN.& EX -
0.5
Valve stem end length IN.& EX -
2
Valve seat width IN.& EX 0.9 - 1.1
-
Valve head radial runout IN.& EX -
0.03
INNER -
Valve spring free length (IN.& EX.) 31.2
OUTER -
33.6
INNER 3.77 - 4.43 kg at length 26.78 mm
Valve spring tension (IN.& EX) -
OUTER 8.86 - 10.4 kg at length 29.78 mm
-
CAMSHAFT + CYLINDER HEAD Unit: mm

ITEM STANDARD LIMIT
IN. - 33.350
Cam height
EX. - 33.000
Camshaft journal O.D. IN.& EX 21.959 - 21.980
Camshaft runout IN.& EX 0.10
Cam chain 20-pitch length 129.9
Rocker arm I.D. IN.& EX 12.000 - 12.018
Rocker arm shaft O.D. IN.& EX 11.966 - 11.984
Cylinder head distortion 0.05
Cylinder head cover distortion 0.05
CYLINDER + PISTON Unit: mm

ITEM STANDARD LIMIT
1 000 - 1 400 kPa 800 kPa
Compression pressure
2
(10.0 - 14.0 kg/cm ) (8.0 kg/cm )
2
Piston to cylinder clearance 0.045 - 0.022 0.120
Cylinder bore 57.000 - 57.015 57.085
56.950 - 56.965
Piston diam 56.880
Measure at 10 mm from the skirt end
Cylinder distortion 0.05
PISTON + PISTON RING Unit: mm
ITEM STANDARD LIMIT

1st R Approx. 7.2 5.6
Piston ring free end gap
2nd R Approx. 5.8 4.8
1st 0.20 - 0.32 0.50
Piston ring end gap
2nd 0.20 - 0.32 0.50
1st 0.180
Piston ring to groove clearance
2nd 0.150
1st 1.01 - 1.03
Piston ring groove width 2nd 1.01 - 1.03
Oil
2.01 - 2.03
1st
Piston ring thickness 0.97 - 0.99
2nd
0.97 - 0.99
Piston pin bore 14.002 - 14.008 14.030
Piston pin O.D. 13.994 - 14.002 13.980
CONROD + CRANKSHAFT Unit: mm

ITEM STANDARD LIMIT
Conrod small end I.D. 14.004 - 14.012 14.040
Conrod deflection 3.0
Conrod big end side clearance 0.10 - 0.45 1.00
Conrod big end width 15.95 - 16.00
Crankshaft web to web width 53.0 0.1
Crankshaft runout 0.05
OIL PUMP
ITEM STANDARD LIMIT
Oil pump reduction ratio 2.000(30/15)
2
Above 10 kPa (0.1 kg/cm )
Oil pressure (at 60OC, 140 OF) Below 30 kPa (0.3 kg/cm 2)
at 3000 r/min.
CLUTCH Unit: mm
ITEM STANDARD LIMIT
Clutch cable play 4
Clutch release screw 1/4 - 1/2 Turn back
Drive plate thickness 2.9 - 3.1 2.6
Drive plate claw width 11.8 - 12.0 11.0
Driven plate thickness 1.60 0.05

Driven plate distortion 0.10
Clutch spring free length 29.5

TRANSMISSION + DRIVE CHAIN Unit: mm

ITEM STANDARD LIMIT
Primary reduction ratio 3.470(59/17)
Final reduction ratio 3.214(45/14)
Gear ratios Low 3.000(33/11)
2nd 1.857(26/14)
3rd 1.368(26/19)
4th 1.143(24/21)
Top 0.957(22/23)
Shift fork to groove clearance 0.10 - 0.30 0.50
No.1&
Shift fork groove width No.2 5.0 - 5.1
No.3 5.5 - 5.6
No.1&
Shift fork thickness No.2 4.8 - 4.9
No.3
5.3 - 5.4
Countershaft length 0
88.0 0.2
(Low to 2nd)
Drive chain Type KMC 428H
Links 118
20 pitch length 259.0
Drive chain sag 10 - 20

CARBURETOR Unit: mm
ITEM SPECIFICATION
Carburetor type MIKUNI BS26SS

Bore size 26
I.D.No. 26-183
Idle r/min. 1450 50 r/min
Flat height 29 0.5
Main jet (M.J.) 110
Main air jet (M.A.J.) 0.6
Jet needle (J,N,) 4DH41-2nd
Needle jet (N.J.) P-0 (390)
Pilot jet (P.J.) 12.5
Starter jet (G.S) 37.5
Pilot screw (P.S.) PRE-SET (2,5/8 turn out)
Pilot air jet (P.A.J.) 1.25
Throttle cable play 0.5-1.0
ELECTRICAL Unit: mm
ITEM SPECIFICATION NOTE
13 O B.T.D.C. below 1 950 r/mim

32 O B.T.D.C. between 4 000-5 000 r/min
Ignition timing
29.9 O B.T.D.C. between 6 000-7500 r/min
34.1 O B.T.D.C. above 9 000 r/min
NGK:CR8E
Type
Spark plug N.D.:U24ESR-N
Gap 0.7 - 0.8
Spark performance Over 8 at 1 atm.
W - O/W
Primary
Approx. 3.5 -4. 5
Ignition coil resistance
Plug cap - O/W
Secondary
Approx.16 - 30 k
L- G
Pick up
Approx. 120 - 200
Generator coil resistance
Y-Y
Charging
Approx. 0.5 - 2.0
Generator no-load voltage More than 70V (AC) at 5000 r/min
Regulated voltage 13.5 - 16.0V at 5 000 r/min
Starter relay resistance Approx. 3-4
Type designation GM7Z-A
Capacity 12V28.8kC(7Ah)/10h
Battery
Standard
1.280 at 20 OC(68 OF)
electrolyte S.G.
Fuse 10A, 15A

BRAKE + WHEEL Unit: mm

ITEM STANDARD LIMIT
Rear brake pedal free travel 20 - 30
Rear brake pedal height 10
Brake disc thickness Front 4.0 0.2 3.0
Brake disc runout Front 0.30
Brake cylinder bore Front 12.700 - 12.743
Master cylinder piston diam. Front 12.657 - 12.684
Brake caliper cylinder bore Front 33.960 - 34.036
Brake caliper piston diam. Front 33.884 - 33.934
Brake drum I.D. Rear 130.7
Brake lining thickness Rear 1.5
Front 0.25
Wheel axle runout
Rear 0.25
Front
Tire size 80/100 - 18 4PR
Rear
90/90 - 18 4PR
Front 1.6
Tire tread depth
Rear 1.6
7-21 SERVICING INFORMATION
SUSPENSION Unit: mm
ITEM STANDARD LIMIT
Front fork stroke 110
Front fork spring free length 485
Front fork oil level 142

Rear wheel travel 75
Swing arm pivot shaft runout 0.6
FUEL+OIL
ITEM SPECIFICATION NOTE
Fuel type Gasoline used should be graded 90 - 97 oc-

tane or higher.
An unleaded or low-lead gasoline type is
recommended.
Fuel tank including reserve 14 L
reserve 2.0 L
Engine oil type and grade SAE 10W/40 SF or SG
Engine oil capacity Change 1100 ml

Filter change 1150 ml
Overhaul 1350 ml
Front fork oil type Fork oil #10
Front fork oil capacity (each leg) 139 ml
TIRE PRESSURE
Normal riding
Cold inflation
Solo riding Dual riding
tire pressure
kPa kg/cm2 Psi kPa kg/cm2 Psi
Front 175 1.75 24 175 1.75 24
Rear 200 2.00 28 225 2.25 32
SERVICING INFORMATION 7-22
WIRE AND CABLE ROUNTING

Clamp
Magneto
Starter relay
Wiring harness
Gear position indicator
Starter motor lead wire
Tail/Brake light
Fuse 10A
Magneto
Tail/Brake light
Wiring harness
Rear turn signal light (R), (L)
Clamp
Clamp
Clamp
Throttle cable
Handle switch wire
Clamp
Wiring harness
Tachometer cable
Horn Throttle cable

Wiring harness
Tachometer cable Wiring harness
Guide Clamp
Magneto
Gear position indicator Ground wire
Clamp
Handle switch wire (R&L)

Clamp
Wiring harness
Horn wire
Fuse 15A
Starter motor Reg/rec

lead wire
Starter motor Clutch cable

Battery terminal lead wire
Rear brake
switch lead wire Ground wire
Battery
Starter relay
Fuse 15A
IGNITION-COIL IGNITER
HANDLE-SW.R
SP F.C. TA
FUEL LIGHTS ENGINE KILL START FUEL-GAUGE REG&REC R-BRAKE SW TURN-RELAY 7-23
COMBINATION METER
O W/B
ON B L
OFF
N 1 2 3 4 5
F-BRAKE SW
B
B
B
R
O
ON
B/W
W/B
OFF
L
O
O
Y
W
W
O
Gr
Lg
Gr
Y/L
O
G/L
Y/B
R/B
Y/G
Y/B
W/Y
W/B
Y/W
B/W
B/W
Br/R
Sb
O/W
O/W
O/W
B/W
Y
B
P
Y
Y
Y
R
O
O
O
Br
Br
Lg
Y/L
Y/B
G/L
Y/B
R/B
Y/G
W/B
B/W
W/Y
B/W
B/W
W/B
Br/R
O/W
WIRING DIAGRAM
FRONT-TURN,R REAR-TURN,R
B/W B/W B/W B/W

SERVICING INFORMATION
Lg Lg Lg Lg
HEAD-LAMP REAR-COMB,LAMP
W W W/B W/B
B/W B/W B/W B/W
Y Y Br Br
Br Br
POSITION-LAMP
REAR-TURN,L
B B B B
B/W B/W B/W B/W
FRONT-TURN,L
R
B/W
P
Y/G
B/W
B/W
R
B/W
R
R
10A
L
L
B
B
Y
B
P
B
P
Y
Y
Y
R
R
W
Lg
Lg
FUSE-BOX
Sb
Y/W
B/W
B/W
B/W
B(G)
12V
STARTER-RELAY 15A
FRAME EARTH ENGINE EARTH BATTERY FUSE-BOX

L
L
Y
Y
Y
Y
B
R
G
O
G
W
Lg
Sb
Y/L
G/L
R/B
Y/W
B/W
W/Y
Br/R
M
HORN
OFF
ON STARTER-MOTOR
N
IGNITION-SW ( ALARM ) 1
DIMMER HORN 2
TURNSIGNAL 3
4
HANDLE-SW,L
5
MAGNETO
GEAR POSITION-SW
WIRE COLOR
B ........... Black O........... Orange B/W .......... Black with White tracer W/Y .......... White with Yellow tracer
Br .......... Brown R .......... Red Br/R ......... Brown with Red tracer Y/B .......... Yellow with Black tracer
G ........... Green P ........... Pink G/L ........... Green with Blue tracer Y/G........... Yellow with Green tracer
Gr ......... Gray Sb ......... Light blue O/W ......... Orange with White tracer Y/L ........... Yellow with Blue tracer
L ........... Blue W .......... White R/B .......... Red with Black tracer Y/W .......... Yellow with White tracer
Lg ......... Light green Y .......... Yellow W/B .......... White with Black tracer
EN125HU
SUPPLEMENTARY SERVICE MANUAL
Prepared by
JIANGMEN DACHANGJIANG GROUP CO., LTD.
October 2004
Part No.:99501-38140-01E
Printed in China
FOREWORD
SUZUKI EN125HU is designed to offer superior performance through lightness in weight

and four-stroke power. The new EN125HU represents another major advance made by
SUZUKI in four stroke motorcycles.
This service manual is prepared primarily for experienced mechanics whose job is
inspecting, repairing and servicing SUZUKI motorcycles. Apprentice mechanics and "do-
it-yourself" mechanics will also find it an extremely useful guide.
Model EN125HU, manufactured to standard specifications, is the main purpose of this

manual. However, EN125HU motorcycles distributed in your country might differ in minor
respects from the standard-specifications of EN125HU and, if they do, it is because some
minor modifications ( which are of no consequence in most cases as far as servicing is
concerned ) has to be made to comply with the statutory requirements of your country.
( Modifications in the 4th paragraph are as follows: )

This manual is for EN125HU motorcycle, which is a variation of EN125-2A for Mexico.
This EN125HU manual, relating only the modifications made on the basis of EN125-2A,
should be used together with "EN125-2A SERVICE MANUAL" ( 99500H06100-01E ) .
SUZUKI distributors are timely informed of our technical modifications and improvements
in this model. Please inquire our distributors for information you need.
SUZUKI MOTOR CORPORATION

JIANGMEN DACHANGJIANG GROUP CO., LTD.
EN125HU MODIFICATIONS MADE ON THE BASIS OF EN125-2A
rear goods rack

front brake oil tank
( canceled )
engine outer
fuel filter appearance
( canceled )
front wheel
rear wheel
kick starter carburetor front brake system

( added )
GROUP INDEX
FRONT WHEEL AND FRONT BRAKE 1
REAR WHEEL AND REAR BRAKE 2
CARBURETOR 3
KICK STARTER 4
WIRING DIAGRAM 5
FRONT WHEEL AND FRONT BRAKE
CONTENTS
FRONT WHEEL AND FRONT BRAKE . . . . . . . . . . . . . . . . . . 1-1 1
FRONT WHEEL ASSEMBLY DETAIL DRAWING . . . . . . . . . . . . 1-1
DISMANTLING OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
WHEEL BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
FRONT WHEEL AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
WHEEL RIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
SPOKE NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
BRAKE SHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
BRAKE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
REFITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
WHEEL BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1-1 FRONT WHEEL AND FRONT BRAKE
FRONT WHEEL AND FRONT BRAKE

FRONT WHEEL ASSEMBLY DETAIL DRAWING
Front tire specification:

2.75-18 4PR
DISMANTLING OF PARTS
FRONT WHEEL
Support motorcycle with center stand or a jack.

Remove speedometer cable and front brake
cable.
Loosen and dismantle front wheel axle nut.

Pull out front wheel axle.
36 52 N m
Tightening torque
3.6 5.2 kg m
FRONT WHEEL AND FRONT BRAKE 1-2
Remove dust boot and oil seal.
Pull out right and left bearings of front wheel.
FRONT BRAKE
Remove the brake shoes.
Dismantle brake cam lever bolt.
5 8N.m
Tightening torque
0.5 0.8kg.m
Remove the brake cam lever.
Remove the oil seal with special tool.
Oil seal dismantling tool 09913-50121
Remove the spring collar with special tool.
Spring collar clipper 09900-06107
Remove the speedometer drive gear unit.

Remove the screw and speedometer drive gear.
INSPECTION
Play
WHEEL BEARING
Fix wheel hub and inspect with hand the play of Play
bearing inner collar. Rotate the inner collar with hand

to see if there is any abnormal noise and if rotation is
easy. Replace bearing in case of abnormality.
FRONT WHEEL AXLE

Check with a dial indicator to see if there is any run-out
in front axle. In case of excessive run-out, front axle
should be replaced.
Dial gauge ( 1/100 ) 09900-20606
Magnetic dial gauge rack 09900-20701

V-block ( 100mm ) 09900-21304
Service limit 0.25mm
WHEEL RIM
Note:
The run-out of wheel rim inspected with the
method described in the right-side figure
should not exceed service limit. Excessive
run-out results from excessive wear or
loosening of wheel bearing. Replacement of
bearing reduces run-out.
In case of failure in reducing run-out by
replacing bearing, adjust spoke tension. In
case adjustment of spoke tension fails in
reducing run-out, replace wheel rim.
Service limit
( axial and radial ) 2.0mm
SPOKE NIPPLE
Inspect and confirm that all spoke nipples are fastened.
If necessary, fastened them with special tools.
4 5N.m
Tightening torque
0.4 0.5kg.m
Spoke nipple spanner 09940-60113
TIRE
Adequate tire tread depth ensures effective braking
and stable riding. Replace tire in case tread depth
reaches wear limit as shown in the right side figure.
Tire service limit 1.6mm

BRAKE SHOE
Brake panel incorporate a brake lining wear limit
indicator. If the lining condition is normal, the brake
camshaft index mark line , when extended, will fall
within the range embossed on the brake panel
(when brake is on).
First check that the brake system is properly

adjusted.
Then check the mark extension line; the brake
should be on at this time.
If the extended line falls outside the indicated range,
replace the brake shoe assembly.
Note:
Replace the brake shoe with a set, otherwise
affected.
Check the brake shoe and decide whether it should

be replaced or not from the thickness of the brake
shoe lining.
Service limit 1.5mm
BRAKE DRUM
Measure the brake drum I.D. to determine the extent of
wear and, if the limit is exceeded by the wear noted,
replace the drum. The value of this limit is indicated
inside the drum.
Service limit 130.7mm
Inspect the drum I.D. for scratch marks. If the I.D.

surface is scratched or otherwise roughened,
smoothen it by grinding with sandpaper.
REASSEMBLY
Reassemble and remount the front wheel in the
reverse order of disassembly and removal, and also
carry out the following steps:
WHEEL BEARING
Install the wheel bearings by using the special tool.
Bearing fitting tools 09924-84510
Apply lubricating grease to bearing.

SUZUKI super lubricating
grease "A" 99000-25010
Install the brake cam lever as shown in illustration.

REAR WHEEL AND REAR BRAKE
CONTENTS
REAR WHEEL AND REAR BRAKE . . . . . . . . . . . . . . . . . . . . . 2-1
REAR WHEEL DETAIL DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
DISMANTLING OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2
REAR SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
WHEEL BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
REAR WHEEL AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
WHEEL RIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
SPOKE NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
BRAKE SHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
BRAKE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
REAR SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
REAR SPROCKET SHOCK ABSORBING BLOCK . . . . . . . . . . 2-4
REFITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
WHEEL BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2-1 REAR WHEEL AND REAR BRAKE
REAR WHEEL AND REAR WHEEL BRAKE

REAR WHEEL ASSEMBLY DETAIL DRAWING
Rear tire specification:

3.00-18 4PR
DISMANTLING OF PARTS
REAR WHEEL
Support motorcycle with center stand;

Screw out rear brake adjusting nut and
dismantle rear brake lever;
Pull out split pin and dismantle torsion bar
tightening nut;
Loosen the nut and bolt on the both side.

Remove the drive chain.
REAR WHEEL AND REAR BRAKE 2-2
Remove the rear wheel axle nut and remove

rear wheel axle;
Remove the chain from the large sprocket;
Remove the rear wheel;
Separate the rear wheel and drive sprocket;
REAR SPROCKET
Flatten the lock washer and screw out the
sprocket nuts;
Remove the sprocket hub and sprocket;
Remove the wheel bearings by using the

special tool in the following procedures.
Insert the adapter in to the wheel bearing.
After inserting the wedge bar from opposite
side, lock the wedge bar in the slit of the adapter.
Drive out the wheel bearing by knocking the
wedge bar.
Caution:
The removed bearing should be replaced.
Bearing remover 09941-50110

REAR BRAKE
Remove the brake shoes.
Remove the brake cam lever.
Remove the brake camshaft, gasket, O-ring

and camshaft swing arm;
INSPECTIONS
Wheel bearing ( see pages 1-4 )
Rear wheel axle ( see pages 1-5 )
Wheel rim ( see pages 1-5 )
Spoke nipple ( see pages 1-5 )
Tire ( see pages 1-5 )
Brake shoe ( see pages 1-6 )
Brake drum ( see pages 1-6 )
REAR WHEEL AND REAR BRAKE 2-4
REAR SPROCKET
Excessively worn sprocket cause chain noise and
accelerate sprocket wear. Inspect wear of sprocket
teeth. In case of excessive wear as shown in the figure,
replace sprocket and chain as a set;
REAR SPROCKET DUMPER LUBBER

Check if there are wear and crack in the dumper lubber.
In case of abnormality, replace it.
REFITTING
Refit and reinstall rear wheel and rear brake in an
order reversed to that of dismantling and separating,
paying attention to the following steps.
BRAKE
Install brake cam lever as shown in the figure.
Note:
When refitting brake shoe, apply lubricating
grease to brake cam sliding surface.
Confirm that brake shoes are free from
grease or else slippage occurs when braking.
WHEEL BEARING
Use special tools in fitting wheel bearings and
wheel hub bearings.
Bearing-fitting tools 09924-84510
Apply SUZUKI super lubricating grease to

bearings.
SUZUKI super
lubricating grease "A" 99000-25010
Tighten the following bolts and nuts at specified torques.
Item N m Kg m
Torsion bar tightening nut 10-15 1.0-1.5
Sprocket tightening nut 18-28 1.8-2.8
Brake cam lever nut 5-8 0.5-0.8
Rear wheel axle nut 50-80 5-8

CARBURETOR
CONTENTS
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
CARBURETOR STRUCTURE DRAWING . . . . . . . . . . . . . . . . . . 3-1
DISMANTLING AND SEPARATING . . . . . . . . . . . . . . . . . . . . . 3-2
DISMANTLING CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
INSPECTION AND FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
FLOAT PIN VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
FLOAT HEIGHT INSPECTION AND ADJUSTMENT . . . . . . . . . 3-5 3
MAIN NOZZLE NEEDLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
REFITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-1 CARBURETOR
CARBURETOR
CARBURETOR STRUCTURE
Jet needle
Piston valve
Pilot air screw
Throttle valve stop screw
Needle valve
Float
Pilot jet
Needle jet
Main jet
Item Specification Item Specification

Carburetor MIKUNI Needle jet N-8
Throttle valve 20.4 Idle speed jet 15
Reticule mark VM22-405 Transient jet 2.5
Idle speed ( r/min ) 1450 50r/min Idle jet orifice ( P.O ) 1.0
Needle valve seat ( V.S ) 1.8
Float level 21.8mm Pilot jet ( P.J ) 27.5
Main jet ( M.J ) 92.5 Pilot air screw ( P.S ) 2-3/4 turns back
Main air jet ( M.A.J ) 1.0 Idle air jet ( P.A.J ) 1.4
Jet needle ( J.N. ) 5EJ50-2 Throttle cable play 0.5-1.0
CARBURETOR 3-2
DISMANTLING AND SEPARATION OF PARTS

DISMANTLING CARBURETOR
Turn fuel switch to "OFF" position;
Remove the fuel hose;
Unscrew bolt and drain gasoline in carburetor;
Warning:
Handle gasoline with care as it is inflammable
and explosive.
Note:
There is no fuel filter on carburetor oil inlet
tube in this model.
Remove the top cap;

Remove the throttle valve;
Remove the carburetor bolts and screw;

Remove carburetor;
Remove the bolts and remove the float

chamber;
3-3 CARBURETOR
Pull out float pin and remove the float chamber;
Remove the needle valve;
Dismantle bolt , remove float needle valve

seat pressure plate and take out float needle
valve ;
Dismantle main jet , needle jet and remove
holder ;
Dismantle pilot jet ;
Dismantle pilot screw , remove spring ,
gasket and O-ring ;
Dismantle screw and spring.
Caution:
Handle with care when fitting and dismantling
nozzles as they are easy to be damaged.
Blow all the blowholes in the carburetor;

Inspect for normality of every part and replace worn or
corroded parts, if any;
CARBURETOR 3-4
Remove the throttle cable clamp from throttle

valve;
Remove the needle jet;
Dismantle top cap unit;
Remove the starter unit;

3-5 CARBURETOR
INSPECTION AND FITTING

FLOAT VALVE
In case there is foreign matter between valve seat and
needle, there is overflow of oil when oil supply
continues. In case wear of valve seat and needle
exceeds the limit, the same trouble occurs. On the
contrary, when the needle is jammed, gasoline shall
not enter float bowl.
In case needle wear is as shown in the figure,

replace it together with valve seat.
INSPECTION AND ADJUSTMENT OF FLOAT HEIGHT

Please float valve at its place and inspect its
height ;
Float height 21.8 1.0mm
In case float height exceeds

specified scope, adjust float
height by means of bent reed;
Fit a new O-ring in float chamber slot;

Fit float chamber;
Tighten screw;
MAIN JET NEEDLE VALVE

Inspect if there is wear in needle valve stem.
Replace it if there is obvious wear.
Fit needle valve clip in the second slot from top;
CARBURETOR 3-6
Fit needle valve in throttle valve as shown in

the figure;
REFITTING
Fit other parts of carburetor in the reverse order
of removal.
KICK STARTER
CONTENTS
KICK STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
DISMANTLING KICK STARTER . . . . . . . . . . . . . . . . . . . . . . . . 4-1
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
REFITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4
4-1 KICK STARTER
KICK STARTER
DISMANTLING KICK STARTER
Remove the bolt and remove the kick starter
;
Remove the clutch cover ;
Remove the kick starting gear washer and

kick starting gear ;
Dismantle bolts , remove kick starting guide

plate and limiting plate ;
Remove kick starting ratchet wheel , spring
and washer ;
KICK STARTER 4-2
Remove the clutch unit ( Refer to "EN125-2A

SERVICE MANUAL" 99500H06100-01E ) ;
Remove the kick starting idle wheel clip ,
washer and remove kick starting idle wheel
and washer ;
Take out kick starting idle wheel shaft after
separating right and left crankcases;
Dismantling cylinder head and cylinder unit,

piston unit and separating right and left
crankcases ( Refer to "EN125-2A SERVICE
MANUAL" 99500H06100-01E ) .
Remove from inside the right side crankcase
kick starting bush clip , kick starting bush
and kick starting return spring ;
To remove the kick starting return spring, pull

out the part clipped in the axle spring
positioning hole, then remove the hook hanger
clipped in right crankcase hole and take out
spring;
Take out kick starting shaft from outside the

right crankcase.
4-3 KICK STARTER
INSPECTION
Inspect wear of parts. Replace parts with obvious wear.
REFITTING
Fit kick starting device in reverse order of removal.
When fitting kick starting ratchet, align it with

the mark.
Fit kick starting bush spring, bush and clip in

the right crankcase and then fit ratchet.
When fitting ratchet, fit spring and washer on
the marked side of ratchet, turn ratchet
counterclockwise and clip ratchet pawl on the
limiting stopper.
When fitting clutch cover, bind the knurled part

of kick starting shaft end with transparent
adhesive tape to prevent it from damaging oil
seal lip .
Evenly apply SUZUKI super grease to the inner
side oil seal lip.
SUZUKI super grease "A" 99000-25010

IGNITION-COIL IGNITER
FUEL HANDLE-SW, R
IL IL LIGHTS ENGINE STOP START FUEL-GAUGE
SPEEDOMETER IL
REG & REC STOP-LAMP, SW TURN-RELAY
IL
1
O WB
N ON B L
2 5
LA01
LA01
EA01
CA07
EA02
MS01
OFF
3 4
FA01
BA05
FRONT-BRAKE
ON
R
O
Y
Y
Y
WB
OFF
BW
O
L
O
O
O
W
W
Sb
Gr
RB
GL
YL
YB
WB
YG
BW
BW
WY
YW
OW
OW
OW
BrR
L
B
O
Y
Gr
Lg
YB
BW
PA01
EB01
EA01
BA01
GA01
BA02
CA06
BA06
AB02
BA07
CA10
DA03
GA02
MC01
MB01
MA01
HA02
PA01
FC03
FB03
BA08
CA04
DA02
RB
GL
YL
R 1.25
O 1.25
O
O
Y 0.75
Y 0.75
Y 0.75
O
WY
Br
BrR
YB
YG
WB
BW
BW 1.25
OW
WB
Y
B
O
Br
Lg
YB
BW
FRONT-TURN, R REAR-TURN, R
BW CA03 BW BW CA11 BW
Lg FB01 Lg LG FB02 LG
HEAD-LAM REAR-COMB, LAMP
W HB01 W WB GA01 WB
BW CA01 BW 1.25 BW GA12 BW
Y HA01 Y Br DA01 Br
Br DA01 Br
POSITION-LAM
REAR-TURN, L
B FC01 B B FC02 B
BW CA14 BW BW CA15 BW
FRONT-TURN, L
R 1.25
YG
BW
CA01 BW 1.25
AC01
BW 1.25
R
R 1.25
R 1.25
BW
EB01
CA09
CA02
L
L
B
B
B
B
R
O
Y
W
Sb
Lg
Lg
BW
BW
BW
YW
B(G)
W
R 1.25
O 1.25
Y 0.75
Y 0.75
Y 0.75
AC01
AB01
GrR
12 V
WIRING DIAGRAM
MC01 STARTER-RELAY 15A

MB01
MA01
FA01
FB01
FC01
FC04
FB04
AB01
BA01
CA13
AB03
HB01
CA05
BA03
BA04
HA01
KA01
KA01
MS02
CA08
MS01
FRAME ENGINE BATTERY FUSE-BOX
EARTH EARTH
L
L
Y
G
G
Y
Y
Y
R
O
W
Sb
Lg
RB
GL
YL
BW
WY
YW
BrR
HORN
OFF
ON STARTER-MOTOR
N
IGNITION-SW ALARM 1
2
DIMMER HORN
TURNSIGNAL 3
4
HANDLE-SW, L 5
NEUTRAL-SW MAGNETO
5

119 PDF

Hochgeladen von

Dokumentinformationen

Originalbeschreibung:

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

119 PDF

Hochgeladen von

Copyright:

Verfügbare Formate

EN125-2A

JIANG MEN DACHANGJIANG GROUP CO., LTD.

Model EN125-2A manufactured to standard specifications is the main subject matter of

SUZUKI MOTOR CORPORATION

FUEL AND LUBRICATION SYSTEM 4

SERIAL NUMBER LOCATIONS

FRONT FORK OIL

Closing angle (Degree)

Signal generator Ignitor unit Ig 2

Ignition coil Battery

Material Part Page Material Part Page

Cam sprocket bolts 3-27

Steering stem 5-16

Dust seal cover and 5-36

Piston pin 3-24

Countershaft bearing 3-44

THREAD LOCK "1342"

SUZUKI BOND No.4

Cylinder head cover 2-4

THREAD LOCK SUPER

*The specifications subject to change without notice.

PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . 2-1

PERIODIC MAINTENANCE SCHEDULE

PERIODIC MAINTERNANCE CHART

PERIODIC LUBRICATION CHART

Interval Km Initial and Every 6 000 km Every 12 000 km

The battery must be removed to check the

For checking specific gravity, use a hydrometer to

An S.G. reading of 1.22 (at 20 OC ) or under means

To install the battery, reverse the procedure

Make sure that the breather pipe is tightly

CYLINDER HEAD NUTS, CYLINDER

Inspect initial 1 000 km and Every 4 000 km

CYLINDER HEAD NUTS

When installing cylinder head cover, apply

EXHAUST PIPE BOLTS AND MUFFLER 5

AIR CLEANER ELEMENT

Clean Every 3 000 km

If the air cleaner is clogged with dust, intake

Remove the left frame cover.

Excessive valve clearance results in valve noise 2

The procedure for adjusting the valve clearance

Thickness gauge 09900-20803

Valve clearance specifications

IN. 0.04 - 0.07 mm

If clearance is off the specification, bring it into

Tappet adjust driver 09917-13210

Reinstall spark plug, valve inspection caps,

Inspect initial 1 000 km Every 4 000 km

Refer to page 3-1.

Remove the carbon deposits with a wire or pin and

Inspect the fuel hose and connections for damage

Clean initial 1 000 km and Every 8 000 km

If the fuel filter is dirty with sediment, fuel will not

Change initial 1 000 km and Every 4 000 km 2

The oil should be changed with the engine hot.

ENGINE OIL FILTER

Replace initial 1 000 km and Every 4 000 km

Replace the oil filter in the following manner:

Replace the filter with a new one.

Refer to page 3-1.

OIL SUMP FILTER