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GSXR-1100 service manual 1989-1992

1. SERVICING INFORMATION FOR U S A MODEL SERVICING INFORMATION 7 10 FOR CANADA MODEL 241 SERVICING INFORMATION FOR SWITZERLAND MODEL n E PE M or A E SERVICING INFORMATION 7 12 FOR ITALY MODEL
2. 713 SERVICING INFORMATION FOR THE OTHER MODELS SERVICING INFORMATION 7 14 WIRE HARNESS CABLE AND HOSE ROUTING WIRE ROUTING Wen tusia a d 745 SERVICING INFORMATION WIRE ROUTING SERVICING INFORMATION 7 16 SPEEDOMETER CABLE ROUTING SERVICING INFORMATION THROTTLE CABLE ROUTING SERVICING INFORMATION 710 CLUTCH HOSE ROUTING SERVICING INFORMATION OIL COOLER HOSE AND AIR CLEANER HOSE ROUTING SRNODE porny Y ds mes oc SERVICING INFORMATION 720 FRONT BRAKE HOSE ROUTING SERVICING INFORMATION REAR BRAKE HOSE ROUTING SERVICING INFORMATION 7 22 FUEL HOSE
3. WIRE HARNESS ROUTING FUEL HOSE AND FUELTANK WATER DRAIN ROUTING REAR BRAKE HOSE ROUTING FRAME COVER INSTALLATION ENGINE HEAT PROTECTOR 1100N 92 MODEL CONTENTS SPECIFICATIONS DIMENSIONS AND ORY mass SERVICE DATA or AS Peas FRONT SUSPENSION
4. 6 Remove the dust seal and seal stopper 7 Separate the inner tube out of the outer wore e careful not damage the inner tube CAUTION The outer tube and Inner tubo ANTIFRICTION metals must bo replaced along with the seal and dust seal when iombling tho front fork B Turm in the spring adjuster and remove it fram the front fork eap CAUTION The Oring ramoved should bo replaced with a now ono INSPECTION DAMPER ROD Inspect the damper rod for wear and damage INNER AND OUTER TUBE Inspect the Inner lube sliding surface and outer tube sliding surface far any scuffing CHASIS FORK SPRING Measure the fork spring tree length I it is shortor than the service Nit raplace It with new ane Service limit 347 mm 13 7 in REASSEMBLY AND REMOUNTING Ronssemble and remount the front fork in the reverse order of Fomoval and disassembly Pay attention to following pomis INNER TUBE METAL Hold thew tubs vertically elem the metal groove and Install the metal by hand shown CAUTION Usa spacial caro to provent damage to the TEFLON coated surface of the Ant Frietion metal whan mounting It DAMPER ROD BOLT Apply THREAD LOCK 1342 to ihe dampar rod bolt and lighten it to the specified torque with the special toot and hexagon wronch 99000 32050 THREAD LOCK 1342 From fork damper 34 46 Nm rod bolt 34 4
5. jet __ 15 mm demede UNI SSB Needle 0 9 pa Plot je ea 3 5 Bypass oemm a e or cues Por O7 wm 5 3 a Vaesm WS 2 5 Storie i wes 4 5 lt pus PRESET re sev PRE SET Pise FS sal out oi oi Tamm E 03 10 cable play me England Eronen Finland Norway Seitrorand Belum 22 WGermany E39 Amema E83 Spain 45 FUEL AND LUBRICATION SYSTEM USA model MIKUNI 8513655 MB 1 mm Float Main jer Main air LS run Jut 5042 yet 3 Pilot jet e 2 Bypass BP 08 mm Pilot outlet wo 07 mn Valve sont Ws 23 mm Starter jet sas ws PRESET Pilot uir jet 135 mm 05 10 mm play 002 004 SPECIFICATION USA model for Castoenial California model only Bore size 36 mm 1 4 in _ mn 1200 100 r min 1100 100 rimin Switzerland model 1100 3rd o s 30 425 PRESET 17 turns 138 mm 1 D NO LOCATION Ench carburetor has LD Number t printed an the carburetor body according to its speci
6. Loose pms Excessive wear Damaged roters Improper chow a Dry or rusted links Missing O ring seats Kinked ar binding links If any defects are found the drive chain must be CHECKING Place the motorcyele an the side stand Laosan the mide nut c Tense thy drive chain fully by turning bath chain ad 4 Count our 2 pans 20 pitehesl on the chin Service Limit 319 4mm 12 6in ADJUSTING Loosen or inhton boil cham a 28 20 10 1 2 in oF shack in the The mark ads that the trant and the motorcycle on tor Altur adjusting the dive chain slack wih securely Titum bath adjusters Reor axlo nut Tightening 85 195 Nev 85 115 kom 815 830 De CLEANING AND LUBRICATIING ps Wash the cham with ke quickly thu must be shortanert CAUTION Da not uso trichlono gasoline ar any similar fluids These fluids have too great 2 dissolving power for this chain and what is more important they can damage the 07 rings lor seals confining the grease in the bush 10 pin elearance Remember high durability comes from the presence of Grease in that clearance PERIODIC MAINTENANCE AND TUNE UP PROCEDURES 212 Alter washing and drying the chair twit heavy weight mator ail CAUTION Do not use any oil sold commercially as drive S
7. 9 mm i WEM STANDARD Crankshaft thrust bearing eae 230 248 thickness 093 0098 242 244 Right side 10 095 0 096 Cranks cur 005 1 002 OIL PUMP STANDARD mr Oi pump rano 189940276 7 AMEN pressure v B0 C 14031 Above 300 kPa 2 0 43 pai Below 600 kPa 160 B5 pel 2000 CLUTCH Uv mm el FEN STANDARD UMT Drive plate thickness 252 268 272 0100 0108 0087 Driven plate 0004 Cinch spring height 012 hive master cylinder bore 14 000 14088 095112059291 latch master cpindor piston diam 13457 13984 05495 0 5906 lich release Cyr are 25 700 36762 14055 14079 Ciuc release cider bintan 35650 35675 14035 1 4045 SO MODEL TRANSMISSION DRIVE CHAIN Unit mm fin Except ratio TEM STANDARD Paty reduction ratio 1565 172 48 reduetion satia 3200 48 15 Gear ratios Low 238413 2nd 1631 39 19 1250 25 20 am 1045 23 22 Top 0 913 21 23 Shift turk to prove clearance Na 1 2 01 03 080 5 No3 10 004 0 012 10020 Shit tork groove wth Nod 50 51 No3 0797 0201 No2 48 49 0189 0193 TAKASAGO RKS32GSV2 Links 20 pitch 3194 length 26 Drive cham slack 25 30 0 12 Gear
8. SELECTION TABLE EXHAUST i i STEERING WIRING DIAGRAM ETT voran ar rer
9. or pisc Melius ov p cian Retighten replace Drain out cest oil Chan ai ar chat Adjust or replace Change trouble Mediom or high speed trout ol fluctuations flow and fuel lav pint ar vacuam qiue point of property at are clogned or loose 2 Air leaking from carburetors int vacuum joint Plot or bypass clogged 4 Starter plunge vos folly eee Main jet or man av yet is cloned 2 Needle ot is clogged 3 valve operates properly segura vawe is wor ar samage 2 Sorina in needle valve broken 3 working proper Fureign haz ted 6 nen val Fuel evet Te on a D CARBURETOR Complain Symptom and possible causes Tomedy Trouble wiih starting 1 Site jt 1s clogged 2 Starter ype clogged Goan 3 Ar leaking rom a joint batwoen starter body and Chock stator body and carburetor for gine Sits et opi Gash eck and oque Creek and Check and tionn Chock and ten Chock and elean Chack and adjust hock and tes Check tote valve lar operation Check and clean Check and adjust pea SERVICING INFORMATION 74 ELECTRICAL ELO I elec gon
10. replace Detective starter relay enlace 35 SERVICING INFORMATION BATTERY D Probable cause Remedy sulfation acidic 1 Yor mougn ecos water he bariery has not white powdery sub eem ana sulfation hus not stance or spots on swe advanced Yoo ter and Incas of plates 2 Battery case cracked Replace the banery Battery Pas been im a riadenn Replace the banery fang the 4 Contaminated pa sulfation has won avanced 100 or uy eres ented Ihe battery and become restore the battery by veniacing the wi the cleri crol rca y with hal erp detached from the matoreyemand ten adjusting 5 6 T The method not conect Cheek the generator regulam and cic connections and make noos soy adjustments to in chau 2 Coll plates hove Inst much al operation result of pave the battery and correct the charg dra systen 3 shorteircus condition extsts will e tory lu excessive accuma the banery tion ol sediments raised by Ihe high wioetinvte SG 4 56 ie od aw eeharge tw fly ad adjust wlec 5 Contaminated vectes Haplace the slocinotyio rechange the tory tw act G Replace the bate Replace the batty and
11. ENASSIS_ 64 CALIPER AND DISC INSPECTION CALIPER Inspect the caliper bore wall for nicks scratches nr other damage PISTON Inspect the piston surtar tor any sersichns or damage RUBBER PARTS Inspect each rubber part for damage and wear oise Using u micrometer check the dise for waar s t be chnckod witii dise and in place The service limas lor the thickness ot thu dises are shown below 09900220206 Micrometer 10 25 mm Service limit Front 4 5 mm 0 18 in 55 mm 0 22 in With thu dise mounted wheel chuck the disc For face runout with a dial gouge as shown 09900 20608 Dial gauge 1 100 mm 09900 20701 Magnetic stand Not available in U S A Service limit 0 30 mm CALIPER REASSEMBLY AND REMOUNTING Reassemble and remount the caliper in the reverse order af removal and disassembly Pay attention to the folowing ports CAUTION Wash the caliper components with fresh brake fluid betore reassombly Never uso cleaning solvent or gasolina 10 wash them Apply broke fluid to thu caliner bore and piston to be inserted into the bore massis CALIPER BOLTS Tighten ach halt f the specified torme Tightening torque 1 20 25 20 25 kgm 145 18 0 Ib 2 27 43 Nem 2 7 43 kom 19 5 310 Ibit 20 26Nm 20 25kgm 145 18010 CAUTION Bleed air from the system after Refer to pago 2 14 MAS
12. 202481 00680 oy lt 400 m Gm 98 UN S i Loera wi pas snp uium Guo ISNYHL WSVONIMS ANGOL 920 SHOCK ABSORBER AND CUSHION LEVER TIGHTENING TORQUE Nn 40 50 110 160 G Apply SUZUKI SUPER GREASE an 6SK RTI ESO MODEL SUSPENSION SETTING FRONT SUSPENSION SETTING TABLE Damping force es Compression Rebound NS a Sends Standard 2 Sitar nat ing fct t REAR SUSPENSION SETTING TABLE Damping forse Qui Compression Rebound tion 1 click don 11 click e s 4 won Thich I click Ri Rebqund C compression i6 Spring adjuster Compression adjuster Rebound adjuster BSXRMHOOL SO MODEL 922 WIRING DIAGRAM 923 esx HOSE ROUTING O
13. WOOK apa eg numis eai Ma a De pug GSX H1100L 90 MODEL This section describes service data service specifications and servicing procedures which SXF JOOK aS model differ trom those of the wars Any differences between K 89 madelland L 30 madeljm specifications and service data ori clearly indicated with the asterisk marks Please referto the sections 1 tough 8 for details which ars not given in this section CONTENTS SPECIFICATIONS e SERVICE DATA TIGHTENING TORQUE 9 14 ENGINE MOUNTING 9 15 CYLINDER HEAD 9 16 STEERING 947 SWINGARM 9 18 SHOCK ABSORBER AND CUSHION LEVER 9 20 SUSPENSION SETTING 9 21 WIRING DIAGRAM 922 HOSE ROUTING 9 23 THROTTLE CABLE ROUTING 9 26 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length Overall wath Overall height Ground clearance Dry mass ENGINE Number of cyhnders Bore Stroke Piston displacement Carburetor Air loaner Startur system Luhriention system TRANSMISSION Transmission pattern Primary roduction Final reduction Gear ratios Low 2nd e Drive chain 2080 mm 81 9 inj 755 mm 28 7 inj 1150 mm 45 3 in 1465 mm 577 in 110 mm 4 3 ia 7218 kg 474 For model 7217 ka 478 Ibsi For E33 model Fourstroke Aircooled with SACS DOHC TSCC 4 78 0 3 07 in 59 0 mm 2 32 in
14. ps Replace Spark plugs soon ich Ajira coumis with 2 dina speed sot Auss carburators 3 gasol Change 4 Dirty elemen w sir came Cleo 5 Spark puns 100 colt Spark plugs become 1 Worn piston ongs pace fouled too soon 2 Piston v opaco 3 Excessive clearance of valve some lo uina 3 Worn ea Royce Spark plug 1 Spark plugs too hot Rete wn type overheat or burn Din 2 The entire overheats up 2 Spr plugs Meno ton toa Generator does net Open hint Imad wios or Yoose lead connections or ep ar carge 2 Shortmd grounded or open generator 3 4 epe chargo but charging rate ia blow the Benne preis Adi est ha upper tw Flaca battery Banarane placa the battery overcharges 2 1 1 3 Regulater poorly leon round connection Unstable charging 1 Lead wire insur ray 10 lication residing in Repair oF tent shore 2 3 Detective regulator nd vector Replace Stories button js net 1 Bate m oF replace 2 Detenine swi 9 3 rushes mut seating propery on commutator in starter
15. 2 14 reassembling master cylin FRONT FORK Ten 245 335 130 700 li Ey 6 Apply SUPER GREASE A Th1342 Apply THREAD LOCK 1342 REMOVAL 1 Remove the lower fairing assembly 2 Suppor the motorcycle with jack or wooden block 3 Remove the front wheel 4 Remove the front fend 5 Remove the front fender brace 09900 00401 L type hexagon wrench Nor Slightly loosen the front fork cap to facilitate ater disassembly before loosening the tront fork clamp bolts When removing the left front fork make sure laasen the steering damper CHASSIS 612 6 Loosen the handlebar holder mounting bolts and 7 Loosen the front fork upper lower clamp Bolts Remove the front forks 09900 00410 Hexagon wrench set available in U S A DISASSEMBLY Y Push the inner tube down and loosen the spring adjuster lock nut and remove the trom fork cap sor spring 2 Invert I fork and stroko It seve 3 Under the Invertad condition of I for a few mites 4 While holding the caliper mount portion 2 by vise romave the damper rod bolt with the special root and hexagon wrench 0994054820 Front fork disassombling tool 09900 00401 17 type hexagon wrench ser 5 Remove the inner rod damper rod oun of the inner tube caution Do nat attempt to disassemble the inner rod damper rod
16. 3 0 e Tighten the starlor cuten mounting 10 the specified torque by using the special toal aus torque wrench Tightening torque 143 157 Nim 143 157 kgm 1035 11351040 09920 34810 Starter clutch holder install the starter idle gear aud is shalt SUZUKI BOND NO 12076 to the s rlacis upper and lower erankeases shawi For USA modo 99104 31140 SUZUKI BOND NO 12078 For the other models 00031140 SUZUKI BOND 12078 install dawal mow yaske and starter chute covey Tighten thw covor bolts securely the gasket to ho Starter elute cover s correctly as shown m the Fig CAUTION Une now gaskot Lo provent leakage Install he generate with hrs bolts Tightening torque 21 29 Nm 21 2 9 kom 150 210 mW NOTE Apply SUZUKI SUPER GREASE A to the generator Oring For U S A modal 99000 25030 SUZUKI SUPER GREASE A For the other models 9900025010 SUZUKI SUPER GREASE Install the starter molor with two bolts wore SUZUKI SUPER GRFASF A to the starter motot O ring Apply a quantity at THREAD LOCK 1342 to the bolts 99000 32050 THREAD LOCK 1342 TS Install the piston rings in the order of oil ring 2nd ving and NOTE Tap ting and 20d ring ditter in the shape of the ring Face Top and 2nd ring have a letter N marked
17. ga CHASSIS REAR SUSPENSION SWINGARM 3 vom Naw p 3 85 115 85 115 D 22 34 22 34 160 245 2 _ 18 28 18 28 10 200 Tor EDA 28 and 33 models For tha other models 6 Apply SUPER GHEASE A CHASSIS 640 SHOCK ABSORBER AND CUSHION LEVER 3 ons we nano 1155 V ey SUPER GREASE E CHASSIS REMOVAL 1 Remove the lower fairing assembly 2 Support the motorcycle with jack or wooden block 3 Remove hoth seats and left and right Tame cover 4 Remove the rear lower lender Remove the rear brake hose unian balt CAUTION Completely wipe off any broke fluid adhering to any part ot motorcycle The fluid reacts chemically wipe paint plastics rubbar materials ete 8 Humave tho c lper mounting bolis 7 Remove the rear axle qut 8 Loosu thu chain adjusters 9 Draw out the shalt 10 Remove thu rear wheel 11 Remove the swingarem pivot 12 Humave the shock ubsorber upper mounting bolt 13 Remove the cushion lever maunting 14 Remove thw shack bs rbor reservoir tank 18 Remove tha rear suspension assembly 18 Remove the shock absorber cushion lover and cush tram the swingarm INSPECTION SWINGARM Inspect the spacer for any flaws or other damage Insert the spncor in tha bearing and check tho play by moving tho spacur up and down If
18. Removal the lower the oil pressure gauge with adaptor Y in the position shown in fiue e Warm up the engine as follows Summer 10 01 2 000 r min Winter 20 min at 2 000 r min e Aftor warm up increase the engine speed to 3 000 t min with the engine tachometer and read the oll pressure gauge 0991574510 pressure gauge 0991574540 Adaptor 0991577330 Meter for high pressura 33 ruat ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE The parts ted below can be removed and runstalled without removing the engine fram the frame Refer t the page listed in each section for removal reist ENGINE LEFT SIDE See page lower Engine sprocket cover Engine sprocket and cham Neutral indicator switch body 319 clutch cover E Start uh 338 Starr iio guar ENGINE CENTER Soe pago Fist pipe muffer Ol cooler 37 Oil hase 37 E 313 pan 320 Sump titer 320 Carburetors 26 Throttle cable Cam chain tensioner 313 Cyimdur hand 313 Camshat s Starter motor 315 Generator ENGINE RIGHT SIDE Signal generator cover Signal generator 316 Oil pressure switch 358 Cluteh 316 Clutch pressure dive and drien plates 7 Oil pursp duven near 318 Generator oi pump drive gears 314 Primary diver ear E Bears shaft ps 318
19. ENGINE LUBRICATION SYSTEM 42 FUEL AND LUBRICATION SYSTEM CYLINDER HEAD COOLING SYSTEM CHART CYLINDER HEAD COVER 341 Q wwe A ou sume rurer Qoam xi FUEL Avo LUBRICATION System 422 CYLINDER HEAD COOLING SYSTEM 423 FUEL AND LUBRICATION SYSTEM OIL COOLER Dil Cooker An Is useri ws ol ven fe opt by compensating far Me haat prod gine TIGHTENING TORQUE Nm 12 60 85 25 30 25 30 180 218 5 35 2 45 255 325 Oil Pressure Regulator The oil pressure regula is threaded into the all passage w Valve relict pan in parallel circuit with the cooler whan il pressive between the entrance and Ive is mounted in the Low Engine Oil Temperature Wu is high and there 15 a great loss ol pressure naide cooler When the relative prassure of the entrance and exit js greater Wan kg cm 600 KPal the callo valve operates bringing ail directly from the pump oil Wer High Engine Temperature Wren ongine oil temperature i high oi 1y is low and relative pressure drops below O kg cm 600 KPa In this case the valve does not operate this allows th
20. Mate tl lower crankcase with the upper crankcase amd tighter the ceunkehafe tightening batts with spe Ihe indicated order Toit Tightening Final Tightoning torque 13 Nem 20 omm bolt 13 kom 20 S5 ibt 145 1788 e Remove the lower crankcase and in the usual many journal bearing oil clearance Standard 0 020 0 044 mm 0 0008 0 0017 in Service Limit 0 08 mm 0 0031 in compresse plas e it the ith at the vadest part exceeds the limit replace the of hearings with new ones referring to 1 table MONE a Check the correspond crankcase jour LD code num ber 1 A or E which are stamped on the rear of upper cronkcase e Check the carresporiing crankshaft journal OD code number 42 7 BY ar which are stamped on ihe crankshaft Bearing selection tabla OD O3 ano Brown 01 Black Brown Yellow Cronkcaso LD sporitication specification 39000 39 008 mm 15354 15357 39008 38016 mw 19387 15361 i Crankshatt journal 0 0 speciticntion Code 00 specification 5 36 992 36000 mm 14170 1417319 36 884 36992 mm 14167 141700 35976 25 984 mm fara 141874 99800 20202 Micrometer 26 50 mm ENGINE jaring thickness specification Grooved boaring wit
21. maximum stresses Th reliatslity ef the uique depends on cans and vestram exercises during rules aro as follows to these breakin engine spoed line Initial 800 km 500 rios Below 5000 r min Up lu 1600 iav 1000 miles Below 7000 r min Over 1600 1000milos Below 11000 r min nari reach oxonieter reading ot 1890 kim 1090 des Yau can subject maroreyei operation However Mo nal 11000 hind Wi CYLINDER IDENTIFICATION Inu our ivluvders oF are identi as N 1 No 2 4 ss from right as voe Dy Ino r seal GENERAL INFORMATION SPECIAL MATERIALS The materials listed below are needed tor maintenance work on the GSXR 100 and should be on hand for ready us They supplement such standard materials as cleaning Mulas lubricants emery cloth ard the ike How to use them and where to use them are described in the text af this manual WATERIAL for USA modai Far other models SUZUKI SUPER GREASE A 0 SUZUKI SUPER GREASE 25910 rre A Ro gt Lo A gt suzuki MOLY PASTE MOLY PASTE prd sooo ue Mid 1 Es Suzuki BOND NO 12078 Amina SUZUKI BOND NO 12078 38000 31140 THREAD LOCK SUPER 1302 THREAD LOCK SUPER 1303 5900032030 3900032030 LOCK 1250
22. pan pasket 6 Cum chain tunsion adj 1 9 tor gasket Exhaust pipe gasket Dil strainar protector gasket Starter motor 10 Fuel cock gasket pi Fuel rank hear 17 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall engin Overall width Ovatall height 5 Wheelbase Ground clearance Dry mass ENGINE Type Number af cylinders Bore Stroke Piston displacement Carburetor Ait clesnec Startur systom Lubrication system TRANSMISSION Clutch Transmission Gwurshilt pattern Primary reduction Final reduction Gwar ratios Low ana am Top Drive chain 2050 imm 80 7 ini 755 mm 29 7 ic 1150 mm 453 1440 mm 86 7 inj 110 mm 4 3 in 211 kg ABS ibs 212 487 210 463 tosh For Switzerland model For Caktornia modal For e other models Fourstroke Air cooled will SACS DOHC TSCC 4 78 0 mm 3 07 m 590 mm 2 32 1127en 68 8 co ini MIKUNI 8573655 four Polyester liber eloment Electric starter Wet sump Wet multi plate type hydraulically operated 5 speed constant mesh down Aun 1 565 72 461 3200 48 15 2384 41 131 7 631 131 19 1250 128 20 1 045 23 22 0913 21 23 TAKASAGO RK532GSV 114 links GENERAL INFORMATION CHASSIS Front suspunsion Rear suspension Steeriny angle Caster Trait Turning radius Front brake Rear brake Wer Front ire sue Rea
23. the 59 ELECTRICAL SYSTEM REASSEMBLY INFORMATION SUZUKI GREASE Avoly HAEAD LOCK 1249 U Garor ven a pest 3 Bumper housing 1 Drea pea Geran or ur te Paca eterno kuin Poca cone aora i ELECTRICAL SYSTEM 6 15 1 Apply SUZUKI MOV PASTE Apply SUZUKI SUPER opty tan 1382 T i Arman Jj Noung prd li INSPECTION CARBON BRUSH When the brushes are worn the motor will be unable produce sufficient torque and the engine wil be difficuli to ttn oven To prevunt this periodically measure the length of the brushes with a vernier calipers roplacing them wher are tao short or chipping 109900 20102 Vernier calipors 200 mm Service Limit Brush 5mm 02 in COMMUTATOR If the commutator surface is dirty starting performance decreases Polish the commutator with 400 or similar Ime ir emery paper when st is dirty Alter polishing it wipe the with a clean dry cloth e with vernier calipers Measure the c mmitator under cut 0990020102 Vernier calipers 200 mm Service Umi Commutator under cur 02 mm 0
24. the siig sure to bring the marked side to the top when fitting them ta the piston The first mambe fo go the vil ring roove a spacer ltr placing the spacer two side Fails designations top and bottom are not apphed ra the spacer sidu null you position each either way Position the gaps of the throe rings as shown Before inserting each piston into the cylinder check that the gaps are so located CYLINDER STUD BOLT LOCATION Wom No Length 168 mm 66 m 157 mm 82 in 164 mm 65 164 mm 6 5 in EXT NOTE When reinstating the cylinder stud bolt 7 apply SUZUKI BOND NO 12078 lightly 10 thread Tightoning torque 13 16 Mm 13 16 kom 95 115 lf For U S A modell 99104231140 SUZUKI BOND NO 12078 For the other models 99000 31140 SUZUKI BOND 12078 152 Check for clogging the oil jets ited on the crankcase NOTE When fitting the piston tien the tangle mark on the piston head to exhaust side gt Be sire to instal the pistons in the f ward removed disassembly ref to the letter mark 4 seribed the piston Have sach piston pin oiled li Place beneath the piston and inst NOTE Be sure ta use new circos Before puting on the cylinder block aud small ends of each conrod and
25. 09916 24311 Solid Pilot N 100 5 0 0991621110 Valve Seat Cutter set NOTE The valve seat contact must be inspected after esch cul Insert the solid piat 1 with a sight rotation Seat the pilot snugly Install the 457 cuner attachment and Y handle Using the 45 cutter descale and clean u or twa Inspect the seat by Une preveousty described smat width measurement procedure If the seat is pitted or buried dilana seat conditioning with the 45 is required NOTE Cut only fhe minimum amount necessary trom the seat prevent ihe possibilty of the valve stem becoming tor clase to the rocker arm for correct valve contact angle the seat with one ENGINE 328 contact area tao high on the valve or if it is toa wide use the 15 cutter to lower and narrow the Contact ares M the contact area ir tom low or toa narrow use the 46 cutter to raise and widen thu con Aller the desired anat position und width 15 use the 45 cutter very lightly to clear up any bur s caused by the previous cutting operations lapping compound after the final cut is made Tho finished valve sant should have velvety smooth finish not a highly polished or shiny finish This will provida a soft surface for the final seating of the valve which will occur during the first fow seconds of angine operation and assamble the head and v
26. Conventional Figures tue 7 M 234 45667890 Cl Toleranca i NE BH SE Components controlled GSX R1 100 are as follows The rarburetor specification for the omis Carburetor Main Needle de Pin 10 No Jar Needle Serow 4020 5043 yaa E PRESET 410610 ADJUST stato models a The pilot sermw jx re set hy the lactory utilizing specialized testing and adjusting procedures The pilot brew is al adjustablu as tho idle circuit is sealed after factory adjustinent Adjust iterom with imoroper replacement or resetting of an retor components may adversely affect carburptar performance and cause the motorcycle to exceed he exhaust emission level limits V persons who ate of Ihesu special carburetor servicing shauld restare the raibure oss o Iheir orginal condition or if unable to effect repairs contact the distributors representative for further technical information and assistance EMISSION CONTROL INFORMATION CANISTER HOSE ROUTING Only for California model EMISSION CONTROL INFORMATION 84 AIR SUCTION SYSTEM Only for California model ES EMISSION CONTROL INFORMATION AIR SUCTION HOSE ROUTING Only for California model a rupi uev DI veg imi rl odi ny op fuas os A inoun ja i gt
27. Brake tid type Dora EMISSION CONTROL INFORMATION CONTENTS EMISSION CONTROL CARBURETOR COMPONENTS 8 7 EVAPORATIVE EMISSION CONTROL SYSTEM 8 2 CANISTER HOSE ROUTING 8 3 AIR SUCTION SYSTEM 8 4 AIR SUCTION HOSE ROUTING 8 5 EMISSION CONTROL INFORMATION EMISSION CONTROL CARBURETOR COMPONENTS GSXH1100 motorcycles are equipped wih precision manutactured carburetors for mission laval conten These carburutars requme special mixture cantral components and other precision adjustments function property There are several cacburotos misture camtral components n sach carburetor assembly Three 3 of these components are machined to much closer tolerances than standard machined t fburutor jets These three 3 particular jets MAIN JET NEEDLE JET PILOT JET must nat be replaced hy standard jets To aid lentos Inese three 3 jats a different design of leiten ond number are used ruplacement of these lose tolerance jets becomes necessary be sure to replace them with the same type close tolerance jets marked as m the examples shown helow The jot needle is also of special manufacture Only one clip position provided on the jet I replacement becomes necessary thy jut needle may only be replaced with an equivalent performing replncurment component Suzuki recommends that Genuine Sueuk Parts bu utilized whenaver possible the best possible performance and durabi
28. For S A model 146 For the other 1575 ear wheel travel 140 rimas 001 PRESSURE SOLO RONG DUAL WONG TIRE PRESSURE kPa koom psi Wa kg cm pu 230 230 200 250 TEAR se 20 200 _ 42 741 SERVIEING INFORMATION FUEL TE SPECIFICATION NOTE Fel wpe Une oniy unleaded gasoline of atleast 87 pump octane 715 or 81 octane Maher rated by the research method e Gasoline containing MTBE Methyl Turitary Buty EtherL less than 10 U S A model ethanol or less than 5 methanol with Sppropnate cosalvents and corrosion Use only unleaded gasoline of at least 87 pump octane 2 2 or 91 octane r For canada model Woher rated by the researc method should be graded 85 85 For the oiber Fuel unk including reserve For california 6 8 4 1 US imp gal modal 2051 For sitaiana 154 45 US Imp 7101 bor 65 44 UsAmp val models ana clima en qi p 521 For the 163 4 4 USAmy wd modele Engine woe SAE 10W 40 API SE or SF Engine capacity 4000 mi Steven 42 35 US Imp at fier 4 200 mi change 4 37 US Imp at Overhaul 164 45 US Imp qt Font fork oil type Front fork oil capacity each leg 1153 16 0 05 ath rd E 418 mi For the otlier 3 14 2 or models
29. Observe the following items without fail when servicing disassembling and reassembling motorcycles L Da not run engine indoors with or no ventilation Bk sure to replace packings gaskets circips O rings and totter pins with new ones CAUTION Never reuse a Alter cirelip has boen removed from shaft it should be discarded and a now cirelip must be installed When installing new circlip cara must be taken not to expand the end gap larger than requirod slip the circlip over the shaft Attor installing a circlip always insure that it is completely seated in its groove and securely fitted 1 Tighten cylinder head and case bolts and nuts beginning with larger diameter and ending with smaller diameter from Vo duit sude channnaliy to the specified tightening torque LI Use spucial tools where specifier LI Use genuino parts and recommended ois I When 2 ar more persons work together attention tu the salety of each other LL Aftur the assembly check parts for tightness and op LE Treat gasoline which ie extremely flammable and highly explosive with gruatust cara Never use pasaline as cleaning solvent Warning Caution and Note are included In this manual occasionally describing the following contents WARNING The personal satety of the cider or bystanders may be involved Disregurdiny ihs information could result personal injury Tese instructions point out sp
30. Parking or position light 4 Tail Brake light 5 21 1 Turn signal light 2 m x Speedometer Eu Fuel level indicator ight a Es Tum signal indicaotr taht a gt cH beam on light T 3 7 Neutral indicaotr ligh ET E A Ol pressure indicator light 7 License light 2 gt E SERVICING INFORMATION BRAKE WHEEL Units mm mi TE Ur fea brake pedal Dra Ba Wege 2 EX i 022 la ice rund 030 012 Mustar cylinder bore 14000 14043 05511 05529 12 700 12743 05000 05017 cylinder piston diam 13957 13984 sylinder piston di gg em 12087 12 04983 04944 Brake caliper cylinder 33960 34010 no 13370 13390 30230 30280 beading 1902 11921 38 180 38256 bal 115031 15061 Broke piston 33878 33 928 teh 13338 13367 30 130 20 180 weis 413862 1 1882 38098 38 148 m 15000 15019 Wie rim nino M Wheel axe runout From Tre sie Front m Tie trend dS 20 SERVICING INFORMATION 740 SUSPENSION Unit mm ir mm STANDARD wr NOTE From fork srake 120 472 Front fork spring free lengths ma Front fork oil level as
31. STARTER SYSTEM Pulling the starter shaft fuel fs draum into the starter circuit from the float chamber Starter jet 82 meters this fuel whieh then into starter pipe 6 and mixes with the ait coming from the float chamber 24 The mixture fuel content reaches starter plunger 37 and mixes again with the air coming a passage extending ram behind the diaphragm Ihe twa successive mixings at fuel with are such that proper fuel air mikture lor starting js produced when the misture Is sprayed our through starter 6 imo the main bare amt merone map voc e FLOAT SYSTEM TFE Floats needle valve 23 associated withthe samu mezl ma amp that as the Noats move up and down the valve 72100 moves Whun tuo level is up i Noat chamber f3 oars Y are up and tel valve P remains pushed up against valve seat Under hve condition no fuel enters chamber As the fuel level talls floats down and needle valve 2 sel adit fuel into he chamber i in this manner woo valve 2 atts and shuts off fuel alternately to maintain a practically constant fuel level inside the chamber EL AND LUBRICATION SYSTEM 4 10 FUEL SYSTEM When turning starter motor negative press pressure works on the diaphragm of fuel cock generated in the combustion chamber This negative through passage way provided in the carbure
32. TIRE PRESSURE IV the tire pressure is toa high oF toa low stwering wall bo auvorsuly affected aud tire wear increased Therefore main tain the garret tire pressure far good raadability or shorter tire Wo will sult Cold inflation lire pressure follows SOLO RIDING DUAL RIDING COLD INFLATION TIRE PRESSURE kg cm psi p FRONT 230 230 mosso amo 250 29 2u az CAUTION Tho standard tire on this motorcycle is 120 70 2817 for front MICHELIN A59 and 160 80 ZRY7 for reir IMICHELIN M59 Tho uso of tiros other than those specified cause instability I is highly recommended to use u SUZUKI Genuine Tire STEERING Inspect Initially at 1000 km 600 miles 2 months and Every 8000 km 4000 miles 12 months thereafter Taper bearings are used in the steering system tor benor Stony should bu iste property for amaoth turning of handlebars Overtight steerma prevents of the hamddlebars and Ina lase steering will cause poor stabity Check thul thore na play in It Inck assembly by supporting the machine that the front wheel is att the round wiih wheel str mari grasp the lower fork tubes near the axle and puli forward I play is found perior siwermy bearing adjustmer page 19 nf this manual PERIODIC MAINTENANCE AND TUNEUP PROCEDURES 248 FRONT FORKS Inspect Initiall
33. and and chuck the continuity Uutweey f 2 with a pocket luster I Were Is no continuity replace it with new one 0990025002 Pock Testor knob indication Lit range TURN SIGNAL RELAY Tt turn signal relay is lovated or the fairing brace Ihe on simal light does nof light the bull repair Ec connection Ihe bulb and circuit checked uri signal rulay may be faulty replace it wath new one wore Be sure that the batiory sed is a pa ESA a D ELECTRICAL SYSTEM 528 BATTERY SPECIFICATIONS 7 ITA TET 1 EAT NT vss ee a MILD In fitting the battery to the motorcycle connect the breathor EG hase ta the battery vent INITIAL CHARGING FILLING ELECTROLYTE Hemave the shart sealed tube a before liling electrolyte Fill thw battery with electrolyte ite sulfuric acid solution wit acid concentration of 38 0 by wuipht having specific gravity of 1 2B at 20 C 68 FH to indicated MAX LEVEL Floctrolyte should be always cooled below 30 C 86 F before lig into battery Leave battery standing for half an hour after filing Add aditional electrolyte it necessary Charge banery wiih current os duscrihed in the rable shown below ERE Ra ma CHARGING TIME Tha charging time tor a new bottory js determined by the mumbur of months that have lapsed since the date al manutacture CONFIRMATION FOR
34. exhaust c 50 Wat the arrow paints flush wih Ihe askorad surface of the hear Ie eam chain w h thes speaker e The other arrow marked 2 is now pai Count the chain roller pins staring fram the roller pin directly above this grow markod 2 and ending with the 22 pin Engage the chain wilh intake sprpcket locating the 224 pin at the above the arrow 3 on Ihe intake sprockot NOTE Tho com cha mow riding on all three sprockets careful to disturb the crankshatt untif Ue ten camshaft journal holders cham idler and cam chain tensioner ace secured the intake ENGINE 365 Esch journal holder is identified with a castor letter Install the dowel pins ta each camsha journal holder Secure the ten camshaf journal holders evenly by tighten ing the camshaft journal holder bolts sequentially Try 10 vuualizo the pressure by moving the wrench dhagonally rom bolt ta another Iram nne carmela journal holder another to secure shafts evenly NOTE Damage 10 head camshaft journal holder thrust surfaces result f tho camshaft journal holders not dawn down evenly Tighten the camshaft journal holder bolts to I torque Tightoning torque 8 12 Nm Q8 12 60 8 5 ibd CAUTION T
35. mal surfauus between upper lawor craukeases as showy in the Fig For U S A model 99104 31140 SUZUKI SOND 12078 For the othar models 99000 31140 SUZUKI BONO NO 12078 e Install a new gasket and the signal generator caver with ive bolts ware the gasket to the signat henevaror 5 correctly as shawo un CAUTION Use a naw gaskot to provent leakage a Betoro installing the head cower maskers an lider heat cover apply SUZUKI BOND NO 12078 tothe rives ul lio cover gt Apply SUZUKI BOND NO 12078 10 the four cam end al the gasket as shawn in Ihe Fi For U S A model 99104 41140 SUZUKI BOND NO 12078 Fur the othar modela 99000 31140 SUZUKI BOND 12078 4 Place the cylinder hend cover an Ye cylin Fit up the gaskets lo the head 4 4 Sent the wight users 19 each exact position CAUTION Replace the gaskets with new ones ta prevent leakage Aller tightening dns hend rover union boite 15 0 the suuvibed tornue tinhten the bead caver holis 4 ta thu specified Tightening torque Head cover union bolt 15 17 Nan 5 17 kgm 11 0 1251640 Head cover 25 13 15 Nm O3 16 kym as m Attach the and left hoses and tighten the balts ta Ihe specified tongue Tightening torque 8 12 Nm 03 12 85 Itt CAUTI
36. 112700 68 8 cuin MIKUNI 8573655 four Polyester fiber element Electric storter Wet sump Wet multi plate type hydraulically operated speed constant mosh down dun 1 585 72 46 3200 8 15 2384 31 13 1631 21 19 1260 25 20 1 045 23 22 0 913 21 23 TAKASAGO RKS32GSV2 118 inks 90 MODEL 52 CHASSIS Front suspension Near suspension Steering angle aster Ton Turing rad gt gt Front brake ur brake Front tive size Muar fre size Front fork stroke Fwar wheel travel ELECTRICAL Ignition timing Spark plug Banory Gonormtor Fu breaker CAPACITIES Fuwl nk Including reserve Engine change with ix change Front fork oil Those specifications subject to change wi Asturick maki indicates the new model specifications Fully Telescopic sprmg ail damped Inner rod type spring pre load fully adjustable damping force com pression 10 and rehound Bway adjustable floating suspension system damped spring sorma preload T way ajustable damping force compression 19way and rebound 19 way adjustable 30 ight amp lel 6510 88 mm 13 90 32 1054 Disc brake Disc brake 130 602R17 180 552R17 120 Tim 158mm 6 20 7 BTD C at 1800 r imin 13 m 1500 r min JRB 50 4
37. 35 Nm 2 2 35 kgm 160 255 STEERING DAMPER Apply a grease to each bnaring and dust sual Refer to page For U S A model 99000 25030 SUZUKI SUPER GREASE A For tho other models 99000 25010 SUZUKI SUPER GREASE e Pince the stuenng bracket i onto the stourmi 4 Turn the steering to Kal eft lack parition clearance u CAUTION Do nor rum the nur f Apply small quantity ol THREAD LOCK mounting batts P Reter to page 6 14 99000 32050 THREAD LOCK 1342 e Tighten the steering damper brackol and by turning the the special torque Beter 817 STEERING TENSION ADJUSTMENT Check the steering movement in the following procedure Remove the lower fairing assembly using lacks ar two right and left positions on the frame down tubes llawor stravqht portions the front wheel unt I Is off rhe by 20 to 30 mm Remove the front sido of steering damper mounting bolt hock vo make sure that the c bles and wi properly routed Wilh the Tant wheel in the straight ahead state hitch the Apring seale tool on one handlebar grip und as shown in the figura and read whe graduation when the nnndiebar starts moving Do the same on the other ert Initial force 200 500 grams 09940 92710 Spring scale I the initia aree read ont Juri either Ina heavy too light adj
38. 4 780 mm 307 inj 58 0 mm 2 32 in 112760 168 8 cuin MIKUNI 8513655 laur 39 models MIKUNI 8574055 four Polvester fiber element Electric starter Wer sump ForFO3 14 33 For the other models Wet multi plate type hydraulically paratud Speed constant mesh down aun 1 585 72 46 3 200 48 15 2384 31 13 1631 31 191 1 250 25 201 1045 23 221 0913 21 23 TAKASAGO RK532GSV2 118 links mem ene SERVICE DATA TIGHTENING TORQUE 1234567890 1234567890 CYLINDER HEAD TAPPET CLEARANCE ADJUSTMENT
39. Dncarbonize the combustion chambers Check the paskerad surface of the cylinder head or distortion with a straightedge and thickness gauge taking a clearance tending at several places indicated W te largest reading 41 any Position of the swaightedge exceeds the Writ replace the head 09900 20803 Thickness gauge Service Limit 0 2 mm 0 008 in VALVE STEM RUNOUT Support the valve with V blocks as shown and check its runout with a dial gauge The valve must he replaced if the minout exceeds the limit Sorvico Limit 0 05 mm 0 002 in VALVE HEAD RADIAL RUNOUT Pince tbo dial gauge at right angles to the valve head tace an tiv valve hend radial runout Wit mensuras mora than the imit replace the valve Service Limit 003 mm 0 001 in VALVE FACE WEAR Visually mspecteach valve forwear of ts e any valva with an abnormally wore face Thu thickness C decreases as the wear of the tace advances Measure the thickness and the thickuess is found to have baen reduced to the limit replace 05 mm 0 02 inj ing tace Replace Sorvico Limit VALVE GUIDE VALVE STEM CLEARANCE Measure the clearance in two divections X and Y perpen Yo each othr by positioning thw diat gauge as shown If the clearance measured exceeds the limit see below then determina whalher the valve ue thu quide should be replaced Yo reduce the clearance to the standard range Intake Exhaust m
40. REAR 250 250 36 200 29 42 Asterisk mark 11 indicates thy mew model specifications dar seman FUEL OIL SPEGFGRTON so Tae Any aries aloe ot pir Brem conan Ret Ter SN Re hen aan TOW uma Forti mai Rt arte than E umano wt pects and Ter oni niente o tat B7 oun at For mode AA Gace and should be 16 95 Grane of Naher Ar nc Fat dha othar Tar ramis 48 4 1US mp oet 2051 For 4 43 qul 210 forth other T Fo rang US i we ont Foc aber 183 44 S n a modes EEL SAE 1009 40 API SE or SH el mei 4 000 ni Hm 4 200 al 100 mi 4 45 US ut Fran ek Tod aires Foo enc e pnta vora Asterisk mark indicates the new Lm del specifications SO MODEL ia TIGHTENING TORQUE CHASSIS zm er Steering stem head put 50 80 50 80 360 580 Frant fork cap bolt 15 30 15 30 10 215 Front lark damper rod holt 34 45 34 48 245 Front brake caliper housiny bolt 20 25 20 25 145 180 EEE For 60328 ond 33 18 28 130 200 oor hrake master cylinder mounting bot 18 28 130 200 Rear brake rod lock nur x 15 20 15 20 110 145 Rear sprocket nut 72 98 72
41. SPRING PRELOAD ADJUSTMENT Faring ti conteret Serrans the sping pr io There we von on cid ofthe agus O pre lond 20d poson Y proves ha mirum pr ood The ato on pain 5 The extenso damping force compres sion sue during trees ba seu by turing he ahr T0 dunt on sie damping ore tam Te edst the compresion ido users domingos tung he countries wil DAMPING FORCE ADJUSTMENT The metro ding for nd compres sn se dra tocan be rhy eure ton Tics al ren po A ro as rend om threo a a nl Mai ae to e wth he ity We ma SUSPENSION DAMPING FORCE ADJUSTMENT aduaneras wein ested by numbers Tough on he a handing damping sus be head Inno stops win ramon va ht 9 ek lance and the edust elo i wre a atento nee Ponton 1 provides or or pisar amour Tris moro dl verom factory win ns NOTE Do not operete rear comer Bion other a te ccs nerd pois pontine 2 Ya 3 a at re ad te da Ung forco wil automaticaly nave ne dono tng fre a mter 4 tet po NOTE recommended mer srg Merten hero ston SS RENA SUSPENSION DAMPING FORCE ADJUSTMENT crease o
42. Tiree phase AC Generator 720 10 10 10 30A 30A For Ea mado For E03 model For E33 model For E03 model 185 1 4 8 8 7 US Imp 210 85 4 6 US mp ga 42 1144 37 USAmp ul 7418 mi 14 0 14 8 US Imp ut motion E33 California U S A model E02 USA model 43 soon SERVICE DATA VALVE GUIDE Unit mm fin mir DTP Dx A ma E 0 35 re 032 018 023 0007 0009 AN Ed NEED E iai 0 1969 0 19731 gt 10 1947 0 1953 TT E T Eo PEE 10 10 MER 0035 0043 gt 0 001 REX gt il 1 38 length 28 mm 1 1 ouren 133 1S tke 269 333 ws at length 335 mm 122 inj DO MODEL CAMSHAFT CYLINDER HEAD Unit mm fini STANDARD Twi Cam hon 39878 229018 33580 z 31533 33573 33240 115702 122181 DE pumai ot esame 0032 0086 010 10 0013 0 0026 0 0059 holder LP 22012 22025 UM 0 8666 0 8671 Gerson journal OB 21958 21980 TES MS 10 8645 0 86541 010 wen 10 004 chain 20 ln 1580 am chain win a PETI cken arm Ib Y 12 000 12418 10 4724 0 4731 hecho am shah OD 10373 1984 INK 04714 04718 plis ond 028 CYLINDER PISTON PISTON RING Unit mm STANDARD 1200 1400 1600 a
43. and cluleh di phragm springs am the elutch pressure plate property e fighter the chuch diaptragrn spang holder nut to the specified torque by using the special tools 03920 34820 Clutch pressure plate holder 0994158010 50 mm socket wrench Tightening torque 90 110 Nm 90 110 kgm 680 7854 install the push rod 1 elnteh sh rand thrust washer inte the countershall hearing Fix the pressure plate lior wi 09900 06108 Snap ring pliers wore When fitting the cirelip make sure that the sharp edge ot thw irc faces outside Con SUZUKI BONO NO 12078 hj ta he mating dcin upper und lower crankcases as shown m For model 99104 31140 SUZUKI BOND NO 12078 For the othar models 99000 31140 SUZUKI BOND NO 12078 Install the dowa pins a now gasket and clutch cover thw cover bolts securely NOTE Fit tho two gaskets 10 the chach cover bolt showar in the Fig CAUTION Use only now gasi NOTE When fepiae n the prossure switch apply SUZUKI BOND NO 12078 its thread lightly For U S A model 39104 31140 SUZUKI BOND NO 12078 For the other models 99000 31 140 SUZUKI BOND NO 12078 Install the signal generator stator with three screws Connect the pressun switch lead w re to the ail presso suites terminal Make sure ta the on the back surface of the simal r
44. 04724 04731 Wacker aha 11973 11988 ERBE 04714 047184 Grider hand toin 4 020 CYLINDER PISTON PISTON RING Unit in TEM STANDARD Tir Gamelan pressure T200 1 400 KPa 1 900 kPa 1214 A Goran pressus difference 200 kPa dion 2 Fr sind leanne D 09091 Cyinder bore 78000 701 78 080 a 0709 30718 80740 71 348 71960 3 0687 3 0693 at 08 ne Worm e str on Ginder dion Lr Fiian ing ee end gap D 10 381 133 SERVICING INFORMATION mm ny Piston ting end gap Piston ring to groove clearance Pist n ing groove wid h Piston ring Wickross Piston pin ore Piston pin 0 0 204 204 der 204 oil 204 035 050 0014 0020 103 0040 0041 101 108 0040 0041 201 203 0079 00801 097 099 0038 0039 099 p 038 0 039 20002 20008 9 7875 0 7877 18996 20 000 07872 0 7874 20030 07886 19 980 0 7865 CONROD CRANKSHAFT Unit mm nl TEM Conrod small and LD Conrod big end side clearance Conrod big end Crank pin width Conrad big end oil clearance Crank pn OD Crankshaft journal ot clearance Crankshaft journal OD Crankshaft thrust clearance STANDARD 20 010 20018 10878 07880 010 020 10 004 0008 2095 2100 0825 0827 2110 2148 0831 0833 0012 0056 0
45. 06 separation separation Trend wear is extraordinarily deformed ar distributed around the tir 7 Serotches al the bead Cord is eut Damape from skidding fat spots Abnormality in the inner liner When repairing lat tre follow the rap instructions and use only recommended repuirina matorials W any one of the following items is observed do not repair the nth 20 mm 0 08 i Ihe roar tie ont re and less tt VALVE INSPECTION Inspect the valve after the tire is removed trom the rim and replace with a new valve the seal rubhor has a Inspect the ramaved valve core and replace wilh the new one the seal rubber is abnormally deformed or worn CHASSIS VALVE INSTALLATION Any dust rust around the valve hole must be cleaner aft Then install the valve in the CAUTION When installing tho volvo tighten the nut iT by hand as much os possible Holding the nut under this condition tighton the lock nut 7 Do not overtighton the as this may distort the rubber packing and cause an air leak TIRE MOUNTING Auply special tire lubricant ar tive CAUTION Never apply grouse or gasoline to the fal soapy liquido the When installing the re make certain that the arrow lacus the diveetion nf wheel rotation and halancing mark of thw with the valve as shown e
46. 2 18 2 1972 737 77610 3 Dual riding 1872 1972 mm 1737 7 26 in 2 CAUTION Do not set the spring to a length less than 187 2 mm 7 37 in or moro than 197 2 mm 7 76 inl CHASSIS CLUTCH MASTER CYLINDER 1 REMOVAL 6 Remove the clutch switch in Place ruy undurnanth the union bolt on the master catch any spilled drops 6t brake Un bolt und disconnect the cluteh hose from rhe mast CAUTION Completoly wipe off any brake fluid adhering to any parts of motorcycle The fluid reacts chemically with paint Plastics rubber materials ete and will damage thom vera Remove the clutch master cylinder by removing its clamp bots DISASSEMBLY AND REASSEMBLY Disassemble and reassemble the chitch master ey samu manner of the front brake master Roter to pages 8 9 and 6 10 lor details ERVICING INFORMATION CONTENTS TROUBLESHOOTING 71 WIRING DIAGRAM 7 8 WIRE HARNESS CABLE AND HOSE ROUTING 7 14 SPECIAL TOOLS 726 TIGHTENING TORQUE 7 29 SERVICE DATA 731 SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine vil not stort Compression too low ors herd te st Vale inarance out of adjustment acuer 2 WON valve ides poor seating of valves Repar or replace Vans 4 Piston rings excessively worn Replace 5 Won
47. 9 13 20 74 8 12 20 25 12 18 15 23 140 180 90 110 18 28 18 28 22 35 00 130 50 70 06 08 30 45 12 04 07 19 53 143 157 25 35 09 13 20 24 08 12 20 25 12 16 15 23 140 180 90 10 18 28 18 28 22 35 300 130 50 60 20 85 45 50 215 325 60 55 30 50 355 380 1035 1338 1 0 285 65 95 148 178 5 145 100 85 115 110 165 1018 1155 550 745 130 200 130 200 160 258 725 940 360 436 305 635 SERVICING FORMATION 730 CHASSIS TEM kom Steering stem head nul 50 50 Front fork upper clamp batt 22 35 160 255 Front fork lower clamp bolt 22 35 160 205 Frant fork cap bole 15 30 1 Front fork damper rod bolt 34 48 248 385 Front as 8515 Front axle pinch bolt 18 28 Handlebar holder mountmy bolt 80 60 360 435 Handlebar holder mountings nut 22 35 2 Front broke caliper mounting bolt 27 43 195 319 Front brake caliper housing bali 20 25 145 180 Front brake pud mounting bolt 15 20 110 145 Front brake master cylinder bolt 05 08 38 Brake hose union bolt Cylinder amp Caliped 20 28 145 190 Air bloodur valve Front amp Read E on os Front rem dise bolt Front taptrost bracket mounting bolt Rear brake caliper housing bolt 80 36 36 Roar torque link nut Front amp Rari 32 34 22 34 For E 02 28 and 33 18 28 18 28 Huur brake master cyli
48. AND FUEL TANK WATER DRAIN HOSE ROUTING SERVICING INFORMATION BATTERY BREATHER ROUTING MUFFLER SUPPORT dampes comp sn lvo SEAT LOCK CABLE SERVICING INFORMATION 7 24 328 SERVICING INFORMATIC RESERVOIR TANK ROUTING SPECIAL TOOLS 228 SERVICING INFORMATION TIGHTENING TORQUE ENGINE head cover union bolt Cylinder head nut Cylinder haad bolt Cylinder base nut Cylinder stud Valve cluarance adjuster lock nur Camshaft journal holder bolt sprocket bolt Rocker arm shaft set balt hose mounting bolt Cylinder head side hose mounting bolt Crankcase aid Gam chain tenssaner bolt Cam chain tensiones spring holder bolt hum or mounting bolt Gam chain guido mounting bait Conrod bearing nut Starter clutch mounting bolt Signal generator bolt Crankcase bolt 6 mm 8mm pump mounting bolt Oil pan bolt Bosh one slave i mur Chat diaphragm spring hold TUTTI NES Mir mauming side Muter mounting far sid Engine sprocket nut Engine mounting 12150 mm 178 mm a a 30 45 a 12 4 7 49 53 143157 26 35
49. CYLINDER DISASSEMBLY Remove the clutch hydraulic Ime by removing the union bolt 1 Remove the gearshift lever and enqine sprocket cover Refer to payo 38 Completely wipe off any cluteh Mid adhering 10 suy part or molarcyele The tli reacts chemically with point plastics rubi ais ote S Remove valve 2 Remove the clutch release cylinder by rervoving ng bolts I and piston retainer Flnce rag over he piston to prever v up Force out piston by using air pun cautio Da not use high pressure air to provon piston damage INSPECTION thw clutch cylinder bore wall tor nicks scratches or thur seal For and woar 1 the piston surface for any scratches or other damage other damage Inspo REASSEMBLY Rensaumble the clutch eylind r m the reverse order of disas sembly and by taking Ie following steps CAUTION 4 Wash the clutch cylindor components with fresh brake fluid before renssembly Navar use cleaning solvent or gasoline to wash them Apply brako fluid to the cylinder bore and piston be inserted into the bora OIL PUMP CAUTION Da not attempt to disassemble the oil pump assembly The pump is available only as an assembly TRANSMISSION moine COUNTERSHAFT DISASSEMBLY Remove the eft end bearing Tand seal P maus he Top gear ci
50. Noa Deve chain Type Driva chain slack Gnarahitt lever 1 631 31 19 1250425720 _ 1045 23 22 0913 21 23 91 03 004 0012 50 61 0197 0201 48 49 0 383 0 193 TAKASAGO RK532GSV 114 links 25 30 10 12 126 _ 9 020 SERVICING INFORMATION 2 36 CARBURETOR SPECIFICATION fot izis eza Carburetor WERT xU E Eres Bore size CN wem socso 4 40690 Float height Main ot 2 2 iri A 5 Lit asa stses 5 2 Noodle jet 8 gt E Bit it Bypas 08 mm B Piot outa a7mm z set 25mm 7 Starter jot ws 45 m z Pilot screw P S PRESET PRESET PRESET tum sa rums Pilot jet 14 mm Tiwottle cable play 05 10mm 10 02 0 04 73 SERVICING FORMATION CARBURETOR SPECICATION upa E03 F33 2 Carburetor type Bore sze De a can 1100 wo 1100 igh 10 mm Main m MJ 110 7T MAD dox nance 503 Needle is maj 9 5 Piot jet xm Bypass Pilot aut E Vin Starter ot
51. Set the bead pushing roller Rotate the operation arm araure he to maunt ihe Dead sampletaly Do ihe bottom head first then Upper Bead Remove whet from the fire and install the valve in the valve stam Before installing the valve core the core Bounce the tire several times while rotating This makes the tire bead uxpond ainwards and thus makes inflation easier wore Before intining that the Balance mark lines up with the valve ster se Pump up ne tire with am WARNING Do inflate the tire to more than 400 kPa 56 psi Tho tire could burst with sufficient force 10 cause severn injury Never stand directly over the tire while Inflating it Check ther rim cast on the tire side walls t most be equidistant from Ihe wheel rim ait the way around the distance betwee the line and wheel rim varies this maces that the bead is nat properly seated this is so dentate the tire complete and unseat the boad for bath sides Coat the bead with lubricant and iry anat After tire la properly seated fo the wheel rni adjust the airpressuim 10 the recommended prossure Correct the wheel balance if necessary WARNING Do nor run repaired tire more than 50 km h 30 moh within 24 hours after tire repairing since the patch may hot be complotely cured 130 km h 80 mph with a ropairod tire
52. a en Jo O 19 o irae Y 200 91 Py 28 oa Paton 0080 6000 0120 09020 0 0024 woven Cynder ove 78900 78 01 78080 20708 20718 ITO 77545 71900 20087730693 zus Measure at 15 mm 0 6 in T Sylar nonton 020 109081 Prion fog Ire and gap E 32 N 0361 25 asaro Crank pin 00 Crankshaft journal il clearance Crankshaft journal 00 Crankshaft lust clearance 37375 38000 14951 14981 0020 0044 0 0008 0 0017 35 275 36 000 14153 14173 805 013 0002 0005 nit STANDARD Pasion und P 020 035 s 0008 0014 19 035 050 10 0014 0020 Psion sing 10 groove clearance 0 007 0160 oy 10 006 Piston ring groove width ta imi 0040 0044 8 10 103 4 0040 0041 201 203 0079 0080 Piston ring thickness T 097 099 10 038 00391 097 080 T 0038 0039 Piston pin bore 20002 20008 20030 07875 07877 07486 Piston pin OD 12993520000 19980 07472 07874 7888 CONROD CRANKSHAFT Unit mi Tw STANDARD wr Conrod amali end 1D 20010 20018 07878 07 0780 Conrod big end sido clearance 010 020 030 0004 0008 on Conrod big end with 2095 2100 0425 0827 Crank pin width 2110 2115 0831 0839 Carod big end eloaranae 0037 0088 0080 0001300022 90031 0 0031
53. abnormi noise anit smooth rotation Replace the bearing there is anything vous Rave the oil pump by 09300 00410 Hexagon wrench ser Not available in U S A mounting bonta Homove the O rings and dawel pins ENGINE 324 ENGINE COMPONENTS INSPECTION AND SERVICING CYLINDER HEAD SERVICING CAUTION Be sure to identify each removed part its location and lay the parts out in groups designated as No 17 No 27 Exhaust Inlet so that each will be restored to the original location during assembly wore When removing the rockar arm shaft remove the rocker arm shaft sel and piny 2 ae 8 mm into rocker arm shaft end and Tighten tho set bolt and plug 2 10 the specified torque Removal of valves completes ordinary disassembling work H valve guides have to bo removed for replacement alter Inspecting related parts carey out the steps shown m value puide servicing Tightoning torque Sot bolt 8 12 0 8 12 kg Plug gt 25 30 Nim 2 8 30kgm 180 21 51 sw Using special tools compensa the valve springs and take off the wo conter halves 1 from valve stem 0991644510 Valve 08916 14910 Valve liter attachment 09916 84510 Tweezers Faka aut the spring retainer inner and Suter s Pull out the valve from tie other sxe 325 ENGINE CYLINDER HEAD DISTORTION
54. also the sliding surface of each piston e Place the dowel pins and nuw cylinder gasket um the sure 10 identify the top surtace by UP mark gasket us shawn in Uno Fig Install piston ring holders in tt Hight resistunce must be averen block With No 2 and No 3 bastons in place Install No 1 amd No 4 pistons and insert them Inte the 0991674521 Holder body 09916 74540 Band Indicated manner Some 10 lower the cylinder Nore Da mat the special 1001 bands or the pistons imo the cylinders walt diheu e Tighten the nut to the specified torque Tightening torque 7 11 Nam 03 13 kam 5 0 80 Ibe ENGINE Place the Dings and two dowel pins on the cylinder CAUTION Replace the O rings with naw ones to prevent oil leakage sure roplacu Hw hod gasket wi prevent gas leakage ware sure the surface by UP mark 1 on tha cylinder head gasket as shown in she Fi Wil the mew Damas omo the pipes auply SUZUKI SUPER GREASE A the Q rings Install the right and lett oll pipes For U S A model 99000 25030 SUZUKI SUPER GREASE For the othor models 9900025010 SUZUKI SUPER GREASE CAUTION Ropince tha O rings with naw anes to prevent oil leakage e Pince the cylinder h
55. am excessive play is notud roplac the bearing with a new one 1 oach dust seal for wear on amago CUSHION LEVER Inspect the spacer for any llaves or pihor damage Insert the spacer in the beating and check the play by moving the spacer up and dawn Ian excostive play is noted replace the bearing with a new nspoet each dust seal for wear and damage CHASSIS SHOCK ABSORBER Inspeet the shock absorber body bearmyy and hose for damage and cil leakage any deflects are found replace the shock absorber with new one SWINGARM PIVOT SHAFT Using a diat gauge check the pivot shalt the runout the 09900220808 Dial gauge 1 100 09900 20701 Magnetic stand 09900 21304 V block set 100 mm vice limit 0 3 mm 0 01 in DISASSEMBLY SWINGARM Rumove the dust seals washers and spacers rom the swingarm pivot 4 Remove the swingarm bearings by usw the special tral 09941 44910 Swingarm hearing remover CAUTION Tho removed bearings should be replaced with now ones fumavo the bearing by using the speci 0332374810 Bearing remover 109930 30102 Stiging shaft CAUTION The removed bearings should bo replaced with new ones cnassis CUSHION LEVER Remove the spacers and dust seals Remove the bearing stopper and drive out the bearing using appropriate took CAUTION The bearing and stopper rings re
56. cam nd ae or ower sth tet A waa ange are con p W come or jurt aprum Aa motori the crudi jou n t pressure Jo ate or otber punctures n Lu Tides es sometimes Vedi won puncta Then epe aa a e e A e E Dur uet ma A a nr s a ere ros lend neh can cout os wil neat up the tes oe to higher Marte may reset a client ds Tene re corel ety talon besar COLD Tne WFLATION PRESSURE ures when Wend i warn t speci o wm DUAL BORE eis wi rs how iu eines momo wr woma sch rc or e UE thon fec es sof the eno 226 fiet tha ple changing vencio Xr P handing characteres 23089 Crack te conis each doy botore you Eso koen 220 ts Y tres show eval anderen o ad flowing scum cama 0 A gt 10 08 a MAE PRESSURE AND LOADING rr ts eto iocos sc ae mter Teen Sse the corect or vicio stares make am conania rin tthe e below Tre pressure shoud wear Over ita checked and pst betore ence fo nala amunt ot Wre incor Gia il est up a res and lod to higher i Si can ende to co esse renga 7 COLO TIE WFLATION PRESSURE NOTE Th
57. holder mul remove the eluteh diaphragm sprinys i11 chinch diaphragm spring saat 2 and clutch pressure plate 3 Altar removing the several clutch plates remove the clutch sleeve hub nur after firmly locking tho chich sleeve hub with cloth huli holdor and hen remove the remainder of clutch drivo plates along wilh the Chueh sleeve hub 09920507 10 Clutch sleave hub holder e Ihe Aut washer c With the spacer removed Ihe primary driven gear integral wite clutch housing is Tree disengage from tire primary drive guar 4 Remove the primary driven gear assembly with the genera pump drive gears Fiona the hust washer 2 Remove tho clip and washer from the gearshift shatt Draw out the gwarshitt shahi and thor ven gunt 12 by removing the sermws 2 0990009003 Impact driver ser wore Where removing the canr driven do 01 tose the nino powt pira Ih and spring A nove the cam Remave the pump driven gear by removing the 09900 08107 Snap ring pliers NOTE Da not fase the circlip pim and washers Rove the starter clutel cover by removing the 09911 73730 5 mm T type hexagon wrench ETT Remove the starter dle gear and Loosen thy starr mount by using the ooi 09920 34810 Startar clutch holder NOTE When removi
58. roar brake light awiteh and brake pedal height aftar installation Refer ta page 2 331 Hor reassembling master REAR WHEEL Apply SUPER GREASE Th 1360 Apply THREAD LOCK SUPER 13601 390 520 110 180 828 CHASSIS REMOVAL 1 Remave the lower fairing assembly 2 Support the motorcycle with a jack or wooden block 3 Remove the caliper mounting bolts 4 Remove the caliper along with torque link at the portion mounting It CAUTION Do not operato the brake podal while dismounting the caliper 5 Remove the rear axle nut 8 Loosen the chain adjusters lef and right 7 Draw aut the axle shaft Disengagu the drive chain ram the rear sprocket 9 Remove the rear whai an drum ID Remave the rear sprocket along oI ne wheel hub 11 Rnmav the dampers the wheel hub 12 dise brake by eemavang the ma 0980000410 Hexagon wrench set Wot available in USA CHASSIS 630 INSPECTION DISASSEMBLY Refer to page 6 34 WHEEL AND SPROCKET DRUM BEARINGS Inspect thy play of the spective hearings by hand whi resi tha wheal Spencker drum Rotae the inner ra hand te speet for abnormal raise amd ratation Renlaer the bearing i nere is a e Dwg eut me wheel boarinqs and sprockor d using prop r toot CAUTION The removed bearings and oil seal should be replaced
59. see the following items 7 Diaphragm Mam jet Gasket and Orig 7 Throttle valve shaft oil seals Main sir jet Pilot serum bleeding hole Nerdie air at bleeding hates Pilot auttet and bypass holes Float FUEL AND LUBRICATION SYSTEM 412 REASSEMBLY Wnen engaging teo corburetors or two pares of carburetors sition the throttle valve control lever 41 correctly Apply THREAD LOCK CEMENT to the upper and lower plates 99000 32040 THREAD LOCK CEMENT Set each throma valve in such a way that top end meets thu foromost bypass This is accomplished by turning e Throttle stop screw and balance screws 4 NOTE The order of throttle balance scrows ddyistiment s as follows ll ho wark monet he carburetor assembly and the following adjustment are necessary Engi il Page 29 Thrortie cable plav Pago 28 Blanc carburetors Page 415 A33 FUEL ANO LUBRICATION SYSTEM BALANCE OF CARBURETORS Check the four carburetars for balancing movement according 10 the fallawing procedures NOTE When balancing the carburetors remove the fuel rank and fuel should be supplied by a s parate fuel tank and bo sure to plo The yel cock Vacuum line CALIBRATING EACH GAUGE Stan up he engine and runt in dling condition war Stop the warmod up engine Remover vacuum inlet cap for No T or Na cylinder Connect ul te four rubber hotes
60. st gt rin seno Ps 3 oun Pilot nie jot 1 35 mm 12 1 38 mm cable lay 05 10mm 92 v ELECTRICAL Unit mm inl ITEM SPECIFICATION I NOTE ignition timing Firing arder Spark plug Spark performance Siynal resistance Ignition resistance 13 ELT DC at 1500 r min 7 BTOC at 1 500 1243 Type 06 07 Gap 10 024 0028 Over 8 10 3 at 1 atm Approx 135 2000 tap Approx 24 32 Plug cop Ping cap Approx 30 40 Primary Secondary Calitarma model only IOPT Cold x 1000 Tester range 87 SERVICING INFORMATION 738 Unit mm SPECIFICATION uE Generator Ship ring OD Limit 1400581 Brush length Limit 4 5 0 18 NS Regulated voltage 13 5V st 5 000 r mi Starter motor Brush length Limit 6 10 2 Commutator x MITSUBA y 02 0008 Staner 1 3 509 Battery designation YB 1ALAZ kl Capacity TAV Kc 120 at 20 PT Turn signal 104 Ignition TOA Tali AS 104 Circuit breaker x 30A WATTAGE Unt We SPECIHCATION ian 177 a Eod as E Yo es ere Headlight 2 80155 60 208 B0 35 200 10 55 gt 2pes B 55 36 2pos
61. stop screw referring engine tachometer reading lits r min 1 100 100 r min 1300 tor E 1B modet 1200 100 r min for E03 Except nia mode CAUTION Do not disturb the pilot screw This component is PRE SET at tha factory by the vory specialized equipment EON E03 USA E18 Switzerland 4 FUEL AND LUMRICATION SYSTEM LUBRICATION SYSTEM OIL PRESSURE Start the engine and check IF the pressure indicator tat is Turned on If it keeps an lighting check the ail pressure indicator ight circuit it s in goed eandition chock the oil pressure in the following manner Hemave thu main oll gallery olus Install the pressure gauge with adaptor 1 in the position shown in the figure 09915 74510 pressure gouge 09915 77330 Motor for high pressura 0991574540 Adaptor Warm up the engine as follows Summer 10 mir at 2000 rmn Winter 20 min ar 2 000 r min wore Engine must be warmed op to C 140 F when checking the After warming increase the Angin speed to 3 000 r min will unine tachometer roading und read the oil press Above 300 kPa 3 0 Bulow 800 kPa 16 0 kg cnt fat 60 C 140 RAR I the oil pressure is lower or higher than the specification several ausus may be considered Low oil pressure is usu
62. thickness laking clearance duoc at several places as indicated If the largest reading any pasition of the exces replace cylinder binc 09900 20803 Thickness gauge Cylinder distortion specification Service Limit 0 2 mm 0 008 in CYLINDER BORE Measure the cylinder b ru at six places any one of the measurements exceeds the limit overhaul the and replace the piston wilh an oversize piston Th Oylinsers must he also rebored accordingly Otherwise the Imbalance might cause excess vibration ar LECT EU p mer onen 2 335 ENGINE Cylinder bora Service Limit 78 080 mm 3 0740 in 0990020508 Cylinder gauge sot PISTON DIAMETER Usa a micrometer measure the p stan s outside diameter at The lace shown in Fig IFihe measurement is less than replace the piston Service Limit 77 880 mm 3 0681 in 09900 20204 Micromerer 76 100 mm PISTON CYLINDER CLEARANCE Asa row above mensurement it she piston FA the tallawiny limit aver piston or replace both cylinder and piston Service Limit 0 12 mm 0 0047 in Piston oversize 0 5 1 0 mm PISTON RING GROOVE CLEARANCE Using a thickness gauge measure the side clearances of the det and 2nd rings I any of the clearances exceeds the limi onines bath pistan and pistan rings 09900220803 Thickness gauge Pinstan ring aroova
63. to the specified toram otero pagu 388 SPARK PLUGS Inspeet at 6000 km 4000 miles 12 months 18000 km 11000 milos 38 mantha and Replace Every 12000 km 7500 miles 24 months e Remove tho swat and fuel tank 2 Remove thy spark ple with the spark plug wre CAUTION tank The ping le va 0 607 min 002 003 inj Tho gap 18 correctly adjusted by using a thickness qi When carbon is dapasited on Ihe spark plin remove the con wall spark plug cleaning machine ar by cocofully luding toot with ported end Me electrode is extremely ar burnt replace the plug Also replace Ihe pl brukon woulman damaged thread erc NGK RBB as listed wr the table shail be Used plug However the heat range ni the plug should be selected ta ment the requirements nt need actual load el ete It the pluys nerd tn he replaced i recommended that plone having a heat rango closest 10 the standard plum in the table hu selected Remove thu plugs and inspect the insulators Proper heat range would be indicated ill msulators are light brown in color f they are baked white they should be replaced by a cold type NGK JR 108 Hocommended spark plug Sisi E LI mat to damage tho fuel hoses when ing the EE 09930 13210 Spark plug socket wrench 09930 14530 Universal joint 09914 24510 T handle 09
64. with bearing by AXLE SHAFT sing a guuna check the und final exceeds limi 09900 20806 Dial gauge 1 100 0990020701 Magnetic stand Not available 09900 21304 V block set 100 mm in USA Servico limit 0 25 mm 0 010 in of For nct and replace WHEEL Maku suta that the Whew runout checked ax shown not exter service init An excessive runout is usually 10 wor or loose wheel brarinqs andi be reduced by replacing ie heaving boa replacement Lais to reduce the minout veplaen Ihe whast Service limit Axial and Radiall 2 0 mm 0 08 in SPROCKET Inspect the spiackst toot for swear IF they are wom ats illustrated replace the spracket and drive chain 1 34 pool Remove the rear sprocket by removing the mounting DAMPER Inspect the dampers for wea damage REASSEMBLY AND REMOUNTING Ronssamhle and ramount the rear whos in the reverse order of removal ond disassembly Pan attention to the following paints WHEEL BEARING Apply aroase to the bearings before installing For U S A model 99000 25030 SUZUKI SUPER GREASE A For the other models 9900025010 SUZUKI SUPER GREASE Install tha whee bearings by usi speci 0992484610 Bearing installer ser Nore First install the right wheel then install the left wheel beating The sealed cover on the bearing is positioned Heter
65. 00 miles 12 months thereafter CYLINDER HEAD the seit Faw Reter to page 3 4 Remove the cylinder head cover First loosen and retighten the nuts to with torque weench sequential in ascene order with the engine cali and ot tank Cylinder head nut 36 40M 35 40 Kam 255 290 ibit e After firmly tightening the 12 nuts tighten the bolt indicated as and B 10 the Cylindor hond bolt 3 8 12 Nm 08 12 kom 6 0 85 Ibi Cylinder nut i 7 11Nm 07 1 1 kom 5 0 When Installing the cylinder head cover apply SUZUKI BOND NO 12078 to the hiad cover groove aps Rotor ro page 3 68 Tighten the head cover bolts thw s Tightening torque 13 15 Mm 1 3 9 5 110 EXMAUST PIPE Tighten the exhaust pipe clamp boit with torque ran ta the specttiod Exhoust pipe clamp bolt 18 28 Nm 18 28k9 130 200160 25 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES AIR CLEANER Clean Every 3000 km 2000 miles and Replace Evary 12000 km 7500 miles both seats Remove bath frame covers Remove the battery the battery holdos by removing the ignitar unit Fomave the air cleaner element by removing Coretilly use sic hose to blaw the dust from the cleaner CAUTION Always use nir pressure on the outside of the cleaner element If air pres
66. 0013 000221 37 376 38 000 14951 1496 0020 0044 0 0008 0 0017 25876 36000 1415414173 005 013 40002 0 005 TMT 20040 0 7890 pon 40 0031 6 0031 SERVICING INFORMATION 7 32 mm nj Clutch release cylinder bore Clutch release cylinder piston TEM STANDARD MIT Crankshaft thrust bearing 238 248 thickness ats 0093 0098 242 244 side S Crankshatt runout 005 10 002 OIL PUMP TEM STANDARD UMIT Oil pump reduction ratio 3818 72 46 X 43 37 Oil pressure at 60 C 14071 Above 300 kPa 30 kg cm 43 psi Below 800 kPa 8 0 kg cm 85 psi m 3000 r min CLUTCH Unit mm inl Em STANDARD Drive plate thickness 262 268 222 E 0100 0106 0087 Driven plate distortion 010 0 004 Gluten spring free 31 42 Clutch master cylinder born 14000 14 043 10 561 1 0 5529 Clutch master cylinder piston diam 13857 13984 0543 05506 35700 35 762 114055 1 4079 35 550 35 675 414035 1 4045 335 SERVICING INFORMATION TRANSMISSION DRIVE CHAIN Unit mm in Except ratio STANDARD Lim Primary reduction ratio 1565 72 46 Final reduction ratio 3200 448 15 Gear canos 2384 31 13 ath Shift fork to groove clearance Shit fork groove warm amp No3 Shut fork thickness No 1 No 2 amp
67. 008 in 517 ELECTRICAL SYSTEM ARMATURE COIL Using packer tester check the for apen and ground by placing probe pins on each commutatar segment und rotor o Test for round and on any two Sequients various places test for open with the brushes Wited off the suace he is found ta be apen cicuited or grounded replace thy armature Continuous uso of a defecieva armate wal cause the starter motor to suddenly ail 09900 25002 Pocke Toster knob indication 11 range on SEAL Check the sual lip for damage or ail leakage If any daniago s found i REASSEMBLY RING CAUTION Replace the O rings with new ones to prevent oll leakage and moisture HOUSING END inside Apply grease to the lip ot oil seal Refer ta page 8 16 For U S A model 99000 25030 SUZUKI SUPER GREASE A For the other models 99000 25010 SUZUKI SUPER GREASE HOUSING END Outside Apply small quantity SUZUKI MOLY PASTE to the armature ond Retos 10 pape 5 1611 99000 25140 SUZUKI MOLY PASTE Apply quantity THREAD LOCK 1342 starter motor housing screws Ratar to page 5 16 13200032050 THREAD LOCK 1342 FLECTRICAL SYSTEM STARTER RELAY INSPECTION Disconnect the lead wire of starter motor at starter relay which is located under the battery holder ignition switen inspect the c the tor
68. 0W 40 viscosity Start up tho ungine and allow it o run for several auconds atidling speed Turm off the engine and wait about one minute then chuck tho oll level through thw Inspection window Gii If the level is below add to that level NECESSARY AMOUNT OF ENGINE OIL Oil change 40 L 4 2 3 6 US Imo ath chango 4 2 L 4 4 3 7 US Imp qu Overhaul engine 5 1 L 5 474 5 US Imp at CAUTION Use SUZUKI MOTORCYCLE GENUINE OIL FILTER onh since tha other makes genuine filters and after market parts may differ in thread spocilications thread diamoter 7 and pitch filtering performance and durability which dico ono could cause engine damage or oll leaks Suzuki automobile genuine filter is also not usable for the motorcycles rictu ein 25 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES FUEL LINES Inspect Initially 1000 km 600 miles 2 months and Every 6000 km 4000 miles 12 months thereafter Roplaco Every four years VAPOR HOSE California model only CARBURETORS IDLE RPM idling adjustment Inspect Initially at 1000 km 600 miles 2 months and Evory 6000 km 4000 miles 12 months thereafter Nore Make this adjustment when the engine is hot 1000 and 1200 r min by turning stop Engin idle spoed 1100 100 min Tor E01 ond othors 1200 1 100 min for E 03 Except California 1100 8 r min tor E18 THROTTLE CABLE PLA
69. 10 correct positions as shown thv Fras CAUTION oplaco the O rings with new onos to prevent oil leakage Install the bil pump to the Kiwor crankease with thrae balis tighten them the specified torque wor Apply a quantity oF THREAD LOCK 1342 to bolts 9900032050 THREAD LOCK 1342 Tightening torque 8 12 Nm 108 12 Kom 60 8 5 ibiri the oit jetstAl fitted on the lower crankcase toi 353 a bearing vinsisand C ringsis an the upper crankcase Install the cauntorshall assembly and assembly the upper crankcase NOTE sure to instal the bearing dowel rs din the respective positions Install the vountershal and to the position Make sure that the coutersha t turns freely wile holdini the eveshafi shift the goor which ss engaged 10 the neutral position wore Before Mring the eronkshalt Journal check the tozetas tud on the erankcinse for 19 Nozzle pesh tina the erankshatt to the upper and lower crankoases be sure to fix the stopper part amd press tro other und Refer to pane 342 CAUTION Do not touch the bearing surfaces with your hands Grasp by tho edge of the bearing shell Install the cam chain guile amp and two dampers 8 properly MOTE Bo suris la fnew the arrow mark on the danim r to the f
70. 38 22 as tho 259 Apply SUPER GREASE A Apply a small unity of THREAD Vock 1302 pr E 25 25 166 woo e 21 618 REMOVAL 1 Remove tho lower fairing assembly middle fairings and upper fairing assembly Support the motorcyele with a jack or wooden block Remove the framt wheel the front forks and steering damper Rumave the left and right handlebars by removing rhe handlebar holder mounting bolts and 6 Remove Ihe aneedameter tachometer bracket mo bolts 7 Disconnect the meter lead wire coupler and remove the mater assembly Remova the stam haad nat 9 Remove the sibermy stew head disconnecting the switch lead wire coupler 10 Remove the brake hose gu mounting hol 11 Remove tho steering stem by using sp cial tool then remove ihu steering stem lower bracket Ming 0994014911 Steering stem nut wrench NOTE Hold the steering stom lower bracket by hand to preven it from filing DISASSEMBLY 1 Remove the steering stem uppur bean 2 the steering stem lower bearing by using the special taois 09941 84510 Boating remover CAUTION Tho romoved boaring should be replaced 3 Drive out the steering stem bearing races upper and lower by using the duit INSPECTION Inspect he remped pans far the follows slinormalities Handleb
71. 520 Asterisk mark indicates the nase Lenodel specifications Sis SO MODEL ENGINE MOUNTING 516 CYLINDER HEAD head plato Thiekness 30 mm 0 12 il waster with cap nut 4 13 Steel washer with normal nut nes Copper washar with n pen CYLINDER HEAD COVER BOLT GASKET e Before installing Weight gaskets apply small quantity of SUZUKI BOND NO 12078 ro both upper and lower sides at the gasket The purpose of thes sualant is ta marv thoroughly provide tight af the gaske 9910421140 SUZUKI BOND NO 12078 Head cover bait 13 15 Nim 1 3 15 kom 95 110 m WS STEERING G Apply SUZUKI SUPER GREASE TEM Cu 380 580 150 255 290 360 160 255 130 200 70 118 SWINGARM y Sine port tret k TIGHTENING TORQUE 0 Nm CE o mt sms 88 016 615 830 1 22 34 160 245 18 28 130 200 60 70 435 505 For 03 28 and 33 Far the other models Apply SUZUKI SUPER GREASE Cotter For EOS 28 and 33 models ones uum 06691 09660 anu 320 OvGvL 09660
72. 8 kom 245 33549 0994054820 Front fork assembler 09900 00401 1 typo hexagon wrench set OUTER TUBE METAL OIL SEAL AND DUST SEAL Clear thu metal geaove of outer tube and metal outer surface Install the puter tube metal seal retasier and seal 0994050112 Front fork oii seo Installer CAUTION Usa special to proven damage to the TEFLON conted surface of the Anti Friction outer tube motal when installing s Ties Lock 1942 615 CHASSIS Atter installing the oil seal install the se ond dust seal 1 AntiFriction metal 2 QU seal vatainee 5 Oil 1 seal stopper ring 5 Dust seal stopper na FORK OIL Use front fork whose viscosity rating mests tho speci tons below Fully stroke Inner rod and inner tube to pump out air trom and outer tube Fork oll woo T Fork capacity musa Imp o WM USA 353m 53 150 Fark capacity Fur thw other 319 MICA 17147 od 9900099044056 SUZUKI FORK OIL 35 Hold the front tark vertical and adjust fork wt tool NOTE When adjusting fork oil evel remove the fork spring and compress the inner tube fully 09943 74111 Fork oil love gauge Standard Far USA 113 mm 4 45 inj ata 148 8 78 10 REBOUND DAMPING FORCE ADJUSTER ANO SPRING ADJUSTER Adjust the dept
73. 900 20803 Thickness gauge CAUTION Confirm the thread size ond reach when replacing the plug It the roach short carbon will be deposited on tho screw portion of the plug hol and engine damage may result NOTE F typu spark plug installed for some specifications R ybe spark plug has resister located at tho center electrode to prevent radio noise PERIODIC MAINTENANCE ANB TUMEMP PROCEDURES 23 ENGINE OIL AND OIL FILTER Replace Initially at 1000 km 600 miles 2 montis and Every 6000 km 4000 miles 12 months thereafter _ should ie replacement at the ubawe intervals should be done together nand while the with the angine change Keep the motorcycle upright Placa an pan below the engine ar the drain plug and filler cap Remove the od filter by using the ail filter wr tool y Apply engine lightly to the gasket rain o by removing neh Special e Install the new filtr turning it by hand untl you o filter gasket contacts the mounting surface Then 2 turns using the oll wrench Spec 09915 40610 Dil filter wrench wore To property tighten the iter uso the spacial toot Newer he Oller by hand Fit the drain plug securely and add fresh throug files The engine wil hold about 4 5 L 4 8 US of il Use API eussilication of SE or SF oll wath SAE 1
74. 910 Valve lifter attachment 09816845 10 Twoozors CAUTION sura restore nach spring and valve to their original positions CAMSHAFT Both camshatis should be checked for runout and also lor wear of cama and journals sf the ung has been noted as giving ubnormul noise or vibration ar lack power output Any of hese onditians may caused by camshafis worn down or ist rted the service The exhaust camshaft cow be distinguished from that of the Intake by the embassed letters EX for exhaust as against letters IN or mika Similarly the righe and be distinyushed by th Ihe lof and a noton fram CAM WEAR Worndown cams uru oflen the cause Df mistimed valve operation resulting in reduced power output The limit at cam wear suecified for both intake and exhaust Sams in term ot height f which s fa be measured with micromuter Replace camshafts if fauna worn down t thu mit Cantinued an next page 09900 20202 Micrometer 25 50 mmi m ENGINE 137 Cam height i Intake cams 33580 mm 1 3220 in Service Limit E haust 33240 mm 1 3087 in CAMSHAFT JOURNAL WEAR Determine whether ur riot wach awn the limit by mensuring the clearance wit ntinlied In place Uso the Dastin ta raad the clearance al he cst portion whch s spaci Camshaft Journal olf clearance IN amp EX Sorvice
75. Code OD specification 37 997 38000 mm 14957 7 4981 in 37 384 37 392 mm 14964 1 4987 in 37876 378 14951 14954 in 09900220202 Micrometer 25 mm Bering thickness 1 2 3 Color Part Thickness Green 1 480 1484 mm 121644800000 0 0583 00582 Black 1484 1488 mm 112 164 48800 080 00584 00586 Brown 1488 1492 mm 12164 48400 0C0 0 0586 0 0587 Yellow 1482 1496 11 2184 4000 000 00687 00889 ini CAUTION Booring should bo roplaco as a set BEARING ASSEMBLY When itg tha Uvarings te the beating and conrod be sur o Tot the stopper part Hirst and press i lhe other end Apply engine or SUZUKI MOLY PASTE 1 the crank pio and bearing surface 39000 25140 SUZUKI MOLY PASTE ENGINE 340 e When mounting the conrod the crankshaft make sure that numeral of the faces rearward 4 Tighten ifie conrod fitting with specified torque Tightening torque 48 53 Nm 49 5 3 355 38 5 Check the conrod movement for smooth I CRANKCASE CRANKSHAFT BEARING SELECTION 4 Inspect wach bearing of upper and lowe crankeases for ary damage 4 Pincethe plagio on onch 09900 22301 Plastiguuge Not available m USA the usual wore Do not place the plastigauge the ait hole and do not rotate shaft whan plastiguuge is in place
76. DATE OF MANUFACTURE Date c manita ats by a rye prt bor Lk sheer Ve ndr sach indic at dis Near the end of charge period adjust the specific gravity of Ah runing ete eto iy lavol Vie MAR LEVEL with DISTILLED WATER SERVICING Visually the surface of tho tattery container any signs of crackmi or electrolyte leakage trom the sides of tie battery have replace the battery with a new one thu bullery termals are found to be coated with mist or am ide white powdury substance then this can be cleaned wh 528 ELECTRICAL SYSTEM Chuck the electrolyte level and add distilled water as neces sary ta raise the electrolyte to sach cell s level Check the battery for proper charge by taking an electrolyte 5 6 reading Ifthereading is 1 22 or less as corrected la 20 C SBF it means thut the battury st 3 run dowa condition find needs recharging NOTE First remove We Cy ad wire Months aer Within Within Over manutactueny 6 9 12 Necessary gt charging hours 200039 RECHARGING OPERATION BASED ON 5 6 READING the SG the hydromotay bring the electrolyte m the Ivdromoter to nye level and read the graduation on the fout Scale bordering bn the meniscus eurved up portion af electro we surface as shown in Figure 09900 28403 Hydrometer Check the roading las correcto vo 20 C with chart so deter
77. GREASE A For the other models 99000 26010 SUZUKI SUPER GREASE A Install the wheel bar 09924 84570 NOTE First install the let wel rm then msta the nghi wheel bearing The sealed coveran the bearing positioned out sido 198 as follows by using the special jaring Installer 65 CHASSIS BRAKE DISC 4 Wake sure that the brake disc is clean and free of any greasy matter Apply THREAD LOCK SUPER 13607 to Ihe dise mounting bolts and tighten them to specified torque Tightening torque 15 25 Nm 15 25 kom 11 0 18 0 1040 99000 32130 THREAD LOCK SUPER 1360 GEARBOX a Batore installing the spoedomer dust seal lip and align the drive lugs IT to the recesses meter gearbox to y gearbox apply grease ta F af the wheal hub and attach the wheel hub For U S A modal 99000 25030 SUZUKI SUPER GREASE A For the other models 99000 28010 SUZUKI SUPER GREASE A 4 Sot the stonpar an the speedometer gearbox to the an the ft ront fork BRAKE CALIPER Tighten the brake caliper mounting bolts to 0 Tightening torque 27 43 Nm 23 43 kom 195 310 10 0 NOTE Push the pistons all the way into the calipor colipers AXLE SHAFT Titten tha alo shal ta the specified peque Tightening torque 85 115 Nm 85 115 kgm 815 83 0 tbtt Tighten the pinch belts ta the speci
78. IL COOLER HOSE AND AIR CLEANER HOSE ROUTING WAS ZO wN Oe mo bed 39002 10 10 HIGH TENSION ORD ROUTING For Switzerland and California models esena 925 THROTTLE CABLE ROUTING GSX R1100M 91 This section describes service data service specifications and servicing procedures wich differ from hase of the GSXR 1001 90 CONTENTS TAPPET SHIM SELECTION TABLE EXHAUST 10 19 ENGINE HEAT PROTECTOR 10 47 HIGH TENSION CORD ROUTING 10 50 101 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall tengih Overall wid Overall eight Wheslbase Ground clearance Dry mass gt ENGINE Number of cylinders Bore Stroke Piston draploverent Carburetor Air eluanor Stoner system Lubrication system TRANSMISSION Transmission Gearshitt pattern Primary reduction Final reduction Geor ratios Low nd m Ton 2 Drive cham 2135 mm 84 1 in For E18 17 models 2215 mm 81 2 in For F 18 18 22 models 2085 mm B2 1 in For the other models 755 mm 29 7 1150 mm 45 3 in 1465 mm 57 7 in 115 mm 4 5 inl 2228 kg 503 227 500 Ibs 7226 kg 498 For E33 model For EI 39 models For Me other models Faurstroke Aircooled with SACS DOHC TSCC
79. Limit 0 150 mm 0 0059 in 09900 22301 Plastigaugo Not available in U S A NOTE Inatatt each holder to thorr originai positions jpege 3 66 Tighten the camshalt holder bolts evenly and diagonally t Ihe specified Tightening torque 8 2 Nm 1 2 kgm 60 B wore not rotate the win plastipauge Homove Ine camshatt and read the width of compressed with envelnpe scale This measure vont shouid be taken at the widest par the journal oil clearance measured exceeds the limit measure the inside diameter of the camshaft journal hoides and outside diameter of the camshatt Revive the cylinder noad pon whieh one exceeds the specification Standard Journal holder 1D IN amp 22 012 22 025 mm 0 8666 0 8671 ENGINE 09900 20208 Micrometer 0 25 mm Standard Camshaft journal O D IN amp EX 21 959 21 980 mm 08645 0 8554 in CAMSHAFT RUNOUT Measure the runout wilh a dial Replace rhe camshatt I Ihe runout exceeds the limit Camshaft runout IN amp EXI Servico Limit 0 1 mm 0 004 in 0990020606 Dial gouge 1 100 mm 10 mm 0990020701 Magnetic stand Not avil 0990021304 V black 100 mr CAM SPROCKET Tha fixed position bf each sprocket on mach camshaft Hotorenined by arrow mark 37 on INTAKE sprocke
80. MAINTENANCE CHART Interval km 1000 12000 16000 24000 mies 500 4000 7500 11000 15000 months 2 12 24 se Battery 1 meet Cylinder head nuts amp exhaust pipe bolts 1 T Gloan every 3000 km 2000 miles replace evury 12000 km 7500 mins Vaive clearance Spark plugs 1 Fuel ines D Vapor hose model only felisa sl hr Vai Engine bi and hiter R D Corburstors rom 1 Gluten Replace every four years 1 0 te 7 thud Replace every years 7 1 i Dri cham La E ubican every FOOD 000 al Brake hoses Replace every Jour years Brakes T 4 0 0 Tires 1 D Steering D zi D D Front fork D Rear suspension E 1 v Chassis bolts and nuts T 1 T NOTE T Tighten inspect Replace PERIODIC MAINTENANCE AND PROCEDURES 22 LUBRICATION POINTS Proper lubrication is important for smooth operation und long Ile of each working part nt the motorcycle Major lubrication points are indicated below 6 Brake Sito stand pivot NOTE Before lubricating each part clean of any rusty spots and wipe off any grease dir or grime Lubricate exposed parts which are subi graba 23 PERIODIC MAINTENANCE AND TUNEUP PROCEDURES MAINTENANCE AND TUNE UP PROCEDURES Thi
81. ON Replace the O rings and ia with new ones to prevent oll leak NOTE When replacing the intake pipes identity the four different intako pigs accordi to wach 1D code 19910 4000 for No 1 1120 4060 No 2 18130 4060 for No 131404000 for No CAUTION Uno new O ring to prevent sucking air from the joint FUEL AND LUBRICATION SYSTEM CONTENTS FUEL TANK FUEL COCK AND FUEL LEVEL INDICATOR SWITCH 4 1 FUEL TANK REMOVAL 41 FUEL COCK REMOVAL es FUEL LEVEL INDICATOR SWITCH REMOVAL 41 INSPECTION AND CLEANING 4 1 FUNDAMENTAL OF FUEL COCK 42 CARBURETOR 3 CONSTRUCTION ag SPECIFICATIONS a4 10 NO LOCATION 45 DIAPHRAGM AND PISTON OPERATION SLOW SYSTEM 47 MAIN SYSTEM 48 STARTER SYSTEM 49 FLOAT SYSTEM 49 FUEL SYSTEM 4 10 DISASSEMBLY 411 INSPECTION AND ADJUSTMENT an REASSEMBLY 442 BALANCE OF CARBURETORS 4 13 LUBRICATION SYSTEM 417 OIL PRESSURE 4 Olt FILTER 4 18 SUMP FILTER 4 18 RELIEF VALVE 4 18 ENGINE LUBRICATION SYSTEM CHART 4 19 ENGINE LUBRICATION SYSTEM 4 20 CYLINDER HEAD COOLING SYSTEM CHART 421 CYLINDER HEAD COOLING SYSTEM 422 COOLER 423 FUEL AND LUBRICATION SYSTEM FUEL TANK FUEL COCK AND FUEL LEVEL INDICATOR SWITCH FUEL TANK REMOVAL ome thes seat Remove the middle tairings Horse Vio Turn tust cock to ON position e Disconnect the fuel level switch Remave
82. R CYLINDER 547 1 CHASSIS FAIRING 2 Sereen Upper laa fairing Lower lum Fairing Mace REMOVAL 1 Remove the lower fairing assembly 2 Remove the middle fairings 3 Disconnect the Irapt turn signal light lend wires remove both front turn signal fights 4 Remove both rear view mirrors 8 Rumave the upper farai assembly 09900 00401 L type hexagon wrench REMOUNTING Fomount the fairings in the reverse ordar of rumaval CHASSIS FRONT WHEEL S Apply SUPER GREASE A Tn1900 Apply THREAD LOCK SUPER 1360 Tightening torque om 15 25 180 85 115 815 930 e E REMOVAL 1 Remove the lawar fairing assembly 2 Support the motorcycle with a jack or wooden block 3 Loosen the axle pinch bolis Loosu the axle shaft 5 Remove both brake calipers 6 Remove the axle shaft and front wheel CAUTION Do not operate the brake lever while dismounting the brake calipers Hang the brake caliper on the motorcycle framo with string etc taking care not ta bend the brake hos 7 Remove both brake discs off the front whee by removing the mounting bolts 0990000410 Hoxagon wrench set Not available in U S A 53 ossis INSPECTION AND DISASSEMBLY SPEEDOMETER GEAR DUST SEAL Inspect the lip ol dust seal for damage WHEEL BEARINGS Insprct the play of the whoel buarings by hand while the
83. Replace the brake pad n set otherwise braking perfor mance will be adversely affacted 213 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES BRAKE PEDAL HEIGHT 4 Loosen the lock nut and rotate tha push rod ta locato brake pedal 65 mm 2 6 in below Ihe top lace footrest Rotighten the lock nut lt 2 fa secure the gus proper position pedal height 3 65 mm 2 6 in BRAKE LIGHT SWITCHES Adjust both brake brake light will come just brake d the brake pedal is depen AIR BLEEDING THE BRAKE FLUID CIRCUIT Arr trapped in the Mud circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the tuli braking performance ofthe brake caliper The presence of airis indicated by spongi ness of thu brake lever and also by back ol att Considering the danger to which such trapped exposes the machine and rider it is essential that after remaunting the Brake and resort beate syslern lo ie normal cam the brake fluid seuit be purged ota ithe toltowetag manner PERIODIC MAINTENANCE AND TUNE UP PROCEDURES 2 14 Fili up the master cylinder reservoir t inspection window for front brake UPPER line for rear brake Replace reservoir to prevent Attach a pipe to the caliper bleeder valve and mse end of the pipe into a receptacle Bleedor
84. STON RING CRANKCASE CRANKSHAFT CLUTCH OIL PUMP TRANSMISSION GEARS ENGINE REASSEMBL Y CRANKCASE CLUTCH SIGNAL GENERATOR STARTER CLUTCH PISTON AND RING CYLINDER CAMSHAFT a COMPRESSION CHECK The compression of a cylinder is good indicator its internal condition The decisi n to overhaul e cylinders is often based the results campcession test mamtenance rucords Kept a vous dealership should Include compres Sian readings for each mamtenance service COMPRESSION Standard Timm Difference 1200 1400 kPa 1000 kPa 200 KPa oro Law compression pressure can indicate any af he following conditions 4 Excossivoly worn cylinder wall Worndown piston or piston rings Piston rings stuck in grooves Poor of valves Ruptured ar otherwise datective cylinder bend gasket tha engine in thu following casos amp Compression pressure In one of the cylinders lus than 1000 kPa 10 kg cm 142 Difference in compression pressure between any two cylinders fs more than 200 kPa 2 Kadem 28 All compression posture are below 1200 KPa 12 170 psy standard even whew Ihay more than 1000 kPa 10 psi COMPRESSION TEST PROCEDURE NOTE Before testing the engine for compression pressure make sure thatthe cylinder head nuts and bolt are tigh
85. SUZUKI SERVICE MANUAL INDE H 7 SERIAL NUMBER LOCATION FUEL AND OIL RECOMMENDATION GENERAL INPONMAMON 12 ENGINE OIL For U S A model SUZUKI recommends the use ot SUZUKI PERFORMANCE 4 MOTOR or an ail which m rated SE or SF under the API American Potroleum Institute classification System The vis rating ls SAE 109 40 SAE 10W 40 motor available solera au aharnate according to the nihi chart ENGINE OIL For the other models Sa ee sura that the rine oi use comes under Won l SE or SF and that ite viscosity rang SAE 1044 40 SAE 10W 40 matar is not available select oer nate according Ia Ihe right char BRAKE AND CLUTCH FLUID Specification and classification DOTA WARNING Since Ihe brake system af thes not use or mv Pe Fant d with alcobas akii UN by the manulbumiren and petroleum hasad Mud For retin Do usn ra inea comaimvrs Novos brake Hind to previous wh brem sor Tor Jani MD FRONT FORK OIL Une fork 06 BREAK IN PROCEDURES During mamilacture only the bust possible mau i wid and all mecid warts are 10 very hinh Sandort ie i to allow the moving parts to BREAKIN bulore wuljecting the iine
86. TER CYLINDER REMOVAL AND DISASSEMBLY 1 Homoya the Iront brake light switch lead wir 2 Place rag und Kutch any spilled drops of brake Huid Remove CAUTION Complexoly wipe off any brake fluid adherin of motorcycle The fluid roucts chemicaliy with pa le 3 Remove the master cylinder a plastics rubbor matos sy 5 Drain 09900 06108 Snap ring pliers Remove thy prstan sucamdary cup primary cun and s Pisan i sper CHASSIS 6 10 MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any seratches or other damage Inspect the peston surface for any scratclies or other damago Inspect the primary cup secondary cup and dust seal wear or dame MASTER CYLINDER REASSEMBLY AND REMOUNTING 2 Fenssemble und romount the master eylinder in the reversa mmaval amd disassembly Pay following points CAUTION Wash the mostor cylinder components with fresh brake fluid botoro renssembly Never use cleaning solvent or gasolina to wash them Apply brake fluid to rho cylinder bore and all the internals to be sorted into the bor jon tothe Y When remount Ihe master hodor mating mark i3 on thw and tighten Ihe upper clamp balt best us shown Tightoning torque 5 0 os 0 Nam kom 35 6 0 Ib CAUTION Blvd from the system dor Rafer
87. USA France Finland E16 Ei EI F21 22 En E28 Nederlands F2 Canada 633 California LSA E39 Austen E53 Spain PERIODIC MAINTENANCE AND TUNE UP PROCEDURES CONTENTS PERIODIC MAINTENANCE SCHEDULE 21 PERIODIC MAINTENANCE CHART 21 LUBRICATION POINTS 22 MAINTENANCE AND TUNE UP PROCEDURES 23 BATTERY 23 CYLINDER HEAD NUTS 8 EXHAUST PIPE BOLTS 24 AIR CLEANER 25 VALVE CLEARANCE 25 SPARK PLUGS 27 ENGINE AND FILTER 2 8 FUEL LINES 29 CARBURETORS 29 CLUTCH 29 DRIVE CHAIN 20 BRAKES 212 TIRES 2 14 STEERING 2 15 FRONT FORKS 216 BEAR SUSPENSION 216 CHASSIS BOLTS AND NUTS 217 21 PERIODE MAINTENANCE AND TUNE UP PROCEDURES PERIODIC MAINTENANCE SCHEDULE IMPORTANT The periodic maintenance intervals and service requirements have heen established in ancartance with EPA regulations Following these mistructions will ensure that the motorcycle will not exceed emission standards and it will asa ensure the reliability and performance of the motorcycle NOTE Mare frequent servicing may be performed on motorcycles that are used under severe conditions however not necessary for ensuring emission level complance The chart below lists the recommended intervals for all the required periodic service work necussity ta thu motorcycle operating at peak pertarmance and economy Mileaqes are expressed in terms ot Kilometer miles and time for your convenience PERIODIC
88. Y Thure should be 0 5 1 0 mm 0 02 0 04 inj play in the throttle cable Adjust hw throttle cable play wath win procedures Lapsen the lock nut and turn the adjuster or ou Ihe spueifiod play obtained Throtile cable play 0 5 Omm 0 02 0 04 WARNING Altor tho adjustment completed check that handlebar m avament does nat raise the engine idle speed and that the throttle grip returns smoothly and automatically CLUTCH Inspect Initially at 1000 km 800 miles 2 months and Every 6000 kin 4000 miles 12 months thereafter hose evory four years Ropioce every two years CLUTCH FLUID LEVEL Kuup motoreycle upright and place the handlebars straight e Check the sl tch tuid level the He eve ie found ta be lower than the lower mark replenish with BRAKE FLUID that the Follow Spocilication and classifi ion DOTA PERIODIC MAINTENANCE AND TUNE UP PROCEDURES 210 WARNING Tho clutch system of this motorcycle is filled with a alycol based brake fluid Do not use or mix different types of tlud such as silicon based and petroleum based Do not use any brake fluid taken rom old used or unsealed containers Naver reuse braka fluid loft over from the last servicing or stored for long periods BLEEDING AIR FROM THE CLUTCH FLUID CIRCUI The clutch circuit may be purged ol am in Romave the lower Fari
89. ad breaks then the bolt has become t Ure praper special Hamer Apr poe A TOR wench ar sz CHASSIS REAR BRAKE Tightening torque Wm Nm 20 25 20 25 135 150 1 28 15 28 130 200 qa z8 18 28 130 200 wo 30 218 260 i oo 06 08 a5 55 624 BRAKE PAD REPLACEMENT 1 the dust seal cover 2 Remove the clips pins and springs 3 Remove the pads CAUTION Do nor operate the brake pedal while dismounting the pads Replace tho brake pad as ser manco will be adversely affoctod CALIPER REMOVAL AND DISASSEMBLY 1 Remove the brake hose union catch Maid in sullable receptacle CAUTION Novar re use thoi and stored for long periods WARNING Brake tid it leaks will Interfere with sate running and discolor painted surfaces Check the brake hosa and hose Joint for cracks und leakage 2 the enliper mounting bolts 3 Remove the torque lik bolt NOTE loosen the calipar housing i re removing the calipor mounting balts disassembly be 4 Remove the Remove the calipor housing bons and sep Remove the Oring NOTE nce separate the caliper halves renace thee Oring with a new 7 over piston 10 prevent and pue
90. ally the result of a clogged l from the passage way damaged o oil pump or a combination of these items High prossun is usualy caused by engine oi wh loo Navy a weight a clogged all passage improper installation of the filter or combination of these items FUEL AND LUBMICATION SYSTEM 4 18 OIL FILTER Nore me Oring of the cl Miter For US A modal 9900025030 SUZUKI SUPER GREASE A Far the othar models 99000 25010 SUZUKI SUPER GREASE OIL SUMP FILTER Whon wash the pan chock to be sur fier istr periodically CAUTION Replace the oil pan gasket und Oring with new onos to provent leakage fram any sign of r ptute also RELIEF VALVE Chuck the hale in the rolit valve for clenging D dls CRANKSHAFT WAL STARTER CLUTCH BUSHING jo 1 ust murum mz i 1 1 D 4 u KER A n F huh 2 y v a JOURNAL BACK ib SURFACE n E TER PASS v CRANKSHAFT JOURNAL BACK SURFACES SURFACE f E MAIN GALLERY n gt 5700 BOLTS En F Wat on E F A OIL PRESSURE SWITCH PLATES D xm AND SYSTEM 4320
91. alve components Fil the and ushaus ports with gasoline to check tor leaks I leaks occur inspect the valve seat and for burrs other things that could prevent the valve from swing WARNING Always use extreme caution when handling gasoline wore After servicing the valve duats bi to adjust the valve clearance after the cylinder head has been rewstalied see page 25 enome VALVE STEM END CONDITION CAUTION 4 Refacing the valve stem and face is permissible whera the length 1 will not be reduced to less than 2 5 mm If this length Becomes shorter than 2 5 mm then the valva must be replaced After installing the valve whose stom end has been ground aff ns above check that the face 2 of valve stem and is above the valve cottar 2 VALVE SPRINGS The forc of the two springs keeps the valve seat tight Weakunod springs sut reduced engine power output and often account Tor the chattering noise coming the valve mechanism Check the valve springs for proper strenat by measuring their trou lengths and also by the force required to compress them IF the pring length is less than the service limi or ifthe force ronived ta eomprss the spray does not fall the range specified replace both the inner and outer springs as a swt CAUTION Roplaca both the valve springs Inner and outer at a time if ono thess is found to be
92. ar distortion Race wear and brinetling Bearing wear or damage Abnormal noise al bearing Distartion Df steering stem Oil leakage of steer Hamper Heavy of steering damper operation a CHASSIS REASSEMBLY AND REMOUNTING Reassemble und remount the steering stem in the reverseorder removal and disassembly Pay attention to the following points OUTER RACES e Press in the upperand lower outer by 09941 34513 Steering outer race installer the special BEARING Place a washur on thw hear by using the special tool 09941 74910 Stooring bearing installer grant to the upper und lowe bear the stueri stem For U S A model 99000 25030 SUZUKI SUPER GREASE A For the other models 1000 25010 SUZUKI SUPER GREASE A STEM NUT 4 Tighten the steering stam nut ta the specified toranu 09940 14911 Stouring stom nut wranch Tiahtoning torque 40 50 Nm A 4 0 50 kym 280 36 0 thts Turn the steering stem lower bracket about hvu or i vo Jolt amid so thar the taper rollar bearing wi seated property e Turn back the stem nut by 1 4 1 2 turn more This adjustment well vary trom motorcycle to motorcycle crassis HANDLEBAR HOLDER 4 Tighten the hanuobar holder mounting bolts and nuts ta the torque Tightening torque Bolt 50 60 Nm 5 0 60 kgm 360 435 ibti Nut 22
93. ator over the luca 2 at the end of cankshatt Nore BOND NO 12078 should be applied tothe groove ol he signal generator lead wire S For USA model 39104 31140 SUZUKI BOND NO 12078 For the other models 99000 31140 SUZUKI BOND 12078 convey as 10 provont leakage 358 ENGINE Hald the crankshaft mening nut and ngen th lire Specified torque Using Bm hexaqon wi 09900 00410 Hexagon wrench setiNot availableim U S A Tightening torque 25 35 Nm 25 35 180 2S ib ti boli Pass the signal generator lead wie through shawn in the crankcase Install the neutral position indicator swich with twa screws wore Wem the neutral position indicator switch be sure caro the spring IT switch cont ct 2 dnd Orian 9 the seat retainer with tour bolts am portion al the relier Insert the clutch push rod Into the countorshalt Pearease the portion of the starter clutch and the crankshaft Use nonllammablo cloanig solvent to wap if the pr greasy matter make these surfaces com pletely wore Apply small quantity of THREAD LOCK SUPER 1303 21308 ta the starter clutch mounting bolt For U S A modell 99000 32030 THREAD LOCK SUPER 13037 For the athar models 9900032100 THREAD LOCK SUPER 1305
94. be sure Vo connect me battery property Y hanging rte toe low o espace the Noter Who wor m use batteries shouid ba Techormed of mont to ry otros or Insofli the tocuclyae up to the pressed specific graviy t tevel or agivet tho 5 by consulting the pay maker s Replace the battery italy sulfate ean the ect consulting ESS too hia battery maker tect Battery discharge 100 rapidly SERVICING INFORMATION 76 CHASSIS Complaint Remedy Heavy steering 2 Replace 3 steerion stem 4 Nor mi eres mounting of inering damper Adusi Wobbly handiebers cass of belonen between right tot forks Replace 2 front fort Rega ar ace 3 hora sale ar eae a Ran oce Wobbly front 2 Winn ont wewel hearings Replace 3 Detect ve v e 4 Inet w e origen 5 dones Hujus Front suspension too 1 Wink Replace E 2 Nar enounh Fork oil Front suspension ioo Fork wil ino 222 su 2 much Disia cossol Noisy front Y hot onn suspension 2 Loose ute Holen Wobbly rear wheal 1 lace 2 3 Fear suspension Weakened ser nbsiten solin too soft 2 Rear s
95. beam ight gt Neutral indicaatr ight Dil pressure indicator light la License 5 Asterisk mark vtieatas the new model specifications ramane WHEEL Ui mo in TEM Umm iar brake pedal eight Braka ica eT 3s put 0008 55 oom 022 Brake disc gt 0012 Master cylinder bore Fer 14000 14043 an 0581105582 _ 12300 12743 aad 055000 03017 Master piston diam nd 13 987 13984 La 05495 0 5506 12587 12584 10 4983 0 49941 Brake Clip einer 33960 34010 bore lia E 1 3370 133901 30230 30 280 vom 1 1902 11921 gt 38 100 28250 15031 1 5081 broke caliper piston 33878 33928 am wo 13338 1 33871 30130 30 180 ene 41 1882 1 18621 38098 38 148 ee 1 3000 1 50191 Wheel rim runout Au gt 29 20 Radiat E axle runout Tr E 025 Br 025 910 Tie sui From 7130 60 2817 ES Rear 180 55 2817 oom Tir wead E 20 ud 1008 SO MODEL 512 SUSPENSION Unit mm won STANDARD Umr 120 Fran Yn spring re on van Fran ov ie us em omar pm shat raro won TIRE PRESSURE SOTO DING DUAL RIDING TIME PRESSURE torent KPa hc mon 220 220 220 220
96. beyond the mit Valve spring free length INNER 35 0 mm 1 38 in Service Limit quem 32 8 mm 1 49 inj vi spring tension INNER 5 3 65 9 28 mm Standard 117 14 3 Ibs 1 10 im OUTER 13 1 15 1 kg 315 mm 289 333 Ibs 124 in 330 REASSEMBLY wach seal and pressit them into position with the finger vip CAUTION Do not reuse the seals NOTE Bo sura 10 ustore the plate 00 the cylinder head of exhaust sido Install the valve spring lowr seals i Wor mako Be careful nor to confu pring d or exhaust 2 the lower seat with the For Intake side 4 Insert the valves with their stems coated molybdenum disulfide lubricant SUZUKI MOLY PASTE all around and along the tul stem length without any break CAUTION Won insorting of the stem sosi ch valve take care not to damage the lip 99000 26140 SUZUKI MOLY PASTE Install ue valve springs with the small pitch partion d faciny cylinder head 4 Largepiteh portion For Exhaust side FA Put on tha valve spring retainer and usim the val press des the sprigs ik the cotter halves ta rhe stem end and release the litter allow the cotter 1 to Wedge between retainer and stem sure that the rounded lip 2 of the cotier his snugly mio the aroave 5 in the stem end 09916 14510 Valve lifter 09916 14
97. ble loosening m the rod Once displaced tha bearing cap wilt bv fited property e Pince the plastigaume axially ou Ihe crank pin avoiding the fil halt a or BDC side as shown the bearing cap with two step torque values Initial tightening torque 22 28 Nm 22 28 kgm 160 200 ib f Final tightening torque 49 53 Nm 53 kgm 355 385 fi 09900 22301 Plastigauge Not avaliable in U S A When Mung bearing cap ta crank pin bo sure 10 discriminate oo end from the other namely front and rear NOTE Mover folate th erankshatt or conrod when piece of 819 clearance thu caps and the width af compressed plnstinsuge with novelope scala This measurement should be takon al thu widest part Cronk pin boring clearance Standard 0 032 0 056 mm 0 0013 0 0022 Service Limit 0 080 mm 0 0031 in clearance excneds the service limit select the specified boating Irom the following table 4 Chock the cormssponding rod D cov Chuck he c rmapondin crank pin OD code number i 2 per Bearing selection Trank pin 2 Code 1 2 3 Conrod 1 Groon Be Brown 101 2 Brawn Yenow 339 tuor 41000 41008 mm 16142 16145 imi 41 008 41018 mm 1 8145 16148 inj Crank pin O D spacification
98. bulb should go out If the bulb remains lit replace the fuel level indicator switch OFF Text bap 12v Battery 525 SYSTEM LAMPS HEADLIGHT NOTE Adjust both Vertical and horizontal after reassembling TAIL BRAKE LIGHT ELECTRICAL SYSTEM_576 TURN SIGNAL LIGHT a gl CAUTION Be not ovetighten the lens fiting SWITCHES Inspect wach awitch for continuity with the packet tester referring 10 the WIRING DIAGRAM If any is found replace the respective swatch assemblies with now ones Rotor 1o thv chapter 7 ol wiring diagram 09900 26002 tes Testar knob indication range OIL PRESSURE SWITCH 4 Cantinuity when engine is stopped Na continuity when engine is running gt NOTE Before inspecting the pressure switch check if the engine level is enough ELECTRICAL SYSTEM RELAY STARTER RELAY The starter relay is located under the battery holder Page 5 18 Yor datas SIDE STAND RELAY The sido stand relay is located under the battery holder 10 page 5 21 tar details HEADLIGHT RELAY for and models The headlight relay Is located on the brace INSPECTION Fisi Cheek the insultar butwoon tE nd 7 witli pocket tester Socond Apply DC 12 volts to i and terminals
99. by using the speciai tool 0991540810 filter wrench NOTE Motor ta page 2 8 for instalacion procedures Homove the cylindar head cooling hoses by removing the bons 4 Remove the cylinder head cover by removing the bolts 91428811 6 mm T typa hoxugon wrench Remove the signal generator cover by removing the bolts 09911 73730 8 mm T typo hexagon wrench Remove the holder bott and spring and thor remove the cam chain tensioner by removing the bolts 09911 73730 5 mm typo hexagon wrench Remove the cam chain lev by removing Me bons Remove Ihe camshaft journal holders by removing the hois Be sure 10 loosen camshaft journa holder bolts evenly by shifting the wrench diagonally Remove Ihe two camshafts intake and exhaust out hu cam ch in quide The cylinder head bucomns Iree for removal wii mat holt ij and twelve 1O mm nuts ore removed 0991174510 Long socket 14 mm 09914 24510 T handle wore When loosening the cylinder heat mits hosen each le by litle a order according to minbars cast on cylinder head CAUTION nor to damage the fins when removing handling the cylinder hond This precaution to eylindor block also e the right and left oil pipes 21 4 Remove the eyfindur ENGINE Firm
100. cified Imi replace it with new 09900 20102 Vernier calipers Service Limit mm 0 32 in CLUTCH DRIVE AND DRIVEN PLATES Measure the tatal Uuckueas of driva and dnveh plates by compressing hem with 4 8 kg load ware Wine atf the ungin oil from the drive aad divin plates with a olan tag and put them anv by pn the surtace plate W the total tmeknoss of drive and driven platos is ot within the specification replace the dive plates with new ones or measure each drive pate Wickness and driven plate distortion Total Wickness ot drive 483 04 mm at 5 kg load and driven ples 182 gt 0 02 at 11 02 Ibs PARTS SUPPLY DATA 21400 40600 Clutch plate assembly 21441 48600 Clutch drive pla 21451 48800 Clutch driven plata the thickness af wach drive plate with a ver calipers wucl drive plate nat within the slaudard range roplace wath a new ane 09900 20102 Vornior calipers Standard Thickness 2 52 2 68 mm 0 100 0 106 in Measure each tiven plate tor distortion a Sickness Henn driven platas which excuu the V 09900 20803 Thickness gauge Service Limit 0 1 mm 0 004 in CLUTCH BEARING Inspect the clutch release bes larly cracks to decido whether it bo reused or should replaced ennagement and disengagement oF the clutch de Bands the condian of this bearing ENGINE CLUTCH RELEASE
101. clearance dst 018 mm 0 007 in Service Limit 2 0 15 min 0 008 in Pinston ring groove width Standard 191 2d 107 1 03 mm 0039 0040 in 201 203 mm 0 079 0 080 in ring thickness Stand 1t amp 2nd 097 0 99 mm 0 038 0039 in ETT 336 PISTON RING FREE END GAP AND PISTON RING END GAP Betara installing pistor rings measure the tree end gap f wach ting using vernier calipers Next tthe ring in the eylinder and measure each ring end gap using thickness gauge I ring has excess end gap replace the Piston ring free and gap 15t mm 0 31 In 24 92 mm 0 36 inl 0890020102 Verrir calipers Sorvica Limit Piston ring end gap di 181 0 7 0 03 in 24 1 0 mm 0 08 in 09900 20803 Thickness gauge ice timit Oversize pistan ring Thu Following two fypes of oversize piston rinus ar bear the following identiticano SY emus m i Ovorsizn ring UEM ines ILLE 05 05 emus Oversize sido rail iust mensura out side diameter ta identify the size PISTON PIN AND PIN BORE Sal bove gauge measure tho piston bove inside diameter and using a micrometer measure the piston pin outside diameter Ifthe difference betwen Ihese que measur ments i more ihan the replace bath piston and
102. d remove the generator driven CAUTION Do not hold the damper housing with a vise because damage ar breakage the damper housing will result 53 ELECTRICAL SYSTEM Attar removing the generator driven guar remove the damper housing iT with a bearing 09913481610 Bearing puller mmi Remove the generator wid cover 4 Disconnect thn staar lead wires and battery lead wire se soldoring iron 4 Remove the brush holder regu luos screws and rectifier to Separate the nener tor housing J from generar end housing 2 ELECTRICAL SYSTEM Remove the votar fram generator end housing 2 10 use i Wand pressa as shown INSPECTION ROTOR BEARING Inspect the rotor bearings for abnormal noise and smoath rotation ta rotate they by hard anvibing unusual remove the bearing with a bvanie bulle 08913 60910 Bearing puller 40 60 mm CAUTION The romovad bouring should be replaced with a now STATOR COIL CONTINUITY CHECK Check thw the lead wiras ot the tutor with pockat tester 1 thore 19 no contiwnty place the stator check that the stator cori is insulated 09900 25002 tostor Tester knob indication 141 range 55 ELECTRICAL SYSTEM ROTOR COIL CONTINUITY CHECK Check the continuity between the twa rings af rotor wiih packer tester If here Is con
103. e x DOWN POSITION ELECTRICAL SYSTEM 520 2 Side stand UP RIGNT ONY The current amp turns ON the rolay and at any transmission positon SIDE STAND ur INSPECTION M ine interlock system does not aper component any abnormality is fo nont with a wow 09900 25002 Packet testor Diodo The diode is locatari ahead pt the The diode pass current anly in one direction Check the continuity between Tand 2 If ty the diode is tn 0004 condition pne check the continuity betweun 12 ond 3 os required 521 ELECTRICAL SYSTEM Neutral switch Disconnect the neutral switch toad and check the continuity between Bl andground with the transmission in NEUTRAL Sidestand switch WES 3 E Side stand ignition interlock relay The sidestand ignition interlock relay is loenn battery holder First check the insulation between 1 and 2 pocket tester Then apply 12 volts to 3 and Vf check the continuity b If here is no continuity replace it with a nuw one 09900 25002 Pocket tester tod and toa tween and Pe range ELECTRICAL SYSTEM 522 COMBINATION METER REMOVAL DISASSEMBLY 4 Remove the upper fairing with the wind screen a Disassemble the combination mater as follows INSPECTION Using thu pocket tester check the conunwity betw
104. e ahove condition sel Ihe variable DC power source ta the 14 5 V V the oes om the Tegulmtor is in Good condition the bul remains it veplacw thw IC regulator 0990025002 Pocket t Tester knob indication DC25V Voir E ava uate powe vint 16 fut on email Insult the dampers tor wear and demana any detects ara found replace the dampers as 4 et Wien instaling the HARDENS apply SUZUKI MOLY PASTE ta the damper surface 99000225140 SUZUKI MOLY PASTE GENERATOR DRIVEN GEAR DAMPER 57 ELECTRICAL SYSTEM REASSEMBLY AND REMOUNTING Fpassemble and remount the generator in the reverse order of disassembly and removal Pay attention fo the following paie Apply grease to the li of tie oi Soa For USA model 99000 25030 SUZUKI SUPER GREASE For the other models 99000 25010 SUZUKI SUPER GREASE A CAUTION The removed oil seal and O rings should bo replaced with Install Ihe bearings and rotor vo ose a hand press as shown NOTE Before reinstating the sli ving side bearing to generator ond ausm lue the ri aud align the expander ring lug with the center of chamfer face at bearing outer race ts tice ELECTRICAL SYSTEM 54 O rings to the bearing retamor screws Apply small quantity of THREAD LOCK 1342 bearing retainer screws 9800032080 THREAD LOCK 1342
105. e oil o be cooled owing through the ail cooler betara ine temperature is low oil viscosity OPERATING PRESSURE OF REGULATORS ELECTRICAL SYSTEM CONTENTS CHARGING SYSTEM 51 DESCRIPTION GENERATOR WITH IC REGULATOR 51 CHARGING OUTPUT CHECK 52 REMOVAL AND DISASSEMBLY 52 INSPECTION 54 REASSEMBLY AND REMOUNTING 57 REASSEMBLY INFORMATION 59 IGNITION SYSTEM 5 10 DESCRIPTION 5 10 INSPECTION 5n STARTER SYSTEM 5 15 DESCRIPTION 5 15 REMOVAL AND DISASSEMBLY 5 15 INSPECTION 5 16 REASSEMBLY 17 STARTER RELAY INSPECTION 5 18 SIDE STAND IGNITION INTERLOCK SYSTEM 5 19 DESCRIPTION INSPECTION COMBINATION METER 5 22 REMOVAL AND DISASSEMBLY 522 INSPECTION FUEL LEVEL INDICATOR 524 INSPECTION 5 24 LAMPS 525 HEADLIGHT 525 TAIL BRAKE LIGHT 5 25 TURN SIGNAL LIGHT 5 26 SWITCHES RELAY STARTER RELAY 5 27 SIDE STAND RELAY 5 27 HEADLIGHT RELAY 527 TURN SIGNAL RELAY 527 BATTERY 5 28 SPECIFICATIONS 5 28 INITIAL CHARGING 5 28 SERVICING 5 28 RECHARGING OPERATION BASED S G READING 5 29 SERVICE LIFE 5 30 ELECTRICAL SYSTEM CHARGING SYSTEM DESCRIPTION GENERATOR WITH IC REGULATOR The generator Iaaturas 9 solid state regulator thar is mounted inside the generator All ruqulator is attached 10 brush holder frame The isompavents ara enclosed into a sold mold regulator voltage setting cannot be adjusted Two brushes carey curren t
106. ead on Ihe Place the cylinder head plane on shown the illustration 4 Cylinder hoad nuts and washers must be fitted in the positions as shown in the Mustration Copper washir wih cap nut pes Steel washer with normal mut 4 pes Normal mut 4 nesl linda block o cylinder hend as de thy twelve 10 men nuts to t torque wrench soquentbally in the needing order ol Tightening torque 36 40 Nam 35 40 285 240150 Alter tintenna the Onn install ane mm and tighten itt the specified torque Tightening torque 12 Nan 108 12kom 60 851640 2st Place ant onan e Me hing aven the sam chore senate the cranks mal direction bru T canter nl CAUTION To turn aver crankshaft torque nut wath a 19 mm wrench Novar my to rotate erankshatt by putting a T type wrench aver tho holt ark on worr ist batara tci th costar caer nalaers 9900025140 SUZUKI MOLY PASTE a The haut mih sim e ates by Ins vanessa IN qr Si by Lav wate 1 inna mat tl e ith mk accurately ined ap ety vd hl o the Slick reed the crm sprache and exhaust pack The exhaust sprocku bears an arro marker T Toni aves
107. ecial service procedures or precautions Wat must he ta avoid Vonage the machine This provides special information to mi ions cemer CAUTION e maintenance easier importan msc REPLACEMENT PARTS When yau any paris use only genuine SUZUKI replacement paris or thairequivalent Genuine SUZUKI pures re high quality parts which are designe and built specifically for SUZUKI vehicles CAUTION Use af replacement parts which not equivalent in quality 1o genuine SUZUKI parts can laad to performance problems and damage GENERAL INFORMATION 15 ASBESTOS INFORMATION Note the tallawing when handling supply part with this WARNING LABEL or any part in the parts list which contains asbostos Operate if possible aut of doors In well ventilated place Preferably use hand tools ar law speed tools equipped if necessary with an appropriate dust extractor facility igh speed tools are used they should always be sa IT possible dampen betare cutung or Dampen dust and place it in a properly closed receptacle and dispose of it safely Any domestis astiostus product lo wliich the above dows not anply which is likely 10 release du Should be replaced nuw due when warn V Breather cover pasket 2 Cliteh cover gask n 3 Signal gunorator Gover pasket 4 Stoner cover gasket
108. een lead wires in the diagram on next page If the comunity measured is incorrect replace the respective parre 09900 25002 Pocket taster Tostor knob indication 1 range nore When making this test u Is nal necessary 1o the combinations meter 52 BIECTRICAL SYSTEM ELECTRICAL SYSTEM 624 FUEL LEVEL INDICATOR Fuel level indicator light oes um mo d Fon E Fuel ove indicator switch INSPECTION 4 Remove the seat With the ignition switch truned on disconnect the two lead wires going into the fuel level indicator switch connect the lead wires from the main wiring harness with a jumper lead and check whether the fuel level indicator light is ON If a LIGHT is indicated the circuit of fuel level indicator light is in good condition If the fuel level indicator light does not light replace the indicator bulb or repair the circuit connec tion Ifthe bulb is in good condition the level indicator switch may be faulty replace indicator switch with anew y From fel tank Jumper led Remove the fuel level indicator switch from the fuel tank Connect 12V battery to the fuel level indicator switch and ground through a 3 4W bulb The bulb should light up after say several seconds if the switch is in good condition de 4 When the switch is immersed in water under the above condition the
109. eplace tho thrust esi places Revlace Replace Rosa Rogioce Rupinco Replace Adjust or rontaet Replace Replace Adjust p Hepat oe Aus opines Reiner SERVICING Complaint Symptom and possible causes Dirty oF heavy exhaust smoke Engine overheats Engine lacks powar Tou much engine Wort piston o cylinders Wor valve quide Gyimder wall scored or soutfed Worn valves stems Defective stem seal Worn ring sida rait Loss of valve clearance Weakened vale sprnas Valve Timing out of adjustment Worn piston sings or cvinders Poor of vales Fouled lum niva incorrect Cloned ets in carburetors Floar lt hambar fol love of 10 Clones al lema 11 Carburetor balancing seven lua 12 Sucking Irom into Too mul Heavy carbon deposit on piston crowns Not n tho pump m logged oi c 2 3 4 Fel level too kw flm cham 5 Wun make pap Remedy with level window dain out excess il Replace Replace Reben or rep Replace Replace Adjust Ast Rontaen
110. er fitting the valve guides refinish thew guiding bores with the to and the guides altar reaming 09916 34570 Valve guide reamer 09916 34541 Reamor handie amer Be sun an meine VALVE SEAT WIDTH Coa the valveseatuniformiy with Prussian blue Fit he valve ami lap cout d seal with Ihe value face in a rotating manner in order to nbtain a clear impression of the seating 1 Ih Opera vae the valve lapper t6 hold the valve head The ringlike dye impression luft on the valve facu be ontinuous without any break In addition the width of the dye ring sth visualized width must he within the following specification Standard Valve oat width u 0 9 1 1 mm 0 036 0 043 inj either requirement is not met cotrect the seat by servicing t as follows VALVE SEAT SERVICING The valve sams for both Intake and exhaust valves aro m chied o two iilforent angles The shat contact surface ix AB and the above Ihn contact surface closest to the chambar is enr to 15 make side Exhaust side 45 N16 oF 122 N16 122 18 CA N20 00121 For U S A model Volvo soot cuttor IN 121 8 122 N 116 ond 8 120 Solid pilot IN 100 5 0 For the othor models 09916 20610 Valve Svat Cutter N 1211 0991620620 Sear Cutter 122 09918 24420 Valve Seat Cutter N 1 16 09916 29010 Seat Cutter N 120
111. ese wear the wow ar molded o When vou replace a tve be suet of tha and epee derent aie or ype of o y be adversely Jas of veni conta irme b iss ih e propor td nd er ia vs rcommend hat en eit Sa eer pr p o tt en you place a ure be ura nl Mee ar pud Be ls fl wheel str te BOO t Proper nl avoid vaca whoo to ee evo Sarok pre om et ad ot is metres mn o he wha s road iode ar on Ses ie wal safe ht a the opr cien ore Section e tr win rin dire pro and rn sof is motorcycle ar ae a Ti monn mot e nerin o wh i road Sesion eine v the row Sess ew the ee acl best smoot a Fer recon Vnlg tee rere Scion wi tt ee potato seid te mowing machine must st
112. f he Samping fre tum acusa ag Deng ausm em byt Y 4 an me ad AS yout th eps you il rena vou taneh sch number poc Wha lost amount of damping force ard position or tha great a moto ah eed RO th factory win te aust sto po E NOTE Do not peat camper inary po than hec or otero postions Wipsiione 2 Y 3 I we und force wil automatica have e sra damp Ing frc ae number 4 ite poen BOTE jo recommended ot spy 2 cant be cone by pow es Sa et SUSPENSION SETTING The standard stings provi comton and 9009 hanging characters for ees ing gonna x REAR BRAKE LIGHT SWITCH ame cover To aj the tat ene oaks rea i ope Res A waune deine yur try erm th i bn Yr eet We um fios nin Tli sd yrs cnn form test Fibre t alo eg ia an cid ature meter conte en Mee re reas condition each day lere yoe ride Aii es how f damage ch a eas or et E s ala cay REAR anake sumen ne PRESSURE AND LOADING he rar taka sue sastre pre ap propor tre loading are imn heck she cover To adus Tora tacos Overcding your es
113. face ta the volside as shown Whar installing the cam guide 1 and pawi lifter 7 apply smalt quantity oF THREAD LOCK 1342 10 the screws 99000 32050 THREAD LOCK 13427 09900 09003 Impact drivor sot ENGINE 35 e Install the gearaluft shaft with the center af the gear an shaft aligned the center af gearshift cam driven gear Install the washer 1 whi 23 oll pump driven gear 3 and washur 4 Foe the pump driven guar wilh the cirio 09000 08107 Snap ring pliers Install the thrust washer 1 onto the countershate NOTE Fim surface of washer is positioned outside Install the guneatorZail pump drive gears onto the primary driven gear 35 ENGINE Install tha primary driven gear assembly onto the counter shaft and apply engine ail tothe needle hearing and spacer Install the thrust washer onta thy countershaf a Install the wava washer seal 5 and wave washer td onta the sleeve iub correctly Install the clutch slnnve hub anto tie countershatt 4 Tinhten the clutch sleeve hub nut o the using the torque wrench und eloteh sieeve 0992080710 Clutch sleeve hub holder Tightening torque 140 160 Nm 1140 180 kgm 1015 7155 Invent hg eluteh elevan plates and dime plates one by on inta the clutch sloeve hub in the preseribed order drven plow fret Pul Ihe clutch pressure plate onto the clutch sleeve hub Put the clutch diaphragm spring swat 1
114. fications FUEL AMD LUBRICATION SYSTEM 45 FUEL AND LUBRICATION SYSTEM SLOW SYSTEM This system supplies during engine operation wit Im Hoat chamber 3 is metered by plot where This misture rich with fuel then goes up through e valve closed or sliahi apenas The fuel tes with air coming in thwaugh pilot Jot 4 passage to piat screw 8 A part af the mixture is discharged ipto the mam bare out of bypass ports The remainder is then meteros by plot screw i and sprayed out Into the main bore through pilot outlet 17 juri am eun e FUEL AMD LUBRICATION SYSTEM 8 MAIN SYSTEM As throttle valve T is opened engine speed fises and this increases negative pressure jn the venturi Consequently the piston valve upward Meanwhile the fuel in finat chamber 3 is metered by main jet and Ihe metered fuel enters hebdle It in which mixes with the air admitted through main aif jet 1 to form an emulsi n The emulsified fuel then passes through the clearance between needle yor f and jet needle 2 and is discharged inta the venti im which it meets mam air siream being drawn by the engine Mixture proportioning is accomplihad in needle 3 the clearance through which the emulsified tuoi must Haw In large br small depending ultimately throttle posit lt ea JAIR MIXTURE sun 43 FUEL AND LUBRICATION SYSTEM
115. fied Tightening torque 18 28 1 8 28 kom 130 20041 CHASSIS 69 FRONT BRAKE Kom Ten 25 80 20 25 145 180 19 20 20 25 33 43 185 010 106 08 48 55 67 CHASSIS BRAKE PAD REPLACEMENT Remove the pads mounting bolt 2 Remove the pads 09900 00410 Hexagon wrench set Not availble in USA CAUTION Do not operate the brake lever while dismounting the pads Replace the brake pad as set othe manco will be adversaly affected CALIPER REMOVAL AND DISASSEMBLY ise braking perior 1 Disconnect the brake hose and catch brake CAUTION Navar reuse tho brake fluid left over from previous servie Ins and stored for long periods WARNING Brake fluid if it leaks will interfore with sate r gand discolor painted surfaces Check the Drake hose and hoso joint tor cracks and eakage 2 the caper Nore Soll thosen the housing to Facilitate Inter before removing the caliper bots 3 Remove the pads 4 ther Euler halves ta remove the Remove Nore Place over the olstons to prevent th m and push out the pistons by ave CAUTION Do not use high pressure air to prevent piston damage 7 Remove thu piston dust seal and pistou soul of the
116. h hole For lower case Calor art Specification 1 190 1494 mm 12229 06800 080 00587 0 0588 Brows 1 494 1498 mm 12229 08800 060 400588 00890 in low 1 98 1 502 mm 12229 06800 000 10 0690 0 0591 ini wore Grooved bearings have the same specifica as the Grooved bearing with od hole These parts numis aro shown as follows 12228 06810 XXX Grooved bearing CRANKSHAFT THRUST CLEARANCE a With me crankshaft figheside thrust bearing end left side thrust insurtad ln the Upper crankcase use Imekness gange to measiem the thrust clearance an the Push the crankshaft to the starter cluteh side that there ts clearance the thrust bearing Thrust clearance 0 05 0 13mm 0 002 0 005 in clearance exceeds the standard range adjust the procedures Standar thrust clearance by the fallow e Remove the rightside thrust bearing and measure its inches with a micrometer I the thickness ol the siie thrust bearing is below standard replace with a new beany and once again perform the thrust clearance measurement is within standard listed above to make ightsido thrust beating thickness Standard 242 244 mm 0 085 0 096 in ae ENGINE a Wthevightside thrust bearing is within the standard range reinsert the righ
117. h to 25 mm Tram the bottom end af the spring adjuster 2 by turning the rebound damping force 1 then instal the spring adjuster to the inner rail us shown in the llustration CHASSIS e Slowly turn the spring adjuster by hand it stops by finger tight 4 Holdm the spring adjuster 2 in this position tighten the lock nut the specified torque Front fork spring adjuster lock nut 13 5 16 5 Nm 135 1 65 kgm 100 12016 FRONT FORK CAP Install the Iront fork cap t the spring adjuster Install he front Fork to the inne the tarque Front fark cap 15 30 Nm 15 30 11 0 215 FRONT FORK REMOUNTING When rermnunting the Front fork assemb he ner Tube 42 5 mm hei D TIGHTENING TORQUE D Front fork upper clamp bolt 22 35 Nm 2 2 35 kom 160 255 1041 2 Front fork lowar clamp bolt 22 35 Nim 22 35 160 255 Ib 3 Handlebar holder mounting 50 60 Nm 5 0 60 kom 36 0 43 5 1 Handlebar holder mounting nutk 22 35 Nm 22 3 5 160 26 5 Ibit NOTE Before tightening the front fender brace mouating and axle pinch bolts move the front fork up and down 4 or 5 times Refer to the 5 20 for steering damper m procedure chassis STEERING Tightening torque Wem Wm 80 80 22 35 40 50 22
118. ho camshaft journal holder bolts are made of a speciol material and much superior in strength compared with other types of high strength bolts Take special caro not to use other typos of bolts instead of special bolts To identify these bolts sach of thom has on its head ENGINE wore sure lo face the arrow mark on tho cum cha iler 10 the front Tighten the four bolts to the specified torque Tightening torque B 12 Nim 108 12 kgm 60 85 Pourabaut 50 mi al angine each pocket i the head Aftor removing the sprin haer 1 and spring unlaek The rachar mechanism and push im thu push al way install new qusket and tbe eum chow linear with two hans and them tn the torque Tightoning torque 6 B Nm 06 08 kam 45 Insart the spring inte the cum chin tenssoer and tighten the siping holder holt the specified torque Tightening torque 30 45 Nm 30 45 kgm 215 325 Ibt CAUTION After installing tho com chain tensioner check 16 sure hat the tensioner works properly by checking the slack of the cam chain wore Turn soe er nkshalt aod check that alt the moving parts such follower camshaft work properly CAUTION Be sure to chack and adjust t page 25 valve clearance Refer to ENGINE 348 Coat SUZUKI BORD 12078 lightly to
119. hrough the The stator windings are assembled housing racliior bridge connected the rotor on the rotor 13 coro that forms part of the generator and changes f Rotor 2 3 Shp ing Bram regula e E Banery terminal tion ternal Rotor col Granna ELECTRICAL SYSTEM 52 CHARGING OUTPUT CHECK Remove the seat 4 Start the engine and keep running at 5 000 1 01 Measure DC voltage between the battery terminals 4 and CY with pocket lester the tester reads under 13 5V heck the stator rectifier anu IC requlatiw mounted m Ihe generatar CAUTION If the pockat tostor is set to voltage is applied across the tost probes damage will result Therefore it is important that the tester knob on the pocket toster be set the proper position before making any mensursmonts 4 current or resistance and NOTE When making this test be sure that the battery s fully charged condition 09900 25002 Pocket tester Tostor knob indication 2 Above DCT3 SV ar STD charging REMOVAL DISASSEMBLY e Remove the seat Anm the lower fairing Disconnent the generator wires page 261 Hamave tha generator e Hold the generator driven oar fo use view and appropriate aan pieces of woods an
120. if gallery plug replace the Orma with new one aod bohtan 10 the specibed rone 099142581 6 mm 0980000410 Hexagon wrench set Not bvallablo in U S A type hoxogon wrench Tightening torque Main oil gallery plug 35 45 Nm 135 45 kom 255 325 Ibm Muke sure that all bolts removed Hammer huhily the wer crankcase sid ner ond ower cr CAUTION D not drop the crankshaft journal bearings from the lower crankcase ENGINE 322 Remave the crankshaft assembly tram the upper crankcase wore B m in mind that Wie crankshaft theusr bearings gt are acted botwaen the shart and Pill put the two dampers 11 and cam guido 2 4 Remove tha O rings 3 and i Renova countorshalt assembly and deiveshiaft assem ware Da wot lose the Crings 7 ard buena pins Hold the forks by have qwarshife fork shalt rhe Tower 12 Unhook the gearshift cam stopper Spring fram the towar crankcase Remove Ve cirelipiti From the cam and ther draw the gearshift cam from the other side 09900 06107 Snap ring pliers Nore When replacing the gearshift cam stooper apply quantity of THREAD LOCK 1342 to sho bolt 000 32050 THREAD LOCK 1342 Remove the quarshilt cam stopper by removing 0890008107 Snap ring pllors NOTE Rotate the bearing 19 by hand to inspect for
121. iinals positive and negative when squeezing the clutch laver and pushin the starter bunan H thu starter relay is In sound condition continuity is found gt 0860025002 Pocket tester TS 1 4 Disconnect the lead wire from the Check the for open ground an The in youd condition it The resi 0990025002 t Tester knob indication 11 range Starter rely resistance 519 ELECTRICAL SYSTEM SIDE STAND IGNITION INTERLOCK SYSTEM DESCRIPTION This side stanid iumition Interlock system is to prevent starting the motorcycle with the side stand left down The system is aperated by an electric circuit provided between Me battery and ignition Se sancti Creu breaker lation set imin OD gur ww aw t 1 2 gt ve The circuit consi position of the TRANSMISSION and SIDESTANO with the The ignition lives only in twa situations us follows Y Transmission NEUTRAL ON Side stand DOWN IFFY The current flaw J turns ON tbe relay Innition lives avan the sidestand ie down This iv ar warming up the enmne of relay lamp diode and switches and decides to live the ignition coil depending on iral and side stand switches working sic STAND sw RELAY DN BATTERY cow NEUTRAL Lam
122. it 105 035 mm 0 014 in 5 0 35 mm 0 014 in 3 26 VALVE STEM WEAR Ut the valvo stum is warn down1a the limit as measured with micrometer where the clearance is lourd to he in excess of the kmit indicated replace Ihr valve the stem is within the then replace the guide After replacing valve or guide be sure to recheck the clearance 09900 20205 Micrometer 0 25 mmi Standard Intake valves 2 965 4 980 min 0 1955 0 1981 jn Exhaust valves 4 945 4 950 mm 0 1947 0 1953 In VALVE GUIDE SERVICING Using the valve guido romae T drive The vatve guide but toward the intake or exhaust camslral side 09916 44310 Valve guide remover in NOTE Discard comoved valve guide subasserbties Only oversized valve guides aro available as replacement parts Part No 47118 08870 lar the Retiniah the valve quide holes in sylinder head wi Framer an hand 09916 34580 Valvo guide roomer 09916 34541 Reamer handie Firs ring vo wach valve guide Be sure to us new ri valve nudes and valve guides removed indisassembly must be discarded Oi tho stom hole tew each valve guido and deve the quide into the guide hole with the valve quid installer 09916 44310 Valve guido removor installor CAUTION Failure to the valve quide hole before driving the new guide into place may result in a damaged guide or head Aft
123. ke fluid con tacting any part of the motorcycle The fluid n with point plastics and rubber materials etc i damage them sevorely 4 Remove the footrest with 08900 00410 Hexagon wronch sat Not available in U S A wore Sat loosen the master cylinder mounting bolts t moving Ihe sight footrest bracket lator desassemby before oit Disconmocs the rear brake swi 6 Pull out the brake pedal comer 7 Remove the master cylinder mouming Remove the master assembly Hank amd hose 9 Remove tho rst seal t special tool 09900 06105 Snap ring pliers e ther push rod pistons sarina CASSIS Remove the ennneetor and Ging CAUTION The removed O ring should be replaced with a new one MASTER CYLINDER INSPECTION CYLINDER PISTON AND CUP SET inspect the cylinder bare wall for ar the pistan surface For any seratchus or Inept the cup ser and pach rubber for wear or d MASTER CYLINDER REASSEMBLY REMOUNTING Reasnmble and remount the master dur uf moval an disassembly Pay Following poi CAUTION Wash the master cylinder components with frosh fluid before ron und the internals be insertod into the bor CAUTION Blood air trom the sys indar Refer ta page 2 14 Adjust tho
124. l ta Haw to the dh POSITION Whan the fun valve Zus wot at the PRI position Haws to the earburptors because that the prol the lever end pushus back the fuel valve against Mo spring tension whe not thraugh the RES side The PRI position is used wher tor xama wer filing the fuel tank fx v of when the motorcyele has buen ION unused for long time pr wher carburetors Nave heen disassembled and repaired Shift the lever ta the ON pasition when The engine begins to run smoothly FUEL AND LUBRICATION SYSTEM CARBURETOR CONSTRUCTION 8 if y THREAD LOCK i A 1 n 1 apo THREAD Lock CEMENT 4 Top 19 a Sprinn seal Brg 14 Washer ut revde 27 Dita Piston vale Needle jet Throttle valve Stwter plunger 4 Pilon jet Main et assy 17 Gat Balance serewe Al vem plate 58 States shalt lever Air vont hose cornetas Fuet nose cnnnaetor Garmuretar set tower Tuerto stop FUEL LUBRICATION SYSIEM_44 SPECIFICATIONS SPECICATION pe gt Te E Bore sive 3 D ioma 4096 40630 1100 1100 E 10mm Float height Me 2 x E 004 1 y Maw ut 1225
125. lip care must be taken not ta oxpand tho ond gap larger than required to slip the circlip ovar tho shaft Attor Installing circlip always insure that i is com pletely seated in groove ond sacuraly fitted NOTE In reassembling the transmission utteotion must be given to the locations und positions of washers and circtigs The cross sectional view gwen here will servo as reference for correctty mounting thv gears washers and cichos Reter to page 346 Whan installing a pay ol Mw FILA ta the side thrust is as shows in e WI installing he gear bushing onto staf alian the fil hole the shaft will bushing hole 3 E 34s ENE When installing the pur the lack washers i and be sur to align the three aronves of the lock washer 3 the Three tabs of the lock washer Before installing the 81 fl mew D ring E onto the hat Apply grmase ta the oil seal and For U S A moda 99000 25030 SUZUKI SUPER GREASE For the other models 99000 25010 SUZUKI SUPER GREASE A TRANSMISSION 9000008 0 00 00 GEARSHIFT FORK GROOVE CLEARANCE Using Ihekness gauge check the gearshift fork clearance in Ihe qenave of its gear The rlenranre for mach of the fark
126. lower and upper crankcase securing bolts and nuts In the specified tarque values Tightening Inia tightening Final tightening torque m wm tn kam xm Bmmbor xs 13 95 24 24 175 NOTE Install the main oil gallery bl Refer to page 321 Fit up the engine around wire 3 to ths correct position as shawn in Fig 099142581 mm Type hexagon wrench 358 ENGINE Attach thu Jl oil pipe Gai wah tho bolt Fira new Dring sand shim 2 Fit a new Gasket and install the sump filter to the lower crankcase CAUTION Replace the gasket and O ring with new ones to prevent oil leakage Seat the washer and install the pressure regulator 310 the oil Tighten th rayulator io We suecilied fom Tightening torque 25 30 Nm 125 kom 180 21 5 01 Dira new gasket install the 08 pan Tighten the pan t the apocilied torque Tightening torque 12 16 Nm 12 1 6 kom 8 5 115100 Fi v new pasket to the correct position as show CAUTION new gasket to prevent leakage e Tightun the orig drain ph Retar to page 7 29 instali the eountorsiaft hann retainerwith rwo screws Nore Apply small quantity of THREAD LOCK 7342 to the two 99000 32050 THREAD LOCK 1342 to the specified torque 4 Install each ear shifting paw into the cam driver gear The lage shaulder A must
127. ly urip the cylinder black at bath ends and INE It straight H the block does nar come lightly tap on the finfess portions af the block with plastic mallet ra make the gasketed loose e Soribe oytinder number rn the head of Ihe respective pistons Place cloth beneath the piston ns nor to drop parts in tha er nkense and remove the 1 wir ora Draw out the piston pin lator that was com each pestan pin in thu sume Remove the starter motor removing the Remove the generator by removing the bolts ENGINE 315 4 Remove Ihe signal rotor by removing the 0990000410 Hexagon wrench sat Not available in USA Disconnect the oil pressure switch lead wire Remove signal generator stator by removing the three e Remove the clutch cover by rumon 09911 73730 5 mm type hexagon wrench Remove the pressure piate iio 10890008108 Snap ring pliers Alot of pressure plate bearing 3 and the clutch push rods and 8 NOTE ites diffi to draw out the push rod 5 use magnetic hand and draw out 2n wr Hemave the eluteh diaphragm spring holder nut special tanis 09920 34820 Clutch pressure plate holder 0994158010 50 socket wrench Att r ramaving the elutchy diaphragm spring
128. mino the recharging time in Hour by constant curren at a charging roto of 1 4 amperes which is tenth at the capacity of the present battery Erectrolyte specie yravity 128 at 20 C 687 Be not ta permit the electrolyte temperature exceed 48 C 113 ut any during the sechargiog operation Interrupt the aperation as necessary to lut thu electrolyte cool down Recharge the battery to the specification Constant voltage charging otherwise called quick charg ing is not recommendable for jt could shorten the life of the ELECTRICAL SYSTEM 520 SERVICE LIFE Lead oxide 1 applied 10 the pale plates of the battery which will come off gradually ih service When the botom f the battery case becomes full af the sediment the battery cannot be uana any mars W the battery is charged tor a Jana ums wad sulfate is generated on the surface of the pole lates and vol deteriorate Ihe performance sulfation Roloc tha balfory wilti row in such a case Wher battery is left lang term without use apt be subject to sulfati wun the mintoreyele is nol used for mare than mont especially during the winter season recharge We battery month at least WARNING Before charging battery remove the seal cap from bach col Keep firo and sparks away from
129. moved once should ba replaced with now ones Remove the maaring Wy using the spec took 09923 74510 Bearing remover 09830 30192 Sliding shalt CAUTION The removed bearings should be replaced with new ones SHOCK ABSORBER Remove the spaces and dust seas R move the stopper and drive out the bearing hy using appropriate tool CAUTION Tha bomring and stopper rings once removed should bo roplacod with now ones CHASSIS saa REASSEMBLY INFORMATION gt NIGHT SIDE Ea nt 30 60Nm mm Toners 4 ovem 3 E Janamari A CUSHON LEVER Point Lower mounting run nu 110 160 Toten p gt Apgiy SUZUKI super Point Front shalt ust re HERD Point shat nun sese a i Apely SUZUKI super grease REASSEMBLY AND REMOUNTING Shock absorber rear cushion lover tods and cushion lover Pay attention to the Reassemble and remount swingarm acini SWINGARM e the bearings mto Ihe swingarm pivot munting pornon 09944 34513 Steering outer NOTE When instating the bearings ooch marked site ot burma faces outside Installer Apply grease to Ihe bearings space
130. n battery being charged When removing battery fro tho motorcycle be sure to remove tho C tormina first CHASSIS CONTENTS FAIRING REMOVAL REMOUNTING FRONT WHEEL REMOVAL INSPECTION AND DISASSEMBLY REASSEMBLY AND REMOUNTING FRONT BRAKE BRAKE PAD REPLACEMENT CALIPER REMOVAL AND DISASSEMBLY CALIPER AND DISC INSPECTION CALIPER REASSEMBLY AND REMOUNTING MASTER CYLINDER REMOVAL AND DISASSEMBLY MASTER CYLINDER INSPECTION MASTER CYLINDER REASSEMBLY AND REMOUNTING FRONT FORK REMOVAL DISASSEMBLY INSPECTION REASSEMBLY AND REMOUNTING STEERING REMOVAL DISASSEMBLY INSPECTION REASSEMBLY AND REMOUNTING STEERING TENSION ADJUSTMENT IGNITION SWITCH 55959299559992955959529999 ARAU rr a e BRAKE 623 BRAKE PAD REPLACEMENT 624 CALIPER REMOVAL AND DISASSEMBLY 624 CALIPER AND DISC INSPECTION 625 CALIPER REASSEMBLY AND REMOUNTING 6 25 MASTER CYLINDER REMOVAL AND DISASSEMBLY 6 26 MASTER CYLINDER INSPECTION 627 MASTER CYLINDER REASSEMBLY ANO REMOUNTING 6 27 REAR WHEEL 628 REMOVAL 629 INSPECTION AND DISASSEMBL Y 630 REASSEMBLY AND REMOUNTING 6 31 TIRE AND WHEEL 634 REMOVAL 634 INSPECTION 636 TIRE MOUNTING 637 REAR SUSPENSION 6 39 SWINGARM 6 39 SHOCK ABSORBER CUSHION LEVER 620 REMOVAL 641 INSPECTION 641 DISASSEMBLY 842 REASSEMBLY INFORMATION 642 REASSEMBLY AND REMOUNTING 645 FINAL INSPECTION AND ADJUSTMENT 645 SUSPENSION SETTING 648 CLUTCH MASTE
131. n down cyber bores oplace oy robore 6 Starter moor cranks Slow 7 Poor sti ni spark Plugs not sparking 1 Fouled spark plugs lean 2 Wot spark plus Elvan ond dig 1 Defect nition Replace Werne Replace ean or replica inan replaces lus oF inl Cinan on replace Engin Fast spark pun al yonerator or Clogged fuel hore Cuan jos carburetors haan Var clearance Ads Noisy engine Excasaiwo volvo chatter Va clearance too Large napus 2 Weokerwid or broken valve replace Wom sum arm shaft Replace Noise appears to coma from pistons T Peters or cylinders worn Gown Combustion era failed with 2 Piston us piston pin bore worn A e e nq uoces wom Noise sonans to come from timing chain T Strecha enen 2 Worn sockets 2 Tension adjuster wot working Noise In came from clutch 1 Woru spines of countershaft oi hub 2 al piares 3 plates and dive 5 Replace Repti Regace aces Replace diver SERVICING INFORMATION 12 Complaint Noisy engine Slip
132. na Keep the motorcycle upright straight Fil up the master cylinder reservoir to the upper em of the Inspection window Replace the reservoir 10 of Attach pipe to the blender valve und Ihe pipa Into rucwptucle Squouze und release ne clutch lover succession and squeeze Ihe lever fu Losin the biveder valve by turning W u n that the Tid run the handiebar tension of the lever causing rio Then close the valve pump and sneeze the levo apon tho valve Repeat thie procuss Rowing mis We racmptacte longe contains air bubbles wore bleeding the system Make sure that there eth Mid reservoir as necessary vta some thud visible in Ihe reservoir e Close Ihi valve and discos ta the upper end of the Bleeder valve tightening torque 6 9 Nm 06 45 B5 lb CAUTION Hunela brake fluid with care the fluid with paint plastics rubber mat als oto M PERIDDIC MAINTENANCE AND TUNEUP PROCEDURES DRIVE CHAIN Inspect Initially at 1000 km 600 miles 2 months and Every 6000 km 4000 milos 12 months thereat and Lubricate Every 1000 km 600 miles od Visti check the drivi chain for possible Bulow dw malareycte by jack and a ws turn thw rear wheel slowly by hand with the shifted 10
133. nder mour TN 18 28 Fuar brake lock mut 18 28 tear wt 6 115 Rear sprocket nut E 4B 72 721 SERVICING INFORMATION SERVICE DATA VALVE GUIDE Unit m INDARD Valve diam E _ 25 Vaive it E Pe 1032 20 0 10004 09061 018 023 10007 00081 Valve gui ia 0020 0047 0 0008 000191 0014 Pe 0040 035 s 0 0016 9 00261 0014 Valve quid ib Valve siem 2308 4940 01955 0 1981 2545 4960 Fe 40 1947 0 1953 Valve ses uno E Valve hend kun E ave stem end igi E Valve seni wi Ares Valve hand ma runout TU E Vae sing Wed aso n mm Valve sping Tension IN amp E innen 117 T 131 1518 315 mm L2 SERVICING INFORMATION 722 CAMSHAFT CYLINDER HEAD Unit mm n STANDARD UMIT height m 33878 33918 33580 maa38 13354 11 3220 33533 33573 33240 13202 13218 41308 Camshaft journal oil clearance 0032 0066 0150 WAR 10 0013 0 0026 100059 Camshaft journal holder LD mes 22012 22025 E 10 8666 086711 OD 21959 21950 E pea 10 8645 086541 amaba ranou EX 2 A 10904 1580 es e 1622 Cam chain pin arrow FT Zand on Tocker m 10 12000 12018
134. ng the starter el teh assembly from the crum haft do not remove The stares clutch mounting bolt hosen the bolt The starter ch lch Doll s 0 c nvunetion with the toot Romave the starter clutch assembly from the crankshaft by th special tool 09930 33720 Rotor romaver Flaten lock portion of the seal retainer and vemove by removing the taur bolts Roms the neutral position indicator switch by remove Inn serves NOTE Da nor lose the Oting V switeh contact 7 spring 3 4 Remave the countershaft bearing rutamnur by removing the Two sorews Remove the plug on the upper crankcase Remove the upper crankcase securing bahis and nut 0991173730 5 mm type hexagon wrench TeS oS Remove the pan by removing the 09911 73730 5 mm T type hexagon wrench Remo the shim and Remove thu oil sump Remove the ltt pi a Remove the eil sump fitter gunde 5 by removing the tia bons e Remove the lower crankcase securing bolts and nut removing he crankshaft ikihtaning bolts loosen them In the descending order of numbers assigned to these NOTE mian bolts are ised lor Die crankshaft ar 3 Before removing the crankshaft bolts remove main gallery plug 6 Whew installing the main o
135. oF balanc 0991313121 Carburotor bal Startup the ening throttle stop keep t running at 1 750 r in by FUEL AND LUBRICATION SYSTEM 414 screw Int the gauge so thal the vacuum acting the tube of that hose will ring the steel ball 2 m the tube to the cuntur line ts Alter making sure that the steel ball stays Steady at the tenter ine disconnect tbe hase ffom inler and connect Me next to th Turn serew ta bring the other sive 4 ta the Hi Repeat the above process an the d and fourth hoses The balancer gauge is now roay for use Im balancing the 415 FUEL AND LUBRICATION SYSTEM BALANCING CARBURETORS Far balancing all the carburetor movement remove all the vachum inlet cups rom each carburetor Connect the balancer gauge hoses to these vacuum inlets and adjust the balance of dor curburetors as follows 4 Start up the and keep it at Y 750 10 engine tachometer reading Acurroetly adjusted carburator has the steel balls tho Nos Y through 4 tubes at the same level balls ore not in correct positions adjust the valve balance sarnws corsectly Adiusiing order is as follows n FUEL AND LUBRICATION SYSTEM 4 15 4 After balancing the carburetors set there speed between 1000 and 1 200 r min by turning the throttle
136. out the piston by Usina qua caution Do not use high pressure air ta provant piston damage Remove the dust soal piston and piston out of ilie catar 3060 y vie CHASSIS CALIPER AND DISC INSPECTION CALIPER Refer PISTON Heter RUBBER PARTS Rear to page 68 Disc Ruten CALIPER REASSEMBLY AND REMOUNTING Re of removal and disassembly Pay to CAUTION Wash the caliper components with fresh brake fluid boforo reassembly Navor use cleaning solvent or gasoline to wash Apply brake fluid ta the caliper bore and pistor Inserted into the bore Blood air from tho system after re IRofer to page 2 14 Tiahtoning torque 1 20 25 Nim 2 0 2 5 kg 145 1801610 2 IFor USA und Canada models 28 Nim 1 8 28 130 200164 Far ho othar models 22 Nm 2 2 kgm 160 24 5 ibi 30 38 Nim 30 3 6 kym 215 26 0 164 1 1 28 Nm 18 2 8 kom 130 200 semble and maunt the caliper Im the reverse to be mbling the calipor 626 MASTER CYLINDER REMOVAL AND DISASSEMBLY Remove the seat 2 Remova the reservoir tank mouting bal master cylinder Unserew the union ter cylinder 3 Placa a tag underneath nion on 10 catch any spilled drops al broke holt and disconnect the rake hose from th CAUTION Immediutely and completely wipe off any bra
137. page NOTE The eugine mounting nuts are selklock ng Once the mut has been removed it is ne longer of use Be sure to use new muts and tighten them to the specified Torque TIGHTENING TORQUE TEM Ww mou 70 88 70 88 mos 50 60 50 60 Oner bol 25 38 23 36 LENGTH Wow 378 mm 70m Bolt iz 150 mm 59 Bol 55 mm 2 2 in 55 2 Spacer RH 0 27 Bush R amp L l 39 mm 15 in 3n tur ENGINE 312 Replace the plug caps on Ihe spark plugs so thar their code markings correspond to the cylinder numbers aeranged in he order of 1 2 3 and 4 from the hand EXT 8 Locate Ihe carburetor clamps as showr Pour 8 1L of engine SAE 10W 40 tion SF into the engine API classifica Several mutus after starting and st hack that the ail lave n OIL CHANGE 4000 mi 4 2 3 5 US Imp at OIL AND FILTER CHANGE 4200 mi 4 4 3 7 US Imp at OVERHAUL 5100 mi 5 4 4 5 US Imp Tighten the engimu sprocket ascending order of numbers Alter remounting the engin route wiring h and hose properly hy referring ta the secuams for wire raming table routing and hose through 24 Adjust the following items ta thu specification Page Throttle cable 2 Drive cham 201 Idling adjustment Balancing carburetors aa ENGINE DISASSEMBLY Remove the oi filter
138. patan Lock SureR 713807 5900027131 5900037131 Drosha od seal Engine pipe rina Starter motor wi sen Whee bearing Steering stom hearing Smack mounting drum Swingarm spacer and dust Cushion levet boaring und Comod bin end beating Chuntershatt and srwerhatt ramtstort journal bearing journal fae monar armature and Gemorator driven Quar Samper latch ever push rod 2 Erankeona ming surince 7 Catch cover manna Cynder he Surface Di etum swatch head wie mme sti bolt Tam sro 1 Cam chain guide bolt us mounting belt GENERAL INFORMATION MATERIAL 2 FART tes models apa em aoe moveret T mea beata retain Gam 5 Sar meter mines hu id 580 mars motor housing stew 39000 068 1 fet 1 Starr clutch mount bot w me L unean Lack suren 1303 THREAD sare 1306 5900037030 250002100 a zu ft ue Er FLUO onare Daraa pova 2900092110 3900023110 E SUZUKI OIL 35000 90044 THREAD CEMENT 5900032040 1 THREAD COCK 1900033040 VS GENERAL INFORMATION PRECAUTIONS AND GENERAL INSTRUCTIONS
139. ping elute Dragging Transmission wil nat Transmission will not shift beck Transmission jumps mt of quar Engine poorly Engine runs poorly in high range Symptom and pomible causes Noise sem to come trom erankshatt 1 Ratthnn bearmns due wear 2 ig end bearings worn and bur 3 Jornal bearmas worn Viet eloarance to large Noise Lo como trom transmission Gears worn rubbing Badly worn spines Primary eae worn vr tung Bachy worn beans Guten contra aut Weakenws cuach spia Wom or persue pima Distorted lunch plates ive and driva Clutch control out o 100 much play 7 Some clutch swings weakened wile others as 3 Distorted prossuro plo or plate 1 Graken cam 2 Distorted or wor gearshift forks on stopper Detetive valve guides Worn rocker ams or stats Spark pun too wide logoed ies pr blanc of Var Wom cats or rocker Vale cur of adiniiment Spark play aps too narro anion wat advance Defeehee Defectie signal Fat charter level 100 low Clogged sir hose in ent Bon ae supply ta Clea amd pram Remedy Replace Replace Replace R
140. piston 2 E Piston pin boro 10 Service Limit 20 030 mm 0 7886 in 337 mome sing mierometer measure the piston pin outside diameter at raa positions Piston pin Servico Limit 19 980 mm 0 7866 in 09800 20208 Micrometer 0 25 mm CONROD SMALL END 1 0 Using a small bore gauge measure The conrod small end inside ameter Conrod and 10 Sorvice Limit 20 040 mm 0 7890 In IV he small nnd insida diameter nxconca the above mit renee the conrod CONROD BIG END SIDE CLEARANCE Chock tho conrod side clearance by using teknes aune thw clearance the limit replacu corrad or Servico Limit 0 3 mm 0 01 inl 09900 20803 Thickness gauge Stondard Big end width 20 95 21 00 mm 10 826 0 827 inl Stondard Crank pin width 2130 21 15 mm 0 831 0833 in 0890020208 Micrometer 0 25 mm 0990020605 Dial calipors 10 34 mm Wot available in USA PIN BEARING SELECTION Loos the bearind nuts and tap the bol plastic hammer to remowe the hearing rap Remove the rods and mark them 10 identity the cylinder position e inspect the bearing surfaces for any sign of fusion pitting Irura or Haws any replace them with a specified set of beatinas ENGINE 338 Never ta remove or loosen the conrod cap bolts due 10 their possi
141. r mounting 5 8 05 08 3 Front brake mounting bolt 27 43 27 43 195 310 2 Front brake housing bolt 20 25 20 28 145 180 2 Front brake pad mounting boit 15 20 15 20 110 145 Front brake master cylinder mounting bolt 5 8 05 08 35 60 J amp Braku and clutch hose union Cylinder amp Cale 20 25 20 25 145 180 WM bloedor valve Front amp Rear 08 09 45 65 11 Front and rear dise boit 15 28 18 28 10 180 W Front footrest racket mauntny bol 21 43 21 43 195 910 AW Swingarm pivot nur 85 115 85 118 616 830 WT Fron footrust nut 35 55 35 55 255 400 1 Rear shock absorber mounting nun Upper Lower 0 60 40 60 790 435 MB Rear cushion level rod mounting pur 110 160 10 160 795 1185 2 Bear brake caliper mounting bolt 18 28 18 28 130 200 1 Rear brake culiper housing balt 30 36 215 245 98 Hear torque link nut Front amp Read 22 150 245 For E03 28 and 33 18 28 130 200 Rear brake master cylinder mounting bolt 18 28 130 200 WO Roar brake rod laek nur 18 28 130 200 Wo Rear axle nut 85 115 615 830 UM sprocket mut 48 72 350 520 ENGINE CONTENTS COMPRESSION CHECK OIL PRESSURE CHECK 2 ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE ENGINE REMOVAL AND REINSTALLATION ENGINE DISASSEMBLY ENGINE COMPONENTS INSPECTION AND SERVICING CYLINDER HEAD VALVE CAMSHAFT CHAIN TENSIONER CYLINDER PISTON PI
142. r tie size Front fork stroke Rear wheel travel ELECTRICAL union typo Innitian timing Spark Battery Generator Fuse Circuit breaker CAPACITIES Fuel tank Inchuding reserva Engine Oil change with filter change rant fork oll ee Telescopic spring oil damped inner rod type spring pretoad fully adjustable damping force com pression 10 way and rebound 8 way adjustable Fullfloating suspension system qas oil damped spring spring pre load fully adjustable daryping force Away adjustable 30 right 5510 mm 139in 32 IOS Disc brake 1win Disc brake 120 702817 180 02 17 120mm 4 Tin 140mm 5 5in Fully Transistorized 7 at 1500 r min 137 BTOC at 1500 r min NOK For California modal For thv other models 2 504 4Ah I0HR Three phase Gonurator 1070 10 0 0 30A 1854 1 US imp gal For California modul For Switeurlandl model For the other models 20 5 Li5 4 4 5 US mp 2101 55 4 6 US Imp yall A2 LI 4 37 US mp 453 m 15 3 16 0 US Imw 04 ATE mia 1 147 USAMp For USA model Farah models These specifications ara subject to change without notice 18 GENERAL INFORMATION COUNTRY OR AREA The senes of symbols the left stand for the countries and areas an the right SYMBOL COUNTRY or AREA General E02 England E03
143. rcl a team the groove and side the circi toward thu Sed drive 09900 06104 Snap ring pliers Slide Top drive naar toward the drive gear and amave the pair ot the lack washers 6 from ck washers and 2nd drive gear slide the par of the ke Toward the Top arive gear 55 the 2nd dive 08 nnd then remove the 2nd drive gear Ti Top drive gear 5 and Ard drive goar amp Remove ie dh ive toa 12 by removing th 0990006707 Snap ring pliers DRIVESHAFT DISASSEMBLY Exch driver pasi on the easily removed by isi ind ullos 09900 06107 Snap ring pliers Y Right end bearing Top driven gear AF Low driven gear 238 driven sear 3 Ath driven gear 7 Lett end bearing 6 3id gear Oil seal Spacer ENGINE COUNTERSHAFT AND DRIVESHAFT REASSEMBLY Assembl the countershatt and diveshaft in the reversi order of disassembly Pay attention to the pats NOTE Bofore installing the gears rarate the bear by hand inspect for abnormal noise and smooth cotation Replace the bean if there is anything unusual Before installing the gems highly coat moiy paste or engine ta the Uriveshatt avid countorshatt 9900025140 SUZUKI MOLY PASTE CAUTION Never ro from shaft it should be discarded a now eirchu must be installed When installing a new eirc
144. rhe tank after iscanneciing all hoses from fuel sock for do 35 pate FUEL COCK REMOVAL the fuel cock assembly by removing the two bolts WARNING Gasoline is very explosive Extreme caro must bo Gaskets must bo replaced with now ones to prevent fuel FUEL LEVEL INDICATOR SWITCH 8 24 loi inspection WARNING Gasoline is very oxplosivo Extreme caro must bo taken Gaskets must bo replaced with now ones ta prevent tun lenkage INSPECTION AND CLEANING flow and lose in engine no FUEL AMD LUBRICATION SYSTEM 42 FUNDAMENTAL OF FUEL COCK It explams of the construction af diaphragm type fuel cock ON Normally used Functions as an auto fuel cock RES Reserve fuel is used Functions as an auto Iuel cock PRE is directly supplied Does not function an auto fuel cock ENGINE STOP CONDITION When the grs je running with he lever inne ON ar RES posicion he fuel valve 21 1 kupi IN ie closed pasion by applyiny pressure and the tension ol spring that fuel will Now to ihe ENGINE RUNNING CONDITION Whun the engine is started a negate pressured is generated in me diaphragm chamber through the vacuum negative pressure pipe which is cannuetod to the carburetor und uiis negative press tansion of spring 2 that the diaphragm 3 Forced ta apon tha uel valva I und ius allow the fue
145. ront and wear to the feft and right ENGINE 3 58 Fit the and 8 CAUTION Replace the Osings with now ones to prevent leakage 4 Bofors installing the crankshaft apply SUZUKI MOLY PASTE to Bach Journal bearing 9900025140 SUZUKI MOLY PASTE install the crankshaft with the cam chain to the crankoase Insert the right and lettthrust bearmys wiih oil grooved facing the crank web Refer to page 3 43 Clean the mating surfaces of the crankcases before match ing the upper and lower ones Install the dowel pins 1o the upper crankcase Apply SUZUKI BOND NO 12078 ro the mating surface of the lower crankense In the follow procedure For U S A model 9910431140 SUZUKI BOND NO 12078 Far tho other models 9900021140 SUZUKI BOND NO 12078 Nore Use of SUZUKI BONO NO 12078 is as follows Make surfaces free from moisture dust aod other foreign materials Spread 00 surfaces tly to orm assemble the cases wit few mous Take extreme care not to apply any BOND NO 12078 to the bearing surfaces to distorted surface as comparatively thick oper even Inyer and Ach the right ike wiih No 1 bolt Placa the copper washers over tho No 9 and No 11 Locat the twu Tighton the crankshaft tightening v ing order of numbors assigned to these bolis tightening ach bolt Vte at bme fo aqualize the pressure Tighten thw
146. rs and dust seals when Installing them For U S A model 99000 25030 SUZUKI SUPER GREASE For tho other models 9900025010 SUZUKI SUPER GREASE A CUSHION LEVER Fore ir bearings cushion lever pivot an mounting portion Install bearing by using aporone NOTE Whon installing the besnnas punchmarkad sale of bearing Faces lt arease to the beannas spacers ar dust seals when installing mem For U S A modal 99000225030 SUZUKI SUPER GREASE For the other models 99000 25010 SUZUKI SUPER GREASE A Titten each nut to Ihe spocified torque ro FINAL INSPECTION AND ADJUSTMENT daving the Alter installen Ihe rear suspension amd following adjustmunts ame required befor motorcycle 7 Drive chain Huur broke gt Tie pressure Shock absorber CHASSIS 645 SUSPENSION SETTING Front and rear suspensions are adjustable according the rider s requirement The high speed capabil cle makes proper suspension seting important Use the following table tn adjust the Wont and rear FRONT SUSPENSION SETTING TABLE Damping Toren reload 2 Compression Rebound Softer 5 Solo riding Standard 5 5 4 3 2 Dual ricino 45 3 4 REAR SUSPENSION SETTING TABLE Spang preload Darin fores Soner 872 1972 mm 737 7761 1 Solo rid Standard 182 2 mm 17 57 1
147. s plays an important u the smanthness and positiveness af the shifting action tt fork Groove clearance 110 0 30 mm 0 004 0 012 im 150 mm 10 020 in hacked 6 noted va exces Tii replace the fork or Its paar or 0990020803 Thickness gauge 0990020102 Vornior calipers Shift fork groove width Standard No 2 Nok 5 00 5 10 mm 0 197 0 201 In Shift fork thicknoss Standard 2 amp 4 80 490 mm 0 1 0 193 in ENGINE REASSEMBLY The is reassembled by oa EN Aa N Checking clearance Checking thickness he steps of disassembly in the raversud order bur there are umber of steps whieh demand spucal descriptions or precautionary measures NOTE Apply to each running and siida part before 352 install the ye 11 cam 2 cam stopper Celle n ET CAUTION Always use new circlips Ji and 14 4 Position the gearshilt cam as shown Fi So that the forks and trunsinussion can he installed wasily NOTE When installing the cam stopper plate i the pin groove 5 with tha pin E shown in the Fig Install la erat forks to the crankeose the coret positions and dictis IT For Sth driven qene 12 For Sud gear 12 For Top driven gear e Orinas fl anil 1 and dowel pins 22
148. s section describes the servicing procedures tor each Dt the Periodic Maintenance requirements BATTERY Inspact Every 6000 km 4000 miles 12 months Remove the seat and battery holder plate i Romow the battery and cy lead wires from the battery the battery from case Check the electrolyte and wravity Add distilled water necessary to keep the surface of the electrolyur above the MIN level line but not above the MAX level For checking hse a hyrromaterta deter the charged condition 09900 28403 Hydro Standard apoeifie gravity 1 28 at 20 C 88 F reading at 1 22 at 20 C or under means that the battery needs rocharging Remove the battery from the ma and charge it with battery charger CAUTION Novor charge a battery while stilt in the machine as damage may result to tho battery or rogulator roctifior Charge maximum of 1 4 amps e intl the battery reverse the procedure described above WARNING Whon installing the battery lead wirm and load tost the i load first e Make sure that the brw lher Hose and vlamaqed and is as shown in the huuto ether ise PERIDDIC MAINTENANCE AND TUNEUP PHOLLDUMES 24 CYLINDER HEAD NUTS AND EXHAUST PIPE BOLTS Tighten Initially at 1000 km 600 miles 2 months and Every 6000 km 40
149. shift lover height 2 6 gt Asterisk mark indieatus new Lunar specifications GSK T0 98 CARBURETOR m E mw roi 29204 ras ES ida va 4 3453 Carburetor 2 h 8573855 Bore size m 0 2 ma 7 40650 _ 40060 0 k E Float height 4 gt 057 0 04 in Main jet TAC gt jot 18mm gt r E Jet WN Ned jet way 3 5 Pior int ws 5 gt Bypass 2 gt Plot outlet ron Valve seat vs Starter jet ws 2 Pilot serow ws eser PRESET PRESET 12 ums ET urns out Em Pilot aic jet was Throttle cable play 05 10 mm 1002 004 in 39 CARBURETOR SPECIFICATION met tas Carburetor ype 8573655 Bore site 36 mm 1 4 ind gt socio 40020 40630 tale t min 1200 100 1100 100 r min 1100 it Float height 14 6 10mm 5 057 004 m Main jet T amo Main air jer 18 mm Jot nodi 5042 5043 COTENT jet lt 0 9 Pilot jet wn 30 17 08 mm D Pilot outlet wor 07 mm Valve svat ws 23 mm gt Starter jet 165 545 Pilot scr PS PRESET TU 1 Va turns Pilot ir Jot aa
150. shifting patel and cam driven gear ENGINE REMOVAL AND REINSTALLATION ENGINE REMOVAL Before taking the engine out af the frame wash the we with a steam cleaner procedure of engine removal is sequentially explained in and engine installation is effected reversing the removal procedure Remove the lower fairing Remove the left amd right middle 1 Hemove both seats Remove the pulion ridar grabber lemove the loft and right frame covers Remove twa fuel tank mounting bolts enome ys fol cack lever after positioning at ON Lift up the tank and disconnect I switch lead wires and fuel hoses the Loosen the respective carburetor clamp screws ENGINE 35 e Pulling out the clips from the aw cleaner case and separate the carburetor assembly from all the outlet tubes and intake pipes Remove the carburetor assembly from Disconnect the throttle cable side e Disconnacting the battery C and 9 lead wires fram the battery terminals remove Ihe battery CAUTION Be sure to disconnect the load wire first Disconnect the following lead wires Bottory lead wire coupler TA Genarator load wires coupler 21 Neutral indicator switch wire coupler 39 Signal generator lead wires coupler 1 pressure indicator switch lead Side stand indicator lead wires coupler 6 Star
151. sure is used on the inside dirt will be Torcad into the pores of the cleaner elamont thus restricting air flow through tho cleaner oloman Aninstali the cleaned or new loaner reverse urdur of removal When installing the uir element the cleaner case make sano that the part CAUTION M driving undar dusty conditions clean tho air oloment mora froquentiy The surest way to accelerate engine wear is to use the engine without the olement or to use ruptured element Make sure that the air clo in good condition at all times Life of the engine denen largely on this component VALVE CLEARANCE Inspect initially at 1000 km 600 miles 2 months and Every 6000 km 4000 mil Lr OR Remove the cylinder head cover Remove the soat The valve clearance specification is different tar both intake amd exhaust valves Valve clearance adjustment must be checked and adjusted 1 at the time of periodic inspection 2 whon thi nism ls serviced and 3 when the camshafts are disturbi removing them for servicing Valve clearance when IN 0 10 0 75 mm 6 004 9 008 in EX 0 18 0 23 mm 0 007 0 009 in PERIODIC MAINTENANCE AMD TUNE PROCEDURES 28 wore Tho com must re it positas 8 ori in orderto check the v le clearance or ta adiust valve clearance Clearance endings should nof be wher with the cam in any other position than these
152. t or arrow marka 71 and 2 on EXHAUST sprockon located shown irr 10 the notch 1 in the sight end ot vach cumshot REASSEMBLY Apply THREAD LOCK SUPER 1303 to the threads of cam sprockes halte and tighten tham t the lollowing tamue value 9900032030 THREAD LOCK SUPER 1303 Tightening torque 24 26 Nm 24 26 kom 175 190 CAM CHAIN TENSIONER The cam chain tensioner is mamtam nd at the proper tension by un automatically adjusted tensioner Unlock the rachet mechanism 11 rf move the push ro in places 10 sew if slides smoothly If any stickiness is noted or rachet mechanism is faulty replace ihe cam chain tensioner assembly with a new one CAM CHAIN IDLER Rotate the sprocket by hand to inspect tor abnormal noise anda smooth rotation detect is found replace the cam chain idiei assembly with new one CAM CHAIN 20 PITCH LENGTH Pll te chain tight to remove any slack then using vernire calipers measure the 20pitch length of cam chain it ameasurus more than the hnit replace the cam chain Sorvice Limit 158 0 mm 6 22 in CAM CHAIN GUIDE wore When replaciog cam chain guide apply SUZUKI THREAD LOCK SUPER 1303 threads of bolt 9900032030 THREAD LOCK SUPER 1303 chain guido mounting bol 4 7 04 07kg 30 501 CYLINDER BLOCK DISTORTION hock the gasketed surface of the evlinder block tor distortion with a straightedge und
153. t side thrust bearing and remove the eft side hast bearing As shawn in the illustration use a thickness gauge ta measure the clearance before inserting af the lath side thrust bearing and select a leftside thrust bearing irum he solvetion table Thrust boaring selection tabla Clearance before Co inserting left sida wort Thrust clearance rust booring 244 249 um tack onan 248 284 mm Groen 244 mm 005 0 43 mm 010010 112228 48000 00 0086 nl 0002 284 2 59 mn L7 400 102m 4SB UOCO Altos sol ctll g left side thrust bearing Insert it and agai clearance measurement lo make dard NOTE Right side thrust bearing has the same specification as the Grevn af sche teost boaring CRANKSHAFT RUNOUT Support the crankshaft with V blocks shawn with te o journals resti ori the blocks Set up the dial qauge as shown and rotate the crankshatt slowly 10 read the runout Replace the crankshaft Uno runout is greater than the limit 0990020606 Dial gauge 1 100 mm 10 mm 09 00 20701 Magnetic stand Up 09900 21304 V hiock 100 mm NO able in USA Crankshaft runout Service Limit 005 mm 0 002 in HONE CLUTCH DIAPHRAGM SPRING Measure the free height of each Spring with u variet calipers each diaphragm spring heights not tha spe
154. tened to the spectet torque raties and valves are property adjusted Warmup the engmo before testing 4 Remove the svat Fairings and fue tank Remove all the spark plugs the compression gauge Din one of the plug holes while taking care that the connection is tight Twat the throttle grip Crank the engine few suconds with the starter and record the maximum gauge reading as the compression of that cylider Repeat this procedure with the other cylinders 09915 84510 Compression gauge 09915 83211 ENGINE OIL PRESSURE CHECK To chuck periodically oil pressure of the passage way in the engine needs 10 judge oughly the of the moving parts DIL PRESSURE SPECIFICATION Above 300 kPa 30 kg cm 43 psi Pontoon aoa a 3 000 r min OW temo at 60 C 014071 Iv tho oll pressure is lower ar higher than the specification the following causes may he considered LOW OIL PRESSURE Clogged oil filter Dil leakage from the all passage way Damaged seal Dulective pump Combination af above items HIGH OIL PRESSURE Used angine which ix too heavy Clogued oi passage way Combination oF above items OIL PRESSURE TEST PROCEDURE ight on keeps on hahting check the pressure indicator ght carcon o check the pressure im th mar
155. ter motor lead wire 7 enome Disconnect all the spark plug caps Remove the cooler CAUTION Bo sure to remove the oil hoses from the oil cooler and remove the cooler mounting bolts Remo fight exha anor exhaust pipe muttier moving the mutter ENGINE Remove the oll drain plug to drain out engine oil Remove two cooler hoses After removing Ihe gearshift lever securing bolt take off the gearshift lever 4 Remove the engine sprocket cover CAUTION Do not operate the clutch lever to prevent clutch piston retainer damage Flatten the engine sprocket nur lock was Homovo the engine sprocket nut brake pedal Loosen the axe nut and chain adjusters Push tha rear wheel forward disengage the drive chain and remove the engine sprocket 4 Remove the engine mounting bolts nuts spacer and brackets NOTE Support the engine with a proper engine jack 4 Gradually litt up the engins ther lower the on the side making suru that it does with the frame 4 Remove the engine through the right side of th wore Jf itis difficult to case mounting screws ENGINE 310 ENGINE REINSTALLATION Reinstall the engu in he reverse order af engine removal isnt the twa tong bolts trom the left side Install the brackets spacers bushes bolts and nuts properly as shown the Hlusteatinn an next
156. tinuity replace the rotor Also check that the rotor is insulated 0990022500 Tester knob indication I range rocket tester SLIP RING I tne ring surhice polish it with 400 fine emery paper to protect the charging performance Alter polis wap the slip a clean dry 09900 20102 Vernier calipers 200 mm Service Lmit Slip ring 00 140 rmn 0 55 inj CARBON BRUSH Measure thu length of brushes 0 shown If it exceeds thu sureice lint replace them with new anos 09900 20102 Varnior calipers 200 mm Service Brush long mm D 18 RECTIFIER Chuck continuity between terminals and ground tester Inad to terminal U und thu other lead ground or other uris than swap the two leads Of the two tester indica tions should be contimoity and the other should non continuity not replace the rectifier assert 09900 25002 Pocket testor Tostor knob indication gt 1 ELECTRICAL SYSTEM 54 IC REGULATOR Use variable DE power source switch bulb and pocke lester check the regulator which requires two steps described below First chock Set the variable DC power saurce to 12 V dnd light replace the IC regulator the ull gi ine switch to thu positon fe bulb does ON 1C regulator has passed Ihe first check Second chock Under th
157. to next pag 1006 822 in iem nom Al f SPROCKET DRUM BEARING AND SPROCKET Install the bearing by using the spucial 1001 09913 75520 Bearing installer Apply grease to the bearing and seal lip For U S A modell 9900025030 SUZUKI SUPER GREASE A For the other models 39000 25010 SUZUKI SUPER GREASE A NOTE When installing the rear sprocket on its mouatmg drom the stamped mark on the sprocket is pasitioned outside e Tighten the sprocket mounting nuts ta the Specified torque Tightoning torque 48 72 Nan 148 72 kgm 380 520140 BRAKE DISC Make sure thal the brake discis clean and free of any greasy mauer Apply THREAD LOCK SUPER 1360 1a the dise mou bolts and them ta the specified taque 99000 32130 THREAD LOCK SUPER 13807 Tightening torque 15 25 Nm 15 25 kam 110 180 TIGHTENING TORQUE Axle nut BS 115 Nm 8 5 11 5 kam 61 5 830 040 Brake caliper mounting bolt 18 28 Nim 1 8 28 kgm 130 20 0 Ibt ADJUSTMENT Adjust thi chant slack after wheel installation Pane 211 cHASSIS 634 TIRE AND WHEEL TIRE REMOVAL The most critical factor of tubeless tire ss the between the wheel rim and tho ure bead Because of this we recommend using a tire changer which is also mors efficient than fie levers Far tie remo
158. tor main essure which is hier than the spring gt fo diaphragm pperanan and us alaws fuel to flow ima carburator Itoat chamber FUEL AND LUBRICATION SYSTEM DISASSEMBLY For carburetor removal rafer to page 35 Disassamblo the carburetor as shown ihe illustration on payo 43 INSPECTION AND ADJUSTMENT NEEDLE VALVE M mas s caught the mating ulace hetwsen the Valve nom and vari oF they ae worn beyond the rms mts i gasing wi continue Rowing and cause ito ovartlow Therefore they should be replaced us a sot i Conversaly 1F lhe needle sticks the gasoline wl flow into Mo Mos char Itsa clean tna float chamber Hout parts and x fuel passage with gasoline FLOAT HEIGHT chuck and adjust the float height out the following 4 avert Ho carburetor hody Gradually lower the Haat and observe the Clearance ete Ihe flot tongue anuk the end oF valve When the tongue just begins to contact the end of valvo stop lowering the float and hold it Then measure the height i rom the Heat chamber mating surface vernier calipers 09900 20102 Vernier calipers 200 mm Float height s 10mm 057 004 a he longue necessary lo bring the beighr standard range NOTE When measuring the height be sore not to compress the Far any damage ar clogging check to
159. twa positions The clearance specibicarion is fos COLD state To tura the vrankshaft foy clearance checking sure fa use 19 wrench and runing direction AN plays should be removed Turn crankshaft t bring the T mark an the roter ta the center hf pick up and also ta bring the notchos Euin the right ends af both camshafts Ex and In to the posit shawn lo this condition read the valve clearance at the valves f n and Ex of No 1 cylinder Fx ol No 2 and In of No 3 Use a thickness q adjusting serew and the valve stem end If the clearance is out ot speciticabon bring it into the spucilied rom by using the special root between 0990020803 Thickness guage 09917 14910 Valve adjust driver CAUTION Both right and loft valve clearances should ba as ns possible Turn the crankshaft 380 ane rotation 10 bring the mark n the rotor to tho cuntur of pick up coil and also ta bring n d the noches J t the positions show Read thu clearance at remaining valves Stand adjustihe A necessary L PERIODIC MAINTENANCE AND TUNE UP PROCEDURES Cam Pasion _ ik Cea aua Came Mum pe en e When installing the cylinder head cover apply SUZUKI BOND NO 12078 thu head cover grove and cam ond aps Refer to page 3 58 4 Tighten the head cover bolts and union bolts
160. uch can damage the 07 rings or seals Tho standard drive chain TAKASAGO RK532GSV SUZUKI recommends that the abovementioned standard drive chain be used for tho replacement BRAKES Inspoct initially at 1000 km 600 miles 2 months and Every 8000 km 4000 miles 12 months thereafter Replace hoses Every four years Change fluid Every two BRAKE FLUID LEVEL Keep the motorcycle upright straight Check the brake thud level by observing h rear brake and lower Both front and rear the brake fluid re When the lovol is below the lower brake fuid that meets the following speci Spacitication and Cla WARNING Tho brake system nt this motorcycle is fined with brake fluid Do use or mix differant typos of fluid such as silicone basod or petroleum based Do not use any brako fluid taken from old used or unsealed containers Never re use brake fluid left over rom Ihe Inst servicing or stored for a long period ification DOTA WARNING Brake tuld f it leaks will interfere with safe running and ly discolor painted surfaces Check the brake hoses and hose joints for cracks and leakage before riding immedi BRAKE PADS The extent of brake pad wear car be checked by observing the qrnoved limit line C on the pai When the wear exceeds the grooved limit ino replace the pads with new ones Refer lo pages 6 7 and 524 CAUTION
161. uspension adi stor set 3 of shock atiserber 4 bae smock bso Roar suspension 1 Rear suspension E too stitt 2 Shock sbsmber sal 3 Noisy rear D suspension 2 war related beaemus 22 SERVICING meORMATION BRAKES Complaint Symptom and possible causes Remedy Insufficion brake 1 of brake fluid from system ar replace power 2 Worn padi Replace 2 Oi adhasion on engaging pads Clean disc and oads 5 Worn aise place 8 Al in system Bleed aic Brake squeaking 1 Carbon adhesion on pad surface surtacn with Sandpaper 2 Ted pad Moy ting 33 Damages when bening Replace A Loose flont whes anto Tighten to sparilied terque Hepler Raplac Exceasive brake vor steaks ka 2 bes 3 Improver of brake 2 Crack 3 Wom piston and or cup Disassemble and clean master mena me Replenish Hu to sposi ied level mr place with Mad Taten to spocie Repince piston SERVICING INFORMATION 7 8 WIRING DIAGRAM GENERAL ENGLAND NORWAY BELGIUM AND AUSTRALIA MODELS
162. ust the specification 1 First lose the front fork upper clamp bolts and steering sony houd nu then adjust the steering stem nut by loosening ar tightening 2 Tighter the head wr and hack the initial force wth t according ta the previously described procedure Tightening torque Stem hund li 50 80 Nm 50 80kom 360 58 0 scale when the handlebar starts Front fork Upper clamp bolt 2 22 36 Nm 22 35 kgm 180 2581501 3 I the initial torne tound within the specified range diustment has ber completed Hold the tront fork lous move them hack and forth and make ire that the steeriog is nor loose 4 Lower tha Jacks amd stall he lower fairing assembly EMASSIS 622 IGNITION SWITCH 8 Ta vemove Ine ignition switeh remove We holt to detach the grilla switeh from the steering stem bracket by usma center punch and hummer Ti install the ignition sinich always bl and follow procures below NOTE Tho spare igation switeh comes exe witi the speciai borts however tha bote ts also available as a spre port new special Usin Ihe special boils attach the rarior switch on stom upper bracket wr pace and run im the special toot 09930 11910 Torx wrench bonis wits Continue turning the tant the 1001 slips from the end or the he
163. val the following tools are required re cbe shi Dpto anm ar duit Mod gus hi aa ale J Remove the valve core from the valvo stem and defi the tee completely Mark the With chalk nore the pasi n ot tro om the rim and rotational direction 12 of he une 838 CHASSIS Place the cunter shaft ito the wheel and fix the wheel with the rim holder 2 Altach he operation arm 3 t the center Attach the boad breaker to the operation arm and dismount the the rim Tun the whenl over and dismount Ihe other bead tram the rim Install the rim guide roller 3 Install the rim protector 6 amd raise the bead with lover ft Sei the tre lever agaist the operation arm and rotate Ihe lever around the rim Repeat this prosodie remove the father bead rom the rim INSPECTION WHEEL Wine off any rubber substance ar rust from the wheel and inspect the wheel rim It any one of the following items is observed replace it with new wheel gt A distortion or crack Any scratohos or flaws in the head Seating area Wheel runout Axial of more than 2 0 mm 0 08 in Thorauyhiy inspect the removed tire an tire Replace with new one 7 puncture split whose total or diameter exceeds 6 0 mm 40 24 m gt A scratch or split at the side wall 7 road duptt loss than 1 6 mm 0
164. valve tightening torque 6 9 Nan 06 09 kom 45 651010 Front brake Blesa the air fram the inboard valve first and then autboard valve e Squoeze and release the brake lever several suocession and the lever fully without roleasin Lausen Ina bieeder valve by tuming quarter af a tur so hat the brake Muid runs into the the of tha brake levee handlebar grip Then close Ihe valve pump levor anu the valve Repeat th Mowing into the retaptacie longer wore bleeding the benke system Make sure that there whys fhid visible in the reserva reservoir to the upper end af the in brake amd UPPER ine for rear brake CAUTION Handle b with paint plastics rubber mas fluid with coro the fluid reacts chemically The only difference bleoding the tront braku is thatthe d by pedal TIRES aspect Initially at 1000 km 1600 milos 2 months and Every 6000 km 4000 miles 12 months thereafter 15 MAINTENANCE AND TUNEUP PROCEDURES TIRE TREAD CONDITION Dperating the motorcycle with excessively worn tires wi riding stabilty and consequent invite dangerous situatian tis highly recommended ta replace a fire when the romaine depth of tire troad reaches Ihe following Tira troad depth limit FRONT 1 6 mm 0 06 in REAR 2 0 0 08 in
165. y 1 35 mm 12mm 136 mm Throttle play 95 10 mm 3 002 004 m ELECTRICAL Unit mm in TEM SPECIFICATION NOTE ming 13 BTDC at 1 500 r min 7 BEDE at 1500 r min California model only Feng order 1243 Spark plug Type NGK anos 05 07 Saw V4 428 OPT Cold tyne Spark pertormance Over 8 0 31 at 1 atm Signal coll resistance Tester range Approx 138 2008 lrition resistance up Gta Tester range Primary Approx 24 320 Dum Secondary Dd can Plug cap Tester range Approx 30 40 kt ma m it SPECIFICATION NOTE Generator Limit 14 0 10 55 Brush length Umit 4 5 0 18 985 voltage Above V1 V at 5 000 r min Starter motor MATE Starter relay resistance 3 50 Type designato Capacity TY 504 d 128 at 20 C 64h Fuse sae Headline E Tum von 104 tonight Power source Circuit bronket WATTAGE uns W SPECIFICATION E Eds tear Hondhant Mn gt 55 dapes 28 does Lo 55 dns Parking or position halt 4 37 2pos m 2 Tu sianal ig 2 Tachomate 3 E E Speedometer light 7 u a Fue leve indicitor igi 3 gt Turm signal indicaotr light 3 High
166. y are m the wheal Rotate the inner race by hand to inspect lor Abnormal noise and smooth rotation Replace the bearing if here v any AXLE SHAFT Using a dial yaugu check ihu axle shaft for runout and replace II If the runout pxeoeds the limit 03900 20606 Dia gauge 1 100 09900 20701 Magnetic stand Not available 09500 21304 V block set 100 mm in USA Service limit 0 25 mm 10 010 inl WHEEL Make suro that the wheel runout checkad as shown dows not exceed the limit An excessive nunout is usually due 10 worm or loosen wheel bearings und cam be reduced by replacing the bearings If hearing replacement tails to reduce Ina runout replace the wheel Sorvic limit Axial and 2 0 mm 0 08 inj Drive out hoth when bearings by using the special taol in the following procedures 09941 50110 Bearing remover Not available in U S A CHASSIS 64 insert tho adaptor into the wheel bearing After inserting the wedge bar rom the opposite side lock ho wedge bar in the slit af the adaptor Drive our the wheel bearing by knocking the werkie bar CAUTION The removed hearings should be replaced with new ones REASSEMBLY AND REMOUNTING Reassemble and remount the trant wheel in the reverse order 1 removal and disassembly Pay aention ta the following points WHEEL BEARING Apply grease t the bearing before anstlting For USA mado 9000026030 SUZUKI SUPER
167. y at 1000 km 600 miles 2 months and Every 12000 km 7500 miles 24 months thereafter Inspect the from forks for leakage scoring or scratches the outer surtace of the inner Tubes Replace any deferte parts it Refer to page 6 12 REAR SUSPENSION Inspect Initially at 1000 km 800 miles Z months and Every 12000 km 7500 miles 24 months thereafter Inspect the rear shock absorber for il leakage ore is play ln the swingarm assembly 217 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES CHASSIS BOLTS AND NUTS Tighten Initially at 1000 km 1500 miles 2 months and Every 8000 km 4000 miles 12 months therea t Tho Nuts and Holts listed below are important satery related parts They must ho robqhtuned whan mocessiry to Ihe specified torque with a torque wrench to page 2 18 for the locations ol the Following nuts and bolts an the motarevcle t TEM Wn kom 1 Storing stem head nut 50 80 50 80 360 580 2 From fork upper camp bolt 22 35 22 38 160 255 Vb Front fork lower clamp balt 32 38 22 35 160 255 Front fork cap bolt 15 30 110 218 8 Front fork damper rad bolt 24 338 o Tran axta ss rm as 115 815 280 T Front axle pineh bolt 28 2 130 200 A Handlebar holder mounting 50 50 50 60 380 435 92 Handlebar holder mounting nut 22 35 22 35 160 205 Clutch master cylinde

GSXR-1100 service manual 1989-1992

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