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Suzuki gz250 User's Manual

1. 4 10 OIL PRESSURE 4 10 OIL FILTER M R 4 10 OIL SUMP 4 10 ENGINE LUBRICATION SYSTEM 4 11 4 1 FUEL AND LUBRICATION SYSTEM FUEL TANK AND FUEL VALVE REMOVAL Gasoline is very explosive Extreme care must be taken Remove the front seat See p 5 1 Remove the fuel tank mounting bolts Turn the fuel valve to ON or RES position Disconnect the fuel hose and vacuum hose Remove the fuel tank Remove the fuel valve INSPECTION FUEL VALVE If the fuel filter is dirty with sediment or rust fuel will not flow smoothly and loss in engine power may result Clean the fuel filter with compressed air Also check the fuel filter for cracks AWARNING Gaskets and O rings must be replaced with new ones to prevent fuel leakage REMOUNTING Remount the fuel tank and fuel valve in the reverse order of removal FUEL AND LUBRICATION SYSTEM 4 2 CARBURETOR SPECIFICATIONS ITEM SPECIFICATION MKUNBSRESS Bees f m Te E IS UN PO PidarpNoi PAI PE Paa oooO 1 Twoewae TV TOT 0 5
2. 3 56 3 57 ENGINE CLUTCH COVER Install the two dowel pins and new gasket Tighten the clutch cover bolts securely A CAUTION Install the new gasket washer to the STARTER IDLE GEAR e Install the starter idle gear A CAUTION Apply engine oil to the starter idle gear 2 GENERATOR COVER e Install the dowel pins and new gasket Install the generator cover and tighten the bolts securely NOTE Install the wire harness clamp with the NEUTRAL SWITCH Install the spring Mand neutral switch contact and new O ring Install the neutral switch ENGINE SPROCKET SPACER Apply SUZUKI SUPER GREASE to the the engine sprocket spacer and the oil seal lip 99000 25010 SUZUKI SUPER GREASE A CAUTION Use a new O ring D Install the engine sprocket spacer onto the driveshaft NOTE The oil the spacer should be on the engine side Be careful that the oil seal lip amp does not turn in Install the oil seal retainer Bend the tabs on the oil seal retainer to lock the bolts Pass through the neutral switch lead wire inside of the guide Clamp the neutral switch lead wire and generator lead wire with the clamp STARTER MOTOR Install the starter motor A CAUTION Use a new O ring NOTE Apply grease to the O ring AM 99000 25010 SUZUKI SUPER GREASE A 3 59 ENGINE PISTON AND PISTON
3. rebound spring from the inner tube Separate the inner tube 1 the outer tube Remove the following s Oil seal Washer Outer tube slide metal 6 Inner tube slide metal The removed oil seal and slide metals should be replaced with new ones A CAUTION e Remove the oil lock piece from the outer tube INSPECTION DAMPER ROD RING Inspect the damper rod ring D for wear or damage If it is worn or damaged replace it with a new one FRONT FORK SPRING Measure the fork spring free length If it is shorter than the service limit replace it with a new one Service Limit 301 mm 11 9 in INNER AND OUTER TUBES Inspect the inner tube sliding surface and outer tube sliding surface for scuffing REASSEMBLY AND REMOUNTING Reassemble and remount the front fork in the reverse order of removal and disassembly Pay attention to the following points ACAUTION Wash each metal part with cleaning solvent be fore reassembly Never reuse fork oil left over from the last serv icing Replace the oil seal and dust seal with new ones during reassembly Hold the inner tube vertically clean the metal groove and install the slide metal by hand A CAUTION Do not damage the Teflon coated surface of the inner tube s slide metal when mounting it Install the outer tube metal D washer and oil 3 to the inner tube IA CAUTION When installing the oil seal onto
4. 6 25 ELECTRICAL SYSTEM WIRE COLOR B Black B W Black with White tracer Gr Gray BI B Blue with Black tracer Light green O G Orange with Green tracer Yellow BI B Neutral vi High bean a signal 1 Lg Turn signal Gr Illumination R NIL j 4 O G Neutral B W High beam illumination INSPECTION Check the continuity between lead wires If there is no continuity replace the respective parts NOTE When checking for continuity it is not necessary to remove the speedometer ELECTRICAL SYSTEM 6 26 LAMPS HEADLIGHT AND POSITION LIGHT Headlight 12V 60 55W Position light 12V 4W Except for E 03 24 28 and 33 models HEADLIGHT BULB REPLACEMENT lt Remove the headlight Disconnect the socket Remove the rubber cap Remove the bulb by removing the bulb holder spring Remove the position light bulb 5 Reassemble the bulb in the reverse order of removal A CAUTION If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure 6 27 ELECTRICAL SYSTEM BRAKE LIGHT TAILLIGHT Brake light Taillight 12V 21 5W BRAKE LIGHT TAILLIGHT BULB REPLACEMENT Remove the rubber cap Dbehind the rear fender Push in on the bulb socket 2 turn it counterclockwise and pull it out Remove the brake light taillight bulb 3
5. Remove the front seat See p 5 1 Remove the luggage SIDE STAND RELAY INSPECTION First check the insulation between and terminals with tester Then apply 12 volts toOand terminals OtoO and to and check the continuity between D and If there is no continuity replace turn signal side stand relay with a new one 6 17 ELECTRICAL SYSTEM DIODE INSPECTION Using multi circuit tester measure the voltage between the 6 terminals in the following table Unit V Probe of tester to 09900 25008 Multi circuit tester set Tester al knob indication Diode test NOTE If the tester read under 1 4V replace the battery of multi circuit tester when do not connecting the tester probes ELECTRICAL SYSTEM 6 18 IGNITION SYSTEM DIGITAL IGNITOR DESCRIPTION The fully transistorized ignition system consists of the following components a generator ignitor igni tion coil and spark plug The ignition timing is programmed and stored in the ignitor The pick up coil is mounted in the generator The induced signal in the pick up coil is sent to the wave form arrangement circuit and the CPU receives this signal and calculates the best ignition timing The CPU outputs the signal to the transistor of the ignition coil output circuit which is connected to the primary windings of the ignition coil which is turned off and on accordingly Thus it induces the secondary current in the
6. 12V 1 7W CHASSIS Front suspension Telescopic coil spring oil damped Rear suspension Swingarm type coil spring oil damped spring preload 5 way adjustable Front fork stroke 000002 120 mm 4 7 in Rear wheel 024 90 mm 3 5 in Steering 40 right and left reri better ore a 32 30 dinde ua 140 mm 5 5 in Turning radius pt rettet eee ees 2 6 m 8 5 ft Er hit brake lt Disc brake di tr DR eg Internal expanding Front tlre SIZe tnu 110 90 16 59P Rear tlie SIZE ettet 130 90 15M C 66P CAPACITIES Fuel tank including reserve 14 L 3 7 3 1 US Imp gal GSO VO Ludis Eo eee 2 9 L 0 8 0 6 US Imp gal Engine oil change 1 300 ml 1 4 1 1 US Imp qt with filter change 1 400 ml 1 5 1 2 US Imp qt 1 700 ml 1 8 1 5 US Imp qt Front fork each IEG 369 ml 12 5 13 0 US Imp oz Specifications are subject to change without notice GENERAL INFORMATION 1 8 COUNTRY AND AREA CODES The following codes stand for the applicable country ies and area s CODE COUNTRY OR AREA General UK U S A Except for Cal
7. 218 o 12 15 1215 1215 45 124 05 08 azs 1145 11 15 08 12 306 0306 215 1215 1215 1248 1245 245 1215 1245 1215 12 15 406 1 1 5 7 i Probe of tester to ELECTRICALSYSTEM 6 22 PICK UP COIL PEAK VOLTAGE Remove the front seat See p 5 1 Remove the luggage box NOTE Be sure that all of the couplers are connected properly and the battery is fully charged Disconnect the ignitor coupler at the jgnitor Measure the pick up coil peak voltage between the Green and Blue lead wires the ignitor coupler Pick up _ gnitor Connect the multi circuit tester with the peak volt adaptor coil coupler as follows coupler ne Probe Green lead wire 2 Probe Blue lead wire Generator TOOL 09900 25008 Multi circuit tester set A CAUTION When using the multi circuit tester and peak volt adaptor refer to the appropriate instruction manual Shift the transmission into neutral turn the ignition switch to the ON position and grasp the clutch lever Press the starter button and allow the engine to crank for a few seconds and then measure the pick up coil peak voltage Repeat the above procedure a few times and measure the highest pick up coil peak voltage Tester knob indication Voltage Pick up coil peak voltage More than 5 0 V Green Blue If the peak voltage measured on the ignitor coupler is lower than the
8. Inspect the ignition coil See p 6 21 Correct Y Measure the pick up coil peak voltage and resistance See pp 6 22 and 23 NOTE _ The pick up coil peak voltage inspection is applicable only with the multi circuit tester couplers Correct Inspect the spark plug See T T 2 4 and 5 Incorrect Incorrect Correct Faulty igniter unit Faulty spark plug Poor Incorrect conne ction of the spark plug cap Faulty ignition coil Incorrect Faulty generator Li fee Open circuit in wiring harness Poor connection of ignition couplers ELECTRICALSYSTEM 6 20 INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE Remove the front seat See p 5 1 Remove the fuel tank See p 4 1 Disconnect the spark plug cap Connect new spark plug to the spark plug cap and ground it to the cylinder head NOTE Make sure that the spark plug cap and spark plug is con nected properly and the battery Is fully charged Measure ignition coil primary peak voltage in the following procedure Connect the multi circuit tester with the peak volt adaptor as follows Probe White lead wire connector Q Probe Ground NOTE Do not disconnect the ignition coil primary wire 09900 25008 Multi circuit tester set A CAUTION When using the multi circuit tester and peak volt adaptor refer to the appropriate i
9. Remove the brake caliper by removing the mounting bolts 2 A CAUTION Never reuse the brake fluid left over from previous servicing and which has been stored for long peri ods of time AWARNING Brake fluid if it leaks will interfere with safe running and discolor painted surfaces Check the brake hose and hose joints for cracks and oil leakage Remove the brake pads See p 5 8 Remove the brake caliper holder Z Remove the spring Place a rag over the brake caliper piston to prevent it from popping out and then force out the piston using compressed air A CAUTION Do not use high pressure air to prevent brake cali per piston damage e Remove the dust seal and piston seal A CAUTION Do not reuse the dust seal and piston seal to pre vent brake fluid leakage BRAKE CALIPER INSPECTION BRAKE CALIPER Inspect the brake caliper cylinder wall for nicks scratches or other damage BRAKE CALIPER PISTONS Inspect the brake caliper piston for any scratches or other damage BRAKE CALIPER REASSEMBLY AND REMOUNTING Reassemble and remount the brake caliper in the reverse order of removal and disassembly Pay attention to the fol lowing points Wash the caliper bore and piston with the specified brake fluid Thoroughly wash the dust seal groove and piston seal groove Specification and Classification DOT 4 A CAUTION Wash the brake caliper components with new brake fluid before reassembl
10. Hold the steering stem lower bracket to prevent it from fal ling e Remove the dust seal upper bearing inner race 3 and upper bearing Remove the lower bearing 6 Remove the ignition switch 6 the special tool 1527 09930 11920 Torx bit JTA0H 09930 11940 Bit holder INSPECTION Inspect the removed parts for the following abnormalities Handlebar distortion Handlebar clamp wear Race wear and brinelling Bearing wear or damage Abnormal bearing noise Distortion of the steering stem Remove the lower bearing outer race Dusing a chisel CHASSIS 5 26 Drive out the steering stem upper and lower bearing races using the special tool 4 Pies 09941 54911 Bearing outer race remover p gt 09941 74910 Steering bearing installer i PA 42 PE REASSEMBLY AND REMOUNTING Reassemble and remount the steering stem in the reverse order of removal and disassembly Pay attention to the fol lowing points Press in the upper and lower outer races using the spe cial tool 09941 34513 Steering race installer Press jn the steering stem lower race Dusing the spe cial tool 122 09941 74910 Steering bearing installer Apply grease to the upper and lower bearings 99000 25010 SUZUKI SUPER GREASE A Tighten the steering stem nut using the special tool Xx 09940 14911 Steering stem nut wrench 9 Steering stem nut 45 N m m 4 5 kg m 32 5 Ib f
11. light R Pass through the handlebar Switch R lead wire under the brake hose Clamp Starter relay Clamp i Starter motor j Clamp Rear brake Wiring harness Rear turn signal Brake ChL NOLVWHOHNI 9NI9IAH3S 7 13 SERVICING INFORMATION Generator lead wire Neutral switch Pick up coil Stator coil SERVICING INFORMATION 7 14 CABLE ROUTING Clamp Clamp Throttle cables Clamp Throttle cable returning cable Clamp Throttle cable pulling cable Wiring harness Throttle cable pulling Throttle cables Clam Brake hose Throttle cables a Starter cable Starter cable Pass the Handlebar switch L outside of t Clamp _ i WG wo Clutch cable Wiring harness Starter cable Clamp Clutch cable 7 Starter cable 7 15 SERVICING INFORMATION Speedometer cable Guide Pass the speedometer cable outside of the brake hose Brake hose ____ Clamp 100 mm 4 0 in 10 mm 0 4 in 4 Do not contact the guide to the caliper rubber bushing Caliper rubber bushing E SERVICING INFORMATION 7 16 Seat lock cable Rear brake switch cable i Rear brake cable Rear brake Clamp cable clip Rear brake cable Rear brake switch cable 7 17 SERVICING INFORMATION FRONT BRAKE HOSE ROUTING Clamp Master Clamp Clamp the br
12. moved for servicing Valve clearance when cold IN 0 03 0 08 mm 0 001 0 003 in EX 0 08 0 13 mm 0 003 0 005 in NOTE The piston must be at top dead center TDC on the compression stroke in order to check or adjust the valve clearance The valve clearance should only be checked when the engine is cold Remove the valve timing inspection plug and generator cover Rotate the crankshaft with a box wrench to set the piston at top dead center TDC on the compression stroke Rotate the crankshaft until the T line on the generator rotor is aligned with the triangle mark Bon the generator cover Insert a thickness gauge into the clearance between the valve stem end and the adjusting screw on the rocker arm 09900 20803 Thickness gauge If the clearance is out of specification adjust it to specifica tion as follows ADJUSTMENT The clearance is adjusted using the special tool and offset wrench Loosen the locknuts D Insert a thickness gauge between the valve stem end and the adjusting screw 2 the rocker arm Adjust the valve clearance by turning the adjusting screw 2 using the special tool while holding the locknuts 1 122 09917 14920 Valve adjuster wrench CAUTION Both the right and left valve clearances should be as closely as possible After the adjustment is completed tighten the locknut se curely Rotate the crankshaft 720 with a b
13. 0 1215 Tighten the cylinder head cover bolts to the specified torque U cylinder head cover bolt 10 N m 1 0 kg m 7 0 Ib ft CAUTION Install the new gasket washer to the A CAUTION Be sure to check the valve clearance See pp 2 3 and 4 Install the valve timing inspection caps CAUTION Use new O rings Dto prevent oil leakage ENGINE 3 64 FUEL AND LUBRICATION SYSTEM CONTENTS FUEL TANK AND FUEL VALVE 4 1 REMOVAL to oap dace eon ada Eid naui Eoi a queda 4 1 INSPECTION t 4 1 REMOUNTING udo xs decur pa 4 1 CARBURETOR 4 2 SPECIFICATIONS dg 4 2 4 2 CONSTRUCTION Cod XR 4 3 REMOVAL 4 4 DISASSEMBE VADE 4 4 EM gc 4 8 INSPECTION AND ADJUSTMENT 4 8 REASSEMBEY td odddedk dc ebd ra a 4 9 REMOUNTING 22 4 9 LUBRICATION
14. Battery runs down quickly Remove accessories Check accessories which use excessive Accessories amounts of electricity are installed No accessories Check the battery for current m t leak NM leaks See p 6 7 urrent leaks Short circuit of the wire harness Loose or disconnected wires Faulty battery No current leaks Y Measure the charging voltage between the battery terminals Faulty battery See p 6 7 Abnormal driving condition Correct Incorrect Measure the continuity of the A 5 a No continuity Faulty stator coils or tat il 6 8 gt stator coll Seep 8 82 disconnected coupler Continuity Inspect generator no load PEGS nelle nivel Faulty generator rotor or voltage See p 6 8 stator coil No good Good Inspect regulator rectifier See p 6 9 No good Faulty regulator rectifier Good Inspect the wirings Short circuit of wire harness No good Poor contact of couplers E Faulty battery Good 4 Battery overcharges Faulty regulator rectifier Faulty battery Poor contact of stator coil coupler 6 7 ELECTRICAL SYSTEM INSPECTION BATTERY LEAK CURRENT INSPECTION Remove the front seat and right frame cover See p 5 1 Turn the ignition switch to the OFF position Disconnect the battery lead wire Connect the tester between the batteryO terminal and the battery lead wire NO
15. Noise mannm ta nnaman fuan thn nnm alani 1 Stretched cam chain Replace cam chain and sprocket 2 Worn cam chain sprocket Replace cam chain and sprocket Repair or replace 3 Improperly working cam chain tension adjuster 1 Worn countershaft spline Replace countershaft 2 Worn clutch hub spline Replace clutch hub 3 Worn clutch plate teeth Replace clutch plate 4 Distorted clutch plate Replace 5 Worn clutch release bearing Replace 6 Weak clutch damper Replace primary driven gear Replace 7 Weak clutch spring Noise seems to come 1 in 8 bearing Replace 2 Worn or burnt crank pin bearing Replace Replace 3 Worn or burnt ball bearing Noise seems to p i Worn or rubbing gear 77 Replace Worn countershaft spline Replace countershaft Worn driveshaft spline Replace driveshaft Worn or rubbing primary gear Replace Worn bearing Replace Weak or broken clutch spring Worn or distorted clutch pressure plate Distorted clutch plate 2 3 4 5 Clutch slips 1 Clutch cable out of adjustment 2 3 4 1 Clutch drags Clutch out of adjustment 2 clutch springs are weak while others are not 3 Worn or distorted clutch pressure plate 4 Distorted clutch plate Transmission will 1 Broken gearshift cam not shift 2 Distorted gearshift fork 3 Worn gearshift pawl 7 3 SERVICING INFORMATION Complaint Symptom and possible causes Tr
16. Remove the oil filter cap by removing the nuts Remove the oil filter and install a new one Install the oil filter cap and tighten the nuts securely NOTE Before installing the new oil filter and oil filter cap make sure that the spring 3 and new O rings are installed correctly Add new engine oil and check the oil level as described in the engine oil replacement procedure Oil viscosity and classification 10W 40 SAE SF or SG API NECESSARY AMOUNT OF ENGINE OIL Oil change 1 300 ml 1 4 1 1 US Imp qt Oil and filter change 1 400 ml 1 5 1 2 US Imp qt Engine overhaul 1 700 ml 1 8 1 5 US Imp qt DRIVE CHAIN Inspect initially at 1 000 km 600 miles 3 months and every 5 000 km 3 000 miles 15 months there after Clean and lubricate every 1 000 km 600 miles Visually inspect the drive chain for the possible defects listed below Support the motorcycle by a jack and a wooden block turn the rear wheel slowly by hand with the transmission shifted to Neutral Loose pins Excessive wear Damaged rollers Kinked or binding links Dry or rusted links Missing O ring seals Twisted or seized links If any defects are found the drive chain must be replaced The standard drive chain is DID520VC5 SUZUKI recommends to use this standard drive chain as a replacement CAUTION ul Tha etandard driva chain NINKINVCH SIIZIIKI replacement 2 11 PERIODIC MAINTEN
17. 1 0 mm 0 02 0 04 in ITEM SPECIFICATION Pl 13F2 e lt Jet needle UN 5085 Neede ki way OMe Pilot jet 171 5 Pilot screw PS PRE SET MEER I D NO LOCATION The carburetor has I D stamped on its body according to its specifications 4 lt 4 5 FUEL AND LUBRICATION SYSTEM CONSTRUCTION Top cap Spring Jet needle holder Washer Spacer Jet needle f wW nm eh ak Tf ti it a C 9 vt 7 Piston valve diaphragm 8 Diaphragm Starter plunger 49 Pilot jet 12 Jet holder Main jet 43 Pilot screw 44 Starter jet 19 Throttle stop screw Float 4 Gasket 48 Needle valve seat 19 Needle valve 3 Float chamber REMOVAL Remove the fuel tank See p 4 1 Remove the starter plunger Loosen the lock nuts B and disconnect the throttle cables 2 Remove the overflow hose and air vent hose Loosen the clamp screws Remove the carburetor DISASSEMBLY Remove the fuel hose and vacuum hose e Remove the throttle stop FUEL AND LUBRICATION SYSTEM 4 4 45 FUELANDLUBRICATION SYSTEM Remove the diaphragm cover Remove the diaphragm Remove the carburetor top cap Remove the spring Sand piston valve along with diaphragm Remove the jet needle holder amp
18. 362 0 004 ENGINE 3 38 3 39 ENGINE BALANCER SHAFT AND BALANCER SHAFT DRIVEN GEAR DISASSEMBLY Disassemble the balancer shaft as shown in the illustration 7 Balancer shaft 2 Key 3 Balancer shaft driven 4 Spring 6 pcs Pin 3 pcs INSPECTION Inspect the balancer shaft and balancer shaft driven gear for wear or damage If any wear or damage is found re place the defective part Measure the free length of each balancer spring using ver nier calipers If any spring is not within the service limit replace all of the spring ca 09900 20101 Vernier calipers Service Limit 10 0 mm 0 39 in REASSEMBLY Reassemble the balancer shaft driven gear in the reverse 4 order of disassembly Pay attention to the following points p Make sure that the punch mark Gyon the inner race is aligned with the punch mark Bon the balancer shaft driven gear D Pin ENGINE 3 40 STARTER CLUTCH AND STARTER DRIVEN GEAR BEARING 1 Starter driven gear 2 Starter clutch 3 Roller 4 Push piece 5 Spring STARTER CLUTCH Install the starter driven gear onto the starter clutch and turn the starter driven gear by hand the gear turns in only one direction The starter driven gear should turn smoothly If excessive resistance is felt while turning the starter driven gear inspect the starter clutch Also inspect the surface of the starter driven gear which contacts the starte
19. A CAUTION If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure Reassemble the bulb in the reverse order of removal ELECTRICAL SYSTEM 6 28 TURN SIGNAL LIGHTS Turn signal light Running light 12V 21 5W For E 03 28 and 33 models Turn signal light 12V 21W For the others TURN SIGNAL LIGHT BULB REPLACEMENT Remove the lens by removing the screws Remove the bulb CAUTION If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure Reassemble the bulb in the reverse order of removal CAUTION Do not overtighten the lens fitting screws 6 29 ELECTRICAL SYSTEM RELAYS STARTER RELAY The starter relay is located behind the right frame cover See pp 6 14 and 15 TURN SIGNAL SIDE STAND RELAY The turn signal relay is corporated with the side stand relay and diode to form the one component part which is called the turn signal side stand relay It is located under the luggage box Remove the front seat See p 5 1 Remove the luggage box INSPECTION Before removing the turn signal side stand relay check the operation of the turn signal light If the turn signal light does not light inspect the bulb turn signal switch and circuit connection If the bulb turn signal switch and circuit connection check
20. ENGINE 3 26 ed 3 27 ENGINE VALVE STEM WEAR Measure the valve stem O D using the micrometer If it is out of specification replace the valve with a new one If the valve stem O D is within specification but the valve stem deflection is not replace the valve guide After replacing the valve or valve guide re check the deflection 09900 20205 Micrometer 0 25 mm Standard Valve stem O D 5 460 5 475 mm 0 2150 0 2156 5 445 5 460 0 2144 0 2150 If valve guides have to be replaced refer to the valve guide servicing steps below VALVE GUIDE SERVICE Remove the valve guide using the special tool 7221 09916 44910 Valve guide remover installer NOTE Discard the removed valve guide subassemblies Only oversized valve guides are available as replace ment parts Re finish the valve guide holes in the cylinder head using the special tools 1551 09916 34561 Valve guide reamer 11 3 mm 09916 34542 Handle NOTE Insert the reamer from the combustion chamber side and always turn the reamer handle clockwise Install a ring onto each valve guide Oilthe stem hole of each valve guide and drive the guide into the guide hole using the special tool 09916 44910 Valve guide remover installer A CAUTION Be sure to use a new valve guide ring and valve guide Cylinder After installing the valve guides
21. FUEL AND LUBRICATION SYSTEM 4 6 Remove the jet needle Holder Spring Washer A Spacer The O ringshould be replaced with a new one T CAUTION gt Remove the float chamber body Remove the screw Remove the float pin amp Remove the float assembly 9 along with the needle valve 9 A CAUTION Do not use a wire to clean the valve seat Remove the screw and needle valve seat 2 Remove the main jet and jet holder Remove the pilot jet Remove the starter jet Remove the pilot screw NOTE Before removing the pilot screw its setting must be de termined Slowly turn the pilot screw clockwise and count the number of turns until it is lightly seated When reassembling the pilot screw you will want to set it to its original position A CAUTION Do not use a wire to clean the passage and jets 4 7 FUEL AND LUBRICATION SYSTEM Remove the pilot air jet No 1 Dand No 2 Remove the needle jet 3 PILOT SCREW REMOVAL For E 03 28 33 Because harsh cleaning solvents can damage the O ring seals In the pilot system the pilot system components should be removed before cleaning Use a 1 8 size drill bit with a drill stop to remove the pilot screw plug Set the drill stop 6 mm from the end of the bit to prevent drilling into the pilot screw Carefully drill through the plug Thread a self tapping sheet metal screw into the plug Pull on the
22. INFORMATION 7 8 WIRING DIAGRAM FOR E 03 28 and 33 7 9 SERVICING INFORMATION FOR E 24 TI LH TVNOSS Hae eri E LL SERVICING INFORMATION 7 10 FOR THE OTHERS saiodi lod IA T XA m A EAM BORO gt At en ong Gu peg SOL VOIONI INT3S 9 4 Handlebar switch L amp R Handlebar switch L amp R Starter motor Clamp Pass through the wiring harness Clamp right side of the clutch cable a speedometer cable brake gov Brake light Taillight hose Rear turn signal light L iso __ 9j Wiring harness Starter motor Clamp Starter motor lead wire Clamp Side stand Rear fender switch Air cleaner Turn signal side stand relay Generator Neutral switch Ignitor Side stand switch Wiring harness Neutral switch Side stand switch Clamp Clamp ONILNOY S NILNOY 3SOH 318V9 SHIM NOLLVNHOJ3NI 9NIDIAH3S 1 4 Wiring hamess Clamp Clamp Handlebar switch L amp R Starter motor Starter motor Wiring harness Ps gt Generator High tension cord Ignition coil Handlebar switch Clamp L amp R Clamp Clamp Battery Rear turn signal terminal
23. ITEM 1 Handlebar clamp bolt 2 Handlebar holder nut 3 Steering stem head bolt 47 0 N m 18 E E 23 E 23 59 lb ft 11 5 32 5 6 Front fork cap bolt 16 5 7 Front fork damper rod bolt 16 5 8 Front axle 47 0 16 5 9 Front axle pinch bolt 29 Front brake caliper mounting bolt 1 Front brake hose union bolt 3 0 3 28 0 2 3 16 5 i 2 22 Rear brake cam lever bolt 7 0 2 17 PERIODIC MAINTENANCE PERIODIC MAINTENANCE 2 18 COMPRESSION PRESSURE CHECK The compression pressure reading of the cylinder is a good indicator of its internal condition The decision to overhaul the cylinder is often based on the results of a compression test Periodic maintenance records kept at your dealership should include compression readings for each mainte nance service COMPRESSION PRESSURE SPECIFICATION Standard 1 000 1 400 kPa 10 0 14 0 kg cm 142 199 psi Low compression pressure can indicate any of the following conditions Excessively worn cylinder wall Worn piston or piston rings Piston rings stuck in grooves Poor valve seating Ruptured or otherwise defective cylinder head gasket COMPRESSION TEST PROCEDURE NOTE Before testing the engine for compression pressure make sure that the cylinder head nuts are tightened to the specified torque values and valves are properly ad justed Have the engine warmed up before testing Make sure that the battery is fully cha
24. RING First install a spacer into the oil ring groove and then install the two side rails The spacer and side rails do not have a specific top or bottom when they new When reassembling used parts install them in their original place and direction 2 A CAUTION When installing the spacer be careful not to allow its two ends to overlap in the piston ring groove INCORRECT Same way in which to distinguish the 1st and 2nd piston rings 1 Their ring face shapes are different 2 The 1st piston ring s face is chrome plated 3 The 2nd piston ring appears darker in color e The 1st and 2nd piston should be installed with their AA marks facing up apiti e Position the piston ring gaps as shown gt EVE NOTE 2 2nd ring ring i Before inserting the piston into the cylinder check that the Lower side rail gaps are properly positioned 2nd ring Upper Side rail 1st ring IN Spacer ENGINE 3460 The following are reminders for piston installation Before Installing the piston pin apply molybdenum solution onto its surface Apply engine oil to the big and small ends of the conrod Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into crankcase Install the piston pin circlip CD with long nose pliers A CAUTION Use a new piston pin prevent circlip failure Install the
25. See pp 7 11 to 18 Install the right footrest and tighten its mounting bolts to the specified torque Front footrest bolt 26 N m 2 6 kg m 19 0 Ib ft After remounting the engine the following adjustments are necessary Pour 1 700 ml 1 8 1 5 US Imp qt of SAE 10W 40 en gine oil graded SF or SG into the engine after overhaul ing it Start up the engine and allow it run for several minutes at idle speed Stop the engine wait a few min utes and check the oil level If the level is below the L line add oil until the level reaches the F line See pp Engine idling speed See p 2 7 Throttle cable See p 2 8 Starter plunger cable play See p 2 9 Clutch lever play See p 2 9 Drive chain slack See p 2 11 Rear brake pedal height and free 1 See p 2 14 2 9 and 10 ENGINE 3 8 3 9 ENGINE ENGINE DISASSEMBLY The procedure for engine disassembly is sequentially ex plained in the following steps e Remove the valve inspection 4 2 Remove the spark plug Remove the valve timing inspection plug and generator cover cap e Rotate the crankshaft and align the T the generator rotor with the markon the generator cover Remove the
26. Service Limit 0 05 mm 0 002 in VALVE FACE WEAR The thickness of the valve face decreases as the face wears Visually inspect each valve face for wear and replace any valve with an abnormally worn face Measure the valve face thickness if it is out of specification replace the valve with a new one 09900 20101 Vernier calipers Service Limit 0 5 mm 0 02 in VALVE STEM RUNOUT Support the valve using V blocks as shown and measure its runout with the dial gauge If the runout exceeds the limit replace the valve 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block 100 mm Service Limit 0 05 mm 0 002 in VALVE HEAD RADIAL RUNOUT Place the dial gauge at a right angle to the valve head face and measure the valve head radial runout If it measures more than the service limit replace the valve 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block 100 mm Service Limit 0 03 mm 0 001 in VALVE STEM DEFLECTION Lift the valve about 10 mm 0 39 in from the valve seat Measure the valve stem deflection in two directions X and Y perpendicular to each other Position the dial gauge as shown If the deflection exceeds the service limit then determine whether the valve or the guide should be replaced with a new one 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand Service Limit Intake and exhaust valves 0 35 mm 0 014 in
27. Service Limit 71 880 mm 2 8299 in Piston oversize 0 5 1 0 mm PISTON CYLINDER CLEARANCE Subtract the piston diameter from the cylinder bore diame ter If the piston to cylinder clearance exceeds the service limit rebore the cylinder and use an oversize piston or re place both the cylinder and the piston Service Limit 0 120 mm 0 0047 in ENGINE 3 34 15 mm 10 6 3 35 ENGINE PISTON RING GROOVE CLEARANCE Measure the side clearance of the 1st and 2nd rings using the thickness gauge If any of the clearances exceed the limit replace both the piston and piston rings 09900 20803 Thickness gauge 09900 20205 Micrometer 0 25 mm Service Limit Piston ring groove clearance 1st 0 180 mm 0 0071 in 2nd 0 150 mm 0 0059 in Standard Piston ring groove width ist 1 01 1 03 0 040 0 041 2nd 1 21 123 mm 0 047 0 048 in Oil 2 51 2 53 mm 0 099 0 100 in Standard Piston ring thickness 1st 0 975 0 990 0 0384 0 0390 in 2nd 1 170 1 190 0 0461 0 0469 Remove carbon from the piston crown ring grooves using a soft metal scraper PISTON RING FREE END GAP AND PISTON RING END GAP Measure the piston ring free end gap using a vernier calipers Next fit the piston ring squarely into the cylinder and measure the piston ring end gap using a thickness gauge If the piston ring s end gap is out of specification replace the piston ring 09900 20101 Vernier
28. brake cam lever as shown Tighten the brake cam lever nut to the specified torque Q Brake cam lever nut 10 N m 1 0 kg m 7 0 Ib fl 5 35 CHASSIS Apply SUZUKI SUPER GREASE A to the brake cam and pin and install the brake shoes MIAH 99000 25010 SUZUKI SUPER GREASE A CAUTION Be careful not to apply too much grease to the cam and pin If grease gets on the lining brake slippage will result REAR WHEEL Tighten the rear torque link nut to the specified torque and install the new cotter pin V Rear torque link nut 13 N m 1 3 kg m 9 5 Ib ft Adjust the drive chain slack after installing the rear wheel See p 2 11 e Tighten the rear axle nut to the specified torque V Rear axle nut 78 N m 7 8 kg m 56 5 lb ft Tighten both chain adjusting nuts securely Adjust the rear brake pedal free travel See p 2 14 REAR SUSPENSION CONSTRUCTION CHASSIS 5 36 lt lt Rear shock absorber 2 Rear torque link 2 Swingarm 4 Spacer Dust seal Dust seal 7 Spacer Drive chain buffer 5 Swingarm pivot shaft d T Rear shock absorber nut Rear torque link nut Rear XA O shock absorber bolt ND ad QD Swingarm pivot nut Left side mz Lo 7 gt Right side 9 3 9 2 2s wfe a fa 2 8mm amp mm 0 32 in 0 32 in 5 37 CHASSIS REMOVAL Remove the rear wheel See
29. brake system after reassem bling the master cylinder See p 2 13 CHASSIS 5 14 Handlebars mt Master cylinder Clearance 5 15 CHASSIS FRONT FORK CONSTRUCTION D O ring 2 Spacer 3 Washer Front fork spring 5 Damper rod ring 5 Damper rod 7 Rebound spring 8 Inner tube 5 Dust seal 19 seal stopper ring 11 Oil seal 42 Washer 42 Slide metal 52 Guide bushing 48 Oil lock piece 5 4 REMOVAL AND DISASSEMBLY Remove the front wheel See p 5 3 Remove the brake caliper See p 5 9 A CAUTION Secure the brake caliper to the frame with a string etc taking care not to bend the brake hose Remove the speedometer cable guide from the left fork leg Remove the front fender and brake hose guide Remove the front fork after loosening the front fork upper and lower clamp bolts D NOTE Slightly loosen the front fork cap bolt to facilitate later disassembly e Remove the front fork cap spacer washer amp and spring amp Invert the front fork and stroke it several times to drain out the fork oil Hold the front fork in the inverted position for a few min utes to allow the fork oil to fully drain Remove the dust seal Mand oil seal stopper e Remove the damper rod 09900 00410 Hexagon wrench set TOOL CHASSIS 5 16 ITN LU 5 17 CHASSIS Remove the damper
30. cylinder head NOTE If the cylinder head cover does not come off lightly tap on the finless portion of it with a plastic mallet to make the gasketed joint loose Remove the rubber cap and then turn the slotted end of cam chain tension adjuster with the flat head screwdriver in the clockwise direction and lock the push rod e Remove the chain tension adjuster by removing the mounting bolts e Remove the camshaft end cap Flatten the lock washer and remove the camshaft sprocket bolts Remove the camshaft and camshaft sprocket CAUTION Do not drop the cam chain into the crankcase Remove the C ring CAUTION Do not drop the C ring into the crankcase Remove the cylinder head nuts diagonally Remove the cylinder head by removing the cylinder head nuts NOTE If the cylinder head does not come off lightly tap on the finless portion of it with a plastic mallet Remove the cylinder head gasket amp and dowel pins Remove the cam chain guide Remove the cylinder by removing the nuts NOTE If the cylinder does not come off lightly tap on the Unless portion of it with a plastic mallet to make the gasketed joint loose ENGINE 3 11 ENGINE Remove the cylinder dowel pins Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into the crankcase Then remove the piston pin with a long n
31. float height to the specified value Float height 13 0 0 5 mm 0 51 0 02 in 09900 20101 Vernier calipers TOOL REASSEMBLY Reassemble the carburetor in the reverse order of disas sembly Pay attention to the following points the throttle stop screw until the throttle valve s bottom endis aligned with the foremost by pass port NOTE When removing the throttle valve applying a small quantity of THREAD LOCK 1342 to the throttle valve mounting screws and tighten them 99000 32050 1342 Face stamped side of throttle valve out Install the needle jet as shown Large diameter side Bore side O Small diameter side Main jet side REMOUNTING Remount the carburetor in the reverse order of removal Adjust the following items to the specification Engine idle r min See pp 2 7 and 8 Throttle cable See p 2 8 Starter plunger cable play See p 2 9 LUBRICATION SYSTEM OIL PRESSURE See p 2 19 OIL FILTER See pp 2 9 and 10 OIL SUMP FILTER When replacing the engine oil make sure that the oil sump filter has no tears or damage Also be sure to clean the oil sump filter periodically See pp 3 16 47 and 51 FUEL AND LUBRICATION SYSTEM 4 10 4 41 FUEL AND LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM CHART CAM
32. ignition coil s secondary winding and produces the spark between the spark plug gap Engine stop Side stand relay switch Fuse o O 5 a T o day Ignitor Ignitor power ON Transistor switch 5 R Ignition coil CPU Main fuse E Central Processing G nr H circui Spark plug Pick up 1 Battery coil cT Bw 2 6 19 ELECTRICAL SYSTEM TROUBLESHOOTING s No spark or poor Spake s S Check the ignition system couplers for poor 1 T connections Correct Measure the battery voltage between input I Correct lead wires O W and B W at the igniter with the ignition switch in the ON position Measure the ignition coil primary peak voltage See 6 Y 1 20 NOTE The ignition peak voltage inspection method is applicable only with Incorrect t the multi circuit Check that the transmission is in neutral and the engine stop switch is in the RUN position Grasp the clutch lever Check that the fuse is not blown and the battery is fully charged before diagnosing Looseness __ Poor connection of couplers Incorrect e Faulty ignition switch Faulty turn signal side stand relay Faulty engine stop switch Broken wire harness or poor connection of z related circuit tester and the peak volt adaptor
33. may be necessary to use a dip type cleaning solution and allow them to soak Al ways follow the chemical manufacturer s instruc tions for proper use and cleaning of the carbure tor components After cleaning reassemble the carburetor with new seals and gaskets INSPECTION AND ADJUSTMENT Check the following items for any damage or clogging FUEL AND LUBRICATION SYSTEM 4 8 Pilot jet Needle jet air bleeding hole Main jet Float Starter jet Needle valve Diaphragm Gasket and O ring Pilot screw Pilot outlet and by pass holes NEEDLE VALVE INSPECTION If foreign matter is caught between the valve seat and the needle valve the gasoline will continue flowing and over flow If the valve seat and needle valve are worn beyond the permissible limits similar trouble will occur Converse ly if the needle valve sticks the gasoline will not flow into the float chamber Clean the float chamber and float parts with gasoline If the needle valve is worn as shown in the illustration replace it along with a new valve seat Clean the fuel passage of the mixing chamber with compressed alr A CORRECT INCORRECT 49 FUELANDLUBRICATIONSYSTEM FLOAT HEIGHT ADJUSTMENT To check the float height turn the carburetor upside down Measure the float height while the float arm is just con tacting the needle valve using vernier calipers Bend the tongue as necessary to bring the
34. p 5 30 Remove the drive chain case Remove the rear brake cable holder Remove the rear brake cable from the swingarm Remove the shock absorbers Remove the swingarm pivot shaft end caps Remove the swingarm pivot nut and washer Remove the swingarm by removing the pivot shaft CHASSIS 5 38 Remove the rear torque link from the swingarm e Remove the chain buffer from the swingarm Remove the spacers INSPECTION AND DISASSEMBLY SWINGARM PIVOT SPACERS AND DUST SEALS Inspect the swingarm pivot spacers and dust seals for damage If any defects are found replace the spacer with a new one SWINGARM NEEDLE BEARINGS Insert the spacers into the needle bearings move the M spacer up and down and check for any play If there is excessive play replace the bearing s with a new one 5 39 CHASSIS Remove the swingarm needle bearings using the special tools 2 09923 74510 Bearing remover 09930 30102 Sliding shaft A CAUTION The removed needle bearings should be replaced with new ones SWINGARM Inspect the swingarm for damage If any defects are found replace the swingarm with a new one CHAIN BUFFER Inspect the chain buffer for wear and damage If any defects are found replace the chain buffer with a new one SWINGARM PIVOT SHAFT Measure the pivot shaft runout using the dial gauge If the pivot shaft exceeds the service limit replace it with a new one 1924 09900
35. pad 7 Spring H 8 Dust seal ENa 04 1 tate Piston seal 82 Piston GT Brake hose union bolt Brake master cylinder mounting bolt Brake caliper mounting bolt 5 Brake pad mounting bolt amp Brake caliper air bleeder valve This brake system is filled with an ethylene glycol based DOT 4 brake fluid Do not use or mix different types of fluid such as silicone based or petroleum based brake fluids Do not use any brake fluid taken from old used or unsealed containers Never reuse brake fluid left over from the last servicing or which stored for long periods of time When storing the brake fluid seal the container completely and keep it away from children When replenishing brake fluid take care not to get dust into the fluid When washing brake components use new brake fluid Never use cleaning solvent A contaminated brake disc or brake pad reduces braking performance Discard contaminated pads and clean the disc with high quality brake cleaner or a neutral detergent A CAUTION Handle brake fluid with care the fluid reacts chemically with paint plastics rubber materials etc BRAKE PAD REPLACEMENT Loosen the brake pad mounting bolt Remove the brake caliper mounting bolts Remove the brake pad mounting Remove the brake pads A CAUTION Do not operate the brake lever during or after brake pad removal Replace the brake pads as a set otherwise braking performa
36. piston with the arrow mark facing towards the exhaust side CYLINDER Before installing the cylinder apply engine oil to the sliding surface of the piston Install the dowel pins into the crankcase and then Install the cylinder gasket A CAUTION Use a new gasket to prevent oil leakage Make sure that the piston rings are properly positioned and insert the piston into the cylinder NOTE When mounting the cylinder keep the cam chain taut The cam chain must not be caught between the cam chain drive sprocket and crankcase when crankshaft is rotated Temporarily tighten the cylinder base nuts Install the cam chain guide 3 61 ENGINE CYLINDER HEAD Install the dowel pins into the cylinder and then install the cylinder head gasket Donto the cylinder A CAUTION Use a new gasket to prevent gas leakage Place the cylinder head onto the cylinder Oylinder head nuts and washers must be installed cor rectly as shown Copper washer Steel washer Tighten the cylinder head nuts 10 mm to the specified torque in a crisscross pattern V cylinder head nut 10 mm 38N m 3 8 kg m 27 5 Ib ft Tighten the cylinder base nuts 2 and cylinder head nuts 6 mm D to the specified torque H Cylinder base nut 10 N m 1 0 kg m 7 0 Ib ft Cylinder head nut 6 mm 10 N m 1 0 kg m 7 0 Ib ft CAMSHAFT Turn the crankshaft counterclockwise and align the line the ge
37. play 10 15 mm 0 4 0 6 in Tighten the lock nuts D ENGINE OIL AND OIL FILTER ENGINE OIL Replace initially at 1 000 km 600 miles 3 months and every 5 000 km 3 000 miles 15 months there after OIL FILTER Replace initially at 1 000 km 600 miles 3 months and every 10 000 km 6 000 miles 30 months thereafter The engine oil should be changed while the engine is warm Oil filter replacement at the above intervals should be done together with the engine oil change ENGINE OIL REPLACEMENT Keep the motorcycle upright Place an oil pan below the engine and drain the engine oil by removing the engine oil drain plug Qand oil filler 9 Tighten the oil drain plug to the specified torque and pour new oil through the oil filler When performing an oil change without oil filter replacement the engine will hold about 1 300 ml 1 4 1 1 US Imp qt of oil Use SF or SG classified API engine oil with a viscosity rating of 10W 40 SAE V oil drain plug 28 N m 2 8 kg m 20 0 Ib ft e Install the filler cap PERIODIC MAINTENANCE 2 10 Start up the engine and allow it to run for a few minutes at idling speed Turn off the engine and wait about one minute then check the oil level through the inspection window 3 If the level is below the F mark add oil to the proper level OIL FILTER REPLACEMENT Drain the engine oil as described in the engine oil re placement procedure
38. re finish their guiding bores using the special tools Be sure to clean and oil the guides after reaming e 09916 34550 Valve guide reamer 5 5 mm 09916 34542 Handle VALVE SEAT WIDTH Coat the valve seat uniformly with Prussian blue Install the valve and attach a valve lapper onto it Tap the coated seat with the valve face in a rotating manner in order to obtain a clear impression of the seating contact The ring like dye impression left on the valve face must be continuous without any breaks In addition the width of the dye ring which is the valve seat width must be within the following specification Standard Valve seat width 49 0 9 1 1 mm 0 035 0 043 in If the valve seat is out of specification re cut the seat VALVE SEAT SERVICE The valve seats for both intake and exhaust valves are ma chined to two different angles The seat contact surface is cut 45 INTAKE SIDE EXHAUST SIDE N 121 N 121 2299 09916 21111 Valve seat cutter set 09916 20610 Valve seat cutter N 121 09916 20620 Valve seat cutter N 122 09916 24450 Solid pilot N 100 5 52 NOTE The valve seat contact area must be inspected after each cut ENGINE 328 Valve seat 3 29 ENGINE When installing the solid pilot rotate it slightly Seat the pilot snugly Install the 45 cutter attachment and T handle Using the 45 cutter descale and clean up the seat Ro tate the cutter one or two
39. seal Incorrect spark plug hot type Overheated engine Loose spark plug Excessively lean air fuel mixture Clean surface with sand paper Readjust brake pad position or replace Replace Replace Change brake fluid Disassemble and clean master cylinder Clean surface with sandpaper Replace Tighten Bleed Check level and add Bleed any air Change Replace Replace Replace Replace Replace Adjust carburetor Adjust carburetor Change Clean or replace Change to hot type spark plug Replace Replace Rebore or replace Replace Replace Change to cold type spark plug Tune up Tighten Adjust carburetor Repair replace or connect properly Replace Replace Generator does not 1 Open or short in lead wires or loose lead connec charge tions 2 Shorted grounded or open stator coil 3 Shorted or panctured regulator rectifier 7 7 SERVICING INFORMATION Complaint Symptom and possible causes Generator charges 1 Lead wires tend to get shorted or open circuited or Repair or tighten but charging rate is loosely connected at terminal Replace below the 2 Grounded or open circuited stator coils or genera Replace Replace specification battery Defective regulator rectifier Defective battery cell plates Generator Internal short circuit in the battery Replace battery overcharges Damaged or defective regulator rectifier Replace Poorly grounded regulat
40. set Foo 09900 20803 Thickness gauge Service Limit 0 10 mm 0 004 in CLUTCH SPRING FREE LENGTH Measure the free length of each clutch spring using vernier calipers If any spring is not within the service limit replace all of the spring Too 09900 20101 Vernier calipers Service Limit 40 9 mm 1 61 in CLUTCH RELEASE BEARING Inspect the clutch release bearing for any abnormality es pecially cracks When removing the bearing from the clutch decide whether it can be reused or if it should be replaced Smooth engagement and disengagement of the clutch de pends on the condition of this bearing ENGINE 3 46 CLUTCH COVER Remove the oil seal retainer Remove the oil seal using the special tool co 09913 50121 Oil seal remover Install the new oil seal using a suitable Install the oil seal retainer NOTE Apply a small quantity of THREAD LOCK 1342 to the oil seal retainer screws 99000 32050 THREAD LOCK 1342 1342 OIL FILTER Remove the oil filter cap Remove the oil filter and install a new one NOTE Before installing the new oil filter and oil filler cap make sure that the spring and new O rings are installed correctly Install the oil filter cap 3 47 ENGINE OIL SUMP FILTER Remove the oil sump filter cap Remove the oil sump filter INSPECTION Check the oil sump filter for any damage or clogs CLEANING Clean the oil sump f
41. standard value measure the peak voltage on the pick up coil coupler as follows 6 23 ELECTRICAL SYSTEM Remove the front seat See 5 1 Remove the fuel tank See p 4 1 Disconnect the pick up coil coupler and connect the mul ti circuit tester with the peak volt adaptor Probe Green lead wire Probe Blue lead wire Measure the pick up coil peak voltage in the same man ner as on the ignitor coupler im Tester knob indication Voltage Pick up coil peak voltage More than 5 0 V Green Blue If the peak voltage on the pick up coil lead wire coupler is ok but on the ignitor coupler is out of specification the wire harness must be replaced If both peak voltages are out of specification the generator must be replaced and re checked PICK UP COIL RESISTANCE Remove the seat and fuel tank and disconnect the pick up coil coupler Measure the resistance between the lead wires and ground If the resistance is not within the specified value the generator stator must be replaced Pick up coil resistance 400 6500 Blue Green x Q Blue Ground Pick up coil coupler B a Generator Generator Peak volt adaptor Pick up coil coupler ELECTRICAL SYSTEM 6 24 SPEEDOMETER REMOVAL AND DISASSEMBLY Remove the speedometer Disassemble the speedometer as follows o 1 Speedometer 2 Speedometer bracket 3 Speedometer cover 4 Socket assy
42. the gearshift forks to their respective gears Install the gearshift cam stopper Install the gearshift cam into the crankcase zi 3 HENS ENGINE 3 50 e Install the gearshift fork shafts NOTE Position the gearshift cam as shown in Fig so that the gearshift fork shafts can be installed easily Install the the gearshift cam stopper spring CRANKCASE Wipe both crankcase mating surfaces with a cleaning solvent Apply SUZUKI BOND 1215 uniformly to the mating surface of the right crankcase and assemble the cases within a few minutes 99000 31110 SUZUKI BOND 1215 3 51 ENGINE Install the dowel pins into the left half of the crankcase Install the O ring A CAUTION Use a new O ring Apply engine oil to the conrod big end and transmission gears Tighten the crankcase bolts to the specified torque W crankcase bolt 11 N m 1 1 kg m 8 0 Ib ft NOTE Install the clamp to the bolt NOTE After the crankcase bolts have been tightened make sure that the crankshaft countershaft and driveshaft ro tate smoothly If these shafts do not rotate smoothly try to free it by tapping with a plastic hammer Install the the gearshift cam stopper GENERATOR ROTOR Remove any grease from the tapered portion of the gen erator rotor and crankshaft Install the washer Dso that the convex side of it faces the crankcase bear
43. the wheel bearings if there is anything unusual 5 CHASSIS 5 4 Remove the wheel bearings as follows Insert the adapter into the wheel bearing After inserting the wedge bar from the opposite side lock the wedge bar into the slit of the adapter Drive out both bearings by striking the wedge bar 09941 50111 Bearing remover The removed bearings should be replaced with new ones A CAUTION FRONT AXLE Measure the front axle runout using the dial gauge If the runout exceeds the limit replace the front axle 7221 09900 20606 Dial gauge 1 100 09900 20701 Magnetic stand 09900 21304 V block set 100 mm Service Limit 0 25 mm 0 010 in WHEEL Make sure that the wheel runout axial and radial does not exceed the service limit when checked as shown An ex cessive amount of runout is usually due to worn or loose wheel bearings and can be corrected by replacing the bearings If bearing replacement fails to reduce the runout replace the wheel Service Limit axial and radial 2 0 mm 0 08 in SPOKE NIPPLE Check to be sure that all nipples are tight and retighten them as necessary using a spoke nipple wrench 1929 09940 60113 Spoke nipple wrench Spoke nipple 4 5 N m 0 45 kg m 3 5 Ib ft 5 5 CHASSIS REASSEMBLY Apply SUZUKI SUPER GREASE A to the bearings be fore installing 99000 25010 SUZUKI SUPER GREASE A Install the wheel bearings usin
44. time Noise labe For 03 24 33 34 Information label For E 03 28 33 9 Vacuum hose routing label For E 33 4 Fuel information label For E 02 24 8 Manual notice labe For 03 33 6 Tire pressure label 2 Warning safety label 8 ICES label For E 28 8 ID label Except for E 03 28 33 49 Safety plate For E 03 28 33 5713977 NOLVWHOJNI TIVH3N39 5 1 GENERAL INFORMATION 1 6 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length 2 160 85 0 Overall width 00 815 mm 32 1 in Overall height 1090 mm 42 9 in Wheelbase tee etta 1450 mm 57 1 in Ground clearance 125 mm 4 9 in Seatheight aiitem tire ins 680 mm 27 8 in Dry mass iei nin ned deeds 137 kg 302 Ibs ENGINE E Four stroke air cooled Number of 2 2 1 BOP ENT 72 0 mm 2 835 in SIIOKG ier Cr toe um d bote 61 2 mm 2 409 in Displacement 249 cm 15 2 cu in Compression ratio 9 0 1 Carburetor 1 eie acted MIKUNI BSR32SS single Alf cleanet otro Eee Non woven fabric element Starter system etes Electric Lubrication system Wet sump TRANSMISSION GUTOR
45. turns Measure the valve seat width after every cut If the valve seat is pitted or burned use the 45 cutter to condition the seat same more NOTE Cut only the minimum amount necessary from the seat to prevent the possibility of the valve stem becoming too close to the rocker arm for correct valve contact angle If the contact area is too high on the valve or If it is too wide use the 15 cutter to lower and narrow the contact area If the contact area is too low or too narrow use the 45 cutter to raise and widen the contact area After the desired seat position and width is achieved use the 45 cutter very lightly to clean up any burrs caused by the previous cutting operations CAUTION DO NOT use lapping compound after the final cut is made The finished valve seat should have a velvety smooth finish and not a highly polished or shiny finish This will provide a soft surface for the final seating of the valve which will occur dur ing the first few seconds of engine operation Clean and assemble the head and valve components Fill the intake and exhaust ports with gasoline to check for leaks If any leaks occur inspect the valve seat and face for burrs or other things that could prevent the valve from sealing Always use extreme caution when handling gaso line NOTE After servicing the valve seats be sure to check the valve ees Contact area too high and too wide on face of va
46. 018 mm 0 4724 0 4731 in REASSEMBLY Reassemble the cylinder head cover in the reverse order of disassembly Pay attention to the following points Apply engine oil to the rocker arm shafts Install the rocker arms D 2 wave washers shafts A CAUTION Use the new O rings to prevent oil leakage Tighten the rocker arm shaft bolts to the specified torque V Rocker arm shaft bolt 10 Nm 1 0 kg m 7 0 Ib ft CYLINDER HEAD IA CAUTION Identify the position of each removed part Orga nize the parts in their respective groups in take or exhaust so that they can be installed in their original locations DISASSEMBLY Remove the cam chain tensioner i e Remove the intake pipe ENGINE 3 24 3 25 ENGINE Compress the valve spring using the special c tools 09916 14510 Valve lifter 09916 14910 Valve lifter attachment Remove the valve cotters from the valve stem 09916 8451 1 Tweezers e Remove the valve spring retainer 2 and valve spring Remove the valve from the combustion chamber side Remove the valve stem seal Remove the valve spring seat CYLINDER HEAD DISTORTION Decarbon the combustion chamber Check the gasket surface of the cylinder head for distortion using a straightedge and thickness gauge Take clearance readings at several places If readings exceed the service limit replace the cylinder head 09900 20803 Thickness gauge
47. 0508 Cylinder gauge set 09900 20803 Thickness gauge 09900 25008 Multi circuit tester set 09900 20805 Tire depth gauge 09900 26006 Tachometer 09910 32840 Attachment 09913 75830 Bearing installer 09910 34510 Piston pin puller 09913 76010 Bearing installer 09913 50121 Oil seal remover 09913 84510 Bearing installer 7 21 09913 85210 Bearing installer 09916 21111 Valve seat cutter set 09916 34561 Valve guide reamer 11 3 mm Zz 09920 13120 Crankcase separator SERVICING INFORMATION 09915 64510 Compression gauge NC 09916 44910 Valve guide remover installer 09920 53740 Clutch sleeve hub holder 09930 10121 Spark plug socket wrench set 22 4 gt 09930 44913 Rotor holder 09930 11920 Torx bit JT40H 09940 14911 Steering stem nut wrench 09915 74510 Oil pressure gauge N 09916 24450 Solid pilot N 100 5 52 09916 84511 Tweezers 09923 74510 Bearing remover 09930 11940 Bit holder Wes g 09940 52880 Front fork oil seal installer set 09916 14510 Valve lifter 09916 34542 Valve guide reamer handle 09917 14920 Valve adjuster wrench Q 09924 84510 Bearing installer set 09930 30102 Sliding shaft 09940 60113 Spoke nipple wrench 09916 14910 Valve lifter attachment 09916 34550 Valve guide reamer 5 5 mm ap 09918 03810 A
48. 1 diseno 3 10 and 60 3 11 and 59 3 11 58 ENGINE RIGHT SIDE See page Oll filter c ieee 3 46 Clutch 2 2 3 12 and 57 Clutch asic uie cte iode 3 12 and 55 Oil PUMP sott rte reto 3 14 and 54 Gearshift shaft 3 14 and 54 Primary drive gear 3 15 and 52 ENGINE 3 2 ENGINE REMOVAL AND REINSTALLATION ENGINE REMOVAL Remove the front seat See p 5 1 Remove the fuel tank See p 4 1 Remove the right frame cover See p 5 1 Disconnect the battery lead wire Drain the engine oil See p 2 9 Remove the right footrest bracket Remove the exhaust pipe bolts Remove the exhaust pipe by removing the bolt Remove the muffler mounting bolt Remove the gearshift link arm 33 ENGINE Remove the engine sprocket cover Flatten the lock washer Remove the engine sprocket nut and washer NOTE When loosening the engine sprocket nut temporarily install the right footrest bracket and depress the brake pedal Remove the engine sprocket NOTE If it is difficult to remove the engine sprocket loosen the rear axle nut and chain adjuster nuts to provide additional chain slack Remove the clutch release arm Loosen the clutch cable adjuster lock remove the clutch cable Remove the left and right cylinder head cover caps Disconnec
49. 2 Rear sprocket 4 Rear axle 2 Rear axle nut Rear brake cam lever nut Rear sprocket mounting nut P j 2 3 gt 7 V ae 7 4 Spring Bearing fy 8 5 Fe o y e CHASSIS 5 30 REMOVAL Remove the rear brake adjusting nut Remove the cotter pin torque link nut Gand bolt Remove the rear axle nut Raise the rear wheel off the ground with a jack or wood en block Loosen the drive chain adjusting nuts amp left and right Remove the rear axle Disengage the drive chain from the rear sprocket Remove the rear wheel Remove the rear brake panel e Remove the rear sprocket with mounting drum from the rear wheel NOTE Before separating the rear sprocket and mounting drum slightly loosen the rear sprocket bolts Remove the rear sprocket damper Remove the drive chain guide and rear sprocket from the rear sprocket mounting drum Remove the brake shoes from the brake panel 531 CHASSIS Remove the brake cam lever bolt and nut Remove the brake cam lever Remove the washer O ring and brake camshaft INSPECTION AND DISASSEMBLY WHEEL BEARING 5 3 4 WHEEL 5 4 WHEEL 5 4 SPOKE NIPPLE etis See 5 4 REAR SPROCKET MOUNTING DRUM BEARING _ See p 5 3 Inspe
50. 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block 100 mm Service Limit 0 3 mm 0 01 in REAR SHOCK ABSORBER Inspect the rear shock absorber for damage and oil leakage If any defects are found replace the rear shock absorber with a new one A CAUTION Do not attempt to disassemble the rear shock absorber It is unserviceable CHASSIS 5 40 REASSEMBLY AND REMOUNTING Reassemble and remount the swingarm and rear shock absorber in the reverse order of removal and disassembly Pay attention to the following points Press the needle bearings into the swingarm pivot using a suitable socket and the special tool See p 5 36 09924 84521 Bearing installer set NOTE Install the needle bearings with the stamped facing out Apply grease to the spacers dust seals and needle bearings AAH 99000 25010 SUZUKI SUPER GREASE A Install the rear torque link to the swingarm Tighten the rear torque link nut to the specified torque 9 Rear torque link nut 13 N m 1 3 kg m 9 5 Ib ft Install the new cotter pin Install the swingarm and tighten the swingarm pivot nut to the specified torque V Swingarm pivot nut 72 Nm m 7 2 kg m 52 0 Ib ft 541 CHASSIS Install the rear shock absorber and tighten the mounting bolts and nuts to the specified torque V Shock absorber mounting bolt nut 29 N m 2 9kg m 21 01b ft NOTE Install the rear shock
51. 5510 Bearing remover installer TOOU The removed oil seal should be replaced with a new one A CAUTION BEARING INSTALLATION Install the bearings using the special tools 09913 75510 Bearing remover installer For 09913 75520 Bearing remover installer 2 5 09913 75830 Bearing remover installer For 09913 84510 Bearing remover installer For 09913 85210 Bearing remover installer For Install the oil seal D into the left crankcase using the special tool 09913 85210 Bearing remover installer TOOL Apply grease to the oil seal lip 99000 25010 SUZUKI SUPER GREASE A Place the washer so that the of it faces towards the oil seal 321 ENGINE Install the left crankcase bearing using the special tool and suitable attachment used beanng e g 09913 75510 Bearing remover installer Install the washer Install the left driveshaft bearing with the bearing retainer Install the bearing retainers NOTE Apply a small quantity of THREAD LOCK 1342 to the bearing retainer screws 99000 32050 THREAD LOCK 1342 Apply grease to the oil seal lip 99000 25010 SUZUKI SUPER GREASE A e Install the driveshaft oil seals shown CAUTION When installing the oil seal Do not block the oil passage ENGINE 3 22 CLUTCH RELEASE CAMSHAFT REMOVAL Remove the oil seal retainer and clutch cable guide
52. 7 0 024 0 028 Spark performance Over 8 0 3 at 1 atm Ignition coil resistance Primary 2 5 terminal CB terminal Secondary 17 28kQ CB terminal Plug cap Y Ignition coil primary peak voltage More than 200 V Generator coil resistance 400 6500 210Wat5 000r min More than 60 V AC at 5 000 r min fel uu Standard 1 320 at 20 C 68 F electrolyte S G 7 31 SERVICING INFORMATION WATTAGE Unit W 17 22 25 34 AINE LE Im EE um pe ctm Posen ake BRAKE WHEEL Unit mm in ITEM STANDARD LIMIT Rear brake pedal free travel 20 30 0 8 1 2 Rear brake pedal height 50 2 0 Brake disc thickness Front 5 0 0 2 0 20 0 01 Brake disc runout Front Master cylinder bore 12 700 12 743 0 4999 0 5017 Master cylinder piston diam 12 657 12 684 0 4983 0 4994 Brake caliper cylinder bore 33 960 34 036 1 3370 1 3400 33 884 33 934 1 3340 1 3360 Brake drum ID pe a it Brake lining thickness 0 06 Wheel rim runout XT 0 08 0 08 Wheel axle runout Front 025 LU 0010 og emn 0 010 Wheel rim size 16XMT2 50 1 52 33 130 90 15 66 SERVICING INFORMATION 7 32 STANDARD LIMIT Tire tread depth SUSPENSION Unit mm in ITEM Front fork stroke 120 Po e 2 Front fork spring free length al 301 Bou 11 9 Front fork oil level 105 21 R
53. 72 015 72 085 2 8346 2 8352 2 8380 Piston diam 71 950 71 965 71 880 2 8327 2 8333 2 8299 Measure at 15 0 6 in from the skirt end Cylinder distortion 0 05 0 002 Piston ring free end gap o 7 0 30 Piston ring end gap 1st 0 10 0 30 0 50 0 004 0 012 0 020 0 10 0 30 0 50 0 004 0 012 0 020 Piston ring to groove clearance 0 180 0 0071 0 150 0 0059 6 0 35 SERVICING INFORMATION 7 28 ITEM STANDARD LIMIT 1 01 1 03 0 040 0 041 2nd 1 21 1 23 0 047 0 048 Piston ring groove width Piston ring thickness 251253 0 099 0 100 lt 0 975 0 990 0 0384 0 0390 2nd 1 170 1 190 0 0461 0 0469 Piston pin bore 18 002 18 008 18 030 0 7087 0 7090 0 7098 Piston pin O D 17 992 18 000 17 980 0 7083 0 7087 0 7079 CONROD CRANKSHAFT Unit mm in ITEM STANDARD LIMIT Conrod small end D 18 006 18 014 18 040 0 7089 0 7092 0 7102 Conrod deflection E X 0 12 Conrod big end side clearance 0 10 0 65 1 0 0 004 0 026 0 04 Conrod big end width 20 95 21 00 0 825 0 827 Crankshaft web to web width 60 0 0 1 us aed Crankshaft runout 088 09 Balancer spring free length 09 88 OIL PUMP ITEM STANDARD LIMIT Oil pump reduction ratio 2 812 68 21 x 33 38 Oil pressure at 60 C 140 F Above 30 kPa 0 3 kg cm 4 3 psi Below 70 kPa 0 7 kg cm 10 0 psi at 3 000 r min CLUTCH Unit mm in ITEM STA
54. AL FRONT SEAT Remove the seat with the ignition key RIGHT FRAME COVER Remove the screw Remove the right frame cover xx hooked part LEFT FRAME COVER Remove the screw Remove the left frame cover xx hooked part Remove the seat lock REAR SEAT Remove the rear seat by removing the bolts REMOUNTING Remount the seats frame covers front and rear fenders in the reverse order of removal CHASSIS 5 2 FRONT WHEEL CONSTRUCTION Dust cover Sy 2 Spacer 3 Bearing 4 Front wheel be 5 Spacer Bearing j 7 Brake disc Speedometer gearbox A Front axle Axle pinch bolt Brake disc bolt Left c V 3s N m Groin 28 0 Ib ft 65N m tf 6 l 16 5 lb ft 5 3 CHASSIS REMOVAL FRONT WHEEL Loosen the axle pinch bolt Loosen the front 2 Raise the front wheel off the ground with a jack or wood en block Remove the front wheel by removing the front axle e Remove the dust spacer Remove the brake disc cep 09900 00410 Hexagon wrench set INSPECTION AND DISASSEMBLY SPEEDOMETER GEARBOX Turn the speedometer gear and check to see that the gear turns smoothly together with the speedometer pinion WHEEL BEARINGS Inspect the play of the wheel bearings by hand while they are in the wheel Rotate the inner race by hand to inspect it for abnormal noise and smooth rotation Replace
55. ANCE CHECKING AND ADJUSTING Remove the rear axle cotter pin For E 28 model Loosen the rear axle nut Tense the drive chain fully by turning chain adjuster nuts Count out 21 pins 20 pitch on the chain measure the distance between the two points If the distance exceeds the service limit the chain must be replaced Drive chain 20 pitch length 319 4 mm 12 57 in NOTE When replacing the drive chain replace the drive chain and sprockets as a set Place the motorcycle on the side stand e Loosen both chain adjuster nuts until the chain has 5 15 mm 0 2 0 6 in of slack at the middle of the chain between the engine and rear sprockets as shown The reference marks S must be at the same position on the scale to ensure that the front and rear wheels are correctly aligned Drive chain slack 5 15 mm 0 2 0 6 in After adjusting the drive chain tighten the rear axle nut D to the specified torque Rear axle nut 65 N m 6 5 kg m 47 0 Ib ft For E 03 28 33 78 N m 7 8 kg m 56 5 Ib ft For the others Recheck the chain slack after tightening the axle nut and readjust if necessary Tighten both chain adjuster nuts securely Install the new cotter pin For E 03 28 33 models CLEANING AND LUBRICATING Clean the drive chain with kerosine If the drive chain tends to rust quickly the intervals must be shortened CAUTION Do not use trichloroethylene gasoline or any sim
56. ASSEMBL Y AND REMOUNTING 5 13 EPONTEORK E tote ete ae en 5 15 CONSTRUCTION 2 E Led 5 15 REMOVAL AND DISASSEMBLY 5 15 INSPECTION 5 17 REASSEMBLY AND REMOUNTING ree 5 18 STEERING eene ttt tente ttt 5 22 CONSTRUCTION erret trente 5 22 REMOVAL AND DISASSEMBLY 5 22 oao 5 25 REASSEMBLY AND 5 26 REAR WHEEL AND REAR BRAKE erre 5 29 CONSTRUCTION erret ttti 5 29 1 5 30 INSPECTION AND 1 5 31 REASSEMBLY AND REMOUNTING erre 5 33 REAR SUSPENSION ertet tens 5 36 CONSTRUCTION rere 5 36 REMOVAL sssssssessssssesssessessuessuesuessucsseesscssessussaeessesseesseesessaeeseeeneenes 5 37 INSPECTION AND DISASSEMBLY eene 5 38 REASSEMBLY AND REMOUNTING eee 5 40 5 1 CHASSIS EXTERIOR PARTS REMOV
57. I D 4 5 500 5 512 0 2165 0 2170 Valve stem 5 460 5 475 0 2150 0 2156 5 445 5 460 0 2144 0 2150 Valve stem runout IN amp EX Valve head thickness IN amp EX Valve stem end length IN amp EX Valve seat width Valve head radial runout IN amp EX Valve spring free length IN amp EX Valve spring tension 40 56 47 62 Ibs at length 35 0 mm 1 38 in 7 27 SERVICING INFORMATION CAMSHAFT CYLINDER HEAD Unit mm in ITEM STANDARD LIMIT Cam height IN 34 990 35 040 34 690 1 3776 1 3795 1 3657 EX 35 030 35 080 34 730 1 3791 1 3811 1 3673 Camshaft journal oil clearance 0 032 0 066 0 150 0 0013 0 0026 0 0059 Camshaft journal holder R side 25 012 25 025 90709852 L side 20 012 20 025 0 7879 0 7884 Camshaft journal O D R side 24 959 24 980 r NN L side 19 959 19 980 7850806 _ Camshaft runout Nax 940 0 004 Rocker arm 1 0 IN amp EX 12 000 12 018 0 4724 0 4731 _ Rocker arm shaft IN amp EX 11 966 11 984 IEEE 471 0478 Cylinder head distortion 0 05 0 002 Cylinder head cover distortion 0 05 0 002 CYLINDER PISTON PISTON RING Unit mm in STANDARD LIMIT Compression pressure 1 000 1 400 kPa 800 kPa 8 110 0 14 0 kg cm kg cm f 142 199 114 Piston to cylinder clearance 0 045 0 055 0 120 0 0018 0 0022 0 0047 Cylinder bore 72 000
58. INITION Torque control required Data beside it indicates specified Apply THREAD LOCK 1360 torque Apply oil Use engine oil unless Apply or use brake fluid otherwise specified Apply molybdenum oil solution mix Measure in voltage range ture of engine oil and SUZUKI MOLY PASTE in ratio of 1 1 Apply SUZUKI SUPER GREASE Measure in resistance range 99000 25010 Measure in current range Apply SUZUKI SILICONE GREASE Measure in diode test range Measure in continuity test range Apply THRE Use special tool 1303 99000 32030 Use fork oil 99000 VERA Y 270 2 War e CONTENTS entere 1 1 GENERAL 8 4 0460 1 1 SUZUKI GZ250X 99 1 3 SERIAL NUMBER 040000 1 3 FUEL AND OIL RECOMMENDATIONS 1 3 1 3 ENGINE OIL 1 4 BRAKE FLUID tcc dtc nc Ne 1 4 FRONT FORK iau trente 1 4 BREAK IN PROCEDURES s ssessssssssssesssessessuessessucsseesseeseesneesseesvenes 1 4 INFORMATION LABELS erret 1 5 SPECIFICATIONS 2222546 detis 1 6 1 1 GENERAL INFORMATION WARNING CAUTI
59. IT TESTER Properly use the multi circuit tester and probes Improper use can cause damage to the motorcycle and tester If the voltage and current values are not known begin measuring in the highest range When measuring the resistance make sure that no volt age is applied If voltage is applied the tester will be damaged After using the tester turn the switch to the OFF position CAUTION Before using the multi circuit tester read its instruction manual 6 3 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS Clutch lever position switch 6 Horn 2 Ignitor 7 Generator 3 Turn signal side stand relay 8 Neutral switch Fuse box Side stand switch gnition coil 19 Regulator rectifier ELECTRICALSYSTEM 64 Starter relay Front brake light switch Main fuse Rear brake light switch amp 8 Battery 58 Starter motor 6 5 ELECTRICAL SYSTEM CHARGING SYSTEM DESCRIPTION The circuit of the charging system is indicated in the figure which is composed of an AC generator regulator rectifier unit and battery The AC current generated from AC generator is converted by rectifier and is turned into DC current then it charges the battery Ignition switch 1 I I 1 l 1 i 1 I 1 1 1 L 1 3 E om AC generator m a u mo an imc mcm ELECTRICAL SYSTEM 6 6 TROUBLESHOOTING
60. NDARD Clutch cable play 10 15 0 4 0 6 Clutch release screw m turn back Drive plate thickness No 1 2 92 3 08 0 115 0 121 3 45 3 55 0 136 0 140 Drive plate claw width 15 9 16 0 0 626 0 630 Driven plate distortion Clutch spring free length 7 29 SERVICING INFORMATION TRANSMISSION DRIVE CHAIN Unit mm in Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3 238 68 21 Final reduction ratio 2 733 41 15 1 000 20 20 0 818 18 22 Shift fork to groove clearance 0 20 0 40 0 60 0 008 0 016 0 024 Shift fork groove width 4 25 4 35 0 167 0 171 Shift fork thickness 3 95 4 05 0 156 0 159 Drive chain DID520VC5 Links 110 EL NNI 20pithlengh 1 3194 ttn sry Drive chain slack jee Oe CARBURETOR ITEM SPECIFICATION fermi E E Main jet M J 115 Jet needle J N 5C60 3rd Needle jet N J Pilot air jet No 1 P A J 1 87 5 Pilot air jet No 2 P A J 2 140 Throttle valve Th V 110 Pilot screw PS 1 g turns out Throttle cable play 2 4 mm 0 08 0 16 in Starter plunger cable play 0 5 1 0 mm 0 02 0 04 in PJ LC Wa SERVICING INFORMATION 7 30 CARBURETOR ITEM E 03 28 Carburetor type MIKUNI BSR32SS Pe WMS 110 Pilot screw 6 PRESET 0 5 1 0 mm 0 02 0 04 in ELECTRICAL Unit mm in 10 B T D C at1 300r min Spark plug Type NGK DR8EA DENSO X24ESR U Gap 0 6 0
61. NON eset dei uice RECHARGING 2 6 1 ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTORS When disconnecting a connector be sure to hold the ter minals do not pull the lead wires When connecting a connector push it in so it is firmly attached Inspect the connector for corrosion contamination and any breakage in the cover COUPLERS With a lock type coupler be sure to release the lock be fore disconnecting it When connecting a connector push it in until the lock clicks shut When disconnecting the coupler be sure to hold the cou pler do not pull the lead wires Inspect each terminal on the coupler for looseness or bends Inspect each terminal for corrosion and contamination CLAMPS Refer to WIRE CABLE AND HOSE ROUTING See pp 7 11 to 18 for proper clamping procedures Bend the clamp properly as shown in the illustration 9 When clamping the wire harness do not allow it to hang down C Do not use wire or any other substitute for the band type clamp CORRECT INCORRECT FUSES When a fuse blows always investigate the cause cor rect the problem and then replace the fuse Do not use a fuse of a different capacity Do not use any substitute for the fuse e g wire SEMI CONDUCTOR EQUIPPED PARTS Do not drop any part that contains a semi conductor e g ignitor unit regulator rectifier When
62. ON NOTE Please read this manual and follow its instructions carefully To emphasize special information the symbol and the words WARNING CAUTION and NOTE have special meanings Pay special attention to the messages highlighted by these signal words WARNING Indicates a potential hazard that could result in death or injury CAUTION Indicates a potential hazard that could result in motorcycle damage NOTE Indicates special information to make maintenance easier or instructions clearer Please note however that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing or lack of servicing of the motorcycle In addition to the WARNINGS and CAUTIONS stated you must use good judgement and basic mechanical safety prin ciples If you are unsure about how to perform a particular service operation ask a more experienced mechanic for advice GENERAL PRECAUTIONS Proper service and repair procedures are important for the safety of the service me chanic and the safety and reliability of the motorcycle When 2 or more persons work together pay attention to the safety of each other When it is necessary to run the engine indoors make sure that exhaust gas is forced outdoors When working with toxic or flammable materials make sure that the area you work in is well ventilated and that you follow all of the manufacturer s instructions Never use gasoline as a cleaning s
63. R MOTOR REASSEMBLY Reassemble the starter motor in the reverse order of disas sembly Pay attention to the following points A CAUTION Replace the O rings with new ones to prevent oil leakage and moisture Apply SUZUKI SUPER GREASE A to the lip of the oil seal A 99000 25010 SUZUKI SUPER GREASE Apply a small quantity of SUZUKI MOLY PASTE to the armature shaft 99000 25140 SUZUKI MOLY PASTE Apply SUZUKI SUPER GREASE A to the O rings AAH 99000 25010 SUZUKI SUPER GREASE Apply a small quantity of THREAD LOCK 1342 to the starter motor housing bolts 79 99000 32050 THREAD LOCK 1342 STARTER RELAY INSPECTION Remove the front seat and right frame cover See p 5 1 Disconnect the battery lead wire Remove the starter relay cover 2 e Disconnect the starter motor lead wires starter relay lead wire coupler Remove the starter relay Apply 12 volts to terminals and B and measure for continuity between the positive and negative terminals If the starter relay clicks and continuity is found the relay is ok 09900 25008 Multi circuit tester set i Tester knob indication Continuity test A CAUTION Do not apply battery voltage to the starter relay for more than five secondes This may overheat and damage the relay coil ELECTRICAL SYSTEM 6 14 starter motor To battery IE un 6 15 ELECTRICALSYSTEM Measu
64. Remove the seal Remove the clutch release cam shaft REASSEMBLY Apply engine oil to the clutch release camshaft as shown in the illustration e Install the clutch release camshaft D washer and oil seal 3 23 ENGINE CYLINDER HEAD COVER CAUTION gt Identify the position of each removed Organize a MZ e N the parts in their respective groups i e intake or e exhaust so that they can installed their original pe locations 1 X 9 DISASSEMBLY Remove the rocker arm shaft bolts 1 Remove the rocker arm shafts 2 Remove the rocker and wave washers CYLINDER HEAD COVER DISTORTION After removing the sealant SUZUKI BOND 1215 from the mating surface of the cylinder head cover place the cylinder head cover on a surface plate and check for distortion with a thickness gauge Check points are shown in Fig 09900 20803 Thickness gauge Service Limit 0 05 mm 0 002 in If the distortion exceeds the limit replace the cylinder head cover ROCKER ARM SHAFT O D Measure the diameter of the rocker arm shafts 09900 20205 Micrometer 0 25 mm 11 966 11 984 mm 0 4711 0 4718 in Standard IN amp ROCKER ARM 1 0 Measure the inside diameter of the rocker arm and check the wear of the camshaft contacting surface 122 09900 20605 Dial calipers Standard IN amp EX 12 000 12
65. SERVICE MANUAL FOREWORD This manual contains an introductory description on the SUZUKI GZ250 and procedures for its inspec tion service and overhaul of its main components Other information considered as generally known is not included Read the GENERAL INFORMATION section to fa miliarize yourself with the motorcycle and its mainte nance Use this section as well as other sections as a guide for proper inspection and service This manual will help you know the motorcycle better so that you can assure your customers of fast and re liable service This manual has been prepared on the basis of the latest specifications at the time of pub lication If modifications have been made since then differences may exist between the content of this manual and the actual mo torcycle Illustrations in this manual are used to show the basic principles of operation and work procedures They may not represent the ac tual motorcycle exactly in detail This manual is written for persons who have enough knowledge skills and tools includ ing special tools for servicing SUZUKI mo torcycles If you do not have the proper knowledge and tools ask your authorized SUZUKI motorcycle dealer to help you Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the service described in this manual Improp er repair may result in injury to the me chanic and may render the motorcycle un sa
66. SHAFT CONROD SMALL END JOURNAL i Ut i Y i M 4 aun CONROD BIG ROCKER ARM END BEARING SHAFT BY OIL FILTER PAS CLUTCH PLATES L 4 gar ees CONTENTS EXTERIOR PARTS weeesssssssssessesssesscssessucssessesssessuesstesuesasesseesessseesseeneeres 5 1 REMOVAL ees ee LM 5 1 REMODNTING ienaa tes te na eS 5 1 FRONT WHEEL 22 tes ce E 5 2 CONSTRUCTION ns acres cus tos 5 2 REMOVAL RO 5 3 INSPECTION AND 1 5 5 3 REASSEMBLY Leno E 5 5 BEMOUNTING EREE cest d 5 6 FRONT BRAKE 5 7 CONSTRUCTION ed cere 5 7 BRAKE PAD REPLACEMENT eren 5 8 BRAKE FLUID REPLACEMENT erret 5 8 BRAKE CALIPER REMOVAL AND DISASSEMBLY 5 9 BRAKE CALIPER INSPECTION een 5 10 BRAKE CALIPER REASSEMBL Y AND REMOUNTING 5 10 BRAKE DISC 5 11 MASTER CYLINDER REMOVAL AND DISASSEMBLY 5 11 MASTER CYLINDER INSPECTION ees 5 13 MASTER CYLINDER RE
67. TE Leakage is evident if the reading is over 1mA Battery current leak Under 1mA A CAUTION Because the current leak might be large turn the tester to the high range first to avoid tester damage Do not turn the ignition switch to the ON position when measuring the current When checking to find the excessive current leak remove the couplers and connectors one by one checking each part CHARGING OUTPUT INSPECTION Remove the front seat and right frame cover See p 5 1 Start the engine turn the lighting switch to ON and the dimmer switch to HI and run the engine at 5 000 r min Measure the DC voltage between the and battery terminals with a tester If the tester reads under 13 5V or over 15 0V inspect the stator coil and regulator rectifier A CAUTION If the tester is set for current or resistance readings and voltage is applied across the test probes damage will result Therefore it is important that the tester knob on the tester be set to the proper position before making any measurements NOTE When making this test be sure that the battery is fully charged Tester Charging output Standard 13 5 15 0V at 5 000 r min ELECTRICAL SYSTEM 6 8 STATOR COIL RESISTANCE Remove the front seat See p 5 1 Remove the fuel tank See p 4 1 Disconnect the stator coil coupler Measure the resistance between the three lead wires using a tester Also check that the
68. Wet multi plate type Transmission 4 2 2 5 speed constant mesh Gearshift 1 down 4 up Primary reduction ratio 3 238 68 21 Final reduction 2 733 41 15 Gear ratios 2 636 29 11 VD C 1 687 27 16 1 263 24 19 iet Rs 1 000 20 20 iid deett 0 818 18 22 Drive DID 520 5 110 links 1 7 GENERAL INFORMATION ELECTRICAL Ignition Electronic ignition Transistorized Ignition timing mI 10 B T D C at 1 300 r min Spark plug i ttti n eom NGK DR8EA or DENSO X24ESR U Battery ied ep beet porto bee dais 12V 21 6 6 Ah 10 HR Generator oa aee Three phase A C generator 20 15 15 15 10 10A Headlight ce te ett eoa dade 12V 60 55W Position 2 12V AW Except for E 03 24 28 33 Brake light Taillight 12V 21 5W Front turn signal light Running light 12V 21 5W E 03 28 33 Turn signal 12V 21W Speedometer 9 12V 1 7W Neutral indicator 12V 3 4W Turn signal indicator light 12V 3 4W High beam indicator light
69. absorbers with the spring tension ad justing holes D facing out Install the rear wheel and rear brake See p 5 35 Adjust the rear shock absorber spring pre load Spring pre load STD 3 5 position After installing the rear suspension and rear wheel adjust the following before riding Drive chain slack See p 2 11 Rear brake free travel See p 2 14 Tire pressure ssssmm See p 2 15 CAUTIONS IN SERVICING LOCATION OF ELECTRICAL COMPONENTS CHARGING SYSTEM DESCRIPTION d sias itudin TROUBLESHOOTING eosin eee INSPEC ON eut tie eir pe ductores STARTER SYSTEM AND SIDE STAND IGNITION INTERLOCK SYSTEM MC STARTER SYSTEM DESCRIPTION eee SIDE STAND IGNITION INTERLOCK SYSTEM DESCRIPTION TROUBLESHOOTING sone tassi tatu quete ae eee ote beige oue STARTER MOTOR REMOVAL AND DISASSEMBLY STARTER MOTOR STARTER MOTOR REASSEMBLY sse STARTER RELAY INSPECTION oee SIDE STAND IGNITION INTERLOCK SYSTEM PART INSPEGCTION ntpote M SS SWITCHES sanc qiero ou piger aon ueniunt BATTERY eo ded eei eke et Se eee bita decas blades SPECIFICATIONS INTTHAL GHAR GING ree od SERVIGI
70. air cleaner element restricting air flow through the air cleaner element Reinstall the cleaned or new air cleaner element in the reverse order of removal When installing the air cleaner element into the air clean er case align the triangle marks on the air cleaner ele ment and the air cleaner case CAUTION If driving under dusty conditions clean the air cleaner element more frequently The surest way to accelerate engine wear is to operate the engine without the element or to use a torn element Make sure that the air cleaner is in good condition at all times The life of the engine depends largely on this component NOTE When cleaning the air cleaner element remove the plug and drain any water from the air cleaner drain hose VALVE CLEARANCE Inspect initially at 1 000 km 600 miles 3 months and every 5 000 km 3 000 miles 15 months there after INSPECTION Remove the front seat See p 5 1 Remove the fuel tank See p 4 1 Remove the cylinder head cover left cap D Disconnect the spark plug cap and remove the spark plug 09930 10121 Spark plug socket wrench set 2 5 PERIODIC MAINTENANCE Remove the valve inspection caps Q 3 The valve clearance specification is different for intake and exhaust valves Valve clearance adjustment must be checked and adjusted 1 at the time of periodic inspection 2 when the valve mechanism is serviced and 3 when the camshaft is re
71. ake a hose securely Brake hose Speedometer cable i Clamp Brake hose Z f Clamp the brake Throttle cables u securely Handlebar switch R After touching the brake hose 7 union to the stopper tighten the union bolt to the specified torque Stopper SERVICING INFORMATION 7 18 CARBURETOR HOSE ROUTING Right Left Right Left Engine side Air cleaner side Carburetor clamp position Air cleaner Carburetor Carburetor air vent hose 1 Carburetor overflow hose 7 19 SERVICING INFORMATION FRAME REAR COVER SET UP Rear fender 7 Rear fender brace SPECIAL TOOLS 09900 00401 L type hexagon wrench set 09900 20101 Vernier calipers 150 mm 09900 20605 Dial calipers 09900 21304 V block set 100 mm 09910 20116 Conrod holder 09913 75510 Bearing installer 09900 00410 Hexagon wrench set 09900 20202 Micrometer 25 50 mm 09900 20606 Dial gauge 1 100 mm 10 mm 09900 22301 09900 22302 Plastigauge 09910 32812 Crankshaft installer 09913 75520 Bearing installer 09900 06107 Snap ring pliers 09900 20203 Micrometer 50 75 mm 09900 20701 Magnetic stand 09900 22401 09900 22403 Small bore gauge SERVICING INFORMATION 7 20 09900 06108 Snap ring pliers 09900 20205 Micrometer 0 25 mm 09900 09004 Impact driver set 09900 2
72. ansmission will not shift back Transmission jumps out of gear Engine idles poorly Engine runs poorly in high speed range Exhaust smoke is dirty or thick Engine lacks power 9 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 w 6 7 8 Broken gearshift shaft return spring Rubbing or stuck gearshift shaft Worn or distorted gearshift fork Worn gear Worn or distorted gearshift fork Weakened gearshift cam stopper spring Worn gearshift pawl Valve clearance out of adjustment Improper valve seating Worn valve guide Worn cam surface Excessive spark plug gap Defective ignition coil Defective pick up coil or ignitor unit Spark plug too cold Incorrect float chamber fuel level Clogged carburetor jet Defective generator Weak valve spring Worn camshaft Insufficient spark plug gap Mistimed valves Ignition not advanced sufficiently due to poorly orking timing advance circuit Defective ignition coll Defective pick up coil or ignitor unit Low float chamber fuel level Clogged air cleaner element 10 Clogged fuel hose resulting in inadequate fuel supply to carburetor amp Excessive amount of engine oil Worn cylinder Worn piston ring Worn valve guide Scored or scuffed cylinder wall Worn valve stem Defective valve stem oil seal Worn oil ring side rail Insufficient valve clearance Weak
73. cables t a ES so NOTE Before lubricating each part clean off any rusty spots and wipe off any grease oil dirt or grime Lubricate exposed parts which are subject to rust with a rust preventative spray especially whenever the motorcycle has been operated under wet or rainy condition 2 3 PERIODIC MAINTENANCE MAINTENANCE AND TUNE UP PROCEDURES This section describes the servicing procedures for each item in the Periodic Maintenance chart EXHAUST PIPE BOLTS AND MUFFLER MOUNTING BOLTS Tighten every 5 000 km 3 000 miles 15 months e Tighten the exhaust pipe bolts D and muffler mounting the specified torque Exhaust pipe 14 1 4 kg m 10 0 Ib ft Muffler mounting bolt 2 29 N m m 2 9 kg m 21 0 Ib ft AIR CLEANER Clean every 3 000 km 2 000 miles If the air cleaner is clogged with dust intake resistance will increase resulting in a decrease in engine output and an increase in fuel consumption Check and clean the air cleaner element in the following manner Remove the front seat See p 5 1 Remove the left frame cover See p 5 1 Remove the air cleaner element T PERIODIC MAINTENANCE 2 4 Carefully use compressed air to clean the air cleaner element CAUTION CAUTION Always apply compressed air to the outside of the air cleaner element If compressed air is applied to the inside dirt will be forced into the pores of the
74. calipers Service Limit Piston ring free end st 7 6 mm 0 30 in 2nd 8 8 mm 0 35 in 09900 20803 Thickness gauge Service Limit Piston ring end gap 1st and 2nd 0 50 mm 0 020 in OVERSIZE RINGS Oversize piston ring The following oversize piston ring is used It bears the fol lowing identification number Piston ring 1st and 2nd 0 5 mm 50 1 0 mm 100 Oversize oil ring The following oversize oil ring is used It bears the follow ing Identification mark Oilring 0 5 mm Painted blue 1 0 mm Painted yellow Oversize side rail Measure the outside diameter to identify the side PIN BORE Measure the piston pin bore inside diameter using the cali per gauge and measure the piston pin outside diameter using the micrometer If either is out of specification or the difference between these two measurements is more than the limits replace both piston and piston pin 09900 20605 Dial calipers 09900 20205 Micrometer 0 25 mm Service Limit Piston pin bore 18 030 mm 0 7098 in Piston pin O D 17 980 mm 0 7079 in De 4 ram ENGINE 3 36 0 5mmO S l OmmO S Oil ring Spacer 3 37 ENGINE CRANKSHAFT AND CONROD 1 Crankshaft RH 2 3 Bearing 2 Crank pin 8 Crankshaft LH CONROD SMALL END 1 0 Measure the conrod small end inside diameter using the dial calipers If the conrod small end inside diameter ex ceeds the servic
75. ct of the rear sprocket mounting drum bearing in the same manner as the wheel bearing Remove the rear sprocket mounting drum bearing as fol lows Remove the dust seal using the special tool co 09913 50121 Oil seal remover A CAUTION The removed dust seal should be replaced with a new one Remove the rear sprocket mounting drum bearing using the special tool 09941 50111 Bearing remover A CAUTION The removed bearing should be replaced with a new one CHASSIS 5 32 Remove the retainer BRAKE DRUM Inspect the brake drum and measure the brake drum 1 0 to determine the extent of wear Replace the brake drum if the measurement exceeds the service limit The value of this limit is indicated inside the brake drum 09900 20101 Vernier calipers Service Limit 130 7 mm 5 15 in TOOL BRAKE SHOES Check the brake shoes and decide whether it should be replaced or not from the thickness of the brake shoe lining Service Limit 1 5 mm 0 06 in A CAUTION Replace the brake shoes as a set otherwise braking performance will be adversely affected REAR SPROCKET DAMPER Inspect the rear sprocket damper for wear and damage Replace the rear sprocket damper if there is anything un usual REAR SPROCKET Inspect the sprocket s teeth for wear If they are worn re place the sprocket and drive chain as a set Normal wear Excessive wear 5 33 CHASSIS REASSEMBLY AND REMOUNTING Reassemb
76. daptor Gr 15 09924 84521 Bearing installer set 09930 34960 Rotor remover Ye EN 09941 34513 Steering outer race installer 09941 50111 Bearing remover NOTE 09941 54911 Bearing outer race remover 09941 74910 Steering bearing installer SERVICING INFORMATION 7 22 09943 74111 Front fork oil level gauge When ordering a special tool please confirm whether it is available or not SERVICING INFORMATION 7 24 CHASSIS ITEM Handlebar clamp bolt Handlebar holder nut Steering stem head bolt Front fork upper clamp bolt Front fork lower clamp bolt Front fork cap bolt Front axle pinch bolt 33 385 Front brake caper mooning w Front brake hose nino j a Swingarm pivot nut 72 Rear axle nut E 03 28 33 23 26 7 25 SERVICING INFORMATION TIGHTENING TORQUE CHART For other bolts and nuts listed previously refer to this chart Bolt Diameter Conventional or 4 marked bolt 7 marked bolt amp mm Conventional bolt 4 marked bolt 7 marked bolt SERVICING INFORMATION 7 26 SERVICE DATA VALVE GUIDE Unit mm in ITEM STANDARD LIMIT N 26 Valve diam 1 0 22 0 9 Valve clearance when cold 0 03 0 08 0 001 0 003 0 08 0 13 0 003 0 005 Valve guide to valve stem p 0 025 0 052 clearance 0 0010 0 0020 0 040 0 067 0 0016 0 0026 Valve stem deflection Valve guide
77. dust Clean CARBURETOR Complaint Symptom and possible causes Starting difficulty 1 Clogged fuel pipe Clean 2 Airleaking from joint between starter body and car Tighten adjust or replace buretor gasket Tighten or replace 3 Airleaking from carburetor joint defective parts Adjust 4 Improperly working starter plunger Idling or low speed Clogged or loose pilot jet Clean or tighten Tighten or trouble Air leaking from carburetor joint replace defective part Clogged pilot outlet port Clean Clean Adjust Clogged bypass port Starter plunger not fully closed Medium or high Clogged main jet Clean Clean speed trouble Clogged needle jet Adjust Clean or Improperly working throttle valve replace Clogged fuel filter Overflow and fuel Worn or damaged needle valve Replace Replace level fluctuations Broken needle valve spring Adjust or replace Clean or Improperly working float replace with needle valve Foreign matter on the needle valve seat Adjust float height Incorrect float chamber fuel level CHASSIS Complaint Symptom and possible causes Steering is heavy Overtightened steering stem nut Adjust Broken bearing race in steering stem Replace Distorted steering stem Replace Low tire pressure Regulate Handlebars 1 Loss of balance between right and left front fork Adjust or replace wobbles legs Repair or replace 2 Distorted front fork Replace 3 Distorted front axle Re
78. e limit replace the conrod 09900 20605 Dial calipers Service Limit 18 040 mm 0 7102 in CONROD DEFLECTION AND CONROD BIG END SIDE CLEARANCE Wear on the big end of the conrod can be estimated by checking the movement of the small end of the rod This method can also check the extent of wear on the parts of the conrod s big end 09900 20701 Magnetic stand 09900 20606 Dial gauge 1 100 mm 09900 21304 V block set 100 mm Service Limit 3 0 mm 0 12 in Push the big end of the conrod to one side and measure the side clearance using a thickness gauge 09900 20803 Thickness gauge Standard 0 10 0 65 mm 0 004 0 026 in Service Limit 1 0 mm 0 04 in If the service limit is exceeded replace crankshaft assembly or bring the deflection and side clearance into specification by replacing the worn parts e g conrod big end bearing and crank pin CRANKSHAFT RUNOUT Support the crankshaft with V blocks as shown Position the dial gauge as shown and rotate the crankshaft slowly to read the runout Correct the runout or replace the crank shaft assembly if the runout is greater than the service lim it rc 09900 20701 Magnetic stand 09900 20606 Dial gauge 1 100 mm 09900 21304 V block set 100 mm Service Limit 0 05 mm 0 002 in REASSEMBLY When rebuilding the crankshaft the width between the webs should be within the standard range Standard width between webs 60 0 0 1 mm 2
79. ead bolt gt Handlebar clamp bolt Handlebar holder nut Front fork upper clamp bolt Front gt fork lower clamp bolt REMOVAL AND DISASSEMBLY Remove the front wheel See p 5 4 Remove the front fork See p 5 15 Disconnect the front brake light switch lead wires Remove the front brake master cylinder Remove the right handlebar balancer Remove the handlebar right switch 2 Disconnect the throttle cables and remove the throttle grip 3 5 23 CHASSIS Remove the left handlebar 2 Remove the handlebar left switch Disconnect the clutch lever position switch coupler Remove the rear view mirror Disconnect the clutch cable Remove the handlebar clamp bolt caps Remove the handlebars by removing the handlebar clamp bolts Remove the headlight Disconnect the headlight coupler Disconnect the lead wire couplers e Remove the headlight housing by removing the mounting nut Remove the steering stem lower cover Remove the front brake hose speedometer cable guide Disconnect the speedometer cable Remove the speedometer Remove the front turn signal light brackets Remove the handlebar holders amp Remove the steering stem head bolt CHASSIS 524 5 25 CHASSIS Remove the steering stem nut using the special tool c 09940 14911 Steering stem nut wrench Draw out the steering stem lower bracket NOTE
80. ear wheel travel 90 2 27 68 Swingarm pivot shaft runout 660 0 3 pn 0 01 TIRE PRESSURE COLD INFLATION NORMAL RIDING TIRE PRESSURE SOLO RIDING DUAL RIDING FRONT 25 FUEL OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump E 03 33 gt or 91 octane or higher rated by the research method Gasoline containing MTBE Methyl Tertiary Butyl Ether less than 1096 ethanol or less than 596 methanol with appropriate cosolvents and corrosion inhibitor is permissible Use only unleaded gasoline of at least 87 pump E 28 octane 757 method or 91 octane or higher rated by the Research Method Gasoline used should be graded 91 octane or The others higher An unleaded gasoline is recommended Fuel tank including reserve 14 L 3 7 3 1 US Imp gal reserve 2 9 L 0 8 0 6 US Imp gal Engine oil type and grade SAE10W 40 APISForSG P 1 300 ml 1 4 1 1 US Imp qt 1 400 ml 1 5 1 2 US Imp qt Overhaul 1 700 ml 1 8 1 5 US Imp qt Engine oil capacity Change Filter change Front fork oil type SUZU 58 08 10 Front fork oil capacity each leg 369 ml 12 5 13 0 US Imp oz Brake fluid type DOT 4 Prepared by SUZUKI MOTOR CORPORATION Motorcycle Service Department June 1998 Part No 99500 32100 01E Printed in Japan 224
81. ec tion on the turn signal light bracket into the hole of steering stem upper bracket Install the handlebar left switch NOTE Insert the projection into the hole of the handlebars Install the handlebar right switch NOTE Apply SUZUKI SUPER GREASE A to the end of the throttle cable AAH 99000 25010 SUZUKI SUPER GREASE Insert the projection into the hole of the handlebars Install the master cylinder See p 5 13 Install the front brake caliper See p 5 10 Install the front fender and front wheel See pp 5 6 and 21 NOTE Hold the front fork legs move them back and forth and make sure that the steering is not loose A CAUTION After performing the adjustment and installing the handlebars rock the front wheel assembly for ward and backward to ensure that there is no play and that the procedure was accomplished correct ly Finally check to make sure that the steering stem moves freely from left to right with its own weight If play or stiffeness is noticeable re adjust the steering stem nut CHASSIS 5 28 5 29 CHASSIS REAR WHEEL AND REAR BRAKE CONSTRUCTION Sco br gt 4 D Spacer 2 Brake panel Brake shoe 67 Spacer 7 Brake camshaft Rear wheel 2 Bearing 32 Damper 27 Drive chain guide 42 Rear sprocket mounting drum 62 Retainer gt 5 Bearing 5 Dust seal Spacer 4
82. ed are all right the turn signal relay may be faulty replace it with a new one NOTE Be sure that the battery is full charged SWITCHES Measure each switch for continuity using a tester switch assemblies with new ones IGNITION SWITCH n o Gr Br LIGHTING SWITCH Except for E 03 24 28 33 DIMMER SWITCH PASSING LIGHT SWITCH Except for E 03 28 33 TURN SIGNAL SWITCH ENGINE STOP SWITCH ELECTRICAL SYSTEM 6 30 If any abnormality is found replace the respective STARTER BUTTON Color ON Y G Position PUSH HORN BUTTON Color Position PUSH lt FRONT BRAKE LIGHT SWITCH Color Position Position OFF ON CLUTCH LEVER Color Position FREE WIRE COLOR Black Orange Br Brown R Red Gr Gray Y Yellow Light blue W White Lg Light green B W Black with White tracer B Y Black with Yellow tracer B R Black with Red tracer O B Orange with Black tracer O BI Orange with Blue tracer O R Orange with Red tracer O W Orange with White tracer O Y Orange with Yellow tracer W B White with Black tracer Y W Yellow with White tracer Y G Yellow with Green tracer 6 31 ELECTRICAL SYSTEM BATTERY Hi Stopper SPECIFICATIONS breather Type designation FTX7L BS lt Capacity 12V 21 6 kC 6Ah 10HR plates Standard electro
83. eeds the limit 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block set 100 mm Service Limit Camshaft runout 0 10 mm 0 004 in CAM CHAIN TENSION ADJUSTER The cam chain tension adjuster is maintained at the proper tension by an automatically adjusted tensioner Insert a flat head screwdriver into the slotted end of the cam chain ten sion adjuster and turn it clockwise to release the tension Remove the screwdriver to make sure that the push rod moves properly If the push rod is stuck or the spring mech anism does not work replace the cam chain tension adjust er assembly with a new one CYLINDER DISTORTION Check the gasket surface of the cylinder for distortion using a straightedge and thickness gauge Take clearance read ings at several places If any reading exceeds the service limit replace the cylinder 09900 20803 Thickness gauge Service Limit 0 05 mm 0 002 in CYLINDER BORE Measure the cylinder bore diameter at six places If any one of the measurements exceed the limit overhaul the cylinder and replace the piston with an oversize piston or 09900 20508 Cylinder gauge set Service Limit 72 085 mm 2 8380 in replace the cylinder PISTON AND PISTON PIN DIAMETER Measure the piston diameter using the micrometer at 15 mm 0 6 in from the skirt end If the piston diameter is less than the service limit replace the piston 09900 20203 Micrometer 50 75 mm
84. er shaft NOTE Apply engine oil to the inside and outside surfaces of the spacer Install the primary driven gear assembly Gand thrust washer onto the countershaft NOTE When engaging the primary drive and driven gears turn the primary driven gear assembly to the counterclockwise Install the clutch sleeve hub and lock washer Install the clutch sleeve hub nut and tighten it to the specified torque using the special tool 09920 53740 Clutch sleeve hub holder v Clutch sleeve hub nut 50 N m 5 0 kg m 36 0 Ib ft Bend the lock washer securely Install the washer seat and spring washer as shown Install the clutch drive plate 2 3 Install the clutch drive plates No 1 and driven plates 6 one by one into the clutch sleeve hub Install the clutch push rod Install the push piece bearing and washer e Install the clutch pressure plate clutch springs and clutch spring mounting bolts Hold the generator rotor using the special tool and tight en the clutch spring mounting bolts to the specified torque in a crisscross pattern 09930 44913 Rotor holder Q Clutch spring mounting bolt 10N m 1 0kg m 7 0 Ib ft NOTE Make sure that the clutch pressure plate is installed cor rectly Loosen the lock nut and turn in the release screw to feel resistance From that position turn out the release screw turn and tighten the lock holding the release screw
85. ershaft 8 Sth drive gear 9 3rd drive gear 10 4th drive gear 11 2nd drive gear REASSEMBLY Assemble the countershaft and driveshaft in the reverse order of disassembly Pay attention to the following points NOTE Before installing the gears apply engine oil to the bearing and inner surface of the each gear CAUTION Never reuse a circlip After a circlip has been removed from a shaft it should be discarded and a new circlip must be installed When installing a new circlip do not expand the end gap larger than required to slip the circlip over the shaft After installing a circlip make sure that it is completely seated in its groove and securely fitted 343 ENGINE When installing a new circlip pay attention to the direc tion of the circlip Fit the circlip to the side where the thrust is as shown in the illustration The rounded side gt Thrust should be against the gear surface Sharp edge Washers and circlips thickness 1 2 mm 0 05 in 1 0 mm 0 04 in 1 0 mm 0 04 in 1 0 mm 0 04 in 2 0 mm 0 08 in 0 5 mm 0 02 in GEARSHIFT FORKS Measure the gearshift fork clearance in the groove of its respective gear using the thickness gauge The clearance for each of the two gearshift forks plays an important role in the smoothness and positiveness of the shifting action Each fork has its prongs fitted into the annular groove provided in its gear During operation there is slidi
86. fe for the rider and passenger SUZUKI MOTOR CORPORATION Motorcycle Service Department COPYRIGHT SUZUKI MOTOR CORPORATION 1998 GROUP INDE GENERAL INFORMATION PERIODIC MAINTENANCE ENGINE FUEL AND LUBRICATION SYSTEM CHASSIS ELECTRICAL SYSTEM SERVICING INFORMATION HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR 1 The text of this manual is divided into sections 2 The section titles are listed in the GROUP INDEX 3 Holding the manual as shown at the right will allow you to find the first page of the section easily 4 The contents are listed on the first page of each sec tion to help you find the item and page you need COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit is its exploded view Work instructions and other service information such as the tightening torque lubricating points and locking agent points are provided Example Front wheel 1 Dust cover i D Bearing P 1 4 Front wheel fo Tt Bearing ET ud 7 Brake disc Speedometer e i V i5 7 gearbox N Spacer 4 Front axle Axle pinch Brake disc bolt ITEM N m kg m 65 23 23 SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing The meaning of each symbol is also included in the table DEFINITION SYMBO L DEF
87. g the special tools as de scribed below 09924 84510 Bearing installer set 09924 84521 Bearing installer set CAUTION First install the left wheel bearing then install the right wheel bearing The sealed cover on the bearings must face to the M outside Left lt c Right side Left 5 lt 5 gt Right side Spacer BRAKE DISC Make sure that the brake disc is clean and free of any grease Apply THREAD LOCK SUPER 1360 to the brake disc bolts and tighten them to the specified torque 4453 99000 32130 THREAD LOCK SUPER 1360 5 Brake disc bolt 23 N m 2 3 kg m 16 5 lb ft CHASSIS 5 6 REMOUNTING Remount the front wheel in the reverse order of removal Pay attention to the following points Apply SUZUKI SUPER GREASE A to the speedometer gearbox 99000 25010 SUZUKI SUPER GREASE A Align the lugs on the speedometer gearbox with the recesses the front wheel Set the speedometer gearbox Dwith cable as shown in the illustration Tighten the front axle to the specified torque V Front axle 65 N m 6 5 kg m 47 0 Ib ft Tighten the axle pinch bolt to the specified torque w Axle pinch bolt 23 N m 2 3 kg m 16 5 Ib ft 5 7 CHASSIS FRONT BRAKE CONSTRUCTION WARNING 7 Reservoir cap Diaphragm LJ 53 Brake piston primary cup 4 4 Brake hose J 5 Brake caliper holder 8 Brake
88. ge 09915 74510 Oil pressure gauge ENGINE ENGINE REMOVAL AND REINSTALLATION ENGINE REMOVAL ENGINE REINSTALLATION ENGINE DISASSEMBLY BALANCER SHAFT AND BALANCER SHAFT DRIVEN GEAR STARTER CLUTCH AND STARTER DRIVEN GEAR BEARING GENERATOR STATOR AND PICK UP COIL 3 1 ENGINE ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE The parts listed below can be removed and reinstalled without removing the engine from the frame Refer to the pages listed in each section for removal and reinstallation instructions ENGINE CENTER Exhaust pipe and muffler Carburetor See page 3 2 and 8 Cam chain tension adjuster 3 9 and 63 Cylinder head cover Camshaft Cylinder head Cylinder PIStOD iiti Starter motor Oil sump filter ENGINE LEFT SIDE See page Gearshift link arm 3 2 Engine sprocket cover 3 3 Engine sprocket 3 3 and 7 Generator cover 3 12 and 57 Generator 3 16 and 52 Starter idle gear 3 16 and 57 Generator stator 3 41 Pick up 3 41 Neutral switch 3 11 and 58 Ms 3 9 and 64 is 3 10 and 62 E 3 10 and 6
89. ied be sure to replace them with new ones Also before installing these new parts be sure to remove any left over material from the mating surfaces Never reuse When installing a new circlip take care not to expand the end larger than required to slip the circlip over the shaft After installing a circlip always ensure that it is completely seated in its groove and securely fitted Use a torque wrench to tighten fasteners to the specified torque Wipe off grease and oil if a thread is smeared with them After reassembling check parts for tightness and proper operation CAUTION To protect the environment do not unlawfully dispose of used motor oil and all other fluids batteries and tires To protect the earth s natural resouces properly dispose of used motorcycles and parts 1 3 GENERAL INFORMATION SUZUKI GZ250X 99 MODEL RIGHT SIDE LEFT SIDE Difference between photographs and the actual motorcycles depends on the markets SERIAL NUMBER LOCATION The frame serial number or V I N Vehicle Identification Number Dis stamped on the right side of the steering head pipe The engine serial number iis located on the left side of the crankcase These numbers are required especially for registering the machine and ordering spare parts FUEL AND OIL RECOMMENDATIONS FUEL Use unleaded gasoline that is graded 91 octane or higher GENERAL INFORMATION 1 4 ENGINE OIL Use only oil
90. ifornia France Sweden Finland E 15 Norway E 16 Denmark E 26 Germany Australia Netherlands Canada California U S A Italy Belgium E 21 Spain E 53 74 0 B JAIN VA N CONTENT S PERIODIC MAINTENANCE 1 2 1 PERIODIC MAINTENANCE CHART eere 2 1 LUBRICATION POINTS eern tentent 2 2 MAINTENANCE AND TUNE UP PROCEDURES 2 3 EXHAUST PIPE BOLTS AND MUFFLER MOUNTING BOLTS 2 3 AIR CLEANER 2 3 VALVE CLEARANCE erento 2 4 SPARK PLUG 2 6 2 7 ENGINE IDLE SPEED enne 2 7 THROTTLE CABLE PLAY tentent 2 7 STARTER PLUNGER CABLE 2 9 2 9 ENGINE OIL AND OIL FILTER eren 2 9 DRIVE CHAIN S obser ona areola Meal ste 2 70 BRAKES VLL en Sih ed ee 2 12 me nn Macc ed eta eee Bare es ent tee details 2 15 STEERING ecciesie ne bmi detenti iot 2 15 ERONT FORK ee ni t A tui bad D LR et 2 16 REAR SUSPENSION eerte ttes 2 16 CHASSIS BOLTS AND NUTS ertet 2 16 COMPRESSION PRESSURE CHECK eene 2 18 OIL PRESSURE CHECK 2 19 2 1 PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The char
91. ilar solvent These fluids have too great a dissolving power for this chain and they can damage the O rings Use only kerosine to clean the drive chain 5 15 mm 0 2 0 6 in PERIODIC MAINTENANCE 2 12 After cleaning and drying the chain oil it with a heavy weight engine oil CAUTION Do not use any oil sold commercially as drive chain oil this type of oil can such oil can damage the 0 rings or seals BRAKES BRAKE Inspect initially at 1 000 km 600 miles 3 months and every 5 000 km 3 000 miles 15 months there after BRAKE HOSE AND BRAKE FLUID Inspect every 5 000 km 3 000 miles 15 months Replace hose every 4 years Replace fluid every 2 years BRAKE FLUID LEVEL Keep the motorcycle upright and place the handlebars straight Check the brake fluid level by observing the lower limit line the front brake fluid reservoir When the brake fluid level is below the lower limit line i replenish with brake fluid that meets the following specifi cation Specification and classification DOT 4 The brake system of this motorcycle is filled with a glycol based brake fluid Do not use or mix different types of fluid such as silicone based and petroleum based fluids Do not use any brake fluid taken from old used or un sealed containers Never re use brake fluid left over from the last servicing or stored for a long period of time Brake fluid if it leaks wi
92. ilter with a compressed air ENGINE 3 48 ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassembly The following steps require special atten tion or precautionary measures should be taken NOTE Apply engine oil to each running and sliding part before reassembling CRANKSHAFT e When installing the crankshaft into the crankcase it is necessary to pull its left end into the left crankcase with the special tools 1921 09910 32812 Crankshaft installer 09910 32840 Attachment 09910 20116 Conrod holder CAUTION Never install the crankshaft into the crankcase by striking it with a plastic hammer Always use the spe cial tool otherwise crankshaft may be misaligned Apply engine oil to the crankshaft bearings nstall the balancer shaft drive NOTE Make sure that the hole in the drive gear is aligned with the pin on the crankshaft BALANCER SHAFT Install the balancer shaft TRANSMISSION Install the countershaft Dand driveshaft assemblies 3 49 ENGINE e Install the washer 2 balancer shaft driven gear washer and shim onto the balancer shaft NOTE Make sure that the key amp is aligned with the keyway Align the punch mark the balancer shaft driven gear with the punch markon the balancer shaft drive gear GEARSHIFT CAM AND GEARSHIFT FORKS Align the pin groove of gearshift cam stopper plate D with the pin Bon the gearshift cam Install
93. in RUN position Listen for a click from the starter relay when the starter button is pushed No click Y Measure the starter relay voltage at the starter relay connectors be tween Y B and BIWO when the starter button is pushed Voltage Y Check the starter relay See pp 6 14 and 15 OK Clicks No voltage No good Check if the starter motor runs when its terminal is connected to the battery terminal Do not use a thin wire because large amount of current flows Run Does not run Faulty starter motor Faulty starter relay Loosen disconnected starter motor lead wire Faulty ignition switch Faulty engine stop switch Faulty clutch lever position switch Faulty neutral switch Faulty side stand relay Faulty starter button Poor contact of connector Open circuit in wire harness Faulty starter relay Poor contact of the starter relay The starter motor runs when the transmission is in neutral but does not run when the transmission is in any position other than neutral with the side stand up Check the side stand switch See pp 6 15 and 16 OK Others No good Faulty side stand switch Open circuit in wire harness Poor contact of connector Faulty starter clutch ELECTRICAL SYSTEM 6 12 STARTER MOTOR REMOVAL AND DISASSEMBLY Disconnect the starter motor lead wire Remove the starter motor Disassemble the starter m
94. ing e Install the bearing 9 Install the starter driven gear Install the generator rotor key onto the crankshaft Install the generator rotor securely Apply a small quantity of THREAD LOCK 1303 to the generator rotor nut 4 12 99000 32030 THREAD LOCK SUPER 1303 Tighten the generator rotor nut to the specified torque using the special tool Gs 09930 44913 Rotor holder 5 Generator rotor nut 160 m m 16 0 kg m 115 5 lb ft DRIVESHAFT RETAINER Install the washer and circlip to the driveshaft CAUTION Use a new circlip PRIMARY DRIVE GEAR Install the cam chain sprocket cam chain sprocket key and primary drive gear key 3 53 ENGINE Install the primary drive gear wave washer and primary drive gear nut NOTE This nut has left hand threads e lignten the primary drive gear nut to the specified torque using the special tool 09930 44913 Rotor holder v Primary drive gear nut 100 N m 10 0 kg m 72 5 Ib ft BALANCER SHAFT BOLT Apply a small quantity of THREAD LOCK 1342 to the balancer shaft bolt lt 2 99000 32050 THREAD LOCK 1342 Tighten the balancer shaft bolt to the specified torque using the special tool 09930 44913 Rotor holder Q Balancer shaft bolt 39 N m 3 9 kg m 28 0 Ib ft GEARSHIFT CAM DRIVEN GEAR Install eac awl into the gearshift cam driven gear Gearsh 2 awl Pin 9 Spring Gearshift cam driven gear NOTE The large sho
95. ing the oil clearance with the camshaft installed in place Measure the clearance using the plasti 09900 22301 Plastigauge 09900 22302 Plastigauge ENGINE 3 32 3 33 ENGINE NOTE Install the cylinder head cover to its original position Tighten the cylinder head cover bolts evenly and diagonally to the specified torque V cylinder head cover bolt 10 m 1 0 kg m 7 0 Ib ft NOTE Do not rotate the camshaft with the plastigauge in place Remove the cylinder head cover and measure the width of the compressed plastigauge using the envelope scale This measurement should be taken at the widest part of the compressed plastigauge Service Limit Camshaft Journal oil clearance 0 150 mm 0 0059 in If the camshaft journal oil clearance exceeds limit measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal Replace the camshaft or the cylinder head depending upon which one exceeds the specification 09900 22403 Small bore gauge Standard Camshaft journal holder I D Right side 25 012 25 025 mm 0 9847 0 9852 in Left side 20 012 20 025 mm 0 7879 0 7884 09900 20205 Micrometer 0 25 mm Standard Camshaft journal O D Right side 24 959 24 980 mm 0 9826 0 9835 in Left side 19 959 19 980 mm 0 7858 0 7866 in CAMSHAFT RUNOUT Measure the runout using a dial gauge Replace the camshaft if the runout exc
96. inspecting the part follow the inspection instruc tions carefully Neglecting proper procedures may cause this part to be damaged ELECTRICAL SYSTEM 6 2 BATTERY 1 The MF battery used in this motorcycle does not require maintenance e g electrolyte level inspection distilled water replenishing During normal charging no hydrogen gas is produced However if the battery is overcharged hydrogen gas may be produced Therefore be sure that there are no fire or spark sources nearby e g short circuit when charging the battery Be sure to recharge the battery in a well ventilated and open area Note that the charging system for the MF battery is dif ferent from that of a conventional battery Do not replace the MF battery with a conventional battery CONNECTING THE BATTERY When disconnecting terminals from the battery for disas sembly or servicing be sure to disconnect the battery lead wire first When connecting the battery lead wires be sure to nect the battery lead wire first f the terminal is corroded remove the battery pour warm water over it and clean it using a wire brush After connecting the battery apply a light coat of grease to the battery terminals Reinstall the cover over the battery terminal WIRING PROCEDURE Properly route the wire harness according to WIRE CABLE AND HOSE ROUTING See pp 7 11 to 18 USING THE MULTI CIRCU
97. is apt to overheat replace with this plug CAUTION Confirm the thread size and reach when replacing the spark plug If the reach is too short carbon will be deposited on the screw portion of the plug hole and engine damage may result CAUTION Before using a spark plug wrench carefully turn the spark plug by finger into the threads of the cylinder head to prevent damage Tighten the spark plug to the specified torque using the special tool 8 spark plug 18 N m 1 8 kg m 13 0 Ib ft 09930 10121 Spark plug socket wrench set FUEL HOSE Inspect every 5 000 km 3 000 miles 15 months Replace every 4 years ENGINE IDLE SPEED Inspect initially at 1 000 km 600 miles 3 months and every 5 000 km 3 000 miles 15 months there after Adjust the throttle cable play See p 2 8 Warm up the engine NOTE Make this adjustment when the engine is hot Connect an electric tachometer to the high tension cord e Start the engine turn the throttle stop screw and set the engine idle speed as follows Engine idle speed 1 300 50 r min For E 03 28 33 1 300 100 r min For the others co 09900 26006 Tachometer THROTTLE CABLE PLAY Inspect initially at 1 000 km 600 miles 3 months and every 5 000 km 3 000 miles 15 months there after Adjust the throttle cable play 6 With the following three steps First step Loosen the lock nut of the throttle returning cable D and
98. le and remount the rear wheel and rear brake in the reverse order of removal and disassembly Pay atten tion to the following points WHEEL BEARING Apply SUZUKI SUPER GREASE A to the bearing be fore installation AH 99000 25010 SUZUKI SUPER GREASE Press fit the bearing to the wheel using the special tools c 09924 84510 Bearing installer set 09924 84521 Bearing installer set A CAUTION First install the right wheel bearing then left wheel bearing The sealed cover on the bearing must face out Left side lt gt Right side Left side lt c Right side Right bearing Left bearing Spacer j Clearance REAR SPROCKET MOUNTING DRUM BEARING Install the rear sprocket mounting drum bearing and dust seal using the special tool 1221 09913 76010 Bearing installer NOTE Apply grease to the bearing and dust seal lip before as sembling the rear sprocket mounting drum 99000 25010 SUZUKI SUPER GREASE CHASSIS 5 34 REAR SPROCKET Tighten the rear sprocket nuts to the specified torque 9 Rear sprocket nut 50 N m 5 0 kg m 36 0 Ib ft NOTE The stamped mark Don the rear sprocket should face to the outside BRAKE CAMSHAFT When installing the brake camshaft apply SUZUKI SU PER GREASE A to the camshaft 99000 25010 SUZUKI SUPER GREASE A BRAKE CAM LEVER Install the new O ring and washer Align the notch on the brake camshaft with the slit in the
99. ll interfere with safe running and immediately discolor painted sur faces Check the brake hose and hose joints for cracks and oil leakage 2 13 PERIODIC MAINTENANCE FRONT BRAKE PADS The extent of brake pad wear can be checked by observing the limit lineCDon the pad When the wear exceeds the limit line replace the pads with new ones See p 5 8 A CAUTION Replace the brake pad as a set otherwise braking performance will be adversely affected AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking per formance of the brake caliper The presence of air is indi cated by sponginess of the brake lever and also by lack of braking force Considering the danger to which such trapped air exposes the machine and rider it is essential that after remounting the brake and restoring the brake system to the normal condition the brake fluid circuit be purged of air in the following manner Fill the master cylinder reservoir to top of the inspection window Replace the reservoir cap to prevent dirt from entering Attach hose to the air bleeder valve and insert the free end of the hose into a receptacle Bleed air from the brake system Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without re leasing it Loo
100. lve 2 4 to 6 e Contact area too low and too narrow on face of valve VALVE SPRINGS Check the valve springs for proper strength by measuring their free length and also the force required to compress them If the spring length is less than the service limit or if the force required to compress the spring does not fall with in the specified range replace the spring 09900 20201 Vernier calipers Service Limit Valve spring free length IN amp EX 40 1 mm 1 58 in Standard Valve spring tension IN amp EX 18 4 21 6 kg 35 0 mm 40 56 47 62 1bs 1 38 in REASSEMBLY Reassemble the cylinder head in the reverse order of dis assembly Pay attention to the following points Install each valve spring seat Apply molybdenum oil solution to the valve stem seal and press fit the seal into position by hand A CAUTION Do not reuse the valve stem seals ENGINE 3 30 35 0 mm 1 38 in 184 21 6 kg X 40 56 47 62 Ibs i b lt 331 ENGINE Apply molybdenum oil solution to the valve stems CAUTION When inserting each valve take care not to dam age the lip of the stem seal e Install the valve springs with the smaller pitch facing the cylinder head Nc Towards Hed Install the valve spring retainer press down the spring using the valve lifter and then install the cotter halves onto the valve stem end Then release the va
101. lve lifter to allow the cotter 2to wedge between the retainer and the valve stem Be sure that the rounded lip S of the cotter fits snugly into the groove 4 the stem end I 09916 14510 Valve lifter 09916 14910 Valve lifter attachment 09916 84511 Tweezers CAUTION Be sure to install all of the parts in their original positions INTAKE PIPE When installing the intake pipe apply grease to the CD ring 99000 25010 SUZUKI SUPER GREASE A CAUTION Use the new O ring to prevent sucking air from the joint NOTE Make sure that the UP mark comes upward CAM CHAIN GUIDE AND CAM CHAIN TENSIONER Check the cam chain guide and cam chain tensioner for wear and damage If it is found to be damaged replace it with a new one CAMSHAFT CAMSHAFT INSPECTION If the engine produces abnormal noises vibration or lacks power a camshaft may be distorted or worn to the service limit The camshaft runout should be checked Also check the cams and journals for wear or damage CAM WEAR Worn down cams are often the cause of mistimed valve operation resulting in reduced power output Measure the cam height using the micrometer Replace a camshaft if the cams are worn to the service limit 09900 20202 Micrometer 25 50 mm Service Limit height IN 34 690 mm 1 3657 in EX 34 730 mm 1 3673 in CAMSHAFT JOURNAL WEAR Determine whether or not each journal is worn down to the limit by measur
102. lyte 1 320 at 20 C 68 F Separator 5 6 fiberglass plate Anode plates 225 Terminal Safety valve INITIAL CHARGING FILLING ELECTROLYTE Remove the aluminum tape which seals the battery filler 5 2 Remove the caps from the electrolyte container NOTE Do not remove or pierce the sealed of the elec trolyte container After completely filling the battery with electrolyte use the caps from the electrolyte container to seal the battery filler holes Insert the nozzles of the electrolyte container into the battery s electrolyte filler holes Hold the electrolyte con tainer firmly so that it does not fall Do not allow any of the electrolyte to spill Make sure that the air bubbles rise to the top of each electrolyte container and leave the electrolyte container in this position for more than 20 minutes ELECTRICAL SYSTEM 6 32 NOTE If air bubbles do not rise from any one of the filler ports tap the bottom of the electrolyte container two or three times Never remove the electrolyte container from the battery while there is still electrolyte in the container After the electrolyte container is completely empty re move it from the battery and wait about 20 minutes Insert the caps firmly into the filler holes so that the top of the caps do not protrude above the upper surface of the battery s top cover A CAUTION The charging system for a MF bat
103. n Slow cranking starter motor Adjust Mistimed valves Adjust Valve clearance out of adjustment Replace park plug not sparking Replace Damaged spark plug Clean or replace Damaged spark plug cap Clean and dry or replace Fouled spark plug Replace Wet spark plug Replace Defective ignition coil Replace Open or short in high tension cord Clean or replace Replace Defective pick up coil or ignitor unit with carburetor needle Valve No fuel reaching the carburetor seat Clean or replace Clogged or defective fuel valve Clean or replace Defective carburetor needle valve Clogged fuel hose Clogged fuel filter 1 2 3 4 5 7 8 5 1 2 3 4 5 7 Engine stalls easily Fouled spark plug Clean or replace Defective pick up coil or ignitor unit Replace Clogged fuel hose Clogged carburetor jet Valve clearance out of adjustment Clean Clean Adjust SERVICING INFORMATION 7 2 Complaint Symptom and possible causes Engine is noisy Excessive valve chatter Noisy engine 1 Excessive valve clearance Adjust 2 Weak or broken valve spring Replace 3 Worn cam surface Replace 4 Worn or burnt camshaft journal Noise Replace enaame ta cama fram tha nicten 1 Worn piston Replace 2 Worn cylinder Rebore or replace 3 Carbon build up in combustion chamber Clean 4 Worn piston pin or piston pin bore Replace Replace 5 Worn piston ring or ring groove
104. n the range amp embossed on the brake panel If the index mark goes beyond the range the brake shoe assembly should be replaced with a new set of shoes BRAKE LIGHT SWITCH Adjust the rear brake light switch so that the brake light will come on just before pressure is felt when the brake pedal is depressed PERIODIC MAINTENANCE 2 14 The extension line of the index mark is within the range The extension line of the index mark is out of the ranae 2 15 PERIODIC MAINTENANCE TIRE Inspect every 5 000 km 3 000 miles 15 months TIRE TREAD CONDITION Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a danger ous situation It is highly recommended to replace a tire when the remaining depth of tire tread reaches the follow ing specification Tire tread depth limit front 1 6 mm 0 06 in rear 2 0 mm 0 08 in 09900 20805 Tire depth gauge _ TIRE PRESSURE If the tire pressure is too high or too low steering will be adversely affected and tire wear increased Therefore maintain the correct tire pressure for good roadability and a longer tire life Cold inflation tire pressure is as follows COLD INFLATION TIRE PRESSURE kPa Kolm psi kPa psi FRONT firs 175 25 178 175 249 29 25 228 33 CAUTION The standard tire fitted on this motorcycle is a 110 90 16 59P for the front and a 130 90 15M C 66P fo
105. nce will be adversely affected Install the new brake pads and brake pad mounting bolt Tighten the brake caliper mounting bolts and brake pad mounting bolt Dto the specified torque Brake caliper mounting bolt 39 N m 3 9 kg m 28 0 Ib ft Brake pad mounting bolt 18 N m 1 8 kg m 13 0 Ib ft NOTE After replacing the brake pads pump with the brake lever a few times to operate the brake correctly and then check the brake fluid level PRARE FLUID REPLACEMENT Place the motorcycle on a level surface and keep the handlebars straight Remove the master cylinder reservoir cap Qand dia Suck up the old brake fluid as much as possible Fill the reservoir with new brake fluid Specification and Classification DOT 4 Connect a cleaner hose to the air bleeder valve and insert the free end of hose into a receptacle Loosen the air bleeder valve and pump the brake lever until the old brake fluid is completely out of the brake system Close the air bleeder valve and disconnect the clear hose Fill the reservoir with new brake fluid to the upper end of the inspection window A CAUTION Bleed air from the brake system See p 2 13 CHASSIS 5 8 5 9 CHASSIS BRAKE CALIPER REMOVAL AND DISASSEMBLY Disconnect the brake hose from the brake caliper by re moving the brake hose union bolt and allow the brake fluid to drain into a suitable receptacle Loosen the brake pad mounting bolt
106. nd relay side stand switch neutral switch starter button engine stop switch ignition switch and battery Pressing the starter button on the right handlebar switch energizes the starter relay causing the contact points to close thus completing the circuit from the starter motor to the battery The starter motor draws about 80 amperes to start the engine Engine stop Ignition switch switch Clutch lever position switch Fuse 20A R o Starter YB motor Y Neutral switch z OY E Starter Starter relay Side stand G BN button relay Side stand 7 f switch SIDE STAND IGNITION INTERLOCK SYSTEM DESCRIPTION This side stand ignition interlock system prevents the motorcycle from being started with the side stand down The system is operated by an electric circuit provided between the battery and ignition coil Engine stop switch 9 as OAW To ignitor and ignition Side stand relay Fuse Ignition switch Neutral indicator light gt Battery Neutral Side stand switch switch WIRE COLOR Green 0 B Orange with Black tracer R Red O W Orange with White tracer 7 Y Blue O Y Orange with Yellow tracer O Orange BI B Blue with Black tracer 6 11 ELECTRICAL SYSTEM TROUBLESHOOTING Starter motor will not run The transmission is in neutral Grasp the clutch lever Turn on the ignition switch with the engine stop switch
107. nents should re main in the left crankcase half When separating the crankcase tap the end of the coun tershaft with a plastic mallet Remove the O ring D Remove the shim 2 washer and balancer shaft driv en gear Remove the washer ENGINE 3 18 e Remove the gearshift cam stopper spring Remove the gearshift fork shafts and gearshift forks Remove the gearshift cam Remove the transmission Remove the balancer shaft V Remove the balancer shaft drive gear gt eS gt _ Remove the crankshaft using the special tool 09920 13120 Crankcase separator 3 19 ENGINE ENGINE COMPONENTS INSPECTION AND SERVICE CRANKCASE BEARINGS BEARING INSPECTION While the bearing is in the crankcase rotate its inner race and check to see that it turns smoothly If it does not turn quietly and smoothly or if there are signs of any abnormali ties the bearing is defective and must be replaced as fol lows BEARING REMOVAL e Remove the bearing retainers D NOTE Remove the driveshaft bearing retainer along with the driveshaft bearing Remove the oil seals using the special tool 09913 50121 Oil seal remover TOOL CAUTION The removed oil seals should be replaced with new ones Remove the bearings CAUTION The removed bearings should be replaced with new ones ENGINE 3 20 e Remove the oil seal using the special tool 09913 7
108. nerator rotor with the mark the generator cover while keeping the cam chain tight CAUTION If the crankshaft is turned without drawing the cam chain upward the cam chain will catch be tween crankcase and cam chain drive sprocket NOTE Just before installing the camshaft into the cylinder head apply molybdenum oil solution to the camshaft journals and cam faces Also apply engine oil to the camshaft journal holders Install the C ring Minto the ring groove of the cylinder head Install the cam chain Install the camshaft and camshaft sprocket 3 Face the notch Qon the camshaft towards the intake side Align the engraved line on the camshaft so it is parallel with mating surface of the cylinder head and oyl inder head cover Engage the cam chain on the camshaft sprocket with the locating pin hole Gat one o clock position NOTE Do not rotate the crankshaft while installing the camshaft or cam chain Install the lock washer so that it is covering the locating pin NOTE Apply a small quantity of THREAD LOCK SUPER 1303 to the threads of the camshaft sprocket bolts 99000 32030 THREAD LOCK SUPER 1303 Tighten the camshaft sprocket bolts to the specified torque 9 Camshaft sprocket bolt 15 N m 1 5 kg m 11 0 Ib ft ENGINE 3 62 3 63 ENGINE Bend the lock we D r securely Camshaft Pin Bolt Lock washer 5 Camshaft sprocket Install the cam
109. ng contact between the fork and gear and when a shifting action is initiated the fork pushes the gear axially If the clearance is too great the meshed gears may slip apart If the clearance exceeds the specification replace the fork its respective gear or both 09900 20803 Thickness gauge Service Limit Gearshift fork to groove clearance 0 60 mm 0 024 in Standard Gearshift fork groove width No 1 No 2 amp No 3 4 25 4 35 mm 0 167 0 171 in Standard Shift fork thickness No 1 No 2 amp No 3 3 95 4 05 mm 0 156 0 159 in PRIMARY DRIVEN GEAR Remove the stopper ring Remove the oil pump drive gear If the internal damper wears play is generated between gear and housing causing abnormal noise If the play is extreme replace the primary driven gear assembly with a new one amp Primary driven gear Damper Clutch housing ENGINE 3 44 3 45 ENGINE CLUTCH CLUTCH DRIVE PLATES Measure the thickness and claw width of the clutch drive plates using vernier calipers If a clutch drive plate is not within the service limit replace the clutch plates as a set 09900 20101 Vernier calipers Service Limit Thickness No 1 2 62 mm 0 103 in No 2 3 15 mm 0 124 in Claw width 15 0 mm 0 590 in CLUTCH DRIVEN PLATES Measure each clutch driven plates for distortion using the thickness gauge If a clutch driven plate is not within the service limit replace the clutch plates as a
110. nstruction manual Shift the transmission into neutral turn the ignition Switch to the ON position and grasp the clutch lever Press the starter button and allow the engine to crank for a few seconds and then measure the Ignition coll prima ry peak voltage Repeat the above procedure a few times and measure the highest ignition coil primary peak voltage Tester knob indication Voltage Ignition coil primary peak voltage More than 200 V AWARNING While testing do not touch the tester probes and spark plug to prevent receiving an electric shock If the voltage is lower than the standard value inspect the ignition coil and the pick up coil See pp 6 21 to 23 6 21 ELECTRICAL SYSTEM IGNITION COIL RESISTANCE Measure the ignition coil resistance in both the primary and 11 7 secondary windings If the windings in sound condition id their resistance should be close to the specified values Ignition coil resistance E Primary 3 50 terminal terminal Secondary 17 28 kQ terminal Spark plug cap IGNITOR Remove the front seat See p 5 1 Remove the luggage box Remove the ignitor Measure the voltage between the terminals in the following table e 09900 25008 Multi circuit tester set Tester knob indication Diode test 4 Probe of tester to e Jo S e po BE 218 1245 1218 1215 0508 218 035
111. nt to 1 exceed any time After recharging wait at least 30 minutes and then mea Battery M i sure the battery voltage using a tester oo f the battery voltage is less than 12 5 recharge the battery again the battery voltage is still less than 12 5V after recharg ing replace the battery with a new one When a battery is left unused for a long time its voltage needs to be regularly measured When the motorcycle is not used for more than one month especially during the winter season measure the battery voltage at least once a month SERVICING INFORMATION CONTENTS TROUBLESHOOTING iaoi inate id toi euo up ee deus lege 7 1 WIRING DIAGRAM iic etie E sabe en beoe eo ee Sateen 7 8 WIRE CABLE AND HOSE 7 11 FRAME REAR COVER SET UP eter toten 7 19 SPECIAL addat 7 20 TIGHTENING TORQUE tto e ton eens sede enemies 7 23 SERVICE DATA ettet mh nce Dese ep eade 7 26 7 1 SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Engine will not start or Compression too low Rebore or replace is hard to start Worn cylinder Replace 5 Worn piston ring Repair or replace Worn valve guide or improper valve seating Tighten Loose spark plug Replace Broken cracked or damaged piston See electrical sectio
112. o longer of any use BOLT LENGTH o rmen Tighten the swingarm pivot nut to the specified torque swingarm pivot nut 72 N m 7 2 kg m 52 0 Ib ft Tighten the frame down tube mounting bolts and nuts to the specified torque v Frame down tube mounting bolt nut 23 N m 2 3 kg m 16 5 Ib ft NOTE Apply a small quantity of THREAD LOCK 1303 to the threads of bolts 3 99000 32030 THREAD LOCK SUPER 1303 3 7 ENGINE Tighten the engine ground wire and the clamp by crank case bolt as shown Clamp the neutral switch lead wire side stand switch lead wire Position the carburetor clamps as shown in the illustra tion Install the clutch release arm as shown In the illustration NOTE Align the release arm slit surface amp with the notch mark on the release camshaft Loosen the rear axle nut and drive chain adjuster nuts Install the engine sprocket as shown Install the drive chain Tighten the engine sprocket nut to the specified torque v Engine sprocket nut 90 N m 9 0 kg m 65 0 Ib ft NOTE When tightening the engine sprocket nut depress the rear brake pedal Bend the lock washer securely Tighten the exhaust pipe bolts and muffler mounting bolt to the specified torque Exhaust pipe bolt 14 1 4 kg m 10 0 Ib ft Muffler mounting bolt 29 N m 2 9 kg m 21 0 lb ft CAUTION Check the wire cable and hose routing
113. olvent To avoid getting burned do not touch the engine engine oil and exhaust system until they have cooled After servicing fuel oil exhaust or brake systems check all of the lines and fittings related to the system for leaks GENERAL INFORMATION 1 2 CAUTION If parts replacement is necessary replace the parts with Suzuki Genuine Parts or their equivalent When removing parts that are to be reused keep them arranged in an orderly manner so that they may be reinstalled in the proper order Be sure to use special tools when instructed Make sure that all parts used in reassembly are clean Lubricate them when specified Use the specified lubricant bond or sealant When removing the battery disconnect the negative cable first and then the positive cable When reconnecting the battery connect the positive cable first and then the negative cable and cover the positive terminal with the terminal cover When performing service to electrical parts disconnect the battery negative cable unless the service procedure requires the battery power When tightening cylinder head and crankcase bolts and nuts tighten the larger sizes first Always tighten the bolts and nuts from the inside working out in a crisscross pattern and to the specified tightening torque Whenever you remove oil seals gaskets packing O rings self locking nuts locking washers cotter pins circlips and certain other parts as specif
114. ont fork cap bolt to the inner tube A CAUTION Use a new O ring to prevent oil leakage Install the front fork to the motorcycle Align the upper surface of the inner tube with the up per surface of the steering stem upper bracket B 5 21 CHASSIS e Tighten the front fork lower clamp bolts and front fork cap bolts to the specified torque Tighten the front fork upper clamp bolts the speci fied torque v Front fork upper clamp bolt 23 N m 2 3 kg m 16 5 Ib ft Front fork lower clamp bolt 33 m 3 3 kg m 24 0 Ib ft Front fork cap bolt 23 N m 2 3 kg m 16 5 Ib ft Install the front fender and tighten the mounting bolts temporarily Install the front brake caliper See p 5 10 Install the front wheel See p 5 8 Move the front fork up and down several times Tighten the front fender mounting bolts securely STEERING CONSTRUCTION S y 2 2 2 z e 3 f QN 2 FN E p A Lu 2 4 c 6 d S3 E 7 KE by See 2 E 5 S 55 o s 5 3 3 4 perc p n m 65 5 3 33 CHASSIS 5 22 t Steering stem upper bracket 2 Handlebar clamp 33 Handlebar holder Steering stem nut Dust seal Bearing upper Bearing lower gt Steering stem Steering stem lower cover 2 Handlebars Handlebar balancer gt Steering stem h
115. or rectifier Clean repair or replace Unstable charging Lead wire insulation frayed due to vibration Repair or replace resulting in intermittent shorting Replace Replace Internally shorted generator Defective regulator rectifier Starter button does Run down battery Recharge or replace not work Defective switch contact Replace Brushes do not seat properly on the commutator in Repair or replace the starter motor Replace 4 Defective starter relay BATTERY Complaint Symptom and possible causes Sulfation or spots on 1 Cracked battery case Replace battery surfaces of cell 2 Battery has been left In a run down condition for a Replace plates long time Battery runs down 1 Incorrect charging method Check generator or regu quickly 2 Battery cell plates have lost much of their active ma lator rectifier circuit con terial as a result of overcharging nections and make nec 3 Internally shorted battery essary adjustment to obtain 4 Excessively low battery voltage specified charging 5 Battery is too old operation Replace battery and correct charging system Replace Recharge Replace Battery sulfation 1 Incorrect charging rate Replace battery When not in use the battery should be checked at least Replace battery if badly once a month and properly charged if necessary to avoid sulfated sulfation 2 battery was left unused in a cold climate for too long SERVICING
116. ose pliers Remove the piston pin using the special tool 09910 34510 Piston pin puller Remove the piston Remove the starter motor 3 e Flatten the lock portion of the oil seal retainer e Remove the oil seal retainer Remove the spacer e Remove the neutral switch amp Remove the neutral switch contact 2 spring amp and O ring Remove the generator cover e Remove the gasket Dand dowel pins Remove the clutch cover Remove the gasket and dowel pins While holding the generator rotor using the special tool remove the clutch spring mounting bolts in a crisscross pattern and remove the clutch springs and clutch pres sure plate 09930 44913 Rotor holder ENGINE 3 12 3 13 ENGINE e Remove the washer 1 bearing clutch push piece and clutch push rod b Remove the clutch drive and driven plates e Remove the spring and washer seat Flatten the lock washer of the clutch sleeve hub nut Remove the clutch sleeve hub nut using the special tool 09920 53740 Clutch sleeve hub holder Remove the clutch sleeve hub Remove the thrust primary driven gear assembly Remove the spacer and thrust washer Remove the circlip and oil pump driven Remove the washer Remove the oil pump 9 A CAUTION Do not attempt to disassemble the oil pump as sembly Remove the gear
117. otor as shown in the illustration 1 Can fxd Oy SY f IV lt gt ut X f A yd 4 M gt y 6 ay f n Y Housing end Outside d A 2 O ring f 2 3 3 Brush spring tf Why t Brush holder j 5 Starter motor case Armature a 2 7 O ring AGH Housing end Inside a lt lt 9 O ring 3 12 O ring 2 pcs 5 Oil seal STARTER MOTOR INSPECTION CARBON BRUSH Inspect the brushes for abnormal wear crack or smooth ness in the brush holder If either carbon brush is defective replace the brush as sembly 6 13 ELECTRICAL SYSTEM COMMUTATOR Inspect the commutator for discoloration abnormal wear or undercut If the commutator is abnormally worn replace the arma ture If the commutator surface is discolored polish it with 400 sandpaper and wipe it using a clean dry cloth If there is no undercut scrape out the insulator with a saw blade ARMATURE COIL INSPECTION Measure for continuity between each segment Measure for continuity between each segment and the armature shaft If there is no continuity between the segments or there is continuity between the segments and shaft replace the ar mature with a new one OIL SEAL INSPECTION Check the seal lip for damage or leakage If any damage is found replace the housing end inside STARTE
118. ox wrench and check that the clearance is within specification SPARK PLUG Inspect every 5 000 km 3 000 miles 15 months Replace every 10 000 km 6 000 miles 30 months Neglecting the spark plug eventually leads to difficult start ing and poor engine performance If the spark plug is used for a long period the electrode gradually bums away and carbon builds up along the inside part of the spark plug In accordance with the Periodic Maintenance chart the spark plug should be inspected cleaned and regapped at the rec ommended intervals Remove the cylinder head cover left cap Disconnect the spark plug cap and remove the spark plug 09930 10121 Spark plug socket wrench set Carbon deposits on the spark plug will prevent good sparking and may cause the engine to misfire Be sure to clean the carbon deposits off periodically If the center electrode is fairly worn down the spark plug should be replaced and the spark plug gap set to the speci fication using a thickness gauge TOOL 09900 20803 Thickness gauge Spark plug gap 0 6 0 7 mm 0 024 0 028 in PERIODIC MAINTENANCE 2 6 Gap 0 6 0 7 mm 0 024 0 028 in 2 7 PERIODIC MAINTENANCE Check the spark plug for burns If any abnormalities are found replace the spark plug as indicated below DR7EA X22ESR U the standard spark plug is apt to get wet replace with this plug EN X27ESR U the standard spark plug
119. place 4 Twisted tire 7 5 SERVICING INFORMATION Complaint Symptom and possible causes Distorted wheel rim Worn front wheel bearing Front wheel 1 wobbles 2 3 Defective or incorrect tire 4 Loose front axle 5 Incorrect front fork oil level 6 Loose wheel spoke Front suspension Weak spring Replace too soft Insufficient fork oil Check level and add Front suspension Excessively viscous fork oil Replace too stiff Excessive fork oil Check level and drain Front suspension Insufficient fork oil Check level and add too noisy Loose front suspension fastener Tighten Rear wheel wobbles Distorted wheel rim Replace Worn rear wheel bearing Replace Defective or incorrect tire Replace Worn swingarm bearing Replace Loose rear axle nut or swingarm pivot nut Tighten Loosen wheel spokes Tighten Loosen rear suspension fastener Tighten Rear suspension Weak rear shock absorber spring Replace too soft Rear shock absorber leaks oil Replace Improper suspension setting Adjust Rear suspension Improperly adjusted rear suspension too stiff Bent swingarm Worn swingarm and rear suspension related bearings Rear suspension too Loose rear suspension fastener Tighten noisy Worn swingarm bearing Replace BRAKES Complaint Symptom and possible causes Brake power 1 Leakage of brake fluid Repair or replace insufficient 2 Worn brake pad Replace 3 Oil in brake pad s
120. r clutch for wear or damage If any wear or damage is found replace the defective part s STARTER DRIVEN GEAR BEARING Install the starter driven gear bearing and gear onto the crankshaft and turn the starter driven gear by hand Inspect the starter driven gear bearing for smooth rotation and any abnormal noise If the bearing does not turn smoothly or there is any abnormal noise replace it DISASSEMBLY Remove the starter driven gear Remove the roller spring and push piece 4 3 41 ENGINE Hold the generator rotor with the rotor holder and re move the starter clutch bolts 52 09930 44913 Rotor holder REASSEMBLY Locate the shim Dto the proper position Apply a small quantity of THREAD LOCK SUPER 1303 to the starter clutch bolts and tighten them to the specified torque while holding the rotor holder ez 99000 32030 THREAD LOCK SUPER 1303 e 09930 44913 Rotor holder v Starter clutch bolt 18 N m 1 8 kg m 13 0 Ib ft GENERATOR STATOR AND PICK UP COIL When replacing the generator stator or pick up coil apply THREAD LOCK 1342 to the generator stator set bolts and pick up coil set bolts and tighten them 99000 32050 THREAD LOCK 1342 ENGINE 3 42 TRANSMISSION DISASSEMBLY Disassemble the transmission gears as shown in the illustration 1 1st driven gear 2 5th driven gear 3 3rd driven gear 4 4th driven gear 5 2nd driven gear 6 Driveshaft 7 Count
121. r the rear The use of tires other than those speci fied may cause instability It is highly recommended to use the specified tires STEERING Inspect initially at 1 000 km 600 miles 3 months and every 10 000 km 6 000 miles 30 months thereafter The steering should be adjusted properly for smooth turning of handlebars and safe operation Overtight steering prevents smooth turning of the handlebars and too loose steering will cause poor stability Check that there is no play in the front fork Support the motorcycle so that the front wheel is off the ground With the wheel facing straight ahead grasp the lower fork tubes near the axle and pull forward If play is found read just the steering See p 5 27 PERIODIC MAINTENANCE 2 16 FRONT FORK Inspect every 10 000 km 6 000 miles 30 months Inspect the front forks for oil leakage scoring or scratches on the outer surface of the inner tubes Replace any defec tive parts if necessary REAR SUSPENSION Inspect every 10 000 km 6 000 miles 30 months Inspect the rear shock absorber for oil leakage and damage Replace any defective parts if necessary CHASSIS BOLTS AND NUTS Tighten initially at 1 000 km 600 miles 3 months and every 5 000 km 3 000 miles 15 months there after Check that all chassis bolts and nuts are tightened to their specified torque Refer to page 2 17 for the locations of the following nuts and bolts on the motorcycle
122. re the starter relay resistance between the terminals Starter relay resistance 3 60 SIDE STAND IGNITION INTERLOCK SYSTEM PART INSPECTION If the interlock system does not operate properly check each component If any abnormality is found replace the component with a new one NEUTRAL SWITCH The neutral switch coupler is located under the fuel tank Remove the front seat See p 5 1 Remove the fuel tank See p 4 1 Disconnect the neutral switch coupler and measure the continuity between Blue and Ground with the transmis sion in neutral Blue Ground ON neutra SIDE STAND SWITCH The side stand switch coupler is located under the fuel tank Remove the front seat See p 5 1 Remove the fuel tank See p 4 1 Disconnect the side stand switch lead wire coupler and measure the voltage between Green and Black White lead wires 09900 25008 Multi circuit tester set Tester knob indication Diode test Green Black White Probe Probe ON UP 0 4 0 6 V right position OFF 1 4 1 5 V DOWN position NOTE If the tester read under 1 4V replace the battery of multi circuit tester when do not connecting the tester probes ELECTRICAL SYSTEM 6 16 TURN SIGNAL SIDE STAND RELAY The turn signal relay is corporated with the side stand relay and diode to form the one component part which is called the turn signal side stand relay It is located under the luggage box
123. rged Remove the related parts and test the compression pres sure in the following manner Install the compression gauge and adaptor in the spark plug hole Make sure that the connection is tight Keep the throttle grip in the fully opened position Press the starter button and crank the engine for a few seconds Record the maximum gauge reading as the cylinder compression 09915 64510 Compression gauge 09918 03810 Adaptor 2 19 PERIODIC MAINTENANCE OIL PRESSURE CHECK Check the oil pressure periodically This will give a good indication of the condition of the moving parts OIL PRESSURE SPECIFICATION Above 30 kPa 0 3 kg cm 4 3 psi Below 70 kPa 0 7 kglcm 10 0 psi at 3 000 r min Oil temp at 60 C 140 F If the oil pressure is lower or higher than the specification the following causes may be considered LOW OIL PRESSURE Clogged oil filter Oil leakage from the oil passage Damaged O ring Defective oil pump Combination of the above items HIGH OIL PRESSURE Engine oil viscosity is too high Clogged oil passage Combination of the above items OIL PRESSURE TEST PROCEDURE Check the oil pressure in the following manner o Install the oil pressure gauge in the position shown Connect an electric tachometer Warm up the engine as follows Summer 10 min at 2 000 r min Winter 20 min at 2 000 r min After warm up increase the engine speed to 3 000 r min and read the oil pressure gau
124. s 4 5 mm 0 18 in Measure the runout using the dial gauge Replace the brake disc if the runout exceeds the service limit TOOL 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand Service Limit Brake disc runout 0 30 mm 0 012 in If either measurement exceeds the service limit replace the brake disc See pp 5 3 and 5 Install the front wheel See p 5 6 MASTER CYLINDER REMOVAL AND DISASSEMBLY Disconnect the front brake light switch lead wiresCD e Remove the brake lever CHASSIS 5 12 Place a rag underneath the brake hose union bolt on the master cylinder to catch any spilt brake fluid Remove the brake hose union bolt SN A CAUTION Immediately wipe off any brake fluid contacting any part of the motorcycle The brake fluid reacts chemically with paint plastics and rubber materi als etc and will damage them severely Remove the master cylinder assembly FC Remove the front brake light switch T Remove the reservoir diaphragm Drain the brake fluid Remove the dust boot Remove the circlip using the special tool Foo 09900 06108 Snap ring pliers 5 13 CHASSIS e Remove the piston secondary cup and return spring MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other damage Inspect the piston surface for any scratches or other dam age Inspect the primary c
125. s which are rated SF or SG under the API clas sification The recommended viscosity is SAE 10W 40 If SAE 10W 40 engine oil is not available select an alterna tive according to the chart 30 20 10 0 10 20 30 40 F 22 4 14 32 50 68 86 104 BRAKE FLUID Specification and classification DOT 4 This motorcycle uses a glycol based brake fluid Do not use or mix different types of brake fluid such as silicone based and petroleum based fluids for refilling the system otherwise serious damage will result to the brake system Never use any brake fluid taken from old used or unsealed containers Never re use brake fluid left over from a last servicing or which has been stored for a long period of time FRONT FORK OIL Use SUZUKI fork oil SS 08 10 BREAK IN PROCEDURES During manufacturing only the best possible materials are used and all machined parts are finished to a very high standard It is still necessary to allow the moving parts to BREAK IN before subjecting the engine to maximum stresses The future performance and reliability of the engine depends on the care and restraint exercised during its early life The general rules are as follows Keep to this break in throttle position Initial 800 km 500 miles Less than 1 2 throttle Up to 1 600 km 1 000 miles Less than 3 4 throttle Upon reaching an odometer reading of 1 600 km you can subject the motorcycle to full throttle operation for short periods of
126. screw head with pliers to remove the plug Carefully clean any metal shavings from the area Slowly turn the pilot screw clockwise and count the num ber of turns until the screw is lightly seated Make a note of how many turns were made so the screw can be reset correctly after cleaning Remove the pilot screw along with the spring washer and O ring After cleaning reinstall the pilot screw to the original set ting by turning the screw in until it lightly seats and then backing it out the same number of turns counted during disassembly Install a new plug by tapping it into place with a punch D Drill stop 2 lug Pilot screw 4 Carburetor body CLEANING LAWARNING Some carburetor cleaning chemicals especially dip type soaking solutions are very corrosive and must be handled carefully Always follow the chemical manufacturer s instructions on proper use handling and storage Clean all jets with a spray type carburetor cleaner and dry them using compressed air Clean all circuits of the carburetor thoroughly not just the perceived problem area Clean the circuits in the carburetor body with a spray type cleaner and allow each circuit to soak if necessary to loosen dirt and varnish Blow the body dry using compressed air A CAUTION Do not use a wire to clean the jets or passage ways A wire can damage the jets and passage ways If the components cannot be cleaned with a spray cleaner it
127. sen the bleeder valve by turning it a quar ter of a turn so that the brake fluid runs into the recep tacle this will remove the tension of the brake lever causing it to touch the handlebar grip Then close the air bleeder valve pump and squeeze the brake lever and open the valve Repeat this process until the fluid flowing into the receptacle no longer contains air bubbles NOTE While bleeding the brake system replenish the brake fluid in the reservoir as necessary Make sure that there is al ways some fluid visible in the reservoir Close the air bleeder valve and disconnect the hose Fill the reservoir with brake fluid to the top of the inspection window V Air bleeder valve 7 5 0 75 kg m 5 5 Ib ft A CAUTION Handle brake fluid with care the fluid reacts chemically with paint plastics rubber materials etc Limit lino 2 REAR BRAKE PEDAL HEIGHT Loosen the lock Adjust the brake pedal height by turning the adjuster to locate the pedal 50 mm 2 0 in above the top face of the footrest REAR BRAKE ADJUSTING Adjust the free travel Bto 20 30 mm 0 8 1 2 in by turning the adjusting nut REAR BRAKE SHOE WEAR This motorcycle is equipped with brake lining wear limit indicator on the rear brake To check brake lining wear perform the following steps Make sure that the rear brake is properly adjusted Depress the rear brake pedal Make sure that the index mark is withi
128. shaft end cap CAM CHAIN TENSION ADJUSTER NOTE Before installing the cam chain tension adjuster lock the tension spring with a flat head screwdriver 9 A Before installing the cam chain tension adjuster turn the v crankshaft counterclockwise to remove any cam chain x slack between the cam chain drive sprocket cam shaft sprocket Install a new gasket and the cam chain tension adjuster onto the cylinder with the two bolts and tighten them to the specified torque Q Cam chain tension adjuster bolt 7 N m 0 7 kg m 5 0 Ib ft After installing the cam chain tension adjuster turn the screwdriver counterclockwise As the slot in the cam chain tension adjuster turns the tension rod advances under the spring force and pushes the cam chain tension adjuster against the cam chain A CAUTION After installing the cam chain tension adjuster check the cam chain slack to make sure that the cam chain tension adjuster is working properly Fit the rubber cap CYLINDER HEAD COVER Pour motor oil in the oil pocket in the cylinder head NOTE Turn the crankshaft and check that all the moving parts e g cam follower camshaft work properly Clean the mating surfaces of the cylinder head and head cover Install the dowel pins Apply SUZUKI BOND 0 1215 uniformly to the mating surface of the cylinder head cover and install it within a few minutes 1 99000 31110 SUZUKI BOND
129. shift shaft e Remove the pawl cam guidedby removing the screws Remove the gearshift cam driven NOTE When removing the cam driven gear do not lose the pawls amp springs Remove the gearshift shaft stopper ENGINE 3 14 3 15 ENGINE While holding the generator rotor using the special tool remove the balancer shaft bolt D 09930 44913 Rotor holder Remove the cam chain Remove the primary drive gear nut using the special tool 09930 44913 Rotor holder A CAUTION The primary drive gear nut has left hand threads Remove the spring washer Remove the primary drive gear Remove the keys Remove the cam chain sprocket 7 Remove the circlip and washer ENGINE 3 16 Remove the shaft and starter idle gear e Remove the generator rotor nut using the special tool 09930 44913 Rotor holder Remove the generator rotor using the special tool 09930 34960 Rotor remover Remove the generator rotor key Remove the starter driven gear amp Remove the washer amp 3 17 ENGINE Remove the gearshift cam stopper Remove the crankcase bolts Separate the left and right crankcases using the special tool 09920 13120 Crankcase separator NOTE Fit the crankcase separator so that the tool arms are in parallel with the side of crankcase The crankshaft and transmission compo
130. stator core is insulated If the resistance is incorrect replace the stator coil with a new one Stator coil resistance 0 1 1 5O GENERATOR NO LOAD PERFORMANCE INSPECTION Remove the front seat See p 5 1 Remove the fuel tank See p 4 1 Disconnect the stator coil coupler Start the engine and keep it running at 5 000 r min Measure the voltage between the three lead wires using a tester If the tester reads under the specified value replace the stator coil and pick up coil or the generator rotor with a new one Generator no load performance More than 60V AC at 5 000 r min When engine is cold 69 ELECTRICAL SYSTEM REGULATOR RECTIFIER Remove the front seat See p 5 1 Remove the fuel tank See p 4 1 Disconnect the regulator rectifier couplers Measure the voltage between the lead wires in the follow ing table 09900 25008 Multi circuit tester set Tester knob indication Diode test Unit V Probe of tester to Y 1245 4245 1244 If the tester lead under 1 4V replace the battery of multi circuit tester when do not connecting the tester probes WIRE COLOR R Red Y Yellow B W Black with White tracer ELECTRICAL SYSTEM 6 10 STARTER SYSTEM AND SIDE STAND IGNITION INTERLOCK SYSTEM STARTER SYSTEM DESCRIPTION The starter system consists of the following components the starter motor starter relay clutch lever position switch side sta
131. t 5 27 CHASSIS Turn the steering stem lower bracket about five or six times to the left and right Loosen the steering stem nut 4 of a tun NOTE This adjustment will vary from motorcycle to motorcycle Make sure that the steering turns smoothly and easily in both directions Install the steering stem upper bracket Install the right and left front forks Tighten the front fork lower clamp bolts Tighten the steering stem head bolt to the specified torque U steering stem head bolt 65 N m 6 5 kg m 47 0 Ib ft Align the upper surface of the front fork inner tube with the upper surface of the steering stem upper bracket Tighten the upper and lower front fork clamp bolts to the specified torque Front fork clamp bolt upper 23 N m 2 3 kg m 16 5 Ib ft lower 33 N m 3 3 kg m 24 0 Ib ft Install the handlebar holders 2 and tighten their nuts temporarily Install the handlebars with the punch mark aligned with the handlebar shown e Tighten the handlebar clamp bolts the specified torque V Handlebar clamp bolt 16 N m 1 6 kg m 11 5 Ib ft NOTE The gap between the handlebar clamp and holder should be even Tighten the handlebar holder nuts tothe specified torque Handlebar holder nut 45 N m 4 5 kg m 32 5 Ib ft Install the handlebar clamp bolt caps NOTE When installing the front turn signal lights insert the proj
132. t below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy Maintenance intervals are ex pressed in terms of kilometers and months and are dependant on whichever comes first NOTE More frequent servicing may be performed on motorcycles that are used under severe conditions PERIODIC MAINTENANCE CHART me Exhaust pipe bolts and muffler mounting bots T T Spakpug 2 11 18 1 4 Twotecslepay 1 4 Cue d LLL Engineoil R R R _Engine oil fitter R R Drive chain Ev qood drm 1 E lb E rena Tires eS Steering 1 Front fork s Rear suspension doo 1 7 Chassis bolts and nuts NOTE I Inspection and adjust clean lubricate or replace as necessary C Clean R Replace Tighten PERIODIC MAINTENANCE 2 2 LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motor cycle Major lubrication points are indicated below Side stand pivot chain and spring hook AH Brake pedal pivot AGH AGH Brake lever holder Throitle
133. t the spark plug cap ENGINE 3 4 Remove the starter plunger Loosen the carburetor clamp screws Remove the carburetor WARNING Gasoline is very explosive Extreme care must be taken Disconnect the engine ground wire Disconnect the crankcase breather hose Disconnect the starter motor lead wire Disconnect the side stand switch coupler e Disconnect the generator couplers Disconnect the neutral switch coupler amp 3 5 ENGINE Support the motorcycle with a jack or wooden block Remove the engine mounting bolts and nuts D Remove the frame down tube mounting bolts and nuts G Remove the lower engine mounting bolt and nut Remove the upper engine mounting bolt and nut 7 NOTE When removing the upper mounting bolt support the en gine with a jack Remove the left and right swingarm pivot end caps Remove the swingarm pivot washer Partially remove the swingarm pivot shaft so that the engine can be removed NOTE Be careful not to draw out the pivot shaft Gradually lower the engine ENGINE 36 ENGINE REINSTALLATION Reinstall the engine in the reverse order of engine removal Install the engine mounting bolts and nuts as shown the following illustration Tighten the engine mounting nuts to the specified torque NOTE The engine mounting nuts are self locking Once the nuts have been removed they are n
134. tery is differ ent from that of a conventional battery Only use the specified MF battery Do not remove the caps once they are installed in the battery CORRECT Measure the battery voltage using a tester The tester should indicate more than 12 5 12 6V DC as shown If the battery voltage is lower than specification charge the battery with a battery charger NOTE Initial charging for a new battery is recommended if two years have elapsed since the date of manufacture Minutes SERVICING Visually inspect the surface of the battery container If any signs of cracking or electrolyte leakage from the sides of the battery have occurred replace the battery with a new one If the battery terminals are found to be coated with rust or an acidic white powdery substance clean the bat tery terminals with sandpaper 6 33 ELECTRICAL SYSTEM RECHARGING OPERATION a Measure the battery voltage using a tester If the voltage LI reading is less than 12 0V DC recharge the battery _ Stop charging with a battery charger A CAUTION When recharging the battery remove the battery from the motorcycle 0 10 20 30 40 50 60 NOTE i Minutes While recharging do not remove the caps on the top of the aaa at 0 40 battery at O Recharging time 0 7A for 5 to 10 hours or for 1 hour 13 I A CAUTION Be careful not to permit the charging curre
135. the inner tube protect their seal lips to prevent seal lip damage Before installing the oil seal apply SUZUKI SU PER GREASE A to its seal lip lightly 99000 25010 SUZUKI SUPER GREASE CHASSIS 5 18 5 19 CHASSIS Tighten the damper rod bolt to the specified torque 09900 00410 Hexagon wrench set V Front fork damper rod bolt 20 N m 2 0 kg m 14 5 Ib ft CAUTION Use a new damper rod gasket to prevent oil leakage Install the oil seal stopper ring dust seal A CAUTION Make sure that the oil seal stopper ring is fitted securely NOTE Before installing the dust seal apply a small quantity of SUZUKI SUPER GREASE A to the lip of dust seal AIAH 99000 25010 SUZUKI SUPER GREASE CHASSIS 5 20 Pour the specified fork oil into the inner tube Fork oil type SUZUKI FORK OIL 55 08 10 99000 99001 SS8 SUZUKI FORK OIL SS 08 Specification Front fork oil capacity each leg 369 ml 12 5 13 0 US Imp oz Hold the front fork leg in a vertical position and adjust the fork oil level using the special tool 09943 74111 Fork oil level gauge Specification Front fork oil level 105 mm 4 1 in NOTE When adjusting the oil level remove the fork spring and compress the inner tube fully Install the fork spring as shown NOTE The end of the fork spring with the smaller pitch should be at the bottom of the front fork Install the fr
136. turn in the adjuster fully into the threads Second step Loosen the lock nut of the throttle pulling cable Turn the adjuster amp in or out until the throttle cable play should be 2 0 4 0 mm 0 08 0 16 in at the throttle grip Tighten the lock nut while holding the adjuster Third step While holding the throttle grip at the fully closed position slowly turn out the adjuster of the throttle returning cable Dto feel resistance Tighten the lock nut while holding the adjuster Throttle cable play 2 0 4 0 mm 0 08 0 16 in After the adjustment is completed check that handlebar movement does not raise the engine idle speed and that the throttle grip returns smoothly and automatically NOTE Major adjustment can be made by the carburetor side ad juster PERIODIC MAINTENANCE 29 PERIODIC MAINTENANCE STARTER PLUNGER CABLE PLAY Starter plunger cable play should be 0 5 1 0 mm 0 02 0 04 in as shown If the play is incorrect adjust it as follows Loosen the lock nut and turn the adjuster 2 in or out until the specified play is obtained e Tighten the lock nut while holding the adjuster Starter plunger cable play 0 5 1 0 mm 0 02 0 04 in CLUTCH Inspect every 5 000 km 3 000 miles 15 months Loosen the lock nut and turn the adjuster fully in Loosen the lock nut and turn the adjuster until the clutch lever play is within specification Clutch lever
137. ulder must face to the outside Apply a small quantity of THREAD LOCK 1303 to the gearshift shaft stopper 99000 32030 THREAD LOCK SUPER 1303 Tighten the gearshift shaft stopper to the specified torque Q Gearshift cam stopper 19 N m 1 9 kg m 13 5 Ib ft ENGINE 3 54 Install the gearshift cam driven gear assembly Install the pawl lifter and cam guide NOTE Apply a small quantity of THREAD LOCK 1342 to the threads of the screws 17 99000 32050 THREAD LOCK 1342 Install the return spring 8 to the gearshift shaft as shown Install the gearshift shaft NOTE Align the center teeth on the gearshift shaft with the center teeth on the gearshift cam driven gear OIL PUMP Apply engine oil to the sliding surfaces of the oil pump case outer rotor inner rotor and shaft before mounting the oil pump Apply a small quantity of THREAD LOCK 1342 to the oil pump mounting screws and tighten them 442 99000 32050 THREAD LOCK 1342 Install the washer and Install the oil pump driven circlip 3 55 ENGINE CLUTCH 217 Clutch pressure plate 2 Push piece Clutch drive plate No 1 T 3 00 4 Clutch driven plate Clutch drive plate No 2 T 3 50 5 Clutch push rod 7 Concaved washer 8 Washer seat Clutch sleeve hub 52 Clutch housing t Oil pump drive gear a e Install the washer and spacer onto the count
138. up secondary cup and dust seal for wear or damage MASTER CYLINDER REASSEMBLY AND REMOUNTING Reassemble and remount the master cylinder in the re verse order of removal and disassembly Pay attention to the following points A CAUTION Wash the master cylinder components with new brake fluid before reassembly Do not wipe the brake fluid off after washing the components When washing the components use the speci fied brake fluid Never use different types of fluid or cleaning solvents such as gasoline ker osine etc Apply brake fluid to the master cylinder bore and all of the master cylinder components be fore reassembly Specification and Classification DOT 4 NOTE When installing the circlip make sure that the sharp edge of the circlip faces outside When reinstalling the brake light switch align the projec tion on the switch with the hole in the master cylinder Or cs Oey aJ Be i i t When remounting the master cylinder onto the handle bars align the master cylinder holder s mating surface amp with punch the handlebars and tighten the upper clamp bolt first V master cylinder bolt 10 N m 1 0 kg m 7 0 Ib ft Install the brake hose union as shown and tighten the union bolt to the specified torque 9 Brake hose union bolt 23 N m 2 3 kg m 16 5 lb ft A CAUTION Bleed air from the
139. urface Clean brake disc and brake pads 4 Worn brake disc Replace 5 Air in hydraulic system Bleed 6 Worn brake shoe Replace 7 Oil in brake shoe surfaces Clean 8 Excessively worn brake drum Replace 9 Excessive brake pedal play Adjust SERVICING INFORMATION 7 6 Complaint Symptom and possible causes Brake squeaks Brake lever or pedal stroke excessive Brake fluid leaks ELECTRICAL No sparking or poor sparking Spark plug is wet or quickly becomes fouled with carbon Spark plug quickly becomes fouled with oil or carbon Spark plug electrodes overheat or burn Carbon adhesion on brake pad surface Tilted brake pad Damaged wheel bearing Worn brake pad Foreign material in brake fluid Clogged return port of master cylinder Brake shoe surface glazed Worn brake shoe Loose front axle or rear axle nut Air in hydraulic system Insufficient brake fluid Incorrect brake fluid Worn brake camshaft Excessively worn brake shoes and or brake drum Loose connection joint Cracked brake hose Worn piston seal Defective ignition coil Defective spark plug Defective pick up coil Defective ignitor unit Excessively rich air fuel mixture Excessively high idling speed Incorrect gasoline Clogged air cleaner element Incorrect spark plug cold type Worn piston ring Worn piston Worn cylinder Excessive valve stem to valve guide clearance Worn valve stem oil
140. valve spring Mistimed valves Worn cylinder Worn piston ring Improper valve seating Fouled spark plug Incorrect spark plug Clogged carburetor jet Incorrect float chamber fuel level Clogged air cleaner element Worn camshaft Air leaked from intake pipe Excessive amount of engine oil Replace Repair or replace Replace Replace Replace Replace Replace Adjust Repair or replace Replace Replace Adjust or replace Replace Replace Replace by hot type plug Adjust float height Clean Replace Replace Replace Regap or replace Adjust Replace ignitor unit Replace Replace Adjust float height Clean or replace Clean and prime Check level and drain Rebore or replace Replace Replace Rebore or replace Replace valve Replace Replace oil ring Adjust Replace Adjust Rebore or replace Replace Repair or replace Clean or replace Replace Clean Adjust float height Clean or replace Replace Tighten or replace Check level and drain SERVICING INFORMATION 7 4 Complaint Symptom and possible causes Engine overheats 1 Heavy carbon deposit on piston crown Clean 2 Not enough oil in the engine Add oil 3 Defective oil pump or clogged oil circuit Replace or clean 4 Too low in float chambers fuel level Adjust 5 Sucking air from intake pipe Retighten or replace 6 Use incorrect engine oil Change 7 Clogged air Intake with
141. y Do not wipe the brake fluid off after washing the components When washing the components use the speci fied brake fluid Never use different types of fluid or cleaning solvents such as gasoline ker osine etc Replace the piston seal and dust seal with new ones Apply brake fluid to all of the seals brake caliper bore and piston before reassembly Install the piston seal as shown in the illustration Apply grease to the brake caliper holder 99000 25100 SUZUKI SILICONE GREASE CHASSIS 5 10 Dust seal 5 11 CHASSIS e Tighten the brake caliper mounting bolts Dand brake pad mounting bolt ito the specified torque Tighten the brake hose union bolt to the specified torque V Brake caliper mounting bolt 39 N m 3 9 kg m 28 0 Ib ft Brake pad mounting bolt 18 N m 1 8 kg m 13 0 Ib ft Brake hose union bolt 3 23 N m 2 3 kg m 16 5 Ib ft NOTE Before remounting the brake caliper push the brake caliper piston all the way into the caliper A CAUTION Bleed air from the system after reassembling the brake caliper See p 2 13 BRAKE DISC INSPECTION qw 134 7 34 Remove the front wheel See p 5 3 Check the brake disc for damage or cracks Measure the thickness using the micrometer Replace the brake disc if the thickness is less than the service limit or if damage is found 2 09900 20205 Micrometer 0 25 mm Service Limit Brake disc thicknes

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