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Manuals and User Guides for Suzuki RM-Z450. We have 3 Suzuki RM-Z450 manuals available for free PDF download: Owner’s Service Manual, Manual

Suzuki RM-Z450 Owner's Service Manual

Suzuki RM-Z450 Owner’s Service Manual (373 pages)

Brand: Suzuki
|
Category: Motorcycle
|
Size: 36.23 MB

Table of Contents
  • Group Index

    9

    • Serial Number Location

      4

    • Replacement Parts

      6

    • Abbreviations Used in this Manual

      8

    • Table of Contents

      9

    • Location of Parts

      11

    • Accessory

      12

      • Side Stand

        12

    • Fuel and Oil Recommendation

      12

    • Operating Instructions

      13

      • Starting the Engine

        13

      • Stopping the Engine

        14

      • Transmission

        14

    • Break-In (Running-In)

      15

      • When the Motorcycle Is New

        15

      • When Engine Parts Are Replaced

        15

    • Exterior Parts

      16

  • Periodic Maintenance

    17

    • Periodic Maintenance

      19

      • Inspection before Practice

        19

      • Inspection before Race

        20

      • (All Items of Inspection before Practice on Previous

        20

      • Periodic Maintenance Chart

        21

    • Spark Plug

      23

    • Air Cleaner

      24

      • Air Cleaner Element Removal

        24

      • Washing

        24

      • Installation

        24

    • Engine Oil and Oil Filter

      25

      • Inspection before Engine Oil Level Check

        26

      • Engine Oil Level Inspection

        26

      • Engine Oil Change

        27

      • Engine Oil Filter Change

        28

    • Oil Strainers

      29

      • OIL STRAINER (No.1) REMOVAL

        29

      • OIL STRAINER (No.2) REMOVAL

        29

      • Inspection

        29

      • OIL STRAINER (No.2) INSTALLATION

        29

      • OIL STRAINER (No.1) INSTALLATION

        29

    • Engine Coolant

      30

      • Engine Coolant Level Check

        30

      • Engine Coolant Replenishment

        31

      • Cooling System Inspection

        31

    • Clutch Cable

      32

      • Major Adjustment

        32

      • Minor Adjustment

        32

    • Throttle Cable

      33

      • Throttle Cable Adjustment

        33

      • Throttle Cable Oil Supply

        33

    • Hot Starter

      34

    • Crankcase Breather Hose

      35

    • Engine Idle Speed

      35

    • Fuel Hose

      35

    • Valve Clearance

      36

      • Valve Clearance Adjustment

        37

    • Cylinder Head, Cylinder and Piston

      40

      • Cylinder Head Inspection

        40

      • Cylinder Inspection

        40

      • Piston Inspection

        40

    • Muffler Silencer

      41

      • Silencer Inspection and Replacement

        41

    • Drive Chain and Sprockets

      42

      • Drive Chain Slack

        42

      • Crankcase Driveshaft Oil Seal

        42

      • Drive Chain Adjustment

        43

      • Drive Chain Plate Wear

        43

      • Drive Chain Lubrication

        44

      • Sprocket Inspection

        44

    • Drive Chain Guide, Buffer and Tensioner Roller

      45

      • Drive Chain Guide Inspection

        45

      • Drive Chain Buffer and Roller Inspection

        45

    • Brakes

      46

      • Brake Fluid Level

        46

      • Brake Pad

        47

      • Front Brake Lever Adjustment

        47

      • Brake Pedal Height Adjustment

        47

    • Front Fork

      48

    • Rear Suspension

      48

    • Wheels and Tires

      48

      • Wheel Rim and Tires Inspection

        48

      • Spoke Nipple and Rim Lock Inspection

        49

      • Tire Pressure

        49

    • Steering

      49

    • Lubrication

      50

    • Compression Pressure Check

      51

      • Compression Test Procedure

        51

    • Oil Pressure Check

      52

      • Oil Pressure Test Procedure

        52

  • Troubleshooting

    53

    • Engine

      54

    • Radiator (Cooling System)

      60

    • Chassis

      61

    • Brakes

      62

    • Electrical

      63

  • Machine Tuning

    64

    • Front Fork Tuning

      65

      • Compression Damping Force Adjustment

        65

      • Rebound Damping Force Adjustment

        65

      • Oil Quantity Minor Adjustment

        66

      • OIL CHANGE (Only for Outer Tube Oil Chamber)

        67

      • Spring Change

        69

      • Front Fork Tuning Procedure

        71

    • Rear Suspension Tuning

      72

      • Compression Damping Force Adjustment

        72

      • Rebound Damping Force Adjustment

        73

      • Spring Pre-Load Adjustment

        73

      • Rear Suspension Tuning Procedure

        74

    • Suspension Balance

      76

      • Balance Test

        76

      • Balancing Tips

        76

      • Engine Removal and Installation

        77

    • Engine Removal and Installation

      78

  • Cylinder Head, Cylinder and Piston

    86

    • Construction

      87

      • Cylinder Head, Cylinder and Piston

        87

    • Engine Top Side Disassembly

      88

      • Cylinder Head Cover Removal

        88

      • Camshafts (Automatic Decomp.) and Cam Chain Tension Adjuster Removal

        88

      • Cylinder Head Removal

        89

      • Cylinder Removal

        91

      • Piston and Piston Ring Removal

        91

    • Engine Top Components Inspection and Service

      92

      • Automatic Decomp. Inspection

        92

      • Camshaft Inspection

        92

      • Cam Chain Tension Adjuster Inspection

        94

      • CAM CHAIN No.2 GUIDE INSPECTION

        94

      • Cylinder Head and Valve Inspection

        95

      • Intake Pipe Removal

        103

      • Intake Pipe Installation

        103

      • Ect Sensor Removal

        103

      • Ect Sensor Inspection

        103

      • Ect Sensor Installation

        103

      • Cylinder Inspection

        104

      • Piston and Piston Ring Inspection

        105

        • Piston Diameter

          105

        • Piston Ring Groove Width

          106

        • Piston Ring Thickness

          106

        • Piston Ring End Gap

          106

      • Crankshaft and Conrod Inspection

        107

    • Engine Top Side Assembly

      108

      • Piston and Piston Ring Installation

        108

      • Cylinder and Cylinder Head Installation

        110

      • Camshaft (Automatic Decomp.) and Cam Chain Tension Adjuster Installation

        112

      • Cylinder Head Cover Installation

        116

    • Cam Chain, Cam Chain Tensioner and Cam Chain

      117

    • No.1 GUIDE

      117

      • Removal

        117

      • Inspection

        117

      • Installation

        118

  • Clutch

    119

    • Construction

      120

      • Clutch

        120

    • Clutch Plate

      121

      • Removal

        121

      • Inspection

        123

      • Installation

        124

    • Primary Driven Gear and Clutch Sleeve Hub

      126

      • Removal

        126

      • Inspection

        127

      • Installation

        127

    • Clutch Release Camshaft

      129

      • Removal

        129

      • Inspection

        129

      • Installation

        130

  • Kick Starter

    131

    • Construction

      132

      • Kick Starter

        132

      • Removal

        133

    • Kick Starter

      133

      • Inspection

        134

        • Installation

          135

  • Gearshifting

    138

    • Construction

      139

      • Gearshift Linkage

        140

      • Removal

        140

      • Inspection

        142

      • Installation

        142

    • Gear Position (Gp) Switch

      145

      • Removal

        145

      • Inspection

        145

      • Installation

        145

  • Transmission and Crankshaft

    146

    • Construction

      147

      • Transmission and Crankshaft

        147

    • Engine Bottom Side

      148

      • Primary Drive Gear Removal

        148

      • Crankcase Separation

        149

      • Transmission Removal

        149

      • Crankshaft Removal

        150

      • Transmission Inspection

        151

      • Conrod Inspection

        152

      • Crankshaft Inspcection

        152

      • Oil Reed Valve Inspection

        152

      • Crankshaft Runout

        152

      • Oil Seal Inspection

        153

      • Oil Seal Removal and Installation

        153

      • Bearing Inspection

        154

      • Bearing Removal and Installation

        154

      • Crankshaft Installation

        157

      • Transmission Installation

        158

      • Crankcase Installation

        160

      • Primary Drive Gear Installation

        161

  • Lubrication System

    162

    • Engine Lubrication System

      163

    • Engine Lubrication System Chart

      163

    • Engine Oil Change

      164

    • Engine Oil Filter Change

      164

    • Engine Oil Level Inspection

      164

    • Oil Pressure Check

      164

    • Oil Reed Valve Inspection

      164

    • Oil Reed Valve Installation

      164

    • Oil Reed Valve Removal

      164

    • Oil Strainer Installation

      164

    • Oil Strainer Removal

      164

    • Oil Strainers Inspection

      164

    • Oil Relief Valve Inspection

      165

    • Oil Relief Valve Installation

      165

    • Oil Seal Inspection

      165

    • Oil Seal Removal

      165

    • OIL PUMP No.1 and No.2 REMOVAL

      166

    • Oil Seal Installation

      166

    • OIL PUMP No.1 and No.2 INSPECTION

      167

    • OIL PUMP No.1 and No.2 INSTALLATION

      168

  • Fi System Diagnosis

    170

    • Precautions in Servicing

      172

      • Electrical Parts

        172

      • Ecm/Various Sensors

        173

      • Electrical Circuit Inspection Procedure

        175

      • Using the Multi-Circuit Tester

        178

    • Fi System Technical Features

      179

      • Injection Time (Injection Volume)

        179

      • Compensation of Injection Time (Volume)

        180

      • Injection Stop Control

        180

      • Fi System Parts Location

        181

      • Fi System Wiring Diagram

        183

    • Ecm Terminal

      184

    • Self-Diagnosis Function

      185

      • Dealer Mode

        185

      • Diagnostic Trouble Code Table

        186

      • Tp Sensor Adjustment

        187

    • Fail-Safe Function

      188

    • Fi System Troubleshooting

      189

      • Customer Complaint Analysis

        189

      • Visual Inspection

        190

      • Self-Diagnostic Procedures

        191

      • Self-Diagnosis Reset Procedure

        191

      • Dtc and Defective Condition

        192

      • 12″ Ckp Sensor Circuit Malfunction

        194

      • 14″ Tp Sensor Circuit Malfunction

        196

      • 15″ Ect Sensor Circuit Malfunction

        198

      • 17″ Iap Sensor Circuit Malfunction

        200

      • 21″ Iat Sensor Circuit Malfunction

        203

      • 23″ to Sensor Circuit Malfunction

        205

      • 24″ Ignition System Malfunction

        206

      • 31″ Gp Switch Circuit Malfunction

        207

      • 32″ Fuel Injector Circuit Malfunction

        209

      • 41″ Fp Relay Circuit Malfunction

        211

      • 63″ Crankshaft Rotation Signal Circuit Malfunction

        213

        • Iap Sensor Inspection

          215

        • Iap Sensor Removal and Installation

          215

        • Tp Sensor Inspection

          215

        • Tp Sensor Removal and Installation

          215

        • Ect Sensor Removal and Installation

          216

        • Iat Sensor Inspection

          217

        • Iat Sensor Removal and Installation

          217

        • To Sensor Inspection

          217

        • To Sensor Removal and Installation

          217

  • Fuel System and Throttle Body

    218

    • Fuel System

      219

      • Construction

        219

      • Fuel Tank and Fuel Pump Removal

        219

      • Fuel Tank and Fuel Pump Installation

        220

      • Fuel Pressure Inspection

        221

      • Fuel Pump Inspection

        222

      • Fuel Discharge Amount Inspection

        223

    • Throttle Body

      224

      • Construction

        224

      • Removal

        225

      • Disassembly

        226

      • Cleaning

        229

      • Inspection

        229

      • Reassembly

        229

      • Installation

        232

      • Fuel Injector Removal

        233

      • Fuel Injector Inspection

        233

      • Fuel Injector Installation

        233

  • Cooling System

    234

    • Construction

      235

    • Engine Coolant

      236

      • Replacement

        236

    • Cooling Circuit

      237

      • Inspection

        237

    • Radiator

      238

      • Inspection

        238

      • Removal

        239

      • Installation

        239

    • Water Pump

      240

      • Removal

        240

      • Inspection

        241

      • Installation

        242

  • Electrical System

    244

    • Cautions in Servicing

      245

      • Connector

        245

      • Coupler

        245

      • Clamp

        245

      • Switch

        245

      • Semi-Conductor Equipped Part

        246

      • Connecting the Battery

        246

      • Wiring Procedure

        246

      • Using the Multi-Circuit Tester

        247

    • Location of Electrical Components

      248

    • Construction

      250

    • Generating System

      251

      • Inspection

        251

    • Ignition System

      254

      • Troubleshooting

        254

      • Inspection

        256

    • Magneto Rotor

      260

      • Removal

        260

      • Installation

        261

    • Stator

      262

      • Removal

        262

      • Installation

        262

  • Front and Rear Wheels

    263

    • Construction

      264

    • Front Wheel

      265

      • Removal

        265

      • Inspection

        265

      • Dust Seal and Bearing Replacement

        266

      • Disc Plate Replacement

        267

      • Installation

        268

    • Rear Wheel

      269

      • Removal

        269

      • Inspection

        270

      • Dust Seal and Bearing Replacement

        270

      • Disc Plate Replacement

        272

      • Rear Sprocket Replacement

        272

      • Installation

        273

      • Rear Wheel Spokes Replacement

        273

  • Front and Rear Brakes

    274

    • Construction

      275

    • Brake Fluid Air Bleeding

      276

    • Brake Fluid Replacement

      277

    • Brake Pads Replacement

      278

      • Front Brake Pads

        278

      • Rear Brake Pads

        278

    • Brake Disc Inspection

      279

    • Caliper

      279

      • Front Caliper Removal and Disassembly

        280

      • Caliper Inspection

        281

      • Caliper Cleaning

        281

      • Front Caliper Reassembly and Installation

        281

      • Rear Caliper Removal and Disassembly

        282

      • Rear Caliper Reassembly and Installation

        283

    • Master Cylinder

      285

      • Front Master Cylinder Removal and Disassembly

        285

      • Master Cylinder Inspection

        286

      • Master Cylinder Cleaning

        286

      • Front Master Cylinder Reassembly and Installation

        287

      • Rear Master Cylinder Removal and Disassembly

        288

      • Master Cylinder Inspection

        289

      • Rear Master Cylinder Reassembly and Installation

        289

    • Brake Lever

      290

      • Removal

        290

      • Installation

        290

    • Brake Pedal

      291

      • Removal

        291

      • Installation

        291

  • Front Fork and Steering

    292

    • Construction

      293

      • Front Fork, Steering

        293

      • Handlebar Controls

        294

      • Removal

        295

      • Disassembly

        296

      • Inspection

        300

      • Reassembly

        302

      • Installation

        308

    • Steering

      309

      • Removal

        309

      • Inspection

        311

      • Bearing Replacement

        312

      • Installation

        313

  • Rear Suspension

    318

    • Construction

      319

      • Rear Suspension

        319

    • Rear Shock Absorber

      320

      • Removal

        320

      • Spring Replacement

        321

      • Inspection

        322

      • Bearing Replacement

        323

      • Oil Replacement

        324

      • Disassembly and Inspection

        327

      • Reassembly

        328

      • Installation

        329

      • Disposal

        329

    • Swingarm

      330

      • Removal

        330

      • Inspection

        332

      • Bearing Replacement

        333

      • Installation

        334

    • Rear Suspension Linkage

      335

      • Removal

        335

      • Inspection

        336

      • Bearing Replacement

        337

      • Installation

        338

  • Servicing Information

    341

    • Service Data

      342

      • Oil Pump

        344

    • Tightening Torque

      351

      • Fi System and Intake Air System

        352

      • Cooling System

        352

    • Special Tools

      355

    • Wiring Diagram

      358

    • Wiring Harness Routing

      359

    • Cable Routing

      361

    • Fuel Hose Routing

      362

    • Radiator Hose Routing

      363

    • Rear Brake Pedal Set-Up

      363

    • Clutch Cable Adjuster

      364

    • Hot Starter Lever Installation

      364

    • Front Brake Hose Routing

      365

    • Rear Brake Hose Routing

      366

    • Handlebar Set-Up

      367

    • Chain Roller Installation

      368

    • Rear Wheel Spokes Installation

      368

    • Specifications

      369

      • Dimensions and Dry Mass

        369

      • Drive Train

        369

    • Optional Parts

      371

    • Spare Parts List

      371

    • Setting Data

      372

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Suzuki RM-Z450 Owner's Service Manual

Suzuki RM-Z450 Owner’s Service Manual (342 pages)

Brand: Suzuki
|
Category: Motorcycle
|
Size: 34.35 MB

Table of Contents
  • Group Index 1

    9

    • Serial Number Location

      5

    • Replacement Parts

      7

    • Table of Contents

      9

    • Location of Parts

      11

    • Accessory

      12

      • Side Stand

        12

    • Fuel and Oil Recommendation

      12

    • Operating Instructions

      13

      • Starting the Engine

        13

      • Stopping the Engine

        14

      • Transmission

        14

    • Break-In (Running-In)

      15

      • When the Motorcycle Is New

        15

      • When Engine Parts Are Replaced

        15

    • Exterior Parts

      16

  • Periodic Maintenance 2

    18

    • Periodic Maintenance

      20

      • Inspection before Practice

        20

      • Inspection before Race

        21

      • (All Items of Inspection before Practice on Previous

        21

      • Periodic Maintenance Chart

        22

    • Spark Plug

      24

    • Air Cleaner

      25

      • Air Cleaner Element Removal

        25

      • Washing

        25

      • Installation

        25

      • Engine Oil and Oil Filter

        26

      • Inspection before Engine Oil Level Check

        27

      • Engine Oil Level Inspection

        28

      • Engine Oil Change

        28

      • Engine Oil Filter Change

        29

      • Oil Strainers

        30

    • Engine Coolant

      31

      • Engine Coolant Level Check

        31

      • Engine Coolant Replenishment

        32

      • Cooling System Inspection

        32

    • Clutch Cable

      33

      • Major Adjustment

        33

      • Minor Adjustment

        33

    • Throttle Cable

      34

      • Throttle Cable Adjustment

        34

      • Throttle Cable Oil Supply

        34

    • Hot Starter

      35

    • Crankcase Breather Hose

      36

    • Engine Idle Speed

      36

    • Fuel Filter

      37

    • Fuel Hose

      37

    • Valve Clearance

      38

      • Valve Clearance Adjustment

        39

    • Cylinder Head, Cylinder and Piston

      42

      • Cylinder Head Inspection

        42

      • Cylinder Inspection

        42

      • Piston Inspection

        42

    • Exhaust Silencer

      43

      • Silencer Inspection and Replacement

        43

      • Silencer Reassembly

        44

    • Drive Chain and Sprockets

      44

      • Drive Chain Slack

        44

      • Drive Chain Adjustment

        45

      • Drive Chain Plate Wear

        45

      • Drive Chain Lubrication

        46

      • Sprocket Inspection

        46

    • Drive Chain Guide, Buffer and Tensioner Roller

      47

      • Drive Chain Guide Inspection

        47

      • Drive Chain Buffer and Roller Inspection

        47

    • Brakes

      48

      • Brake Fluid Level

        48

      • Brake Pad

        49

      • Front Brake Lever Adjustment

        49

      • Brake Pedal Height Adjustment

        49

    • Front Fork

      50

    • Rear Suspension

      50

    • Wheels and Tires

      50

      • Wheel Rim and Tires Inspection

        50

      • Spoke Nipple and Rim Lock Inspection

        51

      • Tire Pressure

        51

    • Steering

      51

    • Lubrication

      52

    • Compression Pressure Check

      53

      • Compression Test Procedure

        53

    • Oil Pressure Check

      54

      • Oil Pressure Test Procedure

        54

  • Troubleshooting

    56

    • Engine

      57

    • Carburetor

      61

    • Radiator (Cooling System)

      61

    • Chassis

      62

    • Brakes

      63

    • Electrical

      64

  • Machine Tuning

    66

    • Carburetor Tuning

      67

      • Principles of Carburetor Tuning

        67

      • Slow System

        68

      • Main System

        70

      • Intermediate System

        70

      • Carburetor Tuning in Practice

        72

    • Front Fork Tuning

      75

      • Compression Damping Force Adjustment

        75

      • Rebound Damping Force Adjustment

        75

      • Oil Quantity Minor Adjustment

        76

      • OIL CHANGE (Only for Outer Tube Oil Chamber)

        77

      • Spring Change

        79

      • Front Fork Tuning Procedure

        81

    • Rear Suspension Tuning

      82

      • Compression Damping Force Adjustment

        82

      • Rebound Damping Force Adjustment

        83

      • Spring Pre-Load Adjustment

        83

      • Rear Suspension Tuning Procedure

        84

    • Suspension Balance

      86

      • Balance Test

        86

      • Balancing Tips

        86

      • Engine Removal and Installation

        88

    • Engine Removal and Installation

      89

  • Cylinder Head, Cylinder and Piston

    98

    • Construction

      99

      • Cylinder Head, Cylinder and Piston

        99

    • Engine Top Side

      100

      • Cylinder Head Cover Removal

        100

      • Camshafts (Automatic Decomp.) and Cam Chain Tension Adjuster Removal

        100

      • Cylinder Head Removal

        101

      • Cylinder Removal

        102

      • Piston and Piston Ring Removal

        103

      • Cam Chain, Cam Chain Tensioner and Cam Chain Guide Removal

        104

    • Engine Top Components Inspection and Service

      105

      • Automatic Decomp. Inspection

        105

      • Camshaft Inspection

        105

      • Cam Chain Tension Adjuster Inspection

        107

      • Cam Chain Tensioner Inspection

        108

      • Cylinder Head and Valve Inspection

        108

      • Oil Seal Inspection

        116

      • Cylinder Inspection

        117

      • Piston and Piston Ring Inspection

        118

        • Piston Ring Groove Width

          119

        • Piston Ring Thickness

          119

        • Piston Ring End Gap

          119

      • Crankshaft and Conrod Inspection

        120

      • Cam Chain, Cam Chain Tensioner and Cam Chain Guide Installation

        121

      • Piston and Piston Ring Installation

        122

      • Cylinder and Cylinder Head Installation

        124

      • Camshaft (Automatic Decomp.) and Cam Chain Tension Adjuster Installation

        126

      • Clutch

        129

      • Cylinder Head Cover Installation

        129

  • Clutch

    130

    • Construction

      131

      • Clutch

        131

    • Clutch Plate

      132

      • Removal

        132

      • Inspection

        134

      • Release Bearing Replacement

        135

      • Installation

        136

    • Primary Driven Gear and Clutch Sleeve Hub

      138

      • Removal

        138

      • Inspection

        139

      • Installation

        139

    • Clutch Release Camshaft

      141

      • Removal

        141

      • Inspection

        141

      • Installation

        142

  • Kick Starter

    144

    • Construction

      145

      • Kick Starter

        145

      • Removal

        146

    • Kick Starter

      146

      • Inspection

        147

        • Installation

          148

  • Gearshifting

    152

    • Construction

      153

      • Gearshift Linkage

        153

      • Removal

        154

      • Gearshift Linkage

        154

      • Inspection

        155

      • Installation

        156

  • Transmission and Crankshaft

    160

    • Construction

      161

      • Transmission and Crankshaft

        161

    • Engine Bottom Side

      162

      • Primary Drive Gear Removal

        162

      • Crankcase Separation

        163

      • Transmission Removal

        163

      • Crankshaft Removal

        164

      • Transmission Inspection

        165

      • Conrod Inspection

        166

      • Crankshaft Inspcection

        166

      • Oil Seal Inspection

        167

      • Oil Seal Removal and Installation

        167

      • Bearing Inspection

        168

      • Bearing Removal and Installation

        168

      • Crankshaft Installation

        171

      • Transmission Installation

        172

      • Crankcase Installation

        174

      • Primary Drive Gear Installation

        175

  • Lubrication System

    178

    • Engine Lubrication System

      179

    • Engine Lubrication System Chart

      179

    • Engine Oil Change

      180

    • Engine Oil Filter Change

      180

    • Engine Oil Level Inspection

      180

    • Oil Pressure Check

      180

    • Oil Seal Inspection

      180

    • Oil Seal Removal

      180

    • Oil Strainers Inspection

      180

    • Oil Strainers Installation

      180

    • Oil Strainers Removal

      180

    • OIL PUMP No.1 and No.2 REMOVAL

      181

    • Oil Seal Installation

      181

    • OIL PUMP No.1 and No.2 INSPECTION

      182

    • OIL PUMP No.1 and No.2 INSTALLATION

      183

  • Fuel System

    186

    • Fuel Tank and Fuel Valve

      187

      • Construction

        187

      • Removal

        187

      • Cleaning and Inspection

        188

      • Installation

        188

    • Carburetor

      189

      • Construction

        189

      • Removal

        190

      • Disassembly

        191

      • Cleaning

        195

      • Inspection

        195

      • Reassembly

        197

      • Installation

        201

    • Throttle Position Sensor

      202

      • Inspection

        202

      • Removal

        203

      • Installation

        203

  • Cooling System

    204

    • Construction

      205

    • Engine Coolant

      206

      • Replacement

        206

    • Cooling Circuit

      207

      • Inspection

        207

    • Radiator

      208

      • Inspection

        208

      • Removal

        209

      • Installation

        209

    • Water Pump

      210

      • Removal

        210

      • Inspection

        211

      • Installation

        211

  • Electrical System

    214

    • Cautions in Servicing

      215

      • Connector

        215

      • Coupler

        215

      • Semi-Conductor Equipped Part

        215

      • Using the Multi-Circuit Tester

        215

      • Switch

        215

    • Location of Electrical Components

      216

    • Construction

      217

      • Electrical System

        217

      • Electrical Circuit

        217

      • Troubleshooting

        218

    • Ignition System

      220

      • Ignition System Peak Voltage Inspection

        220

      • Ignition System Coil Inspection

        221

      • Ignition Coil Primary Peak Voltage Inspection

        221

      • Ignition Coil Inspection

        222

      • Engine Stop Switch Inspection

        222

    • Magneto Rotor

      223

      • Removal

        223

      • Installation

        225

    • Stator

      226

      • Removal

        226

      • Installation

        226

  • Front and Rear Wheels

    228

    • Construction

      229

    • Front Wheel

      230

      • Removal

        230

      • Inspection

        231

      • Dust Seal and Bearing Replacement

        232

      • Disc Plate Replacement

        234

      • Installation

        234

    • Rear Wheel

      235

      • Removal

        235

      • Inspection

        236

      • Dust Seal and Bearing Replacement

        236

      • Disc Plate Replacement

        238

      • Rear Sprocket Replacement

        239

      • Installation

        239

      • Rear Wheel Spokes Replacement

        239

  • Front and Rear Brakes

    240

    • Construction

      241

    • Brake Fluid Air Bleeding

      242

    • Brake Fluid Replacement

      243

    • Brake Pads Replacement

      244

      • Front Brake Pads

        244

      • Rear Brake Pads

        244

    • Brake Disc Inspection

      245

    • Caliper

      245

      • Front Caliper Removal and Disassembly

        246

      • Caliper Inspection

        247

      • Caliper Cleaning

        247

      • Front Caliper Reassembly and Installation

        247

      • Rear Caliper Removal and Disassembly

        248

      • Rear Caliper Reassembly and Installation

        249

    • Master Cylinder

      251

      • Front Master Cylinder Removal and Disassembly

        251

      • Master Cylinder Inspection

        252

      • Master Cylinder Cleaning

        252

      • Front Master Cylinder Reassembly and Installation

        253

      • Rear Master Cylinder Removal and Disassembly

        254

      • Master Cylinder Inspection

        255

      • Rear Master Cylinder Reassembly and Installation

        255

    • Brake Lever

      256

      • Removal

        256

      • Installation

        256

    • Brake Pedal

      256

      • Installation

        257

  • Front Fork and Steering

    258

    • Construction

      259

      • Front Fork, Steering

        259

      • Handlebar Controls

        260

      • Removal

        261

      • Disassembly

        262

      • Inspection

        266

      • Reassembly

        268

      • Installation

        274

    • Steering

      275

      • Removal

        275

      • Inspection

        278

      • Bearing Replacement

        279

      • Installation

        280

  • Rear Suspension

    284

    • Construction

      285

      • Rear Suspension

        285

    • Rear Shock Absorber

      286

      • Removal

        286

      • Spring Replacement

        287

      • Inspection

        288

      • Bearing Replacement

        289

      • Oil Replacement

        290

      • Disassembly and Inspection

        293

      • Reassembly

        294

      • Installation

        295

      • Disposal

        295

    • Swingarm

      296

      • Removal

        296

      • Inspection

        298

      • Bearing Replacement

        299

      • Installation

        300

    • Rear Suspension Linkage

      301

      • Removal

        301

      • Inspection

        302

      • Bearing Replacement

        303

      • Installation

        304

  • Servicing Information

    308

    • Service Data

      309

      • Oil Pump

        311

    • Tightening Torque

      317

    • Special Tools

      321

    • Wiring Diagram

      324

    • Cable Routing

      325

    • Wire Harness Routing

      327

    • Fuel Hose Routing

      328

    • Radiator Hose and Carburetor Hose Routing

      329

    • Rear Brake Pedal Set-Up

      330

    • Magneto Installation

      331

    • Clutch Cable Adjuster

      332

    • Front Brake Hose Routing

      333

    • Rear Brake Hose Routing

      334

    • Handlebar Set-Up

      335

    • Rear Wheel Spokes Installation

      336

    • Front Number Plate Installation

      337

    • Ignition Coil Installation

      337

    • Specifications

      338

    • Optional Parts

      340

    • Spare Parts List

      340

    • Setting Data

      341

Suzuki RM-Z450 Manual

Suzuki RM-Z450 Manual (121 pages)

Brand: Suzuki
|
Category: Motorcycle
|
Size: 2.57 MB

Table of Contents
  • Table of Contents

    4

    • The Sport of Motocross Motorcycling

      6

    • Fuel, Engine Oil and Coolant Recommendations

      10

  • Controls, Equipment and Adjustments

    18

    • Location of Parts

      19

    • Left Handlebar

      22

    • Right Handlebar

      23

    • Fuel Tank Cap

      24

    • Kick Starter Lever

      25

    • Starter Knob

      25

    • Gearshift Lever

      26

    • Rear Brake Pedal

      26

    • Side Stand

      27

    • Suspension Adjustment

      27

    • Suspension Balance

      39

    • Break-In (Running-In) and Inspection before Riding

      40

  • Riding Tips

    46

    • Inspection before Engine Oil Level Check

      47

    • Instructions

      47

    • Starting the Engine

      48

    • Selection of S-Hac (Suzuki Holeshot Assist Control) Mode

      51

    • Selecting a Mode

      53

    • Selection of Ecm Tuning Map

      57

    • Stopping and Parking

      59

  • Inspection and Maintenance

    60

    • Maintenance Schedule

      61

    • Precautions for Maintenance and Setting

      61

    • Replacement Parts

      61

    • Engine Run Time Indication Procedure

      65

    • Engine Run Time Reset Procedure

      67

    • General Lubrication

      69

    • Fuel Tank

      71

    • Air Cleaner

      73

    • Spark Plug

      76

    • Engine Oil

      77

    • Idle Speed Adjustment

      85

    • Throttle Cable Adjustment

      86

    • Clutch Adjustment

      87

    • Fuel Hose

      87

    • Drive Chain

      88

    • Engine Coolant

      91

    • Brakes

      92

    • Tires

      98

    • Spoke Nipple and Bead Stopper

      100

    • Front Fork

      101

    • Rear Suspension

      101

    • Steering

      102

  • Storage Procedure and Motorcycle Cleaning

    104

    • Storage Procedure

      105

    • Procedure for Returning to Service

      106

    • Corrosion Prevention

      107

    • Motorcycle Cleaning

      108

    • Inspection after Cleaning

      110

    • Consumer Information

      112

    • Specifications

      115

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Service Manual for 2013 Suzuki RM-Z450 motocross motorcycles. Service Manual 2013 Suzuki RM-Z450, a great reference for the repair and maintenance.

Service Manual, fix motorcycle yourself with a repair manual.

Content 2013 Suzuki RM-Z450 motocross Service Manual

General information
Location of parts
Accesory
Fuel and oil recommendation
Operating instructions
Transmission
Break-In (Running-In)
Exterior parts

Periodic maintenance
Periodic maintenance
Spark plug
Air cleaner
Engine oil and oil filter
Oil strainers
Engine coolant
Clutch cable
Throttle cable
Hot starter
Engine idle speed
Crankcase breather hose
Fuel hose
Valve clearance

Troubleshooting
Engine
Radiator (cooling system)
Chassis
Brakes
Electrical

Machine Tuning
Front fork tuning
Rear suspension tuning
Suspension balance

Engine removal and installation
Engine removal and installation

Cylinder head, cylinder and piston
Construction
Engine top side disassembly
Engine top components inspection and service
Engine top side assembly
Cam chain, cam chain tensioner and cam chain

Clutch
Construction
Clutch plate
Primary driven gear and clutch sleeve hub
Clutch release chamshaft

Kick Starter
Construction
Kick starter

Gearshifting
Construction
Gearshift linkage
Gear position (GP) switch

Transmission and crankshaft
Construction
Engine bottom side

Lubrication System
Engine lubrication system

FI System Diagnosis
Precautions in servicing
FI System technical features
ECM Terminal
Self-diagnosis function

Fuel System and Throttle Body
Fuel system
Throttle body

Cooling System
Construction
Engine coolant
Cooling circuit
Radiator
Water pump

Electrical system
Ignition system
Charging system
Combination meter
Lamps
Switches
Battery

Front and Rear Wheels
Construction
Front wheel
Rear wheel

Front and Rear Brakes
Construction
Brake fluid air bleeding
Brake fluid replacement
Brake pads replacement
Brake disc inspection
Caliper
Master cylinder
Brake lever
Brake pedal

Front Fork and Steering
Construction
Steering

Rear Suspension
Construction
Rear shock absorber
Swingarm
Rear suspension linkage

Servicing information
Service data
Tightening Torque
Special tools
Wiring diagram
Wire, cable and hose routing
Cable routing
Fuel hose routing
Radiator hose routing
Rear brake pedal set-up
Clutch cable adjuster
Hot starter lever installation
Front brake hose routing
Rear brake hose routing
Handlebar set-up
Rear wheels spokes installation
Chain roller installation
Specifications
Optional parts
Setting data

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Suzuki RM-Z450

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  • Руководство по использованию и ремонту (Owners Service Manual) для Suzuki RM-Z450 (2007)
  • Сервисный мануал (Service Manual) на Suzuki RM-Z450 (2005-2007)
  • Мануал по ремонту (Repair & Service Manual) на Suzuki RM-Z450 (2009)

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  • Suzuki RM-Z450

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  • Сервисная документация

Suzuki RM-Z450 Owner's Service Manual

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  • Contents

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Related Manuals for Suzuki RM-Z450

Summary of Contents for Suzuki RM-Z450

  • Page 1
    RM-Z450 OWNER’S SERVICE MANUAL Part No. 99011-35G52-01A July, 2006…
  • Page 2
    This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator. The manual contains important safety information and instructions which should be read carefully before operating the motorcycle.
  • Page 3
    This manual is presented as a means whereby you carefully. To emphasize special information, the can maintain your RM-Z450 in top working condi- symbol ! and the words WARNING, CAUTION tion at all times. Your riding skill and the mainte- and NOTE have special meanings.
  • Page 4
    You need to prepare for the unex- pected by wearing a helmet and other protective gear, and practicing safe riding techniques to minimize the damage to you and your machine. May all of your rides on your new Suzuki be winning rides!
  • Page 5: Serial Number Location

    SERIAL NUMBER LOCATION The frame number 1 is stamped on the steering head as shown in the photograph. The engine serial num- ber 2 is stamped on the right side of the crankcase assembly. Write down the serial numbers here for your future reference. Frame No.

  • Page 6
    WARNINGS FOR SERVICING ! WARNING ! WARNING Never run the engine indoors or in a Fuel can catch on fire if you do not handle garage. Exhaust gas contains carbon mon- it properly. Gasoline vapors can catch fire oxide, a gas that is colorless and odorless easily.
  • Page 7: Replacement Parts

    NOTE: installing a circlip. Use of replacement parts which are not equivalent • Use special tools where specified. in quality to genuine SUZUKI parts can lead to per- • Use genuine SUZUKI parts and recommended formance problems and damage. oil.

  • Page 8
    Apply THREAD LOCK SUPER “1360” Data beside it indicates specified or equivalent. torque. 99000-32130 Apply oil. Use engine oil or transmission Use SUZUKI FORK OIL SS-05 or oil unless otherwise specified. equivalent. 99000-99001-SS5 Apply molybdenum oil solution. Use SUZUKI REAR SUSPENSION OIL (Mixture of engine oil and SUZUKI SS-25 or equivalent.
  • Page 9: Table Of Contents

    GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE TROUBLESHOOTING MACHINE TUNING ENGINE REMOVAL AND INSTALLATION CYLINDER HEAD, CYLINDER AND PISTON CLUTCH KICK STARTER GEARSHIFTING TRANSMISSION AND CRANKSHAFT LUBRICATION SYSTEM FUEL SYSTEM COOLING SYSTEM ELECTRICAL SYSTEM FRONT AND REAR WHEELS FRONT AND REAR BRAKES FRONT FORK AND STEERING REAR SUSPENSION SERVICING INFORMATION…

  • Page 10
    GENERAL INFORMATION GENERAL INFORMATION CONTENTS LOCATION OF PARTS …………….1- 2 ACCESSORY ………………..1- 3 SIDE STAND ………………1- 3 FUEL AND OIL RECOMMENDATION …………1- 3 OPERATING INSTRUCTIONS …………..1- 4 STARTING THE ENGINE …………..1- 4 STOPPING THE ENGINE …………..1- 5 TRANSMISSION ……………….
  • Page 11: Location Of Parts

    GENERAL INFORMATION LOCATION OF PARTS 1 Clutch lever 2 Hot starter lever 3 Engine stop switch 4 Front brake lever 5 Throttle grip 6 Fuel tank cap 7 Carburetor starter knob 8 Gearshift lever 9 Front suspension compression damp- ing adjuster 0 Front suspension rebound damping adjuster A Kick starter lever…

  • Page 12: Accessory

    Use only unleaded gasoline of at least 95 octane. (Research method) ….For other countries Engine oil: SUZUKI recommends the use of SUZUKI PERFOR- MANCE 4 MOTOR OIL or equivalent engine oil. Use of SF/SG or SH/SJ in API with MA in JASO. The rec- ommended viscosity is SAE 10W-40.

  • Page 13: Operating Instructions

    GENERAL INFORMATION OPERATING INSTRUCTIONS CAUTION Leaving the engine at idling speed after riding will cause engine overheat as this competition motorcycle does not have the radiator cooling fan and coolant reservoir. Riding the motorcycle under severe conditions such as muddy or sandy terrain with high ambient temperature can shorten time to be overheated.

  • Page 14: Stopping The Engine

    GENERAL INFORMATION When the engine is already warm or restarts: 1) Pull the hot starter lever 1. 2) Kick the engine over, leaving the throttle closed without using the starter knob. 3) Return the hot starter lever back immediately after the engine starts.

  • Page 15: Break-In (Running-In)

    GENERAL INFORMATION BREAK-IN (RUNNING-IN) WHEN THE MOTORCYCLE IS NEW CLOSED CLOSED 1) Warm up the engine before starting off. 2) Ride for 60 minutes using less than 1/2 throttle opening. 3) Ride for 60 minutes using less than 3/4 throttle opening. FULL NOTE: OPEN…

  • Page 16: Exterior Parts

    GENERAL INFORMATION EXTERIOR PARTS 5 N·m (0.5 kgf-m, 3.5 lb-ft) 5 N·m (0.5 kgf-m, 3.5 lb-ft)

  • Page 17
    – MEMO –…
  • Page 18
    PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE ……………. 2- 3 INSPECTION BEFORE PRACTICE …………2- 3 INSPECTION BEFORE RACE (All items of inspection before practice on previous page plus) ..2- 4 PERIODIC MAINTENANCE CHART ………… 2- 5 SPARK PLUG ………………..2- 7 AIR CLEANER …………………
  • Page 19
    PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS EXHAUST SILENCER …………….2-26 SILENCER INSPECTION AND REPLACEMENT …….. 2-26 SILENCER REASSEMBLY …………..2-27 DRIVE CHAIN AND SPROCKETS …………. 2-27 DRIVE CHAIN SLACK …………….2-27 DRIVE CHAIN ADJUSTMENT …………. 2-28 DRIVE CHAIN PLATE WEAR ………….. 2-28 DRIVE CHAIN PLATE WEAR …………..
  • Page 20: Periodic Maintenance

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE INSPECTION BEFORE PRACTICE WHAT TO CHECK CHECK FOR Spark plug • Heat range, fouled electrode, tightness • Loose high-tension cord Air cleaner element • Dust • Lubrication Engine oil Oil level Coolant Coolant level Cooling system •…

  • Page 21: Inspection Before Race

    PERIODIC MAINTENANCE INSPECTION BEFORE RACE (All items of inspection before practice on previous page plus) WHAT TO CHECK CHECK FOR Clutch Clutch disc plates wear and distortion Brake pads Wear Sprockets Wear Cleanliness Fuel tank Leakage Fuel hose • Damage •…

  • Page 22: Periodic Maintenance Chart

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE CHART It is very important to inspect and maintain the machine regularly. Follow the guideline in the chart. The life of parts varies depending on the riding conditions. Perform more often than shown in the chart if you use the motorcycle under severe conditions.

  • Page 23
    PERIODIC MAINTENANCE Interval Every Every Every races race 3 races 6 races Remarks Service Every Every Every hours Item 2 hours 6 hours 12 hours Tire — — Inspect every 20 min. up to initial 2 hours Spoke nipple — —…
  • Page 24: Spark Plug

    PERIODIC MAINTENANCE SPARK PLUG • Remove the seat. (!5-2) • Remove the radiator covers and fuel tank. (!5-2) • Disconnect the spark plug cap. • Remove the spark plug. » 09816-00141: Spark plug wrench NOTE: Remove the dirt around the spark plug before removing the spark plug to prevent dirt from entering the combustion cham- ber.

  • Page 25: Air Cleaner

    PERIODIC MAINTENANCE AIR CLEANER AIR CLEANER ELEMENT REMOVAL • Remove the left frame cover. • Remove the wing nut 1. • Remove the element 2 from the element holder. WASHING • Fill a washing pan large enough to hold the element with a non-flammable cleaning solvent A.

  • Page 26: Engine Oil And Oil Filter

    PERIODIC MAINTENANCE NOTE: Follow the instructions below to keep the air cleaner element dry when cleaning the motorcycle. • Cover the element with vinyl bag. • Install the left frame cover. • Cover the inlet hole on the frame cover in order to prevent water from coming into the air cleaner box.

  • Page 27: Inspection Before Engine Oil Level Check

    2-10 PERIODIC MAINTENANCE INSPECTION BEFORE ENGINE OIL LEVEL CHECK • Before starting the engine, check that there is sufficient oil for operating the engine. CAUTION If the engine is started with insufficient or no oil, the engine components will possibly be damaged. NOTE: The oil level measurement may become inaccurate unless the motorcycle is held upright as the motorcycle inclination affects…

  • Page 28: Engine Oil Level Inspection

    PERIODIC MAINTENANCE 2-11 ENGINE OIL LEVEL INSPECTION • During inspection, hold the motorcycle in an upright position on a level surface. NOTE: The oil level measurement may become inaccurate unless the motorcycle is held upright as the motorcycle inclination affects the oil level.

  • Page 29: Engine Oil Filter Change

    2-12 PERIODIC MAINTENANCE ENGINE OIL FILTER CHANGE • Drain the engine oil as described in the engine oil replace- ment procedure. • Remove the oil filter cap 1 and spring 2 with oil filter 3. • Apply engine oil lightly to the gasket of the new oil filter before installation.

  • Page 30: Oil Strainers

    PERIODIC MAINTENANCE 2-13 OIL STRAINERS OIL STRAINER (No.1) REMOVAL • Drain engine oil. (!2-11) • Remove the engine oil strainer cap. CAUTION Do not lie the motorcycle to prevent dirty engine oil into the oil circuit when removing the oil strainer (No.1).

  • Page 31: Engine Coolant

    2-14 PERIODIC MAINTENANCE ENGINE COOLANT ENGINE COOLANT LEVEL CHECK % WARNING You can be injured by scalding fluid or steam if you open the radiator cap when the engine is hot. Do not open the radiator cap when the engine is hot. Wait until engine cools.

  • Page 32: Engine Coolant Replenishment

    PERIODIC MAINTENANCE 2-15 ENGINE COOLANT REPLENISHMENT • Use an anti-freeze and Summer engine coolant which is com- patible with aluminum radiator, mixed with distilled water at the ratio of 50:50. NOTE: The radiator, cylinder and cylinder head are made of aluminum alloy.

  • Page 33: Clutch Cable

    2-16 PERIODIC MAINTENANCE CLUTCH CABLE Adjust the clutch cable play as follows: MAJOR ADJUSTMENT • Loosen the lock-nut 1. • Turn adjuster 2 so the clutch lever has 10 – 15 mm (0.4 – 0.6 in) play at the clutch lever end before pressure is felt. •…

  • Page 34: Throttle Cable

    THROTTLE CABLE OIL SUPPLY • Remove the throttle case 1. • Apply oil to the throttle cable. • Apply SUZUKI SUPER GREASE “A” to the throttle cable spool. ‘ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent…

  • Page 35: Hot Starter

    2-18 PERIODIC MAINTENANCE HOT STARTER Adjust the hot starter cable play as follows: • Loosen the lock-nut 1. • Turn adjuster 2 so the hot starter lever clearance A mea- sured at the lever holder obtains 2 – 3 mm (0.08 – 0.12 in) when squeezing the lever until pressure is felt.

  • Page 36: Engine Idle Speed

    PERIODIC MAINTENANCE 2-19 ENGINE IDLE SPEED • Adjust the throttle cable play. (!2-16) • Warm up the engine. NOTE: Make this adjustment when the engine is hot. • Connect the multi-circuit tester to the high-tension cord. • Start the engine, turn the throttle stop screw 1 and set the engine idle speed as follows.

  • Page 37: Fuel Hose

    2-20 PERIODIC MAINTENANCE FUEL HOSE • Inspect the fuel hose for damage and fuel leakage. If any defects are found, the fuel hose must be replaced. • Replace the fuel hose every four years. FUEL FILTER • Drain the fuel. •…

  • Page 38: Valve Clearance

    PERIODIC MAINTENANCE 2-21 VALVE CLEARANCE • Remove the seat. (!5-2) • Remove the radiator covers and fuel tank. (!5-2) • Disconnect the spark plug cap. (!2-7) • Remove the spark plug. (!2-7) • Remove the cylinder head cover and its cylinder head cover gasket.

  • Page 39: Valve Clearance Adjustment

    2-22 PERIODIC MAINTENANCE VALVE CLEARANCE ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim. • Remove the intake or exhaust camshafts. (!6-4) • Remove the tappet 1 and shim 2 by fingers or magnetic hand.

  • Page 40
    PERIODIC MAINTENANCE 2-23 (INTAKE SIDE)
  • Page 41
    2-24 PERIODIC MAINTENANCE (EXHAUST SIDE)
  • Page 42: Cylinder Head, Cylinder And Piston

    PERIODIC MAINTENANCE 2-25 CYLINDER HEAD, CYLINDER AND PISTON CYLINDER HEAD INSPECTION • Remove the cylinder head. (!6-4) • Decarbonize the combustion chambers. • Inspect for pinholes, cracks and other damage. • If any defects are found, replace the cylinder head with a new one.

  • Page 43: Exhaust Silencer

    2-26 PERIODIC MAINTENANCE EXHAUST SILENCER SILENCER INSPECTION AND REPLACEMENT • Remove the baffle mounting bolts. • Remove the baffle 1 and inner plate 2. • Inspect the glass wool 3 for clogging with carbon deposit or tar. • Replace the glass wool 3 with a new one if necessary.

  • Page 44: Silencer Reassembly

    • Install the baffle and diffuser. • Tighten four bolts. NOTE: Apply SUZUKI BOND to the circumference of the silencer pipe and diffuser. ( 99000-31140: SUZUKI BOND “1207B” or equivalent • The baffle mounting bolt is of flanged type which tightens the body 3, baffle 1 and inner plate 2 together.

  • Page 45: Drive Chain Adjustment

    2-28 PERIODIC MAINTENANCE DRIVE CHAIN ADJUSTMENT • Loosen the axle nut 1. • Loosen the lock-nuts 2 and adjust the drive chain slack to the specification by turning the adjusters 3. Make sure that the right and left adjuster plates 4 are at the same position on scales 5.

  • Page 46: Drive Chain Lubrication

    PERIODIC MAINTENANCE 2-29 DRIVE CHAIN LUBRICATION • Remove the chain clip and joint from the drive chain and remove the drive chain. • Clean the drive chain with kerosine. CAUTION Do not use trichloroethylene, gasoline or any similar solvent. These fluids will damage the O-ring seals. Use only kerosine to clean the drive chain.

  • Page 47: Drive Chain Guide, Buffer And Tensioner Roller

    2-30 PERIODIC MAINTENANCE DRIVE CHAIN GUIDE, BUFFER AND TENSIONER ROLLER DRIVE CHAIN GUIDE INSPECTION • Inspect the drive chain guide 1 for bends and damage. NOTE: The drive chain can hit a bent guide causing noise and drive chain wear. •…

  • Page 48: Brakes

    PERIODIC MAINTENANCE 2-31 BRAKES BRAKE FLUID LEVEL • Inspect the brake fluid level in both front and rear reservoirs. If the brake fluid level is lower than LOWER mark A, replenish the reservoir with the specified brake fluid to the UPPER line. (!16-14) Inspect brake pad wear and brake fluid leakage if the brake fluid level decreases.

  • Page 49: Brake Pad

    2-32 PERIODIC MAINTENANCE BRAKE PAD Wear limit • Inspect the brake pads for wear. If the brake pads are worn, replace them with new ones. (!16-5) NOTE: * Pump the brake lever and pedal several times to restore the Wear limit brake pads after replacing the brake pads.

  • Page 50: Front Fork

    PERIODIC MAINTENANCE 2-33 FRONT FORK • Move the front fork up and down several times and inspect for smooth movement. • Inspect for damage and oil leaks. • Inspect the bolts and nuts for tightness. • If any defects are found, replace the front fork with a new one. •…

  • Page 51: Spoke Nipple And Rim Lock Inspection

    2-34 PERIODIC MAINTENANCE SPOKE NIPPLE AND RIM LOCK INSPECTION • Inspect the spokes for tension by squeezing the spoke nip- ples. • Retighten the spoke nipples with a spoke nipple wrench so as all spokes have same tension. $ Spoke nipple: 6 N·m (0.6 kgf-m, 4.5 lb-ft) CAUTION Improperly tightening the spoke nipples can damage the wheel.

  • Page 52: Lubrication

    A. Lightweight oil such as WD-40 or penetrating oil B. Aerosol type Chain Lube C. SUZUKI SUPER GREASE “A” (or equivalent grease) or Water-proof wheel bearing grease Follow the schedule closely. The disassembly necessary to lubricate many components is in itself valuable preventative maintenance.

  • Page 53: Compression Pressure Check

    2-36 PERIODIC MAINTENANCE COMPRESSION PRESSURE CHECK The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to replace the cylinder is often based on the results of a compression test. COMPRESSION PRESSURE SPECIFICATION (Automatic decomp. actuated) Standard 430 –…

  • Page 54: Oil Pressure Check

    PERIODIC MAINTENANCE 2-37 OIL PRESSURE CHECK Check the oil pressure periodically. This will give a good indication of the condition of the moving parts. # Oil pressure: 50 kPa (0.5 kgf/cm², 7.1 psi) at 1 950 r/min, oil temp. at 50 °C (122 °F) Low or high oil pressure can indicate any of the following conditions: LOW OIL PRESSURE * Clogged oil filter…

  • Page 55
    – MEMO –…
  • Page 56: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING CONTENTS ENGINE ………………….3- 2 CARBURETOR ……………….. 3- 6 RADIATOR (COOLING SYSTEM) ………….. 3- 6 CHASSIS ………………… 3- 7 BRAKES …………………. 3- 8 ELECTRICAL ………………..3- 9…

  • Page 57: Engine

    TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. • Valve clearance out of adjustment Adjust • Worn valve guides or poor seating of valves Repair or Replace • Mistiming valves Adjust •…

  • Page 58
    TROUBLESHOOTING Complaint Symptom and possible causes Remedy Noisy engine Excessive valve chatter • Too large valve clearance Adjust • Weakened or broken valve springs Replace • Worn tappet or cam surface Replace • Worn and burnt camshaft journal Replace Noise seems to come from piston •…
  • Page 59
    TROUBLESHOOTING Complaint Symptom and possible causes Remedy Engine lacks power. Defective engine internal parts • Loss of tappet clearance Adjust • Weakened valve springs Replace • Valve timing out of adjustment Adjust • Worn piston ring or cylinder Replace • Poor seating of valves Repair •…
  • Page 60
    TROUBLESHOOTING Complaint Symptom and possible causes Remedy Slipping clutch • Weakened clutch springs Replace • Worn or distorted pressure plate Replace • Worn or distorted clutch plates Replace • Insufficient throttle cable play Adjust Dragging clutch • Some clutch spring weakened while others are not Replace •…
  • Page 61: Carburetor

    TROUBLESHOOTING CARBURETOR Complaint Symptom and possible causes Remedy Starting difficulty. • Improperly working starter knob — • Improperly working hot starter lever — • Clogged starter jet passage Clean • Maladjusted pilot screw Adjust • Maladjusted throttle stop screw Adjust •…

  • Page 62: Chassis

    TROUBLESHOOTING CHASSIS Complaint Symptom and possible causes Remedy Heavy steering • Overtightened steering stem nut Adjust • Broken bearing in steering stem Replace • Distorted steering stem Replace • Not enough pressure in tires Adjust Wobbly handlebars • Loss of balance between right and left front forks Adjust •…

  • Page 63: Brakes

    TROUBLESHOOTING BRAKES Complaint Symptom and possible causes Remedy Insufficient brake • Leakage of brake fluid from hydraulic system Repair or replace power • Worn pads Replace • Oil adhesion of engaging surface of pads Clean disc and pads • Worn disc Replace •…

  • Page 64: Electrical

    TROUBLESHOOTING ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor • Defective ignition coil Replace sparking • Defective spark plug Replace • Defective CDI unit Replace • Defective magneto Replace • Open-circuited wiring connections Check and repair Spark plug soon •…

  • Page 65
    – MEMO –…
  • Page 66: Machine Tuning

    MACHINE TUNING MACHINE TUNING CONTENTS CARBURETOR TUNING …………….4- 2 PRINCIPLES OF CARBURETOR TUNING ………. 4- 2 SLOW SYSTEM ………………4- 3 MAIN SYSTEM ………………4- 5 INTERMEDIATE SYSTEM …………..4- 5 CARBURETOR TUNING IN PRACTICE ……….4- 7 FRONT FORK TUNING …………….4-10 COMPRESSION DAMPING FORCE ADJUSTMENT ……

  • Page 67: Carburetor Tuning

    Riders who are not familiar with the operation and jetting procedures of the KEIHIN carburetor should have their local authorized Suzuki dealer perform these alterations. Mechanically experienced riders can alter the carburetor settings based on the following information and specifications.

  • Page 68: Slow System

    MACHINE TUNING As shown below, each of the asterisk (*) marked parts is located between the air/fuel passage and has its own air/fuel mixture adjustable range in terms of the throttle valve opening. The chart indicates that the car- buretor can supply correct air/fuel mixture to the engine in any range because of the overlapping adjustable range of the each part.

  • Page 69
    MACHINE TUNING PILOT SCREW (P.S.) The pilot screw controls volume of the air/fuel mixture in slow range. Pilot screw specifications indicate the number of turns out from the lightly seated position. Air/fuel mixture Pilot screw turn out Lean 1 turn out 1 and 1/4 turns out 1 and 1/2 turns out 1 and 3/4 turns out…
  • Page 70: Main System

    MACHINE TUNING MAIN SYSTEM MAIN JET (M.J.) The main jet, like the slow jet, meters fuel flow. Each jet size is indicated by a number. Larger number means a larger bore diameter and fitting a larger number main jet enriches the air/fuel mixture.

  • Page 71
    MACHINE TUNING Jet needle clip position To adjust the air/fuel mixture with the jet needle, change position of the needle clip which is set in the 5th groove. The lower Lean groove the clip is moved to, the higher the jet needle rises and the larger the clearance with the main nozzle becomes, resulting in a richer air/fuel mixture ratio.
  • Page 72: Carburetor Tuning In Practice

    MACHINE TUNING CARBURETOR TUNING IN PRACTICE In the previous section, basic principles of carburetor tuning have been discussed. Described in this section are the bases for carburetor tuning required when coping with variations in air (oxygen) concentration. VARIATION IN AIR (OXYGEN) CONCENTRATION AND CARBURETOR CONDITIONS As the air, affected by the temperature, altitude and humidity, gets expanded or compressed, air (oxygen) concentration varies accordingly.

  • Page 73
    MACHINE TUNING JUDGING AIR/FUEL MIXTURE INCLUDED PARTS AND OPTIONAL PARTS For proper carburetor tuning, it is necessary to Main jet know how to judge the air/fuel mixture made in the Air/fuel carburetor; whether too rich, too lean or properly SIZE P/NO.
  • Page 74
    MACHINE TUNING 2 Adjustment of main system Jet needle With the throttle opened 3/4 to full, make main sys- Air/fuel SIZE P/NO. tem adjustment monitoring the air/fuel mixture con- mixture dition after completion of slow system settings. Lean NKZV 13383-35GK0 * Make sure to adjust the main system before NKYV 13383-35GJ0…
  • Page 75: Front Fork Tuning

    4-10 MACHINE TUNING FRONT FORK TUNING The front fork compression and rebound damping force, and oil level are adjustable for rider’s preference, rider’s weight and course condition. NOTE: * Break-in new front forks before attempting adjustment. * Be sure to adjust both right and left front forks equally. * Inspect the following items before attempting adjustment.

  • Page 76: Oil Quantity Minor Adjustment

    Operating the motorcycle with the fork oil quantity unevenly adjusted can cause handling instability. Never mix different types of fork oil. Different oils may cause chemical reaction and deteriorate. # 99000-99001-SS5: SUZUKI FORK OIL SS-05 or equivalent…

  • Page 77: Oil Change (Only For Outer Tube Oil Chamber)

    4-12 MACHINE TUNING OIL CHANGE (Only for outer tube oil chamber) • Remove the front forks. («17-4) • Thoroughly clean the fork before disassembly. CAUTION The fork oil quantity must be adjusted equally on both fork legs to provide equal performance. Scratches or other damage on the inner tube or on the oil seal lip will cause oil leak.

  • Page 78
    MACHINE TUNING 4-13 • Slide down the outer tube. • Pour the specified amount of fork oil into the outer tube. # 99000-99001-SS5: SUZUKI FORK OIL SS-05 or equivalent Identification Oil quantity Parts No. Spring rate (Slit mark Oil quantity…
  • Page 79: Spring Change

    4-14 MACHINE TUNING SPRING CHANGE • Remove the front forks. («17-4) • Thoroughly clean the fork before disassembly. CAUTION The fork oil quantity must be adjusted equally on both fork legs to provide equal performance. Scratches or other damage on the inner tube or on the oil seal lip will cause oil leakage.

  • Page 80
    US/Imp oz) 320 – 414 ml 385 ml (10.82/11.27 – 51171-35G30 (13.01/13.56 13.99/14.58 US/Imp oz) US/Imp oz) 315 – 408 ml 380 ml (10.65/11.09 – Hard 51171-35G40 (12.84/13.38 13.79/14.37 US/Imp oz) US/Imp oz) # 99000-99001-SS5: SUZUKI FORK OIL SS-05 or equivalent…
  • Page 81: Front Fork Tuning Procedure

    4-16 MACHINE TUNING FRONT FORK TUNING PROCEDURE Test ride the motorcycle and find out how the front suspension reacts on various types of surface. According to the symptom noticed, adjust the front fork to the best setting for rider and race track conditions. To adjust, attempt changing fork oil capacity and compression and rebound damping force following the instructions below.

  • Page 82: Rear Suspension Tuning

    MACHINE TUNING 4-17 REAR SUSPENSION TUNING The rear suspension compression and rebound damping force, and spring pre-load are adjustable for rider’s preference, rider’s weight and course condition. NOTE: * Break-in the rear suspension when riding with a new rear cushion unit. («1-6) * Inspect the following items before attempting adjustment.

  • Page 83: Rebound Damping Force Adjustment

    4-18 MACHINE TUNING REBOUND DAMPING FORCE ADJUSTMENT NOTE: To set the adjuster, you must gently turn the adjust screw clock- Soft Hard wise until it stops, then back it out the recommended number of turns. Do not force the adjust screw past the stopped position, or you may damage the adjuster.

  • Page 84: Rear Suspension Tuning Procedure

    MACHINE TUNING 4-19 REAR SUSPENSION TUNING PROCEDURE • Adjust the rear suspension according to the rider’s weight and preference by referring to the table below. Spring Part No. Spring rate Marking paint Set-length adjustable range 51 N/mm 62211-37FJ0 Silver (5.1 kgf/mm) Soft 53 N/mm 247 –…

  • Page 85
    4-20 MACHINE TUNING After the sag measurement has been set 104 mm (4.09 in), test ride the motorcycle and adjust the suspen- sion for the rider and track conditions referring to the guide below. SYMPTOM SECTION ADJUSTMENT PROCEDURE Feels too hard overall •…
  • Page 86: Suspension Balance

    MACHINE TUNING 4-21 SUSPENSION BALANCE Balancing the front to rear suspension properly is the most critical adjustment for suspension performance. If the front forks are adjusted harder than the rear suspension, such as changing to heavier front fork oil, stiffer compression and rebound setting, air pressure build up in the forks and so on, the front forks will collapse less on bumps.

  • Page 87
    – MEMO –…
  • Page 88: Engine Removal And Installation

    ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL AND INSTALLATION CONTENTS ENGINE REMOVAL AND INSTALLATION ……….5- 2 REMOVAL ………………… 5- 2 INSTALLATION ………………5- 6…

  • Page 89: Engine Removal And Installation

    ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL AND INSTALLATION REMOVAL • Drain engine oil. (!2-11) • Drain engine coolant. (!13-3) • Remove the seat 1. • Remove the radiator covers 2, left and right. • Remove the right frame cover 3. •…

  • Page 90
    ENGINE REMOVAL AND INSTALLATION • Remove the exhaust pipe 5 and exhaust pipe gasket 6. • Remove the muffler 7. • Remove the front protectors, left and right. • Remove the radiator mounting bolts, left and right. • Disconnect the radiator hose 8, 9. •…
  • Page 91
    ENGINE REMOVAL AND INSTALLATION • Disconnect the magneto lead wire coupler A and clamp. • Disconnect the clutch cable B. • Remove the carburetor. (!12-5) • Disconnect the spark plug cap. • Remove the cotter pin C, washer D and clip E. •…
  • Page 92
    ENGINE REMOVAL AND INSTALLATION • Remove the drive chain clip M and release the drive chain. • Remove the circlip N and engine sprocket O. # 09900-06107: Snap ring pliers • Remove the front engine brackets P, left and right. •…
  • Page 93
    ENGINE REMOVAL AND INSTALLATION INSTALLATION Install the engine in the reverse order of removal. Pay attention to the following points: • Fit the swingarm in its position and hold it with the swingarm pivot shaft. • Mount the engine on the frame. •…
  • Page 94
    • Install the gearshift lever in the correct position. $ Gearshift lever bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Apply grease to the brake pedal pivot bolt. % 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the brake pedal and brake pedal spring. (!19-23)
  • Page 95
    ENGINE REMOVAL AND INSTALLATION • Install the clip D, washer E and cotter pin F. CAUTION Replace the cotter pin F with a new one. • Install the kick starter lever in the correct position. (!8-7) $ Kick starter lever bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) •…
  • Page 96
    ENGINE REMOVAL AND INSTALLATION • Tighten the connector clamp bolt K temporarily. NOTE: When install the connector clamp, fit the convex part of the con- nector clamp onto the concave part of muffler. • Check the clearance between exhaust pipe and radiator hose. •…
  • Page 97
    – MEMO –…
  • Page 98
    CYLINDER HEAD, CYLINDER AND PISTON CYLINDER HEAD, CYLINDER AND PISTON CONTENTS CONSTRUCTION ………………6- 2 CYLINDER HEAD, CYLINDER AND PISTON ……..6- 2 ENGINE TOP SIDE ………………6- 3 CYLINDER HEAD COVER REMOVAL ……….6- 3 CAMSHAFTS (AUTOMATIC DECOMP.) AND CAM CHAIN TENSION ADJUSTER REMOVAL ……..
  • Page 99: Construction

    CYLINDER HEAD, CYLINDER AND PISTON CONSTRUCTION CYLINDER HEAD, CYLINDER AND PISTON 14 N . m (1.4 kgf-m, 10.0 lb-ft) 46 N . m (4.6 kgf-m, 33.5 lb-ft) 10 N . m (1.0 kgf-m, 11 N . m 7.0 lb-ft) (1.1 kgf-m, 8.0 lb-ft) 10 N .

  • Page 100: Engine Top Side

    CYLINDER HEAD, CYLINDER AND PISTON ENGINE TOP SIDE CYLINDER HEAD COVER REMOVAL • Remove the seat. (!5-2) • Remove the radiator covers and fuel tank. (!5-2) • Disconnect the spark plug cap and remove the spark plug. (!2-7) • Remove the cylinder head cover 1 and cylinder head cover gasket.

  • Page 101: Cylinder Head Removal

    CYLINDER HEAD, CYLINDER AND PISTON • Remove the cam chain tension adjuster cap bolt 3 and spring. • Remove the cam chain tension adjuster 4 and its gasket. • Remove the camshaft journal holders 5. NOTE: Loosen the camshaft journal holder bolts diagonally. •…

  • Page 102: Cylinder Removal

    CYLINDER HEAD, CYLINDER AND PISTON • Remove the cylinder head base bolts 3. • Loosen the cylinder base bolt 4. • Remove the cylinder head bolts and washers. NOTE: When loosening the cylinder head bolts, loosen each bolt little by little diagonally. •…

  • Page 103: Piston And Piston Ring Removal

    CYLINDER HEAD, CYLINDER AND PISTON • Remove the cylinder gasket 2 and dowel pins. PISTON AND PISTON RING REMOVAL • Remove the cylinder. (!6-5) • Place a clean rag over the cylinder base to prevent the piston pin circlip 1 from dropping into the crankcase. •…

  • Page 104: Cam Chain, Cam Chain Tensioner And Cam Chain Guide Removal

    CYLINDER HEAD, CYLINDER AND PISTON CAM CHAIN, CAM CHAIN TENSIONER AND CAM CHAIN GUIDE REMOVAL • Remove the cylinder head. (!6-4) • Remove the magneto cover and magnet rotor. (!14-10 to -11) • Remove the cam chain No.1 guide 1. •…

  • Page 105: Engine Top Components Inspection And Service

    CYLINDER HEAD, CYLINDER AND PISTON ENGINE TOP COMPONENTS INSPECTION AND SERVICE AUTOMATIC DECOMP. INSPECTION • Check the decomp. cam moves smoothly and shaft 1 rotates together. • If any abnormal condition are found, replace the camshaft assembly. CAMSHAFT INSPECTION CAUTION The camshaft assembly can not be disassembled.

  • Page 106
    CYLINDER HEAD, CYLINDER AND PISTON CAM WEAR • Measure the cam height H using the micrometer. • Replace a camshaft if the cams are worn to the service limit. » Cam height H Service Limit IN.: 33.27 mm (1.310 in) EX.: 33.39 mm (1.315 in) # 09900-20202: Micrometer (25 –…
  • Page 107: Cam Chain Tension Adjuster Inspection

    6-10 CYLINDER HEAD, CYLINDER AND PISTON • If the camshaft journal oil clearance measured exceeds the 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.

  • Page 108: Cam Chain Tensioner Inspection

    CYLINDER HEAD, CYLINDER AND PISTON 6-11 CAM CHAIN No.1 GUIDE, CAM CHAIN No.2 GUIDE AND CAM CHAIN TENSIONER INSPECTION • Inspect the contacting surface of the cam chain guides and cam chain tensioner. • If it is worn or damaged, replace it with a new one. CYLINDER HEAD AND VALVE INSPECTION VALVE DISASSEMBLY •…

  • Page 109
    6-12 CYLINDER HEAD, CYLINDER AND PISTON • Remove the valve spring retainer 4 and valve spring 5. • Remove the valve 6 from the combustion chamber side. • Remove the valve stem seal 7 and spring seat 8. CAUTION Do not reuse the removed valve stem seal. •…
  • Page 110
    CYLINDER HEAD, CYLINDER AND PISTON 6-13 VALVE STEM RUNOUT • Support the valve using V-blocks and check its runout using the dial gauge as shown. • If the runout exceeds the service limit, replace the valve. » Valve stem runout (IN & EX): Service Limit:0.05 mm (0.002 in) # 09900-20607: Dial gauge (1/100 mm) 09900-20701: Magnetic stand…
  • Page 111
    6-14 CYLINDER HEAD, CYLINDER AND PISTON VALVE STEM WEAR • If the valve stem is worn down to the limit, as measured with a micrometer, replace the valve. • If the stem is within the limit, then replace the guide. •…
  • Page 112
    CYLINDER HEAD, CYLINDER AND PISTON 6-15 • Cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 – 150 °C (212 – 302 °F) with a hot plate. CAUTION Do not use a burner to heat the valve guide hole to prevent cylinder head distortion.
  • Page 113
    6-16 CYLINDER HEAD, CYLINDER AND PISTON • If the seat width W measured exceeds the standard value or seat width is not uniform, refuse the seat using the seat cutter. » Valve seat width W: Standard: 0.9 – 1.1 mm (0.035 – 0.043 in) VALVE SEAT SERVICING The valve seats 1 for both the intake valve 2 and exhaust valve 3 are machined to three different angles.
  • Page 114
    CYLINDER HEAD, CYLINDER AND PISTON 6-17 • 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.
  • Page 115
    6-18 CYLINDER HEAD, CYLINDER AND PISTON • Install the valve spring with the small-pitch portion A facing cylinder head. A Small-pitch portion B Large-pitch portion C UPWARD D Paint • Put on the valve spring retainer 2, and using the valve lifter, press down the spring, fit the valve cotter halves to the stem end, and release the lifter to allow the valve cotter 3 to wedge in between retainer and stem.
  • Page 116: Oil Seal Inspection

    • Remove the retainer 1 and plug 2. • Remove the oil seal 3. OIL SEAL INSTALLATION • Apply SUZUKI SUPER GREASE “A” to the oil seal clip. ‘ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Fit a new oil seal with special tools.

  • Page 117: Cylinder Inspection

    6-20 CYLINDER HEAD, CYLINDER AND PISTON CYLINDER INSPECTION CYLINDER DISTORTION • Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance read- ing at several places indicated. • If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder.

  • Page 118: Piston And Piston Ring Inspection

    CYLINDER HEAD, CYLINDER AND PISTON 6-21 PISTON AND PISTON RING INSPECTION PISTON DIAMETER • Using a micrometer, measure the piston outside diameter at 15 mm (0.59 in) A from the piston skirt end. • If the measurement is less than the limit, replace the piston. «…

  • Page 119: Piston Ring Groove Width

    6-22 CYLINDER HEAD, CYLINDER AND PISTON PISTON RING-TO-GROOVE CLEARANCE • Decarbonize the piston ring and piston ring groove. • Measure the side clearances of the 1st piston ring using the thickness gauge. • If any of the clearances exceed the limit, replace both the pis- ton and piston ring.

  • Page 120: Crankshaft And Conrod Inspection

    CYLINDER HEAD, CYLINDER AND PISTON 6-23 CRANKSHAFT AND CONROD INSPECTION For inspection other than the following, refer to page 10-7. CONROD SMALL END I.D. • Using a small bore gauge, measure the inside diameter of the conrod small end. • If the inside diameter of the conrod small end exceeds the limit, replace the conrod.

  • Page 121: Cam Chain, Cam Chain Tensioner And Cam Chain Guide Installation

    6-24 CYLINDER HEAD, CYLINDER AND PISTON CAM CHAIN, CAM CHAIN TENSIONER AND CAM CHAIN GUIDE INSTALLATION Install the cam chain and cam chain tensioner in the reverse order of removal. Pay attention to the following points: • Install the cam chain tensioner 1. $ Cam chain tensioner bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft) •…

  • Page 122: Piston And Piston Ring Installation

    CYLINDER HEAD, CYLINDER AND PISTON 6-25 PISTON AND PISTON RING INSTALLATION Install the piston and piston ring in the reverse order of removal. Pay attention to the following points: PISTON RING • Install the piston rings in the order of oil ring and 1st ring. •…

  • Page 123
    6-26 CYLINDER HEAD, CYLINDER AND PISTON PISTON • Install the piston with the punch mark 1 facing towards the exhaust side. • Before installing the piston pin, apply MOLYBDENUM OIL SOLUTION onto its surface. % MOLYBDENUM OIL SOLUTION • Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into crankcase.
  • Page 124: Cylinder And Cylinder Head Installation

    • Thoroughly wipe off oil from the fitting surface of the crank- case. • Apply SUZUKI BOND “1215” to the crankcase as shown. ) 99000-31110: SUZUKI BOND “1215” or equivalent • Install the dowel pins into the crankcase and then install the cylinder gasket 1.

  • Page 125
    6-28 CYLINDER HEAD, CYLINDER AND PISTON CYLINDER HEAD • Install the dowel pins into the cylinder and then install the cyl- inder head gasket 1 onto the cylinder. CAUTION Use a new gasket to prevent gas leakage. • Place the cylinder head 2 on the cylinder. CAUTION Do not drop the cam chain into the crankcase.
  • Page 126: Camshaft (Automatic Decomp.) And Cam Chain Tension Adjuster Installation

    CYLINDER HEAD, CYLINDER AND PISTON 6-29 CAMSHAFT (AUTOMATIC DECOMP.) AND CAM CHAIN TENSION ADJUSTER INSTALLATION Install the camshaft and cam chain tension in the reverse order of removal. Pay attention to the following points: CAMSHAFT (AUTOMATIC DECOMP.) • Place a wrench over the crankshaft and turn it counter-clock- wise to align the TDC mark A with the center of the groove B of the timing inspection hole.

  • Page 127
    6-30 CYLINDER HEAD, CYLINDER AND PISTON • Pull the exhaust side of the cam chain taut to install the camshaft sprocket (exhaust side). • Turn the exhaust camshaft so that the timing mark C is aligned with the gasket surface of the cylinder head.
  • Page 128
    CYLINDER HEAD, CYLINDER AND PISTON 6-31 CAM CHAIN TENSION ADJUSTER • Retract the push rod by pushing the stopper 1. • Install a new gasket 2. CAUTION Use a new gasket to prevent oil leakage. • Install the cam chain tension adjuster 3 with “UP” mark faced upward.
  • Page 129: Clutch

    • Install the new gasket to the cylinder head cover. CAUTION Use the new gaskets to prevent oil leakage. • Apply SUZUKI BOND to the end caps of the cylinder head cover gasket as shown. * 99000-31140: SUZUKI BOND “1207B” or equivalent •…

  • Page 130
    CLUTCH CLUTCH CONTENTS CONSTRUCTION ………………7- 2 CLUTCH ………………..7- 2 CLUTCH PLATE ………………7- 3 REMOVAL ………………… 7- 3 INSPECTION ………………7- 5 RELEASE BEARING REPLACEMENT ……….7- 6 INSTALLATION ………………7- 7 PRIMARY DRIVEN GEAR AND CLUTCH SLEEVE HUB ……7- 9 REMOVAL …………………
  • Page 131: Construction

    CLUTCH CONSTRUCTION CLUTCH 10 N . m (1.0 kgf-m, 7.0 lb-ft) 90 N . m 9.0 kgf-m, 65.0 lb-ft Drive No. 1 plate (Black paint) Drive No. 2 plate (Green paint) Driven No. 1 plate (Silver) Driven No. 2 plate (Gray)

  • Page 132: Clutch Plate

    CLUTCH CLUTCH PLATE REMOVAL • Drain engine oil. (!2-11) • Remove the brake pedal. (!16-18) • Remove the clutch cover 1 and its gasket. • Hold the clutch housing with the special tool. CAUTION Be careful not to damage the clutch housing or clutch plates.

  • Page 133
    CLUTCH • Remove the clutch drive plates 4 and driven plates 5. NOTE: Mark the paint mark A to the clutch driven No. 2 plate. Mark the paint mark. A Clutch driven No. 2 plate B Clutch driven No. 1 plate C Direction of outside •…
  • Page 134: Inspection

    CLUTCH INSPECTION DRIVE PLATE • Measure the drive plate thickness. # Drive plate thickness Service Limit: 2.77 mm (0.109 in) » 09900-20101: Vernier calipers • Inspect the drive plates for wear, distortion and discoloration. • If the drive plate thickness is found to have reached the limit, replace it with a new one.

  • Page 135: Release Bearing Replacement

    CLUTCH PUSH ROD • Inspect the push rod for wear and damage. • If any defects are found, replace the push rod with a new one. RELEASE BEARING • Inspect the release bearing for play, discoloration, wear and seizure. • Move the inner race by finger and inspect for smooth move- ment.

  • Page 136: Installation

    CLUTCH INSTALLATION Install the clutch plates in the reverse order of removal. Pay attention to the following points: • Install the spring washer seat 1 and spring washer 2 onto the clutch sleeve hub correctly. • Apply engine oil to the drive plates 3 and driven plates 4. •…

  • Page 137
    CLUTCH • Install the clutch springs and clutch spring set bolts. • Hold the clutch housing with the special tool. CAUTION Be careful not to damage the clutch housing or clutch plates. » 09920-53740: Clutch sleeve hub holder • Tighten the clutch spring set bolts to the specified torque. NOTE: Tighten the clutch spring set bolts diagonally.
  • Page 138: Primary Driven Gear And Clutch Sleeve Hub

    CLUTCH PRIMARY DRIVEN GEAR AND CLUTCH SLEEVE HUB REMOVAL • Remove the clutch cover. (!7-3) • Remove the pressure plate and clutch plates. (!7-3, -4) • Flatten the lock washer 1. • Hold the clutch sleeve hub with the special tool and loosen the nut 2.

  • Page 139: Inspection

    7-10 CLUTCH INSPECTION • Inspect the clutch sleeve hub and primary driven gear for wear and cracks. • If necessary, replace the sleeve hub or driven gear. • Inspect the needle bearings and spacer for damage and wear. • If any defects are found, replace the bearing or spacer. INSTALLATION Install the primary driven gear and clutch sleeve hub in the reverse order of removal.

  • Page 140
    CLUTCH 7-11 • Tighten the clutch sleeve hub nut with the special tool to the specified torque. » 09920-53740: Clutch sleeve hub holder % Clutch sleeve hub nut: 90 N·m (9.0 kgf-m, 65.0 lb-ft) • Make sure the clutch sleeve hub for smooth movement. •…
  • Page 141: Clutch Release Camshaft

    7-12 CLUTCH CLUTCH RELEASE CAMSHAFT REMOVAL • Disconnect the clutch cable 1. NOTE: Loosen the clutch cable adjuster when disconnecting. • Remove the clutch cover and its gasket. (!7-3) • Remove the pressure plate and push rod. (!7-3) • Pull the clutch release camshaft 2 out of crankcase. INSPECTION CLUTCH RELEASE CAMSHAFT •…

  • Page 142: Installation

    Pay attention to the following points: • Apply SUZUKI MOLY PASTE to the clutch release camshaft. & 99000-25140: SUZUKI MOLY PASTE or equivalent • Apply SUZUKI SUPER GREASE “A” to the oil seal lips. ‘ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent •…

  • Page 143
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  • Page 144: Kick Starter

    KICK STARTER KICK STARTER CONTENTS CONSTRUCTION ………………8- 2 KICK STARTER ………………8- 2 KICK STARTER ………………. 8- 3 REMOVAL ………………… 8- 3 INSPECTION ………………8- 4 INSTALLATION ………………8- 5…

  • Page 145: Construction

    KICK STARTER CONSTRUCTION KICK STARTER 23 N·m (2.3 kgf-m, 16.5 lb-ft) 10 N·m (1.0 kgf-m, 7.0 lb-ft)

  • Page 146: Removal

    KICK STARTER KICK STARTER REMOVAL • Drain engine oil. (!2-11) • Drain engine coolant. (!13-3) • Remove the brake pedal. (!16-18) • Disconnect the radiator hose 1. • Remove the right front protector 2. • Remove the kick starter lever 3. •…

  • Page 147: Inspection

    KICK STARTER • Remove the following parts from the kick starter shaft 8: Return spring 9 Kick starter C Spring guide 0 Snap ring D Shim A Shim E Spring B Kick starter drive gear F » 09900-06107: Snap ring pliers •…

  • Page 148: Installation

    KICK STARTER INSTALLATION Install the kick starter in the reverse order of removal. Pay atten- tion to the following points: • Install the kick starter guide 1. # Kick starter guide bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Install the kick starter drive gear 2 and shim 3 to the kick starter shaft.

  • Page 149
    KICK STARTER • Install the shim 8 and spring 9 to the kick starter shaft. • Install the kick starter shaft assembly to the crankcase. NOTE: Securely engage the stopper portion C of the kick starter with the stopper guide D. •…
  • Page 150
    KICK STARTER • Install the kick starter lever so that its punch mark F aligns with the truncated spline G. • Tighten the kick starter lever bolt to the specified torque. # Kick starter lever bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) •…
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  • Page 152: Gearshifting

    GEARSHIFTING GEARSHIFTING CONTENTS CONSTRUCTION ………………9- 2 GEARSHIFT LINKAGE …………….. 9- 2 GEARSHIFT LINKAGE …………….9- 3 REMOVAL ………………… 9- 3 INSPECTION ………………9- 4 INSTALLATION ………………9- 5…

  • Page 153: Construction

    GEARSHIFTING CONSTRUCTION GEARSHIFT LINKAGE 10 N . m (1.0 kgf-m, 7.0 lb-ft) 24 N . m (2.4 kgf-m, 17.5 lb-ft)

  • Page 154: Removal

    GEARSHIFTING GEARSHIFT LINKAGE REMOVAL • Drain engine oil. (!2-11) • Drain engine coolant. (!13-3) • Remove the gearshift lever 1. NOTE: Mark the gearshift shaft head at which the gearshift lever slit set for correct reinstallation. • Remove the right crankcase cover and clutch assembly. (!7-9, 8-3) •…

  • Page 155: Inspection

    GEARSHIFTING • Remove the gearshift pawls 8, pins 9 and springs 0. • Remove the gearshift cam driven gear pin A and gearshift cam stopper plate B. • Remove the gearshift cam stopper C, spring D and washer INSPECTION • Inspect the gearshift shaft 1 for bends and damage. •…

  • Page 156: Installation

    GEARSHIFTING INSTALLATION Install the gearshift in the reverse order of removal. Pay atten- tion to the following points: • Install the washer 1, spring 2 and gearshift cam stopper 3. NOTE: Install the spring 2 to the hole A. # Shift cam stopper bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) •…

  • Page 157
    GEARSHIFTING • With the pawls held in pushed position, install the pawl lifter • Install the gearshift cam driven gear and pawl lifter. • Apply THREAD LOCK SUPER to the screws. • Tighten the screws. $ 99000-32030: THREAD LOCK SUPER “1303” or equivalent •…
  • Page 158
    GEARSHIFTING • Align the mark on the gearshift shaft head with the gearshift lever matching surface. • Tighten the gearshift lever bolt to specified torque. # Gearshift lever bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) INSPECTION AFTER INSTALLATION • Engine oil level and oil leakage (!2-11) •…
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  • Page 160
    TRANSMISSION AND CRANKSHAFT 10-1 TRANSMISSION AND CRANKSHAFT CONTENTS CONSTRUCTION ………………10- 2 TRANSMISSION AND CRANKSHAFT ……….10- 2 ENGINE BOTTOM SIDE …………….10- 3 PRIMARY DRIVE GEAR REMOVAL ……….10- 3 CRANKCASE SEPARATION …………. 10- 4 TRANSMISSION REMOVAL ………….. 10- 4 CRANKSHAFT REMOVAL …………..
  • Page 161: Construction

    10-2 TRANSMISSION AND CRANKSHAFT CONSTRUCTION TRANSMISSION AND CRANKSHAFT 90 N . m (9.0 kgf-m, 65.0 lb-ft)

  • Page 162: Engine Bottom Side

    TRANSMISSION AND CRANKSHAFT 10-3 ENGINE BOTTOM SIDE • Remove the engine. (!5-2 to -5) NOTE: The following parts must be removed before disassembling the engine bottom side (crankcase). • Remove the cylinder head, cylinder and piston. (!6-4 to -6) • Remove the magneto cover. (!14-10) •…

  • Page 163: Crankcase Separation

    10-4 TRANSMISSION AND CRANKSHAFT CRANKCASE SEPARATION • Remove the engine sprocket spacer 1 and two O-rings 2. • Remove the oil strainer cap 3 and oil strainer (No.1). (!2-13) • Remove the crankcase bolts and engine oil drain plug 4. •…

  • Page 164: Crankshaft Removal

    TRANSMISSION AND CRANKSHAFT 10-5 • Remove the gearshift fork shaft 4. • Remove the gearshift cam 5. • Remove the gearshift forks 6. • Remove the countershaft assembly 7 and driveshaft assem- bly 8. CRANKSHAFT REMOVAL • Remove the crankshaft with the special tool. CAUTION Be careful not to damage the thread part of the crank- shaft.

  • Page 165: Transmission Inspection

    10-6 TRANSMISSION AND CRANKSHAFT TRANSMISSION INSPECTION • Inspect the gear teeth, dogs, and gearshift grooves for abnor- mal wear and damage. • Inspect the bushings and splines for abnormal wear and dis- coloration. • If necessary, replace defective parts with a new one. •…

  • Page 166: Conrod Inspection

    TRANSMISSION AND CRANKSHAFT 10-7 • Measure the gearshift fork groove width with a vernier cali- pers. # Gearshift fork groove width Standard: 4.95 – 5.05 mm (0.195 – 0.199 in) » 09900-20101: Vernier calipers CONROD INSPECTION • For conrod inspection other than the following, refer to page 6-??.

  • Page 167: Oil Seal Inspection

    Oil seal 2: $ 22 Attachment Oil seal 3: $ 17 Attachment • Apply grease to each oil seal lip. % 99000-25010: SUZUKI SUPER GREASE “A” or equivalent NOTE: Be sure to check the direction of the crankshaft bearing oil seal 4 before fitting them.

  • Page 168: Bearing Inspection

    TRANSMISSION AND CRANKSHAFT 10-9 BEARING INSPECTION • Inspect the bearings for play, discoloration, wear and seizure. • Move the inner race by finger and inspect for smooth move- ment. • If it does not move smoothly, replace the bearing with a new one.

  • Page 169
    10-10 TRANSMISSION AND CRANKSHAFT • Remove the bearings 2, 8. » 09921-20240: Bearing remover set Bearing 2, 8: Remover 20 mm • Remove the bearing 4. » 09941-64511: Bearing/Oil seal remover 09930-30104: Sliding shaft • Remove the bearing 9. » 09921-20200: Bearing remover 09930-30104: Sliding shaft •…
  • Page 170
    TRANSMISSION AND CRANKSHAFT 10-11 INSTALLATION • Press the new bearings with the special tools. Bearing 1: $ 55 Attachment Bearing 2, 8: $ 42 Attachment Bearing 3, 6: $ 72 Attachment Bearing 4: $ 40 Attachment Bearing 5: $ 52 Attachment Bearing 7: $ 37 Attachment Bearing 9: $ 15 Attachment «…
  • Page 171: Crankshaft Installation

    10-12 TRANSMISSION AND CRANKSHAFT CRANKSHAFT INSTALLATION • Fit the crankshaft into the left crankcase with the special tools. NOTE: Use the attachment (inner driver attachment 3) for crankshaft bearing inside diameter. » 09910-32812: Crankshaft installer 1 09911-11310: Crankshaft installer attachment 2 09913-70210: Bearing installer set (Inner driver attachment 35 mm 3)

  • Page 172: Transmission Installation

    TRANSMISSION AND CRANKSHAFT 10-13 TRANSMISSION INSTALLATION 28.5 mm (1.12 in) NOTE: Install the snap ring in the groove and locate its end as shown in the illustration. Thrust Sharp edge • Apply engine oil to the following parts: driveshaft, counter- shaft, transmission gears, bearings.

  • Page 173
    10-14 TRANSMISSION AND CRANKSHAFT • Install the gearshift forks 3, 4. • Install the gearshift cam 5 and gearshift shaft 6. NOTE: Turn the gearshift cam to the neutral position and confirm that the driveshaft and countershaft turn without resistance. •…
  • Page 174: Crankcase Installation

    TRANSMISSION AND CRANKSHAFT 10-15 CRANKCASE INSTALLATION • Fit the dowel pins and gasket 1. CAUTION Replace the gasket 1 with a new one. • Fit the right crankcase on the left crankcase. • Install the bracket A to the bolt. (!19-24) •…

  • Page 175: Primary Drive Gear Installation

    10-16 TRANSMISSION AND CRANKSHAFT • Apply grease to Oil seal lip and O-rings 5. % 99000-25010: SUZUKI SUPER GREASE “A” or equivalent CAUTION Replace the O-rings with new ones. • Fit the O-rings 5 and spacer 6 to the driveshaft.

  • Page 176
    TRANSMISSION AND CRANKSHAFT 10-17 • Connect the crankcase breather hose 4. • Install the oil pump No.1, No.2 and oil pump idle gear. (!11-6) • Install the gearshift linkage. (!9-5) • Install the kick idle gear and kick starter shaft. (!8-5) •…
  • Page 177
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  • Page 178: Lubrication System

    LUBRICATION SYSTEM 11-1 LUBRICATION SYSTEM CONTENTS ENGINE LUBRICATION SYSTEM …………11- 2 ENGINE LUBRICATION SYSTEM CHART ……..11- 2 ENGINE OIL LEVEL INSPECTION …………. 11- 3 ENGINE OIL CHANGE ……………. 11- 3 ENGINE OIL FILTER CHANGE …………11- 3 OIL PRESSURE CHECK …………..11- 3 OIL STRAINERS REMOVAL …………..

  • Page 179: Engine Lubrication System

    11-2 LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM CHART CAM SPROCKET & CAM CHAIN CAMSHAFT BEARINGS IN & EX CAM FACES CONROD SMALL END CAMSHAFT CYLINDER WALL JOURNALS OIL NOZZLE CYLINDER HEAD CYLINDER RIGHT CRANKCASE CLUTCH CRANKSHAFT RIGHT CRANKCASE COUNTER SHAFT RIGHT END COVER…

  • Page 180: Engine Oil Level Inspection

    LUBRICATION SYSTEM 11-3 ENGINE OIL LEVEL INSPECTION (!2-11) ENGINE OIL CHANGE (!2-11) ENGINE OIL FILTER CHANGE (!2-12) OIL PRESSURE CHECK (!2-37) OIL STRAINER REMOVAL (!2-13) OIL STRAINER INSPECTION (!2-13) OIL STRAINER INSTALLATION (!2-13) OIL SEAL REMOVAL • Remove the snap ring 1. «…

  • Page 181: Oil Seal Installation

    • Fit the new oil seal with the special tools. » 09913-70210: Bearing installer set Oil seal: # 22 Attachment • Apply SUZUKI SUPER GREASE to the oil seal lip. $ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the snap ring 1.

  • Page 182: Oil Pump No.1 And No.2 Inspection

    LUBRICATION SYSTEM 11-5 • Remove the oil pump No.2 shaft 2, pin 3, inner rotor 4 and outer rotor 5. OIL PUMP No.1 AND No.2 INSPECTION • Check the oil pump with each part for any defects or wear. • Replace the defective parts with a new one.

  • Page 183: Oil Pump No.1 And No.2 Installation

    11-6 LUBRICATION SYSTEM OIL PUMP No.1 AND No.2 INSTALLATION OIL PUMP No.1 Install the oil pump No.1 in the reverse order of removal. Pay attention to the following points: • Install the oil pump No.1 cover 2, oil pump No.1 plate 3 and pin 4 to oil pump driven gear shaft 1.

  • Page 184
    LUBRICATION SYSTEM 11-7 OIL PUMP No.2 Install the oil pump No.2 in the reverse order of removal. Pay attention to the following points: • Install the pin 2 to oil pump No.2 shaft 1. • Install the inner rotor 3 to oil pump No.2 shaft 1. NOTE: Fit the slot A of the inner rotor to the pin 2.
  • Page 185
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  • Page 186: Fuel System

    FUEL SYSTEM 12-1 FUEL SYSTEM CONTENTS FUEL TANK AND FUEL VALVE …………… 12- 2 CONSTRUCTION …………….12- 2 REMOVAL ………………. 12- 2 CLEANING AND INSPECTION …………12- 3 INSTALLATION ………………. 12- 3 CARBURETOR ………………12- 4 CONSTRUCTION …………….12- 4 REMOVAL ……………….

  • Page 187: Fuel Tank And Fuel Valve

    12-2 FUEL SYSTEM FUEL TANK AND FUEL VALVE CONSTRUCTION REMOVAL » WARNING Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Remove the seat. (!5-2) • Remove the fuel tank. (!5-2) • Drain fuel. • Remove the fuel valve 1. •…

  • Page 188: Cleaning And Inspection

    FUEL SYSTEM 12-3 CLEANING AND INSPECTION If the fuel strainer is dirty with sediment, fuel will not flow smoothly and loss in engine power may result. Clean the fuel strainer with compressed air. INSTALLATION Install the fuel tank and fuel valve in the reverse order of removal.

  • Page 189: Carburetor

    12-4 FUEL SYSTEM CARBURETOR CONSTRUCTION 1 Clip 2 Jet needle 3 Throttle valve Throttle position sensor 5 Slow air jet 6 Starter jet 7 Pilot screw 8 Slow jet 9 Main jet 0 Float valve A Float B Leak jet C Throttle stop screw…

  • Page 190: Removal

    FUEL SYSTEM 12-5 REMOVAL » WARNING Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Remove the seat and radiator covers. (!5-2) • Turn the fuel valve to the OFF position. • Place a container beneath the drain hose, drain fuel from the float chamber by loosening the drain screw 1.

  • Page 191: Disassembly

    12-6 FUEL SYSTEM • Remove the throttle pulley cover 6. • Loosen the lock-nuts 7. • Remove the throttle cables from the pulley. DISASSEMBLY • Remove the hot starter valve 1 and spring from the hot starter cable. • Remove the drain hose, fuel hose and air vent hoses. NOTE: Do not remove the throttle position sensor 2 unless it is neces- sary to replace it.

  • Page 192
    FUEL SYSTEM 12-7 • Remove the throttle valve assembly 5. • Disassemble the throttle valve assembly. 6 Throttle valve A Spring 7 Bearing B Needle set screw 8 Jet needle C Floating valve 9 Clip D Seal 0 Collar • Remove the throttle shaft E with the link arm F, spring G, plastic washer H and steel washer I.
  • Page 193
    12-8 FUEL SYSTEM • Remove the acceleration pump cover K. • Remove the spring L, O-rings M and diaphragm N. • Remove the float chamber O from the carburetor body. • Remove the drain plug P and leak jet Q. •…
  • Page 194
    FUEL SYSTEM 12-9 • Remove the following parts. Z Main jet [ Main nozzle Buffer plate ] Starter jet ^ Slow jet • Remove the slow air jet a.
  • Page 195: Cleaning

    12-10 FUEL SYSTEM CLEANING » WARNING 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.

  • Page 196
    FUEL SYSTEM 12-11 FUEL LEVEL • Remove the drain hose and then install a proper cap 1 to the carburetor drain. • Remove the drain screw and than connect the special tool. $ 09913-14541: Fuel level gauge • Hold the carburetor in the proper angle with a stand. Lateral direction: Horizontal Carburetor set position…
  • Page 197: Reassembly

    12-12 FUEL SYSTEM FLOAT HEIGHT • Tilt the carburetor until the float arm B just touches the float valve rod. • Measure the float height A. % Standard float height: 8.0 mm (0.315 in) $ 09900-20101: Vernier calipers • If necessary, slightly bend the float arm B to change the float height.

  • Page 198
    Replace the O-rings with new ones. • Apply thin coat of the grease to the O-ring. CAUTION Replace the O-ring with a new one. & 09900-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the pilot screw 0. NOTE: Turn in the pilot screw 0 until it lightly seats, then back it out the counted number of turns.
  • Page 199
    12-14 FUEL SYSTEM • Apply SUZUKI SILICONE GREASE to the throttle shaft. ‘ 99000-25100: SUZUKI SILICONE GREASE or equivalent • Hook the return spring onto the stopper of the throttle pulley. • Insert the throttle shaft and install the steel washer A, plastic washer B and link arm C.
  • Page 200
    FUEL SYSTEM 12-15 CAUTION Replace the gasket with a new one. • Reassemble the hot start valve E to the hot start cable end. ACCELERATION PUMP TIMING If turn the stop screw of the acceleration pump, adjust the accel- eration pump timing after assemble the carburetor. •…
  • Page 201: Installation

    12-16 FUEL SYSTEM INSTALLATION Install the carburetor in the reverse order of removal. Pay atten- tion to the following points: • Fit the projection on the carburetor body in the depression of the intake pipe. INSPECTION AFTER INSTALLATION • Wire, cable and hose routing (!19-18 to -22) •…

  • Page 202: Throttle Position Sensor

    FUEL SYSTEM 12-17 THROTTLE POSITION SENSOR INSPECTION THROTTLE POSITION SENSOR INPUT VOLTAGE • Disconnect the throttle position sensor coupler 1. • Shift the transmission into neutral. B/Bl • Start the engine. • Measure the throttle position sensor input voltage using the multi circuit tester.

  • Page 203: Removal

    12-18 FUEL SYSTEM REMOVAL • Remove the carburetor. (!12-5) • Remove the throttle position sensor using the special tool. $ 09930-11950: Torx wrench, T25 INSTALLATION • Install the throttle valve with the throttle position sensor. NOTE: Align the throttle shaft end A with the groove B of throttle posi- tion sensor.

  • Page 204
    COOLING SYSTEM 13-1 COOLING SYSTEM CONTENTS CONSTRUCTION ………………13- 2 ENGINE COOLANT ………………. 13- 3 REPLACEMENT ……………… 13- 3 COOLING CIRCUIT ………………. 13- 4 INSPECTION ………………13- 4 RADIATOR ………………..13- 5 INSPECTION ………………13- 5 REMOVAL ………………. 13- 6 INSTALLATION ……………….
  • Page 205: Construction

    13-2 COOLING SYSTEM CONSTRUCTION 10 N . m (1.0 kgf-m, 7.0 lb-ft) 11 N . m (1.1 kgf-m, 8.0 lb-ft)

  • Page 206: Engine Coolant

    COOLING SYSTEM 13-3 ENGINE COOLANT REPLACEMENT $ WARNING Engine coolant may be harmful if swallowed or if it comes in contact with the skin or eyes. If engine cool- ant gets into the eyes or contacts the skin, flush the eyes or wash the skin thoroughly, with plenty of water.

  • Page 207: Cooling Circuit

    13-4 COOLING SYSTEM COOLING CIRCUIT INSPECTION • Remove the radiator cap. $ WARNING * Engine coolant may be harmful if swallowed or if it comes in contact with the skin or eyes. If engine coolant gets into the eyes or contacts the skin, flush the eyes or wash the skin thoroughly, with plenty of water.

  • Page 208: Radiator

    COOLING SYSTEM 13-5 RADIATOR INSPECTION RADIATOR • Visually inspect the radiators and hose for damage. • Fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver. RADIATOR CAP • Fit the cap to the radiator cap tester. •…

  • Page 209: Removal

    13-6 COOLING SYSTEM REMOVAL $ WARNING * Engine coolant may be harmful if swallowed or if it comes in contact with the skin or eyes. If engine coolant gets into the eyes or contacts the skin, flush the eyes or wash the skin thoroughly, with plenty of water.

  • Page 210: Water Pump

    COOLING SYSTEM 13-7 WATER PUMP REMOVAL $ WARNING Engine coolant may be harmful if swallowed or if it comes in contact with the skin or eyes. If engine cool- ant gets into the eyes or contacts the skin, flush the eyes or wash the skin thoroughly, with plenty of water.

  • Page 211: Inspection

    13-8 COOLING SYSTEM • Remove the shim 3 and water pump shaft 4. • Remove the oil seal. CAUTION Replace the removed oil seal with a new one. NOTE: If there is no abnormal condition, the oil seal removal is not nec- essary.

  • Page 212
    COOLING SYSTEM 13-9 • Press the oil seal with the suitable size socket wrench. • Apply SUZUKI SUPER GREASE to the oil seal lip. & 99000-25010: SUZUKI SUPER GREASE “A” or equivalent IMPELLER AND WATER PUMP SHAFT • Hold the water pump shaft with a wrench and tighten the impeller to the specified torque.
  • Page 213
    13-10 COOLING SYSTEM WATER PUMP CASE • Install the dowel pins and oil filter 1. • Install the spring 2 and a new gasket 3. • Apply engine coolant to the gasket 3. CAUTION Use a new gasket to prevent engine oil/coolant leak- age.
  • Page 214: Electrical System

    ELECTRICAL SYSTEM 14-1 ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING …………… 14- 2 CONNECTOR ………………14- 2 COUPLER ………………. 14- 2 SEMI-CONDUCTOR EQUIPPED PART ……….14- 2 USING THE MULTI-CIRCUIT TESTER ……….14- 2 SWITCH ………………..14- 2 LOCATION OF ELECTRICAL COMPONENTS ……..14- 3 CONSTRUCTION ………………

  • Page 215: Cautions In Servicing

    14-2 ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTOR • When connecting a connector, be sure to push it in until a click is felt. Click • Inspect the connector for corrosion, contamination and break- age in its cover. COUPLER Click • With a lock type coupler, be sure to release the lock when dis- connecting, and push in fully to engage the lock when con- necting.

  • Page 216: Location Of Electrical Components

    ELECTRICAL SYSTEM 14-3 LOCATION OF ELECTRICAL COMPONENTS 1 Engine stop switch 4 CDI unit 2 Ignition coil 5 Pick-up coil 3 Throttle position sensor 6 Magneto…

  • Page 217: Construction

    14-4 ELECTRICAL SYSTEM CONSTRUCTION ELECTRICAL SYSTEM 80 N . m (8.0 kgf-m, 58.0 lb-ft) ELECTRICAL CIRCUIT Throttle position sensor Engine stop switch B/Br B/Br B/Br B/Bl B/Bl B/Bl Magneto W/Bl Ignition coil CDI unit Y Y Y Spark plug WIRE COLOR: G: Green B/Bl: Black with Blue tracer B/W: Black with White tracer…

  • Page 218: Troubleshooting

    ELECTRICAL SYSTEM 14-5 TROUBLESHOOTING No spark or poor spark Step 1 1) Check the ignition system couplers for poor connections. Is there connection in the ignition system couplers? Go to Step 2. Poor connection of couplers Step 2 1) Measure the ignition coil primary peak voltage. («14-8) Is the peak voltage OK? Go to Step 3.

  • Page 219
    14-6 ELECTRICAL SYSTEM Step 7 1) Check the stator. Is the stator OK? Go to Step 8. Faulty stator Step 8 1) Measure the engine stop switch resistance. («14-9) Is the resistance OK? • Faulty CDI unit • Open or short circuit in wire harness Faulty engine stop switch…
  • Page 220: Ignition System

    ELECTRICAL SYSTEM 14-7 IGNITION SYSTEM IGNITION SYSTEM PEAK VOLTAGE INSPECTION • Disconnect the magneto lead wire coupler 1. • Connect the multi-circuit tester with peak volt adaptor as shown. • Measure the highest peak voltage by depressing the kick starter pedal several times forcefully. # Stator coil peak voltage + Black/Red –…

  • Page 221: Ignition System Coil Inspection

    14-8 ELECTRICAL SYSTEM IGNITION SYSTEM COIL INSPECTION • Disconnect the magneto lead wire coupler 1. • Measure the exciter, charge and pick-up coils resistance. # Stator coil resistance 24 – 40 Ω Exciter Black/Red – Red/White 1.6 – 3.2 Ω Charge Yellow –…

  • Page 222: Ignition Coil Inspection

    ELECTRICAL SYSTEM 14-9 IGNITION COIL INSPECTION • Remove the seat and fuel tank. («5-2) • Disconnect the ignition coil lead wire coupler 1 and spark plug cap 2. • Measure the ignition coil resistance. # Ignition coil resistance White/Blue – 0.17 –…

  • Page 223: Magneto Rotor

    14-10 ELECTRICAL SYSTEM MAGNETO ROTOR REMOVAL • Drain engine oil. («2-11) • Remove the seat and fuel tank. («5-2) • Disconnect the magneto lead wire coupler and clamp. • Remove the left front protector 1. • Remove the gearshift lever 2. («9-3) •…

  • Page 224
    ELECTRICAL SYSTEM 14-11 • Remove the magneto rotor nut with a special tool. ! 09930-44560: Rotor holder • Remove the magneto rotor with a special tool. ! 09930-35020: Rotor remover • Remove the magneto rotor key 5.
  • Page 225: Installation

    14-12 ELECTRICAL SYSTEM INSTALLATION • Remove any grease from the tapered portion A of the mag- neto rotor and crankshaft B. • Fit the magneto rotor key 1 into the crankshaft. • Install the magneto rotor. • Tighten the magneto rotor nut to the specified torque with a special tool.

  • Page 226: Stator

    ELECTRICAL SYSTEM 14-13 STATOR REMOVAL • Remove the magneto cover. («14-10) • Remove the stator 1. • Remove the clamp 2 and pick-up coil 3. • Remove the grommet 4. INSTALLATION • Apply THREAD LOCK to the stator set bolts and tighten them. ( 99000-32050: THREAD LOCK “1342”…

  • Page 227
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  • Page 228: Front And Rear Wheels

    FRONT AND REAR WHEELS 15-1 FRONT AND REAR WHEELS CONTENTS CONSTRUCTION ………………15- 2 FRONT WHEEL ………………15- 3 REMOVAL ………………. 15- 3 INSPECTION ………………15- 4 DUST SEAL AND BEARING REPLACEMENT ……..15- 5 DISC PLATE REPLACEMENT …………15- 7 INSTALLATION ……………….

  • Page 229: Construction

    15-2 FRONT AND REAR WHEELS CONSTRUCTION 90 N . m (9.0 kgf-m, 65.0 lb-ft) 25 N . m (2.5 kgf-m, 18.0 lb-ft) 30 N . m (3.0 kgf-m, 21.5 lb-ft) 12 N . m (1.2 kgf-m, 8.5 lb-ft) 35 N . m (3.5 kgf-m, 25.5 lb-ft)

  • Page 230: Front Wheel

    FRONT AND REAR WHEELS 15-3 FRONT WHEEL REMOVAL • Remove the front axle nut 1. • Loosen the left axle holder bolts 2. • Place the motorcycle on a block to lift front wheel off the ground. • Loosen the right axle holder bolts 3. •…

  • Page 231: Inspection

    15-4 FRONT AND REAR WHEELS INSPECTION SPACER AND DUST SEAL • Inspect the right and left dust seals 1 and wheel spacers 2 for wear and cracks. • If any defects are found, replace the spacer together with the dust seal. NOTE: Apply grease to the spacer and dust seal before reassembling.

  • Page 232: Dust Seal And Bearing Replacement

    FRONT AND REAR WHEELS 15-5 WHEEL BEARING • Turn the inner race by finger and inspect it for smooth move- ment. • Inspect for bearing damage. • If any defects are found, replace the bearing with a new one. DUST SEAL AND BEARING REPLACEMENT •…

  • Page 233
    • Fit the dust seals and apply grease to their lips. NOTE: When installing the dust seal, place the manufacturer’s code indicated side of the dust seal outside. » 09913-70210: Bearing installer set Bearing: #40 Attachment $ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent…
  • Page 234: Disc Plate Replacement

    FRONT AND REAR WHEELS 15-7 DISC PLATE REPLACEMENT • Remove the disc plate. • Apply THREAD LOCK SUPER to the bolts. % 99000-32110: THREAD LOCK SUPER “1322” or equivalent • Tighten the bolts to the specified torque. & Disc plate bolt: 12 N·m (1.2 kgf-m, 8.5 lb-ft) INSTALLATION •…

  • Page 235: Rear Wheel

    15-8 FRONT AND REAR WHEELS REAR WHEEL REMOVAL • Loosen the rear axle nut 1. • Place the motorcycle on a block to lift the rear wheel off the ground. • Remove rear axle nut 1 and washer 2. • Remove the rear axle shaft 3 and chain adjuster washers 4. •…

  • Page 236: Inspection

    FRONT AND REAR WHEELS 15-9 INSPECTION WHEEL SPACER AND DUST SEAL • Inspect the rear wheel spacers 1 and dust seals 2 for wear and cracks. • If any defects are found, replace the spacer together with the dust seal. NOTE: Apply grease on the spacer and dust seal before reassembling.

  • Page 237
    • Remove the spacer 2 and bearing with the special tool. » 09921-20240: Bearing remover set (Remover 25 mm) • Apply grease to the wheel bearings. $ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Assemble the bearings with the special tools, using the suit- able spacer A match for the outside dimension of bearings.
  • Page 238: Disc Plate Replacement

    When installing the dust seal, place the manufacturer’s code indicated side of the dust seal outside. » 09913-70210: Bearing installer set Oil seal: #42 Attachment $ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent DISC PLATE REPLACEMENT • Remove the disc plate.

  • Page 239: Rear Sprocket Replacement

    15-12 FRONT AND REAR WHEELS REAR SPROCKET REPLACEMENT • Remove the rear sprocket. NOTE: Install the rear sprocket as the letter on the sprocket surface faces outside. • Tighten the nuts to the specified torque. & Rear sprocket nut: 30 N·m (3.0 kgf-m, 21.5 lb-ft) INSTALLATION Left Right…

  • Page 240: Front And Rear Brakes

    FRONT AND REAR BRAKES 16-1 FRONT AND REAR BRAKES CONTENTS CONSTRUCTION ………………16- 2 BRAKE FLUID AIR BLEEDING …………..16- 3 BRAKE FLUID REPLACEMENT …………… 16- 4 BRAKE PADS REPLACEMENT …………… 16- 5 FRONT BRAKE PADS ……………. 16- 5 REAR BRAKE PADS …………….16- 5 BRAKE DISC INSPECTION …………..

  • Page 241: Construction

    16-2 FRONT AND REAR BRAKES CONSTRUCTION 10 N·m (1.0 kgf-m, 7.0 lb-ft) 23 N·m 23 N·m (2.3 kgf-m, (2.3 kgf-m, 16.5 lb-ft) 16.5 lb-ft) 10 N·m 23 N·m (1.0 kgf-m, 7.0 lb-ft) (2.3 kgf-m, 16.5 lb-ft) 18 N·m (1.8 kgf-m, 13.0 lb-ft) 29 N·m (2.9 kgf-m, 21.0 lb-ft)

  • Page 242: Brake Fluid Air Bleeding

    FRONT AND REAR BRAKES 16-3 BRAKE FLUID AIR BLEEDING «#WARNING Brake fluid can be hazardous to humans and pets. Brake fluid is harmful or fatal if swallowed, and harm- ful if it comes in contact with your skin or eyes. Keep brake fluid away from children.

  • Page 243: Brake Fluid Replacement

    16-4 FRONT AND REAR BRAKES • Connect a transparent tube to the bleeder valve and set the other end into a receptacle. • Loosen the bleeder valve and pump the brake lever/pedal until air bubbles stop coming out from the reservoir. •…

  • Page 244: Brake Pads Replacement

    FRONT AND REAR BRAKES 16-5 BRAKE PADS REPLACEMENT FRONT BRAKE PADS • Remove the cap 1 and pad mounting pin 2. • Remove the brake pads 3. NOTE: Replace the two brake pads as a set. • Fit the new brake pads into the caliper. •…

  • Page 245: Brake Disc Inspection

    16-6 FRONT AND REAR BRAKES BRAKE DISC INSPECTION • Inspect the brake disc for damage. • Measure the front and rear brake disc thickness. & Brake disc thickness Service limit (Front): 2.5 mm (0.10 in) (Rear): 3.5 mm (0.14 in) •…

  • Page 246: Front Caliper Removal And Disassembly

    FRONT AND REAR BRAKES 16-7 FRONT CALIPER REMOVAL AND DISASSEMBLY • Place a rag under the brake hose union bolt to catch spilled brake fluid. • Remove the union bolt 1. • Disconnect the brake hose. • Remove the caliper mounting bolts 2. •…

  • Page 247: Caliper Inspection

    ! Specification and classification: DOT 4 • Install the springs and boots. • Apply SUZUKI SILICONE GREASE to the caliper axles. ‘ 99000-25100: SUZUKI SILICONE GREASE or equivalent • Install the caliper bracket.

  • Page 248: Rear Caliper Removal And Disassembly

    FRONT AND REAR BRAKES 16-9 • Tighten the caliper mounting bolts 1 to the specified torque. $ Brake caliper mounting bolt: 25 N·m (2.5 kgf-m, 18.0 lb-ft) • Tighten the brake pad mounting pin 2 to the specified torque. $ Brake pad mounting pin: 18 N·m (1.8 kgf-m, 13.0 lb-ft) •…

  • Page 249: Rear Caliper Reassembly And Installation

    16-10 FRONT AND REAR BRAKES • Remove the caliper bracket 5 from the caliper. • Remove the boots 6 and 7. • Remove the spring 8. • Wrap the caliper with a rag to prevent brake fluid scatter and piston pop-out. •…

  • Page 250
    FRONT AND REAR BRAKES 16-11 • Install the springs and boots. • Apply SUZUKI SILICONE GREASE to the caliper axles. ‘ 99000-25100: SUZUKI SILICONE GREASE or equivalent • Install the caliper bracket. • Install the brake pads. • Tighten the brake pad mounting pin temporarily.
  • Page 251: Master Cylinder

    16-12 FRONT AND REAR BRAKES MASTER CYLINDER «#WARNING Brake fluid can be hazardous to humans and pets. Brake fluid is harmful or fatal if swallowed, and harm- ful if it comes in contact with your skin or eyes. Keep brake fluid away from children. Call your doctor immediately if brake fluid is swallowed, and induce vomiting.

  • Page 252: Master Cylinder Inspection

    FRONT AND REAR BRAKES 16-13 • Remove the dust boot 5. • Remove the snap ring 6 with snap ring pliers. ( 09900-06108: Snap ring pliers • Remove the washer 7 and piston/cup set 8. MASTER CYLINDER INSPECTION • Inspect the cylinder bore and piston for scuffing, wear and damage.

  • Page 253: Front Master Cylinder Reassembly And Installation

    • Apply grease to the brake lever pivot bolt and contact point between piston and brake lever. ) 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Tighten the pivot bolt and nut to the specified torque. $ Brake lever pivot nut: 6 N·m (0.6 kgf-m, 4.4 lb-ft) Brake lever pivot bolt: 6 N·m (0.6 kgf-m, 4.4 lb-ft)

  • Page 254: Rear Master Cylinder Removal And Disassembly

    FRONT AND REAR BRAKES 16-15 REAR MASTER CYLINDER REMOVAL AND DISASSEMBLY • Drain brake fluid. (%16-4) • Remove the cotter pin, washer and then master cylinder rod pin 1. • Remove the master cylinder mounting bolts and master cylin- der 2. •…

  • Page 255: Master Cylinder Inspection

    • Apply grease to the contact point between piston and push rod. ) 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Set the brake hose end between the hose stoppers, then tighten the brake hose union bolt 1 to the specified torque.

  • Page 256: Brake Lever

    • Apply grease to the brake lever adjuster return spring, pivot bolt and contact point between piston and brake lever. ) 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Tighten the pivot bolt and nut to the specified torque.

  • Page 257: Installation

    • Remove the master cylinder rod pin 4. • Remove the brake pedal pivot bolt 5 and return spring 6. INSTALLATION • Apply SUZUKI SUPER GREASE to the oil seal and brake pedal pivot bolt. ) 99000-25010: SUZUKI SUPER GREASE “A”…

  • Page 258: Front Fork And Steering

    FRONT FORK AND STEERING 17-1 FRONT FORK AND STEERING CONTENTS CONSTRUCTION ………………17- 2 FRONT FORK, STEERING …………..17- 2 HANDLEBAR CONTROLS …………..17- 3 REMOVAL ………………. 17- 4 DISASSEMBLY ………………. 17- 5 INSPECTION ………………17- 9 REASSEMBLY ………………17-11 INSTALLATION ……………….

  • Page 259: Construction

    17-2 FRONT FORK AND STEERING CONSTRUCTION FRONT FORK, STEERING 25 N . m (2.5 kgf-m, 18.0 lb-ft) 100 N . m (10.0 kgf-m, 72.5 lb-ft) 23 N . m 30 N . m (3.0 kgf-m, 21.5 lb-ft) (2.3 kgf-m, 16.5 lb-ft) 35 N .

  • Page 260: Handlebar Controls

    FRONT FORK AND STEERING 17-3 HANDLEBAR CONTROLS 25 N·m (2.5 kgf-m, 18.0 lb-ft) 6 N·m (0.6 kgf-m, 4.5 lb-ft) 6 N·m (0.6 kgf-m, 4.5 lb-ft)

  • Page 261: Removal

    17-4 FRONT FORK AND STEERING REMOVAL • Place the motorcycle on a block to lift front wheel off the ground. • Remove the front wheel. (!15-3) • Remove the front number plate 1. • Remove the protector 2. • Remove the handlebar. NOTE: Mark the paint mark A to the matching surface of handlebar holder and handlebars before removing.

  • Page 262: Disassembly

    FRONT FORK AND STEERING 17-5 DISASSEMBLY • Set rebound and compression damper settings to the mini- mum settings (softest) before disassembling. Record the set- ting before turning the adjuster. • Thoroughly clean the fork before disassembly. CAUTION Scratches or other damage on the inner tube or on the oil seal lip will cause oil leakage.

  • Page 263
    17-6 FRONT FORK AND STEERING • Clamp the axle holder 2 with a vise. Protect the axle holder with a rag when using a vise. • Loosen the center bolt 3 completely with a 21 mm socket wrench. # WARNING Clamping the axle holder too tight can damage it which will affect riding stability.
  • Page 264
    FRONT FORK AND STEERING 17-7 • With the outer tube compressed by hands, remove the special tool. CAUTION Removing the lock-nut 4 and pushing the inner rod thread into the damper rod will damage the inner rod oil seal. Do not remove the lock-nut 4 from the inner rod. •…
  • Page 265
    17-8 FRONT FORK AND STEERING INNER TUBE • Separate the inner tube 1 out of the outer tube 2. • Remove the slide bushing 3 from the inner tube 1. • Remove the following parts from the inner tube 1. Guide bushing 4 Seal retainer 5 Oil seal 6…
  • Page 266: Inspection

    FRONT FORK AND STEERING 17-9 • Drain the fork oil from the damper rod assembly by moving the inner rod several strokes. INSPECTION CENTER BOLT • Inspect the adjuster rod of the center bolt for damage. If it is damaged, replace it with a new one. COMPRESSION DAMPER UNIT •…

  • Page 267
    17-10 FRONT FORK AND STEERING DAMPER ROD ASSEMBLY • Inspect the damper rod assembly for scratches or bending. If it has scratches or is bent, replace it with a new one. FORK SPRING • Measure the free length of front fork spring. •…
  • Page 268: Reassembly

    FRONT FORK AND STEERING 17-11 REASSEMBLY NOTE: * Clean all fork parts before reassembling. * Replace the O-rings, oil seal and dust seal with new ones. * Apply specified front fork oil when installing the O-rings, slide bushing, guide bushing, damper unit and other sliding parts. INNER TUBE •…

  • Page 269
    $ Fork oil quantity (Inside the damper rod): 193 ml (6.52/6.80 US/lmp oz) % 99000-99001-SS5: SUZUKI FORK OIL SS-05 or equivalent • With the damper rod held immovable in fully extended posi- tion, gently install the compression damper unit 4 to the sub-…
  • Page 270
    FRONT FORK AND STEERING 17-13 • Hold the bottom (flat part) of the sub-tank. • Tighten the compression damper unit 4 to the specified torque. & Compression damper unit: 30 N·m (3.0 kgf-m, 21.5 lb-ft) • With the damper rod held in vertical position, slowly move the inner rod several strokes.
  • Page 271
    17-14 FRONT FORK AND STEERING • With the damper rod in horizontal position, move the inner rod by hand to inspect it if operating smoothly. • If the inner rod is not extend, repeat the “COMPRESSION DAMPER UNIT” procedures (Pour the specified amount fork oil and discharge an excess of oil).
  • Page 272
    FRONT FORK AND STEERING 17-15 • Clamp the axle holder with a vise. Protect the axle holder with a rag when using a vise. # WARNING Clamping the axle holder too tight can damage it which will affect riding stability. Do not clamp the axle holder too tight.
  • Page 273
    • Pour the specified amount of fork oil into the outer tube. $ Oil quantity (When standard fork spring is used): 385 ml (13.01/13.56 US/lmp oz) % 99000-99001-SS5: SUZUKI FORK OIL SS-05 or equivalent • Raise the outer tube and temporarily tighten the fork cap bolt (sub-tank).
  • Page 274: Installation

    FRONT FORK AND STEERING 17-17 INSTALLATION • Install the front fork with the line T aligned with the upper sur- face of the upper bracket. • Check that the air valve A is positioned at the front. • Tighten the fork lower clamp bolts to the specified torque. &…

  • Page 275: Steering

    17-18 FRONT FORK AND STEERING STEERING REMOVAL HANDLEBARS • Place the motorcycle on a block to lift front wheel off the ground. • Remove the front number plate and protector. (!17-4) • Remove the clamps. • Remove the engine stop switch 1. •…

  • Page 276
    FRONT FORK AND STEERING 17-19 • Remove the handlebar holder bolts and remove the handle- bars. NOTE: Mark the paint mark to the matching surface of handlebar holder and handlebars before removing. STEERING STEM • Remove the front wheel 1. (!15-3) •…
  • Page 277
    17-20 FRONT FORK AND STEERING • Remove the handlebar holder set bolts and nuts. • Remove the steering stem nut with the special tools. » 09940-14911: Steering nut socket wrench 09940-14960: Attachment • Remove the steering stem lower bracket. NOTE: Hold the steering stem lower bradcet by hand to prevent it from falling.
  • Page 278: Inspection

    FRONT FORK AND STEERING 17-21 INSPECTION STEERING STEM • Inspect the needle bearings for wear. • Inspect the steering stem for distortion. • Replace the defective parts with a new one. • Inspect the bearing outer races for wear. • If any defects are found, replace the bearing with a new one. •…

  • Page 279: Bearing Replacement

    17-22 FRONT FORK AND STEERING BEARING REPLACEMENT • Remove the lower bearing. • Fit the lower bearing with the special tool. » 09925-18011: Steering bearing installer NOTE: Replace the outer race and bearing as a set. • Remove the upper outer race with the special tools. «…

  • Page 280: Installation

    Install the steering in the reverse order of removal. Pay attention to the following points: STEERING STEM • Apply grease to the bearings. ( 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Fit the steering stem lower bracket, upper bearing and steer- ing stem nut.

  • Page 281
    17-24 FRONT FORK AND STEERING • Install the front forks to the steering stem and tighten the lower clamp bolts temporarily. • Tighten the steering stem head nut to the specified torque. & Steering stem head nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft) •…
  • Page 282
    FRONT FORK AND STEERING 17-25 • Apply grease to the throttle cable and their hole. ( 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Align the matching mark D on the handlebars with the throttle holder matching surface. • Tighten the screws securely.
  • Page 283
    17-26 FRONT FORK AND STEERING ” mark on the left grip with the matching mark F • Align the “ on the left handlebar end. • Align the matching mark G on the handlebars with the clutch lever holder matching surface. •…
  • Page 284
    REAR SUSPENSION 18-1 REAR SUSPENSION CONTENTS CONSTRUCTION ………………18- 2 REAR SUSPENSION …………….18- 2 REAR SHOCK ABSORBER …………..18- 3 REMOVAL ………………. 18- 3 SPRING REPLACEMENT …………..18- 4 INSPECTION ………………18- 5 BEARING REPLACEMENT …………..18- 6 OIL REPLACEMENT …………….18- 7 DISASSEMBLY AND INSPECTION ………..
  • Page 285: Construction

    18-2 REAR SUSPENSION CONSTRUCTION REAR SUSPENSION 80 N . m (8.0 kgf-m, 58.0 lb-ft) 60 N . m (6.0 kgf-m, 43.5 lb-ft) 80 N . m (8.0 kgf-m, 58.0 lb-ft) 80 N . m 60 N . m (8.0 kgf-m, (6.0 kgf-m, 58.0 lb-ft) 43.5 lb-ft)

  • Page 286: Rear Shock Absorber

    REAR SUSPENSION 18-3 REAR SHOCK ABSORBER REMOVAL • Place a block under chassis tube. • Remove the seat. (!5-2) • Loosen the air cleaner clamp screw. • Remove the right frame cover. (!5-2) • Remove the muffler and rear frame assembly. •…

  • Page 287: Spring Replacement

    18-4 REAR SUSPENSION • Remove the rear shock absorber lower mounting bolt and nut. NOTE: If necessary, move the swingarm up or down to facilitate this mounting bolt/nut removal. • Remove the rear shock absorber. SPRING REPLACEMENT • Loosen the lock-nut 1 with the special tool and turn it fully to the end of the thread.

  • Page 288: Inspection

    REAR SUSPENSION 18-5 • Adjust the spring set length and tighten the locknut. # Standard spring set length: 7.3 mm (0.29 in) compressed from the free length Spring set length adjustable range: 247 – 263 mm (9.72 – 10.35 in) [at spring free length 265 mm (10.42 in)] a: Hardest spring setting b: Softest spring setting…

  • Page 289: Bearing Replacement

    • Apply grease to the needle roller bearings and install them. • Apply grease to the dust seals and spacers. • Install the spacers A and B. A for Right side B for Left side % 99000-25010: SUZUKI SUPER GREASE “A” or equivalent…

  • Page 290: Oil Replacement

    REAR SUSPENSION 18-7 OIL REPLACEMENT TOOLS AND EQUIPMENT • Following tools and equipment are required to perform oil replacement. 1 Screwdriver or small punch 7 Rags 2 Vise* 8 Nitrogen tank 3 Drain Pan 9 Filler Hose and Nozzle 4 Oilcan 0 Regulator Assembly 5 Beaker A Owner’s Service Manual…

  • Page 291
    Be sure to extend the rod after filling the oil. • Tilt the shock absorber unit as shown and pour the fresh rear suspension oil fully into the reservoir. 99000-99001-S25: SUZUKI REAR SUSPENSION OIL SS-25 or equivalent # Oil capacity: 395 ml (13.35/13.91 US/Imp oz) •…
  • Page 292
    REAR SUSPENSION 18-9 • Replace the O-rings on the compression adjuster assembly with new ones. • Reinstall the compression adjuster assembly 1. $ Compression adjuster assembly: 30 N·m (3.0 kgf-m, 21.5 lb-ft) • Fill the rear shock absorber unit with nitrogen gas to 784 kPa (8.0 kgf/cm , 113.8 psi).
  • Page 293: Disassembly And Inspection

    18-10 REAR SUSPENSION DISASSEMBLY AND INSPECTION • Clean and dry the rear shock absorber. • Remove the spring from the rear shock absorber. (!18-4) • Turn the rebound damping force adjuster to the softest posi- tion. • Press the valve with a screwdriver to bleed out nitrogen gas. (!18-7) •…

  • Page 294: Reassembly

    • Fit the stopper to the shock absorber body. • Fill the specified rear suspension oil in the rear shock absorber. (!18-8) 99000-99001-S25: SUZUKI REAR SUSPENSION OIL SS-25 or equivalent # Oil capacity: 395 ml (13.35/13.91 US/Imp oz) • Reinstall the compression adjuster assembly. (!18-9) •…

  • Page 295: Installation

    18-12 REAR SUSPENSION INSTALLATION Install the rear shock absorber in the reverse order of removal. Pay attention to the following points: • Tighten the rear shock absorber lower mounting bolt and nut to the specified torque. NOTE: If necessary, move the swingarm up or down to facilitate this mounting bolt/nut tightening.

  • Page 296: Swingarm

    REAR SUSPENSION 18-13 SWINGARM REMOVAL • Place the motorcycle on a block to lift rear wheel off the ground. • Remove the rear wheel. (!15-8) • Remove the chain guide. • Remove the rear brake hose guide. • Remove the rear master cylinder mounting bolts. •…

  • Page 297
    18-14 REAR SUSPENSION • Down the rear brake pedal, remove the pivot shaft. • Remove the swingarm. • Remove the chain buffer. • Remove the plates. • Remove the following parts from the swingarm. Spacer 1 Oil seal 2 Washer 3 Thrust bearing 4 Dust seal 5 Spacer 6…
  • Page 298: Inspection

    REAR SUSPENSION 18-15 INSPECTION PIVOT SHAFT • Measure the pivot shaft runout with the dial gauge and V-blocks. • If any the runout exceeds the limit, replace the pivot shaft with a new one. # Swingarm pivot shaft runout Service Limit: 0.3 mm (0.01 in) «…

  • Page 299: Bearing Replacement

    • Remove the bearings with the special tool. » 09921-20240: Bearing remover set • Press the new bearings with the special tool. » 09924-84521: Bearing installer • Apply grease to the bearings. % 99000-25010: SUZUKI SUPER GREASE “A” or equivalent…

  • Page 300: Installation

    7 Spacer 4 Thrust bearing • Apply grease to the dust seals, bearings and oil seals. % 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Apply THREAD LOCK SUPER to the plate mounting screws. ‘ 99000-32110: THREAD LOCK SUPER “1322”…

  • Page 301: Rear Suspension Linkage

    18-18 REAR SUSPENSION REAR SUSPENSION LINKAGE REMOVAL • Place a block under the chassis tubes. • Remove the lower drive chain control roller nut 1. • Remove the rear cushion rod bolt and nut. • Remove the cushion lever bolt and nut. •…

  • Page 302: Inspection

    REAR SUSPENSION 18-19 INSPECTION • Inspect the cushion rod and cushion lever for damage. • Inspect the dust seals, oil seals and spacers for damage. • Replace the defective parts with a new one. • Insert the spacers into the bearings and inspect them for excessive play and smooth movement.

  • Page 303: Bearing Replacement

    ( 6: right side) * Position the needle roller bearing cages by referring to the illustration of page 18-22. • Apply grease to the needle roller bearings and install them. % 99000-25010: SUZUKI SUPER GREASE “A” or equivalent…

  • Page 304: Installation

    Pay attention to the following points: • Position the dust seals 1 so that the manufacturer’s code indicated side of the seals face outside. ( 2: inside) • Apply grease to the dust seals. % 99000-25010: SUZUKI SUPER GREASE “A” or equivalent…

  • Page 305
    18-22 REAR SUSPENSION • Tighten the cushion lever, cushion rod and swingarm nuts to the specified torque. Left Right 4 mm (0.16 in) 4 mm (0.16 in) 4 mm (0.16 in) 4 mm (0.16 in) $ Tightening torque: A: 60 N·m (6.0 kgf-m, 43.5 lb-ft) B: 60 N·m (6.0 kgf-m, 43.5 lb-ft) C: 80 N·m (8.0 kgf-m, 58.0 lb-ft) D: 80 N·m (8.0 kgf-m, 58.0 lb-ft)
  • Page 306
    REAR SUSPENSION 18-23 Left Right CAUTION Improperly reassembled rear suspension linkage bolts can interfere with suspension move- ment and damage the rear suspension linkage. * Make sure that the rear shock absorber rebound damping adjuster on the bottom bracket of the rear shock absorber is located to the right side.
  • Page 307
    – MEMO –…
  • Page 308: Servicing Information

    SERVICING INFORMATION 19-1 SERVICING INFORMATION CONTENTS SERVICE DATA ………………19- 2 TIGHTENING TORQUE …………….19-10 SPECIAL TOOLS ………………19-14 WIRING DIAGRAM ………………19-17 CABLE ROUTING ………………19-18 WIRE HARNESS ROUTING …………..19-20 FUEL HOSE ROUTING …………….19-21 RADIATOR HOSE AND CARBURETOR HOSE ROUTING ….. 19-22 REAR BRAKE PEDAL SET-UP …………..

  • Page 309: Service Data

    19-2 SERVICING INFORMATION SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.42) — (1.14) Tappet clearance (when cold) 0.09 – 0.16 — (0.004 – 0.006) 0.17 – 0.24 — (0.007 – 0.009) Valve guide to valve stem 0.010 –…

  • Page 310
    SERVICING INFORMATION 19-3 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 33.57 – 33.62 33.27 (1.322 – 1.324) (1.310) 33.69 – 33.74 33.39 (1.326 – 1.328) (1.315) Camshaft journal oil clearance 0.032 – 0.066 0.150 IN. & EX. (0.001 –…
  • Page 311: Oil Pump

    19-4 SERVICING INFORMATION CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end I.D. 19.010 – 19.018 19.040 (0.7484 – 0.7487) (0.7496) Conrod deflection — (0.12) Conrod big end side clearance 0.20 – 0.65 (0.008 – 0.026) (0.04) Conrod big end width 19.75 –…

  • Page 312
    SERVICING INFORMATION 19-5 TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 2.583 (62/24) — Final reduction ratio 3.500 (49/14) — Gear ratios 2.000 (30/15) — 1.611 (29/18) — 1.363 (30/22) — 1.166 (28/24) —…
  • Page 313
    19-6 SERVICING INFORMATION ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Ignition timing 15° B.T.D.C. at 1 950 r/min. Spark plug Type NGK: DIMR8A10 0.9 – 1.0 (0.035 – 0.039) Spark performance Over 8 (0.3) at 1 atm. 72 – 127 Ω Pick-up coil resistance R –…
  • Page 314
    SERVICING INFORMATION 19-7 ITEM STANDARD LIMIT Wheel rim runout Axial — (0.08) Radial — (0.08) 1.60 × 21 Wheel rim size Front — 2.15 × 19 Rear — Wheel axle runout 0.25 Front — (0.010) 0.25 Rear — (0.010) TIRE ITEM STD/SPEC.
  • Page 315
    19-8 SERVICING INFORMATION SUSPENSION Unit: mm (in) ITEM STANDARD LIMIT NOTE Front fork stroke — (12.2) Front fork inner tube — O.D. (18.5) Front fork spring free 494 ± 2.5 487 (19.17) length (19.45 ± 0.10) Front fork damping Rebound MAX –…
  • Page 316
    (1.4/1.1 US/Imp qt) Air cleaner element oil type MOTUL AIR FILTER OIL or equivalent filter oil Front fork oil type SUZUKI FORK OIL SS-05 or an equivalent fork oil Front fork oil capacity 385 ml Outer tube oil (each leg) (13.01/13.55 US/Imp oz)
  • Page 317: Tightening Torque

    19-10 SERVICING INFORMATION TIGHTENING TORQUE ENGINE PART N·m kgf-m lb-ft Cylinder head cover bolt (Initial) (Final) 10.0 Spark plug Cylinder head bolt (Initial) 18.0 (Final) 33.5 Cylinder head base bolt Cylinder base bolt Camshaft journal holder bolt Primary drive gear nut 65.0 Magneto rotor nut 58.0…

  • Page 318
    SERVICING INFORMATION 19-11 PART N·m kgf-m lb-ft Engine mounting nut (upper) 40.0 32.5 Engine mounting nut (lower) 32.5 Engine mounting nut (front) 40.0 Engine mounting bracket nut (upper) 29.0 Engine mounting bracket nut (front) 29.0 Engine sprocket cover bolt Kick starter lever bolt 16.5 Fuel filter mounting bolt 0.44…
  • Page 319
    19-12 SERVICING INFORMATION CHASSIS PART N·m kgf-m lb-ft Handlebar clamp bolt 18.0 Front fork upper clamp bolt (right and left) 16.5 Front fork lower clamp bolt (right and left) 16.5 Steering stem head nut 10.0 72.5 Front fork cap bolt 25.5 Lock-nut/center bolt 16.0…
  • Page 320
    SERVICING INFORMATION 19-13 For other bolts and nuts not listed in the table, refer to this chart. Conventional or “4” marked bolt “7” marked or crown headed bolt Bolt Diameter A (mm) N·m kgf-m lb-ft N·m kgf-m lb-ft 0.15 0.23 0.45 0.55 16.5…
  • Page 321: Special Tools

    19-14 SERVICING INFORMATION SPECIAL TOOLS 09900-20101 09900-00410 09900-06107 09900-06108 09900-09003 Vernier calipers Hexagon wrench set Snap ring pliers Snap ring pliers Impact driver set (150 mm) 09900-20202 09900-20204 09900-20205 09900-20102 Micrometer Micrometer Micrometer 09900-20530 Vernier calipers (25 – 50 mm) (75 –…

  • Page 322
    SERVICING INFORMATION 19-15 09911-11310 09913-10750 Crankshaft installer Compression gauge 09913-14541 09913-50121 09913-70210 attachment adaptor Fuel level gauge Oil seal remover Bearing installer set 09915-64512 09915-74510 Compression gauge Oil pressure gauge 09916-10911 09916-14510 09916-14521 Valve lapper set Valve lifter Attachment 09916-34550 09916-34580 09916-44910 09916-34542…
  • Page 323
    19-16 SERVICING INFORMATION 09940-14911 09930-30104 09940-14960 Rotor remover slide 09930-35020 09930-44560 Steering nut socket 09940-34581 shaft Rotor remover Rotor holder wrench Attachment F 09940-52861 09941-34513 09941-53630 09941-54911 09940-40211 Front fork oil seal Steering race Front fork top cap Bearing outer race Adapter installer set installer…
  • Page 324: Wiring Diagram

    SERVICING INFORMATION 19-17 WIRING DIAGRAM IGNITION COIL CDI UNIT ENGINE STOP SWITCH Ground : Pickup THROTTLE coil POSITION SENSOR MAGNETO WIRE COLOR Black Blue Green Yellow B/Bl: Black with Blue tracer B/Br: Black with Brown tracer B/G: Black with Green tracer B/R: Black with Red tracer B/W:…

  • Page 325: Cable Routing

    19-18 SERVICING INFORMATION CABLE ROUTING…

  • Page 326
    SERVICING INFORMATION 19-19…
  • Page 327: Wire Harness Routing

    19-20 SERVICING INFORMATION WIRE HARNESS ROUTING…

  • Page 328: Fuel Hose Routing

    SERVICING INFORMATION 19-21 FUEL HOSE ROUTING : The clamp screw head should face..Down side. Down side. 4.4 N . m (0.44 kgf-m, 3.2 lb-ft) Backward. The chamfer side of washer faces outside.

  • Page 329: Radiator Hose And Carburetor Hose Routing

    19-22 SERVICING INFORMATION RADIATOR HOSE AND CARBURETOR HOSE ROUTING Radiator (R) Pass the fuel hose above the intake pipe. Carburetor hose * Air vent hose (clear) 4pcs Fuel hose * Drain hose (black) 1pc Pass through the hose into the hose guide. Radiator (L) Radiator breather hose Forward left side.

  • Page 330: Rear Brake Pedal Set-Up

    SERVICING INFORMATION 19-23 REAR BRAKE PEDAL SET-UP…

  • Page 331: Magneto Installation

    19-24 SERVICING INFORMATION MAGNETO INSTALLATION…

  • Page 332: Clutch Cable Adjuster

    SERVICING INFORMATION 19-25 CLUTCH CABLE ADJUSTER Quick adjuster Turn to tighten Tur urn to tighten n to tighten the clutch cab the clutch cable tension. le tension. the clutch cable tension. Tur urn to loosen Turn to loosen n to loosen the clutch cable tension.

  • Page 333: Front Brake Hose Routing

    19-26 SERVICING INFORMATION FRONT BRAKE HOSE ROUTING Front brake hose Front brake master cylinder Front brake hose Hose guide Stopper Set the brake hose end between the hose stopper, then tighten the brake hose union bolt to the specified torque. Front fork protector Front brake hose Clamp…

  • Page 334: Rear Brake Hose Routing

    SERVICING INFORMATION 19-27 REAR BRAKE HOSE ROUTING…

  • Page 335: Handlebar Set-Up

    19-28 SERVICING INFORMATION HANDLEBAR SET-UP Assemble throttle cables as to show this drawing. Throttle cable Marking on drawing position. (Pull side) Match “ ” mark of grip (L) with marking. Upper side Throttle cable 30˚ (Return side) Marking on drawing position. Match slit of throttle case with marking.

  • Page 336: Rear Wheel Spokes Installation

    SERVICING INFORMATION 19-29 REAR WHEEL SPOKES INSTALLATION…

  • Page 337: Front Number Plate Installation

    19-30 SERVICING INFORMATION FRONT NUMBER PLATE INSTALLATION Number plate band Number plate band Handlebar Hot starter cable Clutch cable VIEW A IGNITION COIL INSTALLATION High-tension cord Cushion Tube Align the cushion edge with VIEW A High-tension cord Cushion the high-tension cord tube.

  • Page 338: Specifications

    SERVICING INFORMATION 19-31 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length …………2 185 mm (86.0 in) Overall width…………830 mm (32.7 in) Overall height …………. 1 260 mm (49.6 in) Wheelbase …………1 480 mm (58.3 in) Ground clearance……….350 mm (13.8 in) Seat height …………

  • Page 339
    19-32 SERVICING INFORMATION CHASSIS Front suspension ……….Telescopic, coil spring, oil damped Rear suspension ……….Link type, coil spring, oil damped Front suspension stroke……..310 mm (12.2 in) Rear wheel travel ……….310 mm (12.2 in) Caster …………..25° 30’ Trail …………..
  • Page 340: Spare Parts List

    SERVICING INFORMATION 19-33 SPARE PARTS LIST ITEM PART NAME PART NUMBER Q’TY PARTS SET, SPARE 19900-35G30 GASKET, MAGNETO COVER 11483-35G10 GASKET, CLUTCH COVER OUTER 11484-35G10 GASKET, EXHAUST, PIPE 14181-35G00 CONNECTOR, MUF JT 14771-29F00 FILTER COMP, ENGINE OIL 16510-35G00 O-RING, WATER POMP CASE 17431-35G10 LEVER, BRAKE 57310-37F00…

  • Page 341: Setting Data

    19-34 SERVICING INFORMATION SETTING DATA DATE RACE/COURSE TEMP./HUMIDITY WEATHER COURSE COUDITION MAIN JET JET NEEDLE SLOW JET AIR SCREW FLOAT LEVEL SPARK PLUG OIL LEVEL COMP. ADJ. POSITION RE-BOUND ADJ. POSITION SPRING SPRING SPRING SET LENGTH COMP. ADJ. POSITION LOW COMP.

  • Page 342
    WARNING Failure to follow these safety precautions may increase your risk of injury: ¹ ¹ Wear a helmet, eye protection, and bright protective clothing. ¹ Don’t ride after consuming alcohol or other drugs. This owner’s service manual contains important safety information.

AiM User guide

Kit for SoloDL on

Suzuki RMZ – 4 stroke

250 cc 2010-2013

450 cc 2008-2013

Release 1.01

1

1

Models and years

This manual explains how to connect SoloDL to Suzuki RMZ Engine Control Unit (ECU). Supported models are:

Suzuki RMZ 250cc – 4 stroke

Suzuki RMZ 450 cc – 4 stroke

2010-2013

2008-2013

2

Kit content and part number

Suzuki RMZ – 4 stroke – 2008-2013 AiM kit for SoloDL part number is:

V0256924CS

. The kit – shown here below – contains:

1 Bar Pad for bikes without cross brace for

SoloDL with thermoformed cover and Velcro already mounted (

1

)

1 fixing plate (

2

)

4 Allen screw (

3

)

1 Allen key (

4

)

1 cable for Suzuki RMZ 2008-2013 (

5

)

Suzuki RMZ cable (

5

) – part number

V02569240

– and Bar Pad for SoloDL (

1

) – part number

DNKTKPMSOL0

– can be bought separately as spare parts.

1

The draw here below shows constructive scheme of cable

V02569240

.

2

3

Installation and connection

To install SoloDL on your Suzuki RMZ remove the original bar pad and install AiM pad following the instructions you can download from www.aim-sportline.com

– download documentation Area.

Images here below show the original bar pad on the left and AiM one on the right.

3

3.1

Installation and connection on Suzuki RMZ 2013

To connect SoloDL to your bike ECU use SDS connector you find behind the bike radiator and shown here below. Pull it down along the metallic tongue highlighted in the image below on the left until you have the result shown on the right.

Remove the black rubber cap sliding it along the cable as shown here on the right.

4

Unplug Suzuki cable as shown here below and in the image.

Plug AiM cable (

1

) in the connectors shown here above (

2a

and

2b

) as in the scheme below. This way you can continue managing different Suzuki original ECU maps.

5

Replace the cap you removed and shown below on the left. Open the rubber band “E” shown below on the right, insert cable “F” of AiM wiring and close the band.

Make cable “G” of the image above on the right pass through the bike radiator, along the chassis as shown below on the left. Band it with the other cables highlighted below on the right.

6

Images below show the cable free on the left and banded on the right.

Make AiM cable pass around the fork plate (“F” here below on the left) and connect AiM cable to

SoloDL (image on the right).

7

3.2

Installation and connection on Suzuki RMZ 450 cc

2008-2012 and 250 cc 2010-2012

In Suzuki RMZ 450 cc 2008-2012 and 250 cc 2010-2012 bikes the connector – circled in the image on the right – is under the number plate indicated in the image on the left.

The connection is to be made as explained in the previous paragraph. Once this operation performed, the cable you connected has to pass between the bike plate and the bar pad. Images here below show the cable path.

8

When the metallic connector is plugged in SoloDL band the exceeding part of cable: the result is shown here below.

9

4

Configuration with Race Studio 2

Before connecting SoloDL to Suzuki RMZ ECU set it up using AiM Race Studio 2 software. The parameters to select in the logger configuration are:

ECU Manufacturer “Suzuki”

ECU model “RMZ”

5

«Suzuki» «RMZ» protocol

Channels received by SoloDL connected to «Suzuki» «RMZ» protocol are:

ECU_1 ECU_RPM

ECU_2 ECU_TPS

RPM

Throttle Position Sensor

ECU_5 ECU_CLT

ECU_6 ECU_IAT

Engine coolant temperature

Intake air temperature

ECU_7 ECU_MAP Manifold Air pressure

ECU_8 ECU_BAROM Barometric

ECU_9 ECU_BOOST Difference between Manifold Air Pressure and Barometric Pressure

Technical note

: not all data channels outlined in the ECU template are validated for each manufacturer model or variant; some of the outlined channels are model and year specific, and therefore may not be applicable.

10

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