RM250 Owners Service Manual 1991

TABLE OF C O N T E N T S
GENERAL I N S T R U C T I O N S 1
PERIODIC M A I N T E N A N C E 2
TROUBLESHOOTING 3
MACHINE TUNING
ENGINE DISMOUNTING A N D MOUNTING 5

CYLINDER, PISTON AND EXHAUST VALVE 6
CLUTCH
KICK STARTER 8
TRANSMISSION AND CRANKSHAFT 9
FUEL SYSTEM 10
COOLING SYSTEM 1 1 1 1
ELECTRICAL SYSTEM 12
FRONT AND REAR WHEELS 13
FRONT AND REAR BRAKES 14
FRONT FORK AND STEERING 15
REAR SUSPENSION 16
SERVICE DATA 17
SPECIAL TOOLS 18
WIRE, CABLE AND HOSE ROUTING 19
SPECIFICATIONS 20

1-1 GENERAL INSTRUCTIONS
LOCATION OF PARTS
2 Co)
0 C l u t c h lever
Engine kill s w i t c h
CD T h r o t t l e grip
LT F r o n t brake lever
Fuel t a n k cap
Carburator choke knob
0 G e a r s h i f t lever
0 K i c k starter lever
R e a r brake pedal
. - -
GENERALINSTRUCTIONS 12
FUEL
This motorcycle is of the two-stroke design, which requires
a premixture of gasoline and oil.
Gasoline: Unleaded gasoline minimun 9 5 octane (RON).

Engine oil: MOTUL CENTURY 300 2T
SHELL SUPER M
B.P. RACING
CASTROL R30
CASTROL TTS (A545)
CASTROL A747 Gasoline Oil
(L ) ( ml )
BELL-RAY MC-100
5.0 250
Mixing ratio: 2 0 : 1
10.0 500
Fuel tank capacity: 11.0 L (2.9 US gal)
15.0 750
a CAUTION 20.0 1000
A mixture containing too little oil will cause piston sei- Gasoline Oil
zure. Too much oil will cause excessive carbon formation ( gal. ) ( qt )
resulting in preignition, fouled spark plug and loss of en- 1.0 4/5
gine power. 2.0 1-3/5
Mix fuel and the engine oil at the ratio of 20:1 3.0 2-2/5
4.0 3 1 /5
NOTE: 5.0 5
M i x gasoline and the engine oil thoroughly when the
temperature is below 0 C ( 3 2 " 1
oils can separate easier than mineral oils.
U s e premix ture oil as soon as possible, o r lubrica-
tion performance o f the engine o i l can decrease.
D o n o t mix vegetable-based oil and mineral oil.
I n s e r t the end of the breather hose into the steering
stem head after refueling.
21 PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
INSPECTION BEFORE PRACTICE
W H AT TO CHECK CHECK FOR

Spark plug Heat range, fouled electrode, tightness
Loose high-tension cord
Air cleaner element Lubrication
Transmission oil Oil level
Coolant Coolant level
Cooling s y s t e m Radiator hose damage
Coolant leak
Clutch Smooth operation
Throttle I Play
Smooth operation
Brake f l u i d Fluid level
Brakes Brake lever/pedal play
Operation
Drive chain I Slack, lubrication, chain joint clip condition
Drive chain guide/buffer Wear, damage
Suspension I Smooth operation
Wheels I Spoke tension
Rim lock tighteness
Tires Tire pressure
Steering Smoothness, play
Exhaust pipe Firm fixation
Bolts and n u t s Tightening torque
INSPECTION BEFORE RACE
W H AT TO CHECK CHECK FOR
All items o f inspection

before practice
Air cleaner Cleanliness
Clutch C l u t c h disc plates w e a r and distortion
Brake pads I Wear
Sprockets Wear
Fuel tank Leakage
F u e l filter
Fuel line Damage
Exhaust pipe Damage
Piston and Cylinder I C o m b u s t i o n Chamber carbon deposit
P i s t o n head carbon deposit
P i s t o n and cylinder w e a r
-r&
PERIODIC MAINTENANCE 2-2
PERIODIC MAINTENANCE CHART

It is very important to inspect and maintain the machine regularly. Follow the guideline in the chart.
A life of parts varies depending on the riding conditions. Perform more often than shown in the chart
if you use the motorcycle under more often than shown in the chart if you use the motorcycle under
severe conditions.
Interval races Every Every Every Every
race 2 races 3 races 5 races
Remarks
Servic Every 1 Every2 Every3 Every5
Item HRS 31/2 HRS 5
11/2 HRS 2
Spark plug I I I R
Air cleaner C C C
Transmission oil R Change after 1st initial break-in
l & C l & C l & C l & C
Replace radiator hose and coolant
Cooling-system every year.
Flashing for overhaul o r storage.
Clutch I I I I
Throttle and I I I R
clutch cable
Carburetor I I I I
I
Fuel line
Replace every 4 years.
Piston
R
Piston ring
Cylinder head,
cylinder, exhaust C
valve and muffler
R
Drive chain Adjust slack every 3 0 minutes.
Clean and lubricate after every race.
A
Engine sprocket
Check and retighten sprocket bolts
Rear sprocket R at initial and subsequent 1 0 minutes
of riding and each race thereafter.
Drive chain buffer
R
Drive chain guide
Kick starter lever Apply grease after every race.
Brake I I I Replace brake hose and fluid every
I
year.
Front fork oil R Change after 1st initial break-in.
Check abnormality of front fork inner
Front fork air
I i I I frequently a n d a p p l y t h e grease t o
pressure the p i v o t i n g p o r t i o n a s necessary.
Rear suspension Check r e a r s u s p e n s i o n s y s t e m
system pivoting I I I I frequently and apply the grease to the
portion pivoting portion as necessary.
Tire I I I I
Inspect ever 2 0 min. u p t o initial 2
Spoke nipple hours then check before each ride. First loosen then tighten.
Steering I I I I
Bolts and nuts T T T T Retighten every 1 hour.
NOTE: R =Replace, C =Clean, T = Tighten, IInspect and clean, adjust lubricate

or replace i f necessary
2-3PERIODICMAINTENANCE
SPARK PLUG
Inspect t h e spark plug condition, electrode color, carbon
deposits, spark plug gap, and washer damage, after remov-
ing the spark plug.
NOTE: R e m o v e the dirt around the spark plug before remov-
ing the spark plug to prevent dirt from entering the combusi-
ton chamber.
Inspect the porcelain t i p color.
Porcelain tip color Cause

Hot type spark plug
Advanced ignition timing
White (overheated) Lean fuel/air mixture
Deteriorated fuel
Cold type spark plug
Retarded ignition timing
Black (fouled) Rich fuel/air mixture
Rich oil/gasoline mixture
Clean the spark plug with a brush or wire and check the spark
plug gap w i t h a thickness gauge.
Spark plug gap: 0 . 5 - 0 . 6 mm
(0.020-0.024 in)
Standard Spark plug
B8EGV ... UK, Australia

NGK
BR8EV ... Canada, France
A CAUTION
Changing the spark plug heat range improperly can damage
the engine.
Select the spark plug heat range only after adjusting the
ignition timing, carburetor settng and oil/gasoline mixture.
Tighten the spark plug with specified tighteing torque af-

ter tightening the spark plug temporaly with fiugers.
Tightening torque: 2 5 - 3 0 N.m

( 2 . 5 - 3 . 0 kg-m, 1 8 . 0 - 2 1 . 5 lb-ft)
AIR CLEANER
Air Cleaner Element Removal
Remove the frame cover and seat.
Remove the air cleaner cap.
Remove screw CI).
Remove outer element and inner elemtnefrom the ele-

ment holder.
Washing
Fill a washing pan large enough to hold the element with
a non-flammable cleaning solvent 'AD. Immerse the element t 7-
V
in the solvent and wash it.
,,_-_i!_, 1
Squeeze the element by pressing it between the palms of
t
both hands to remove excess solvent. Do not twist or wring --:- --- ----1
the element or it will develop cracks. 1\,,,.
D r y the element in a plastic bag, pour in some foam filter
.,,----'
oil S a n d w o r k the oil into the element. e,
Squeeeze the element to remove excess oil.
Installation
A p p l y grease to the element holder where it contacts the
element.
Install the inner and Outer elements onto the element holder
as triangle mark q ) faces upward.
a CAUTION
Improper element installation allows dust and dirt to enter
into the combustion chamber. It can result in piston and
cylinder wear.
Be sure to check the element seals properly after installing

the elements.
Install the air cleaner cap.
NOTE.' R u n n i n g the engine without the air cleaner cap can

vary carburettor?. D o n o t remove the air cleaner cap.
2-5 PERIODIC MAINTENANCE
TRANSMISSION OIL
Transmission Oil Level Inspection and Replenishment
Place the motorcycle on level ground and hold the motor-
cycle vertically.
Run the engine for a f e w minutes and stop it. Wait 2 - 3
millutes.
Remove oil level screw C h e c k that the oil comes out
of the hole.
I f the oil does not come out of the hole, open oil filler cap
and add the specified oil until the oil comes out of the
oil level hole.
Ti g h t e n t h e f i l l e r c a p a n d o i l l e v e l s c r e w f i r m l y.
Transmission Oil Change
Wa r m u p the engine.
Place t h e motorcycle o n t h e level ground and hold t h e
motorcycle vertically.
Remove filler c a p CI) a n d drain p l u g O . Drain t h e o i l
thoroughly.
Tighten the drain plug firmly.
Pour 6 5 0 ml (0.7 US qt) o f SAE 1 0 W- 4 0 motor oil.
S t a r t the engine and idle it a f e w minutes.
Inspect the oil level.
(Only for U.S.A.)
Suzuki recommends the use o f SUZUKI PERFORMANCE 4
MOTOR OIL or an oil which has 1 0 W - 4 0 viscosity rating.
COOLANT
Coolant Level Check
AWARNING
You can be injured by scalding fluid or steam if you open
the radiator cap when the engine is hot.
S
Do not open the radiator cap when the engine is hot. Wait
until engine cools.
Remove the radoator cap.

Check that the coolant level is at the bottom o f the inlet
hole, replenish the radiator w i t h specified coolant.
Ti g h t e n the radiator cap securely.
PERIODICMAINTENANCE 2-6
Mr
ACAUTION
Improperly tightening the radiator cap cannot obtain the

specified pressure in the cooling system and it will cause
coolant overflow.
Tighten the radiator cap until it locks firmly.
NOTE:
T h i s motorcycle does not have an overflow tank at the end
of breather hose. Therefore, coolant level man decrease
while riding. Check the coolant level every time before
riding.
W h e n replenishing coolant, be sure to use coolant mixed
with distilled water at the ratio o f 5 0 : 50. A d d i n g only
water wil dilute coolant and it may decrease cooling per-
formance.
Coolant MES
Use SUZUKI GOLDEN CRUISER 1200 or equivalent anti-freeze
and Summer coolant which is compatible with aluminum radi- 1
ta.da coltz.
ator at the ratio o f 5 0 : 5 0 .
SUZUKI G O L D E N CRUISER
NOTE: 1200NA
I N o n - A m m e tvpeI 1 2 . 0 0
The radiator, cylinder and cylinder head are made o f alumi- 99000-99032-10X
num alloy. Using non-recommended coolant may corrode alu-

minum alloy and may clog the coolant passageways.
AWARNING
Coolant is harmful if swallowed or if it comes in contact
with your skin or eyes.
Keep coolant away from children and pets. Call your doc-
tor immediately if coolant is swallowed and induce vomit-
ing. Flush eyes or skin with water if coolant gets in eyes
or comes in contact with skin.
Cooling System Inspection

Inspect the following items before practice and races.
Coolant leakage
Radiator hose cracks and deterioration
Radiator mounting condition
Radiator breather hose condition
Radiator fin condition.
CLUTCH
Adjust the clutch cable play as follows:
Major Adjustment
Loosen lock n u t T .
Tu r n adjuster s o t h e c l u t c h c a b l e h a s 2 - 3 m m
( 0 . 0 8 - 0 . 1 2 in) play at the clutch lever holder before pres-
sure is felt.
Ti g h t e n lock nut
Minor Adjustment
Loosen lock n u t .
Tu r n adjuster 4 s o t h e c l u t c h c a b l e h a s 2 - 3 m m
( 0 . 0 8 - 0 . 1 2 in) play at the clutch lever holder before pres-
sure is felt.
Ti g h t e n lock n u t .
THROTTLE CABLE
Adjust the throttle cable play as follows:
Loosen lock n u t II).
Tu r n adjuster so the throttle cable has 0 . 5 - 1 . 0 m m
( 0 . 0 2 - 0 . 0 4 in) play.
Ti g h t e n lock n u t
Remove the throttle housing cover.

A p p l y oil t o the throttle cable.
A p p l y grease t o the throttle cable spool.
FUEL LINE
Repalce fuel line every four years.
CYLINDER HEAD, CYLINDER AND PISTON

Cylinder Head
Remove the cylinder head. k 6 - 2 )
Remove c a r b o n deposits f r o m c o m b u s t i o n c h a m b e r
surface.
Inspect for pinholes, cracks and other damage.
Cylinder
Remove the cylinder. ( 6 - 2 )
Remove carbon deposits from t h e exhaust port.
Check for scratches and wear on the cylinder sleeve.
Piston
Remove the piston. ( J.
Remove carbon deposits from the top surface of the piston.
Check for scratches, cracks, and wear around the piston
bosses.
Remove minor scuffs with # 600 * 8 0 0 sand paper.
Check piston ring wear. Remove carbon deposits from the
piston ring groove.
EXHAUST VALVE
Remove the exhaust valve. ( 6

Remove carbon deposits from the exhaust valve and ex-
haust valve guide.
Check for wear and damage.
DRIVE CHAIN AND SPROCKETS

Drive Chain Slack
Place the motorcycle on the side stand.
Inspect the drive chain slack at the middle point between
the t w o sprockets.
Drive chain slack: 4 5
2-9PERIODICMAINTENANCE
Drive Chain Adjustment

Remove cotter pin a n d loosen axle n u t .
Loosen lock nut and adjust the drive chain slack to the
specification b y turning adjuter Ft)
Check that both right and left alignment mark a r e at the
same position.
Tighten the axle nut. Replace the cotter pin with a new one.
Tightening torque: 8 5 - 1 1 5 N.m
( 8 . 5 - 11 . 5 kg-m, 6 1 . 5 - 8 3 . 0 lb-ft)
Ti g h t e n the lock nut.
NOTE: P u l l the upper drive chain tight and lock it by placing

a bar between the drive chain and rear sprocket while tight-
ening the axle nut. This will prevent the chain adjusters from
coming to have play.
20th Pitch Length

Pull the drive chain tight and measure the 20th pitch length.
Service limit: 3 2 3 . 8 mm (12.75 in)
Drive Chain Lubrication

Remove the chain clip and master link from the drive chain
and remove the drive chain.
NOTE
Be careful not to bend the chain clip.
Inspect for wear and damage of the drive chain and replace
it i f necessary.
Clean the drive chain with non-flammable cleaning solvent.

Do not use gasoline t o clean the drive chain.
D r y the drive chain.
A p p l y Suzuki Chain Lube or an equivalent to the link plates
and rollers.
Reassemble the drive chain.
NOTE:
Reassemble the drive chain clip so the slit end faces opposite
the direction o f rotation.
A d j u s t the drive chain slack.
7
-
Sprocket Inspection
Inspect the engine sprocket and rear sprocket for wear and
cracks. Reprace the sprockets as necessary.
NOTE:
When replaceing a worn sprocket, i r i s likely t h a t the drive
chain w i l l need to be replaced as w e l l
DRIVE CHAIN GUIDE, BUFFER, TENSIONER ROLLER

Drive Chain Guide
Inspect the drive chain guide for bends and damage.
NOTE:
The drive chain can hit a bent guide causing noise and drive
chain wear.
Inspect the chain guide defence 2 f o r wear.
Drive Chain Guide Buffer

Inspect the drive chain guide buffer 3 f o r wear and cracks.
NOTE:
The drive chain can touch the swing arm directly if the chain
guide buffer is worn out. This will cause drive chain and swing
arm damage.
Drive Chain Tensioner Roller

Inspect the drive chain tensioner rollers 4 , f o r wear.
Inspect the tensioner roller bolts for tightness.
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, replenish
the resrvoir with the specified brake fluid to the UPPER level.
Inspect brake pad wear and brake fluid leakage if the brake
fluid level decreases.
Brake fluid: D O T 4
A WARNING
Brake fluid can be hazardous to humans and pets. Brake
fluid is harmful or fatal if swallowed, and harmful if it comes
in contact with your skin or eyes.
Keep brake fluid away from children. Call your doctor im-
mediately if brake fluid is swallowed, and induce vomiting.
Flush eyes or skin with water if brake fluid gets in eyes or
comes in contact with skin.
A CAUTION
The use of any fluid except DOT4 brake fluid from a sealed
containter can damage the brake system and lead to an ac-
cident.
Use only DOT4 brake fluid from a sealed container. Never

use or mix different types of brake fluid.
A CAUTION
Spilled brake fluid can damage painted surface and plastic
parts.
Be careful not to spill any fluid when filling the brake fluid
reservoir. Wipe spilled full up immediately.
Brake Shoe
Inspect the brake shoes for wear. I f the brake shoes are
worn, replace them w i t h n e w ones. ( 1 4 - 3 )
Brake shoe wear limit: 1 . 5 mm ( 0 . 0 6 in)
NOTE:
P u m p the brake lever/pedal several times to restore the
brake pads after replacing the brake pads.
Replace both right and left pads together when replace-
ing the brake peads.
1.5 m m
Front Brake Lever Adjustment

Adjust the brake lever play as follows:
Loosen lock nut a
Tu r n in o r out adjuster to obtain the specified play.
Brake lever play: 0 . 1 - 0 . 3 mm ( 0 . 0 0 4 - 0 . 0 1 2 in)
Tighten t h e lock nut.
a CAUTION
Brake lever play less than 0.1 m m ( 0 . 0 0 4 in) can cause
brake dragging.
Do not adjust the brake lever play less than 0.1 mm (0.004
in).
Brake Pedal Height Adjustment

Adjust the rear brake pedal height as follows:
Loosen lock nut T . Turn in bolt a s far as it will go.
Loosen lock n u t .
A d j u t the brake pedal height by turning the adjuster ri)
to locate the pedal 5 m m ( 0 . 2 in) below the top face
of the foot rest.
Tighten lock nut
Turn adjuster ',..
Tighten lock nut (i).
FRONT FORK
M o v e the front fork up and d o w n several times and in-
spect for smooth movement.
Inspect for damage and oil leaks.
Inspect the bolts and nuts for tightness.
REAR SUSPENSION
M o v e the rear suspension up and d o w n several times
and inspect for smooth movement.
Inspect for damage and oil leaks.
Inspect the bolts and nuts for tightness.
WHEELS A N D TIRES
Wheel Rim
Inspect the wheel bearing for rattles Replace the bearings
if necessary. ( 1 3 - 3 )
Inspect the wheel rim runout. ( = 13-3)
Spoke Nipple and Rim lock

Inspect the spokes for tension. Retighten the spoke nip-
ples with a spoke nipple wrench as all spokes have same
tension.
Inspect the rim lock for tightness.
Tire Pressure
Inspect front and rear tire pressure.
Cold inflation tire 7 0 - 1 1 0 kPa
pressure: ( 0 . 7 - 1 . 1 kg/cm', 1 0 - 1 6 psi)
-
Inspect the steering by moving the front fork up and down,
and right and left. If the steering has play or binds, inspect
steering stern head n u t tightness and steering bearings.
( 15-7)
LUBRICATION
Apply grease or oil t o the moving parts t o increase durability and prevent wear.
No. ITEM LUBRICANT FREQUENCY COMMENTS

1. Inner cable A Pre-race and between Run oil throught cables. Unit i t
ends, lever every race exists the lower end. Lube the
cable ends where they pivot.
2. Throttle grip, A Pre-race Lightly oil the inside o f throttle
throttle hous- spool, Keep free from dirt.
ing, cable
3. Rear brake C Pre-race Grease the brake pedal pivot.
pedal
4. Svvingarm C Every 3 races/ More Clean and pack the bearings.keep
often according t o con- seals fresh.
ditions
5. Floater pivot C Every 3 races/More Clean and pack the bearings.keep
points often according t o con- seals fresh.
ditons
6. Steering stem C Every 5 races/More Clean and pack the bearings.keep
bearings often according t o con- seals fresh.
ditions
7. Choke shaft A Pre-race Lightly oil the plunger shaft.
8. Drive chain B Pre-race and between Keep chain thoroughly lubed a t
every moto all times. A l w a y s check wear
and alignment.
The following materials are necessary:

A. L i g h t w e i g h t oil such as W D - 4 0 or penetrating oil.
B. Aerossol type Suzuki Chain Lube
C. Water-proof wheel bearing grease.
pf
,b4 I
1lo
11
Follow the schedule closely. The disassembly necessary to lubricate many components is in itself valu-
able preventative maintenance. It allows you to inspect for wear, fatigue, adjustment and fastener tight-
ness and i t allows you t o clean o u t the grit which otherwise cannot be gotten out.
TIGHTENING TORQUE
PART N.m kg-m lb-ft
26-30 2.6-3.0 19.0-21.5

Cylinder head nut
30-40 3.0-4.0 21.5-29.0
Magneto rotor nut
36-40 3.6-4.0 26.0-29.0
Cylinder nut _
Clutch sleeve hub nut 60-80 6.0-8.0 43.5-58.0
60-80 6.0-8.0 43.5-58.0
Primary drive gear bolt
Exhaust valve arm bolt 4-6 0.4-0.6 3.0-4.5
25-30 2.5-3.0 18.0-21.5
Spark plug
Handlebar clamp bolt 20-30 2.0-3.0 14.5-21.5
Front fork upper clamp bolt (right and left) 20-30 2.0-3.0 14.5-21.5
Front fork lower clamp bolts (right and left) 20-30 2.0-3.0 14.5-21.5
80-100 8.0 10.0 58.0-72.5
Steering stem head nut
Front fork cap bolt 25-35 2.5-3.5 18.0-25.5
50-55 5.0-5.5 36.0-40.0
Front fork piston rod nut
5-8 0.5-0.8 3.5-6.0
Master cylinder set bolt (front)
8-12 0.8-1.2 6.0-8.5
Master cylinder set bolt (Rear)
Brake hose union bolt (front and rear) 15-20 1.5-2.0 11.0-14.5
15-20 1.5-2.0 11.0-14.5
Brake pad mounting bolt (front and rear)
Brake caliper mounting bolt (front) 18-28 1.8-2.8 13.0-20.0
6-9 0.6-0.9 4.5-6.5
Brake bleeder plug (front and rear)
Front axle holder nut 9 - 11 0.9-1.1 6.5-8.0
Front axle shaft 50-80 5.0-8.0 36.0-58.0
37-45 3.7-4.5 27.0-32.5
Engine mounting nuts
Rear axle nut 8 5 - 11 5 8 . 5 - 11 . 5 61.5-83.0
30-40 3.0-4.0 21.5-29.0
Rear sprocket nut
Spoke nipple 2-3 0.2-0.3 1.5-2.0
50-80 5.0-8.0 36.0-58.0
Rear swingarm pivot nut (engine mounting)
Rear shaock absorber fitting nut (upper and 40-60 4.0-6.0 29.0-43.5
lower)
Rear cushion lever center nut 80-120 8.0-12.0 58.0-87.0
Rear cushion lever front nut 60-100 6.0-10.0 43.5-72.5
Rear cushion rod n u t 80 120 8.0-12.0 58.0 87.0
For other bolts and n u t s n o t listed in t h e table, refer to this chart.
Bolt Conventional or " 4 " marked bolt " 7 " marked bolt
Diameter
(mm) N.m kg-m lb-ft N.m kg-rn lb-ft
4 1.0-2.0 0.1-0.2 0.7-1.5 1.5-3.0 0.15-0.3 1.0-2.0
5 2.0-4.0 0.2-0.4 1.5-3.0 3.0-6.0 0.3-0.6 2.0-4.5
6 4.0-7.0 0.4-0.7 3.0-5.0 8.0-12.0 0.8-1.2 6.0-8.5
8 10.0-16.0 1.0-1.6 7 . 0 - 11 . 5 18.0-28.0 1.8-2.8 13.0-20.0
10 22.0-35.0 2.2-3.5 16.0-25.5 40.0-60.0 4.0-6.0 29.0-43.5
12 35.0-55.0 3.5-5.5 25.5-40.0 70.0-100.0 7.0-10.0 50.0-72.5
14 500-800 5.0-8.0 36.0-58.0 110.0-160.0 11 . 0 - 1 6 . 0 7 9 . 5 - 11 5 . 5
16 80.0-130.0 8.0-13.0 58.0-94.0 170.0-250.0 17.0-25.0 123.0-181.0
18 136,0-190.0 13.0-19.0 94.0-137.5 200.0-280.0 20.0-28.0 144.5-202.5
3-1 TROUBLESHOOTING
TROUBLESHOOTING
ENGINE
Possible Cause Remedy
Complaint
Fuel deterioration Replace
Engine does n o t
start o r hard t o No fuel f l o w t o t h e carburetor
Clean
start Fuelcock clogged
Fuel hose clogged Clean o r replace
Fuel tank cap breather hose clogged Clean
Carburetor float valve malfunction Replace
Carburetor overflow pipe clogging Clean
Carburetor air v e n t pipe clogging Clean
Too rich fuel/air mixture in combustion chamber Scavenge
Incorrect ignition timing Adjust or replace
_,- 1 0-2
No spark at spark plug
Low compression
Piston ring w o r n o r stuck Replace
Cylinder w o r n Replace
A i r leak f r o m cylinder gasket Replace
A i r leak f r o m crankshaft oil seal Replace

Engine stalls
Fouled spark plug Clean o r replace
Fuel hose clogged Clean o r replace
Air cleaner clogged Clean o r replace
Clean
Carburetor jets clogged
Low compression
Piston ring w o r n or stuck Replace
Cylinder w o r n Replace
A i r leak f r o m cylinder gasket Replace
A i r leak f r o m crankshaft oil seal Replace
Carburetor fuel level maladjustment Adjust
Insufficient Fuel deterioration Replace

Brake dragging Adjust or replace
power
Exhaust pipe cracked o r clogged w i t h carbon Replace or clean
Exhaust valve maladjustment Adjust
Exhaust valve carbon deposits Clean
Air cleaner element clogged Clean or replace
Carburetor jets clogged Clean o r replace
Incorrect fuel level in carburetor Adjust
Incorrect spark plug gap Adjust or replace
Cylinder or piston ring w o r n Replace
Reed valve mulfunction Replace
Incorrect ignition timing pl
Adjust or replace
TROUBLESHOOTING 3-2
Complaint Possible Cause Remedy

Engine runs poorly Wide spark plug gap Adjust or replace
in l o w speed range Carburetor air s c r e w maladjustment Adjust
Incorrect carburetor fuel level Adjust
Weak ignition Replace
Generator short circuit Replace
Engine runs poorly Narrow spark plug gap Adjust or replace
in high speed range Incorrect carburetor fuel level Adjust
Retarded ignition timing Adjust or replace
COI u n i t malfunction Replace
Ignition coil damage Replace
Air cleaner element clogged Clean o r replace
Generator short circuit Replace
Exhaust pipe cracked Replace
Exhaust valve malfunction Clean, adjust or
replace
Piston ring s t u c k Replace
Exhaust valve does Carbon deposits on exhaust valve Clean
not w o r k Exhaust valve damage Replace
Governer damage Replace
Cam damage Replace
Valve spring damage Replace
Spark plug does Ignition coil malfunction Replace
not ignite Spark plug malfunction Replace
Generator malfunction Replace
CD! u n i t malfunction Replace
Wide spark plug gap Modify
Engine kill s w i t c h malfunction Repair or replace
Carbon deposits on Too rich fuel/air mixture Adjust
spark plug porcelain Too rich oil/gasoline mixture Adjust
Improper spark plug heat range Replace
Spark plug Improper spark plug heat range Replace
electrodes damage Overheating --
Loose spark plug Tighten
Too lean fuel/air mixture Adjust
3-3 TROUBLESHOOTING
Overheating Low coolant level Replenish

Coolant leak Rapeir
Too lean fuel/air mixture Adjust
Incorrect ignition timing Adjust o r replace
Water pump malfunction Adjust or replace
Cylinder head carbon deposits Clean
Cylinder head 0 - r i n g damage Replace
Exhaust pipe carbon deposits Clean o r replace
Improper spark plug heat range Replace
Clutch slipping Adjust o r replace
Radiator cap loose Tighten
Radiator fins damaged Repair or replace
Excessive coolant Radiator hose cracked o r damaged Replace
level decrease Loose radiator hose connection Repair
Radiator cracked o r damaged Repair or replace
Water pump cover mating surface damage Replace
Water pump cover crack Replace
Water pump cover gasket damage Replace
Water seal w e a r or damage Replace
Radiator cap seal damage Replace
Incorrect radiator cap valve pressure Replace
Cylinder or cylinder head cracked Replace
Cylinder, cylinder head gasket damage Replace
Clutch does n o t Clutch lever play maladjustment Adjust
disengage Clutch spring damage Replace
Clutch plates distortion Replace
Clutch slipping Clutch cable play maladjustment Adjust
Weakened clutch spring Replace
Clutch pressure plate wear Replace
Clutch plate distortion Replace
Clutch plates w o r n Replace
Transmission does Gearshift cam damage Replace
not s h i f t Gearshift fork distortion Replace
Gearshift pawl w e a r Replace
Transmission gears Gearshift fork groove wear or damage Replace
jump o u t , Gearshift fork distortion or w e a r Replace
Gearshift cam stopper damage Replace
Gearshift lever Weakened gearshift return spring Replace
Gearshfit lever sticking Repair or replace
1does n o t return
TROUBLESHOOTING 34
CHASSIS

_
Heavy handling Steering stem n u t overtightening Adjust
Steering head bearings damaged o r rusted Replace
Steering stem distortion Replace
Front wheel Loose spoke nipples Adjust
wobbling Wheel distortion Replace
Front wheel bearing damage Replace
Incorrect tightening torque Retighten
Rear wheel Loose spoke nipples Adjust
wobbling Wheel distortion Replace
Rear wheel bearing damage Replace
Swing arm p i v o t bearing damage Replace
Incorrect tightening torque Retighten
Soft f r o n t Weakened spring Replace
suspension Low oil level Replenish
Low f o r k oil viscosity Replace
Damping force maladjustment Adjust
Damping valve malfunction Replace
Hard f r o n t High f o r k oil level Adjust
suspension High f o r k oil viscosity Replace
Damping force maladjustment Adjust
Inner tube distortion Replace
Soft rear Weakened spring Replace
suspension Damping force maladjustment Adjust
Low gas pressure Adjust
Hard rear Damping force maladjustment Adjust
suspension Damper rod distortion Replace
Rear suspension pivoting portion o u t o f grease Lubricate
Poor braking B r a k e pads w o r n Replace

Improper air bleeding Bleed A i r
Dirty pads and disc Clean
Brake fluid leak Repair
Brake noise Brake pads w o r n Replace
Brake disc w o r n Replace
Dirty brake pads and disc Clean
4-1 MACHINE TUNING
MACHINE TUNING PRINCIPLES OF CARBURETOR TUNING

CARBURETOR Carburetor Components and Functions
The carburetion o f your motorcycle w a s care- The carburetor consists of a number of parts as
fully selected after extensive testing. Yo u will shown below. The asterisk (*) marked parts are
find t h a t the carburetion will function smooth- precisely machined, which meter the intake air
ly under many varied operating conditions. For (oxygen) and fuel so that the air/fuel mixture ra-
best results w e recommend t h a t t h e adjust- tio is controlled accurately. They can be divid-
ments and carburetion jeting be left "as is" from ed by three operation-related groups; pilot (slow)
the f a c t o r y. system, intermediate system and main system,
and t h e y achieve their functions in each cor-
Some riders may operate their motorcycle un- responding throttle opening range. It is neces-
der extreme operating conditions such as; very sary t o have a full understanding o f them f o r
high altitudes or extreme cold and hot temper- proper carburetor tuning.
atures. In these circumstances the jetting of the
carburetor or other adjustments may need to be
altered slightly. Riders who are not familiar with
the operation a n d j e t t t i n g procedures o f t h e
Mikuni carburetor should have their local autho-
rized Suzuki dealer perform these alterations.
Mechanically experienced riders can alter t h e
carburetor settings based on t h e following in-
formation and specifications,
Carburetor Specifications
Bore 38 m m
Main j e t # 370
Jet needle 6AEL01-60-3rd
Needle jet (R-1) N o t adjustable
Cut-away 3.5
Pilot jet # 50
Air s c r e w 1-
Float height 16.0 1 .0 r a m ( 0 . 5 5
0 . 0 4 in)
# 3 5 0 , # 3 6 0 , # 3 8 0 and
Spare main jet:
#390
5. Starter plunger
6. * A i r screw
7. * M a i n j e t
1. T o p cap 8 . * P i l o t jet
2. Spring 9 . Float
3. * J e t needle 1 0 . N e e d l e valve ass'y
4. T h r o t t l e valve 11 . Clip
MACHINE TUNING 4-2
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 indi-
cates that the carburetor can supply correct air/fuel mixture to the engine in any range because o f
the overlapping adjustable range o f the each part.
TUNING PARTS THROTTLE VA LV E OPENING

i
MAIN JET 0
JET NEEDLE
1111.1111
NEEDLE CLIP POSITION -------------
PILOT JET A N D PILOT 7 1 . 111111111

AIR SCREW
Va 1 /
THROTTLE OPENING
I I I I
0 M A I N SYSTEM a ) INTERMEDIATE SYSTEM P I L O T SYSTEM
When performing carburetor tuning first find Out Pilot Air Screw
in w h a t t h r o t t l e opening r a n g e a n i m p r o p e r
air/fuel mixture is supplied, by checking the color
of exhaust smoke, spark plug, throttle response,
power, etc. Second, replace or adjust the part(s)
related t o the throttle opening range b y refer-
ring t o t h e f o l l o w i n g instructions. T h e sizes
referred to in the illustrations are those of stan-
dard setting.
Pilot Jet
The pilot air screw is located in the inlet air pas-

sage and meters the air for the pilot system. A s
it has a right-hand thread, tightening i t makes
the passage narrower, allowing less amount of
intake air to f l o w and resulting in richer air/fuel
mixture. Air flow adjustment is effective within
a range o f 1 / 2 - 2 turns out.
The pilot jet meters the fuel supplied t o the pi-

lot system. Each jet size is indicated by a num-
ber. Larger number means a larger bore diameter
and fitting a larger numbered pilot jet enriches
the air/fuel mixture.
4-3 MACHINE TUNING
Needle Clip Position Main Jet
Lean
c
Rich 1 5
The jet needle is linked to the throttle valve by The main jet, like the pilot jet, meters fuel f l o w.
means o f the needle clip. I t s l o w e r part is ta-
pered and i t has five grooves c u t in the upper
part w h e r e the needle clip fits.
To adjust the air/fuel mixture w i t h the jet nee-

dle, change the position of the needle clip which
is set in the 3rd groove. The lower groove the
clip is moved to, the higher the jet needle rises
and the larger the clearance with the needle jet
becomes, resulting in a richer air/fuel mixture
ratio.
Jet Needle
Charging the needle itself also controls air/fuel

mixture ratio particularly on lower mid-throttle
opening. Size 6 5 indicates t h a t O.D. i s 2 . 6 5
mm. The smaller the O.D. The richer the air/fuel
mixture becomes.
EX. 6 A E . . 1 0 1 -64-3rd
6AEJ01 -65-3rd
6AEJ01-66-3rd
MACHINETUNING 4-4
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 copying with variation in air (oxygen) con-
centration.
Variation in Air (Oxygen) Concentration and Carburetor Conditions
As the air, affected b y the temperature, altitude and humidity, gets expanded or compressed, air
(oxygen) concentration varies accordingly. Each o f these three factors affects the air in different
ways, and the following graphs show their effects respectively in terms of the oxygen concentration
1%1
100 100
90 9 0
0
< 80 8 0
uJ
0
0
>-
X
0 1 1 1 1 1 I I I I 1
-100 1 0 2 0 3 0 4 0 ["CI 5 0 0 1000 1500 2000 2500 1m] 20 4 0 6 0 8 0 1 0 0 1%i
10 3 0 5 0 7 0 9 0 11 0 1 Ifti
ATMOSPHERIC TEMPERATURE A LT I T U D E H U M I D I T Y
In the above graphs, oxygen concentration is graduated on the vertical axis while the temperature,
altitude and humidity are on the horizontal axis respectively. Oxygen concentration is set 1 0 0 % un-
der the cnditions o f 2 0 C ( 6 8 " F ) , 0 m ( 0 ft) and 5 0 % humidity. The standard carburetor setting
is chosen t o obtain the best engine performance under these conditions.
The graph at the left shows that the oxygen concentration changes about 1 0 % in the 0 " t o 4 0 C
temperature difference, the one in the center shows about 20"/0 change in the 0 to 2 0 0 0 m attitude
difference and the one at the right shows about 5')/o change in the 0 to 1 0 0 % humidity difference.
As for humidity, its normal range is from 2 0 to 9 5 % . Therefore the possible effect o f humidity on
the oxygen concentration is so little that it can be disregarded. Consequently, w e can say that the
oxygen concentration varies by as much as 209/o depending on the temperature and altitude under
normal riding conditions. On the other hand, different from the air, the fuel (gasoline) hardly changes
in volume even when such environmental conditions change. Therefore, increase in oxygen concen-
tration w i l l make the air/fuel mixture leaner and decrease w i l l enrich it.
As the carburetor mixes gasoline and air, w h i c h are metered b y each jet in varying proportions t o
suit throttle opening, the air/fuel mixture is affected if the air concentration itself aries as described
above. Then proper engine power output can n o t be attained and, should the mixture become too
lean, a piston seizure may result. To compensate for such change in the air concentration, i t is re-
quired to carry out carburetor tuning beforehand. This requirement applies to all models of motorcy-
cles and AT V s if they are used in areas where temperature and altitude range widely. The next section
describes the procedure o f the above tuning in detail.
4.5 MACHINE TUNING
Spare Parts and Optional Parts

Judging Air/Fuel Mixture
Main iet
,
For proper carburetor tuning, it is necessary to
know how to judge the airlfuel mixture made SIZE P'NO
in the carburetor; whether too rich, too lean or # 330 09491-66002
properly mixed. Given below are the symptoms 09491-68002
observed when the engine is not supplied with #340
the proper air/fuel mixture ratio from the carbu- * # 350 09491-70011
retor. Check each item as reference for judging *#360 09491-72011
the air/fuel mixture condition.
#370 09491-74003
_
When air/fuel mixture is too rich *#380 09491-76003
1) The engine noise is dull and intermittent. * # 390 09491-78005
2) The engine condition becomes worse when
the choke is applied. # 400 09491-80010
3) The engine condition becomes worse as it is #410 09491-82007
warmed up. 09491-84004
# 420
4) The engine condition improves when the air
cleaner is removed. # 430 09491-86002
5) The spark plug is fouled with carbon (wet and # 440 09491-88001
oily).
6) The exhaust gas produces heavy smoke. Pilot jet
When air/fuel mixture is too lean SIZE P/NO

1) The engine overheats. 09492-35016
#35
2) The engine condition improves when the
choke is applied. # 40 09492-40020
3) Acceleration is poor. #45 09492-45026
4) The spark plug is burned white.
# 50 09492-50018
5) The speed of the engine fluctuates and lack
of power is noticed. # 55 09492-55013
6) The speed of the engine fluctuates and lack # 60 09492-60013
of power is noticed.
#65 09492-65007
7) Detonation and pinging are experienced.
# 70 09492-70008
Tuning Procedure
The following indicates the correct tuning proce- Jet needle
dure for this motorcycle. Understand the proce-
dure by first riding the motorcycle where it will SIZE P/NO.
be used and adjust the engine to the best con- 13383-28C60
6AEL01-59-3rd
dition after judging the airlfuel mixture.
6AEL01-60-3rd 13383-28070
Carburetor standard setting 6AEL01-61-3rd 13383-28C80
Main jet : # 370
Jet needle : 6AEL01-60-3rd
Pilot jet : # 50 NOTE:
Pilot air screw :1
SHADED: STANDARD
: SPARE PARTS
NONE : OPTIONAL PARTS
MACHINE TUNING 4-5
Measurement of temperature and altitude
Ex. Temperature: 7 C (44.6F)

Altitude : 1 3 0 0 m (4 300 ft)
Selection of main jet and pilot jet
Atomosphe-
ric tempera- 'C -10 0 10 20 30 40
ture
Altitude
0 14 32 50 68 86 104
410 400 380 370 3 6 0 3 5 0

0 0
60 60 55 55 5 5 ,- 5 5
400 390 370 370 350 340
250 820 55 55
60 60 5 5 5 5
390 370 - / 360 340 330
500 1640 50 50
60
55), 5 5 / 330
380 370,z 3 6 0 z 3 5 0
750 2460 50
55 5 5 7 5 5 0
380 370 3 5 0 340" 330
1000 3280 50
55 55 5 0 v
370 330 Z
1250 4100 50
55 50
360
1500 4920
55 5 0 5 0
Ex. Selected jets

Main jet: # 340
Pilot jet: # 50
Find 7C (44.6F) temperature in the horizon-

tal column and 1 3 0 0 m (4 300 ft) altitude in
the vertical column. Where they meet, 340/50,
indicates t h e proper main/pilot j e t numbers
respectively.
If the the temperature and altitude are between

the columns, select the larger number jets to be
on the safe side.
4-7 MACHINE TUNING
0 A d j u s t m e n t o f pilot system 1) Adjust the air/fuel mixture by turning the pi-

1) Set t h e p i l o t a i r s c r e w a s s p e c i f i e d . lot air s c r e w w i t h i n 1 / 2 - 2 turns out.
2 ) See if the selected pilot jet is correct or not 1/2 t u r n o u t
1-3/4 t u r n o u t
by judging ;.he air/fuel mixture. If air/fuel mix-
ture is rich, replace i t w i t h smaller one. I f 2 turns o u t
air/fuel mixture is lean, replace it with larger 2) If the mixture can not be adjusted by the pilot
one. screw within 1 / 2 - 2 turns out range, readjust
the pilot system .
( ) Final adjustment o f intermediate system

Ex. P i l o t jet # 55
If air/fuel mixture is rich, replace it with
# 50 pilot jet. If air/fuel mixture is lean,
replace i t w i t h # 60 pilot jet.
A d j u s t m e n t o f main system
With the throttle opened 3 / 4 to full, make main
s' t e r n adjustment monitoring the air/fuel mix-
ture condition after completion of pilot system
setings.
* I f selection o f t h e main j e t is b e t w e e n t h e
columns, take the larger number main jet first Fine tune the intermediate system by changing
to prevent the piston seizure' the clip position.
* M a k e sure to adjust the main system before
adjusting t h e interrndiate system.
Ex. M a i n jet # 370

If air/fuel mixture is rich, replace it with
# 360 main jet. I f air/fuel m i x t u r e is
lean, replace i t w i t h # 380 main jet. I
() A d j u s t m e n t o f intermediate system
Monitor the air/fuel mixture condition and ad-
just the intermediate system b y selecting t h e
r - ) e r needle size. Changing standard needle
wunin o n e size (larger o r smaller) w i l l c o v e r
almost any race condition. Size 5 5 and 51 are
rarely used.
0 Final adjustment o f pilot system

After a proper standard setting has been ob-
tained by the procedure (j) through .,16), fine tune
the carburetor according to the actual race con-
ditions.
-
MACHINETUNING 4-8
The following table shows the carburetor jetting

selections for typical conditions which particu-
larly affect the carburetion to a large degree.
When adjusting the carburetion, refer to this ta-
ble for finding suitable jet selections.
Below 1 0 ' C 10C-25"C Over 2 5 C

J ET
(76F) (76'F (103F)
Main jet # 380 # 370 # 360
e
2 Jet needle 6AEL1-60-4th 6AEL1-60-3rd 6AEL1-60-3rd
-
E Pilot jet # 50 # 50 # 50
'a
z 1-
Air screw 1 1
Main jet # 390 #380 # 370

_e.
E' Jet needle 6AEL1-60-5th 6AEL1-60-4th 6AEL1 -60-3rd
>
2 Pilot jet #50 #50 #50
riz
cn
Air screw 1- 1-M 1-1/2
4-9 MACHINE TUNING
FRONT FORK
The front fork compression and rebound damping force, oil
level, air pressure and spring pre-set is adjustable for rider's
preference, riders w e i g h t and course condition,
NOTE:
Break-in new front forks before attempting adjustment.
-4)
B e sure to adjust both right and left front forks equally.
Compression Damping Force Adjustment

R e m o v e t h e rubber cap.
T u r n in the compression damping force adjuster unitl i t
stopsstiffest position.
Turn o u t t h e adjuster and c o u n t the number o f clicks.
Larger n u m b e r o f clicks provides s o f t e r compression
damping force.
Standard seting: 1 2 t h click
Re-fit t h e rubber cap.
Rebound Damping Force Adjustment

T u r n in the rebound damping force adjuster until it stops
stiffest position.
T u r n o u t t h e adjuster and c o u n t the number o f clicks.
Larger number of clicks provides softer rebound damp-
ing f o r c e .
Standard setting: 1 0 t h click
Air Pressure Adjustment

Place a block under the chassis tube t o lift the f r o n t a
wheel o f f the ground.
,-- Remove the air valve and equalize the air pressure in the
front forks t o atmospheric pressure.
Standard air pressure: k g / c m ' ( 0 psi)
R e - f i t t h e air valve
Front Fork Oil Replacement and Oil Level Adjustment

R e m o v e t h e f r o n t forks. 5 - 2 )
R e m o v e t h e f r o n t fork caps and spring. 1 5-2)
D r a i n f r o n t fork oil. (r7-
Place the front fork vertically in fully compressed position.
P o u r specified front fork oil up to the top level of the outer
tube.
C y c l e the rod slowly until bubbles stop coming to the sur-
face o f t h e oil (appoximately ten times).
_,*__
, '
-
MACHINE TUNING 4-10
Front fork oil: S U Z U K I FORK OIL SS-05
NOTE; P o u r front fork oil up t o the top o f the outer tube

to f i n d bubbles while bleeding air.
M o v e the outer tube up and d o w n about 1 5 0 mm ( 5 . 9

in) storke until bubbles stop corning to the surface of the
oil.
H o l d the front forks vertically and wait several minutes.
Measure the front fork oil level w i t h the front fork fully
compressed.
0 0 9 4 3 - 7 4 11 F r o n t fork oil level gauge
Standard oil level: 1 3 5 m m ( 5 . 3 in)
Oil level adjustment range: 1 2 5 - 1 5 5 m m 1 4 . 9 - 6 . 1 in)
Oil level Oil quantity

125 m m ( 4 . 9 in) 637 m l ( 2 1 . 5 US oz)
130 m m (5.1 in) 6 2 8 m l ( 2 1 . 2 US oz)
135 nnnn ( 5 . 3 in) 6 1 9 ml ( 2 0 . 9 US oz)
140 m m ( 5 . 5 in) 6 1 0 ml ( 2 0 . 6 US oz)
145 m m ( 5 . 7 in) 601 m l ( 2 0 . 3 US oz)
150 mnn ( 5 . 9 in) 592 ml ( 2 0 . 0 US oz) 25 1
130 inrn 45.1 i n /

155 nnm (6.1 in) 583 m l ( 1 9 . 7 USS oz) 35 rnrn 45.3 ,
140 mm (5,5 iM
NOTE: A n oil level lower or higher than the above range 1 4 5 rnrin 4 5 . 7 i n )
will affect the front fork performance. Be sure to adjust the 150 rnrn 45.0 in/
155 rnrn 46.1 ,

front fork o i l level within t h e above range.
Stroke ( mm)
Front Fork Mounting Height Adjustment

Reassemble the front forks. (.7:r15-4)
A d j u s t the front fork mounting height from outer tube
top surface t o upper bracket t o p surface, t o 8 . 9 m m
(0.35 in),
M o u n t t h e front forks. ( n r 1 5 - 5 )
4-11 MACHINE TUNING
Front Fork Tuning Procedure

Test ride the motorcycle and find o u t 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, a t t e m p t changing f o r k oil capacity and compression/rebound damping fol-
lowing t h e instructions below.
SECTION ADJUSTMENT PROCEDURE

SYMPTOM
Jump 1. Adjust b o t h t h e compression and rebound
Feels t o o hard overall
Large bumps damping t o a s o f t e r setting.
Series o f medium 2. Decrease f o r k oil.
bumps
Jump 1. Adjust t h e compression damping t o a stiffer
Feels t o o s o f t overall
and b o t t o m s Large b u m p setting.
When braking 2. Increase f o r k oil.
Jump 1. Decrease f o r k oil.
Feels t o o hard near
i d o f travel
Jump 1. Adjust t h e compression damping t o a stiffer
, eels t o o s o f t near end
of travel a n d b o t t o m s Large b u m p settting.
2. Increase f o r k oil
harshly
Feels t o o hard in t h e Jump 1. Adjust t h e compression damping t o a softer
Large b u m p setting.
beginning o f stroke
Series o f medium
bumps
Series o f small
Feels t o s o f t and Series o f medium 1. Adjust t h e rebound damping t o a s t i ff e r
unstable bumps setting.
Series o f small b u m p s
a Jump 1. Adjust the rebound damping t o a s t i ff e r
Bounces
Large b u m p setting.
Bounces Series o f small b u m p s 1. Adjust the rebound damping t o a softer
setting.
NOTE:
When adjusting t h e f r o n t f o r k o i l capacity, m a k e sure t h a t t h e o i l level is w i t h i n t h e specified
range. A l s o , t h e capacity should be increased or decreased b y 5 m m (approx. 5 m 0 a t a time.
When adjusting the damping setting, a t t e m p t turning the adjuter 1 t o 2 click stops a t a time f o r
each adjustment.
." .17: -
MACHINE TUNING 412
REAR SUSPENSION
The r e a r suspension compression a n d rebound d a m p i n g
force, and spring preload is adjustable for rider's preference,
rider's weight and course condition.
NOTE: Break-in the rear suspension when riding with a n e w

rear cushion unit. ( 1 - 4 )
Compression Damping Force Adjustment
Tu r n in the compression damping force adjuster until it

Tu r n o u t the adjuster and count t h e number o f clicks.
Larger n u m b e r o f clicks provides s o f t e r compression
damping force.
Standard setting: l l t h click
Rebound Damping Force Adjustment

Tu r n i n t h e rebound d a m p i n g f o r c e a d j u s t e r u n t i l i t
Tu r n o u t the adjuster and count t h e number o f clicks.
Larger number of clicks provides softer rebound damp-
ing force.
Standard setting: 1 6 t h click
Spring Preload Adjustment

Lossen the lock nut. Turning the adjuster wihtout loosen-
ing the lock nut.
Tu r n t h e a d j u s t e r clockwise o r c o u n t e r c l o c k w i s e t o
change the spring preload.
Tighten the lock nut.
Spring set length Adjustable range: 2 3 8 - 2 4 8 . 5 m m

( 9 . 4 - 9 . 8 in)
5-1 ENGINE DISMOUNTING AND MOUNTING
ENGINE DISMOUNTING AND MOUNTING

DISMOUNTING
R e m o v e t h e frame covers and seat.
R e m o v e t h e radiator cover.
T u r n t h e fuelcock lever to the " O F F " position and dis-
connect t h e fuel hose.
R e m o v e t h e t w o bolts and band f r o m t h e fuel tank.
R e m o v e t h e fuel tank.
Drain t h e transmission oil. (E..7' 2-5)
D r a i n coolant. 1 1 - 2 )
R e m o v e t h e exhaust pipe fitting springs and bolt.
R e m o v e the m u ff l e r f i t t i n g b o l t s .
R e m o v e t h e exhaust pipe and muffler.
D i s c o n n e c t the radiator hose.

D i s c o n n e c t the lead wires.
R e m o v e the spark plug.
R e m o v e t h e carburetor.
R e m o v e t h e engine sprocket cover.
R e m o v e t h e drive chain.
ENGINE DISMOUNTING AND MOUNTING 5-2
R e m o v e t h e clutch release arm.

R e m o v e the engine mounting bolts and plates.
Remove t h e swing arm p i v o t shaft.
NOTE: T h e swing arm w i l l come o f f when the swing arm

pivot shaft is completely removed.
R e m o v e the engine f r o m t h e frame.
ENGINE MOUNTING
M o u n t the engine on t h e frame.
Ti g h t e n t h e engine mounting nuts.
Tightening torque
N.m kg-m lb-ft
' 37-45 3.7-4.5 27.0-32.5
( 37-45 3.7-4.5 27.0-32.5
37-45 3.7-4.5 27.0-32.5
50-80 5.0-8.0 36.0-58.0
NOTE: R e p l a c e the self-locking nuts w i t h n e w ones.
Reassemble t h e parts in t h e reverse order o f removal.
NOTE: R o u t e the cables a n d lead wires correctly.

( 19-1 )
After mounting t h e engine, inspect t h e following items.

Transmission oil level ( 2 - 5 )
C o o l a n t level ( 2 - 5 )
Throttle cable play ( 2 - 7 )
C l u t c h lever play ( :7- 2-7)
D r i v e chain slack ( 2 - 8 )
CYLINDER, PISTON AND EXHAUST VALVE 6-1
CYLINDER, PISTON AND EXHAUST VALVE
2 . 5 - 3 . 0 kg-m A 4
2.6 3.0 kg-m
t c
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6-2 CYLINDER, PISTON AND EXHAUST VALVE
CYLINDER HEAD REMOVAL

R e m o v e the fuel tank.
D r a i n coolant. ( 1 1 - 2 )
Loosen t h e clamp and disconnect the radiator hose.
R e m o v e the spark plug.
R e m o v e the exhaust piep. ( 5 - 1 )
R e m o v e the engine mounting bracket.
R e m o v e the cylinder head.
NOTE: L o o s e n the cylinder head nuts diagonally to prevent

the cylinder head distortion.
-4 R e m o v e the cylinder head 0-rings.
CYLINDER REMOVAL
R e m o v e the exhaust pipe. (E_T- 5-1)
R e m o v e the carburetor. ( 1 0 - 2 )
R e m o v e the exhaust valve rod cover.
U n h o o k the stopper and remove the exhaust valve rod.
R e m o v e the four cylinder nuts.
NOTE: L o o s e n t h e cylinder nuts diagonally.
Remove t h e radiator hose connecting r i g h t and l e f t

radiators.
R e m o v e the cylinder.
R e m o v e the gasket.
Remove the reed valve. ( 1 0 - 3 )
PISTON REMOVAL
R e m o v e the piston pin circlip.
NOTE: P l a c e cloth on the crankcase to prevent the piston

pin circlip f r o m dropping into t h e crankcase chamber.
R e m o v e the piston pin.

R e m o v e t h e piston.
R e m o v e the con-rod small end bearing.
CYLINDER,PISTON AND EXHAUST VALVE 6-3
EXHAUST VALVE REMOVAL

Remove t w o s c r e w s and retainer.
R e m o v e t h e exhaust valve cap, spring and spacer.
R e m o v e t h e exhaust valve shaft stopper screw.
Remove t h e exhaust valve cover.

R e m o v e t h e arm stopper screw. Remove t h e exhaust
valve shaft.
R e m o v e t h e exhaust valve guide stopper screws.
Remove t h e exhaust valves.
CYLINDER HEAD INSPECTION

Remove carbon deposits f r o m the cylinder head.
Inspect the cylinder head for cracks around the spark plug
hole.
I n s p e c t f o r cylinder head distortion.
Service limit : 0 . 0 5 m m ( 0 . 0 0 2 in)
CYLLINDER INSPECTION
Remove carbon deposits f r o m the exhaust port.
I n s p e c t the cylinder for cracks and replace the cylinder
if necessary.
I n s p e c t the cylinder bore f o r wear and scratches.
NOTE: C h r o m e - p l a t e d cylinder bore can n o t be m o d i f i e d

such as boring a n d honing.
Inspect f o r cylinder distortion.
Service limit : 0 . 0 5 m m 10.002 in)

M e a s u r e t h e cylinder b o r e f o r w e a r a t p l a c e w i t h a
cylinder gauge at 2 0 m m f r o m t h e t o p surface.
NOTE: T h e cylinder bore must be measured perpendicular

to t h e crankshaft axis direction.
Standard : 6 7 . 0 0 0 - 6 7 . 0 1 5 mm ( 2 . 6 3 7 8 - 2 . 6 3 8 4 in)
09900-20508 : Cylinder gauge set ( 4 0 - 8 0 mm)
PISTON A N D PISTON RING INSPECTION

R e m o v e the piston ring f r o m t h e piston ring groove.
R e m o v e carbon deposits f r o m t h e piston.
I n s p e c t the piston f o r wear, scratches and damage.
M e a s u r e the piston outer diameter at 2 4 m m ( 0 . 9 4 in)
from t h e skirt end. 24 nnm
(0.94 in)
Service limit : 66.880 mm (2.6331 in)
09900-20203 : Micrometer ( 5 0 - 7 5 mm)
M e a s u r e t h e piston pin bore and piston pin diameter.
Service Limit
Piston pin bore 18.030 mm (0.7098 in)
Piston pin O.D. 17.980 mm (0.6724 in)
R e m o v e carbon deposits from piston ring and piston ring

groove.
F i t the piston ring into the ring groove and measure the
clearance w i t h a thickness gauge.
Standard : 0 . 0 2 0 - 0 . 0 6 0 mm ( 0 . 0 0 0 8 - 0 . 0 0 2 4 in)
F i t t h e piston ring i n t o t h e cyllinder and measure t h e

piston ring end gap w i t h a thickness gauge.
M e a s u r e t h e piston ring free end gap.

EXHAUST VALVE INSPECTION

Remove carbon clepsits from the exhaust valve and valve
guide.
I n s p e c t the exhaust valve and valve guide for wear and
scratches.
I n s p e c t the return spring f o r spring tension.

I n s p e c t t h e spacer for cracks and w e a r.
t:
11111 4E10 I
CON
Measure the c o n
F i t the piston pin and bearing into the con-rod small end
and check the play.
PISTON RING A N D PISTON REASSEMBLING

A p p l y engine oil to the piston ring and piston ring groove.
F i t the piston ring into the piston ring groove so the piston
ring end comes t o the piston ring locating pin.
A p p l y engine oil t o t h e piston pin and bearing.
F i t t h e bearing t o t h e con-rod small end.
F a c e t h e arrow mark on the piston t o p t o t h e exhaust

port side and f i t t h e piston.
F i t the piston pin and piston pin circlip. Piston pin circlip
end should fuce upside.
NOTE:
Replace t h e piston pin circlip w i t h a n e w one.
P l a c e cloth on the crankcase t o prevent piston pin cir-
clip f r o m dropping into the crankcase chamber.
EXHAUST VALVE REASSEMBLING

A p p l y engine oil t o the exhaust valve and valve guide.
F i t t h e shaft t o t h e exhaust valves.
NOTE: F i t the shaft of long side to the right exhaust valve.
F i t t h e exhaust valves into the cylinder.

Ti g h t e n t h e exhaust valve guide stopper screws.
Reassemble t h e exhaust valve shaft and a r m stopper.
Apply thread lock " 1 3 0 3 " and tighten t h e bolt.
Tightening torque : 4 - 6 1\11n
(0.4 0.6 kg-m, 3 . 0 4.5 lb-ft)
F i t the c o v e r and tighten t h e screws.
CYLINDER REASSEMBLING
F i t t h e n e w gasket. Fit the dowel pins.
F i t t h e reed valve t o t h e cylinder.
Move t h e piston t o t h e t o p dead center.
A p p l y engine oil t o t h e cylinder bore.
H o l d the piston and piston ring, and insert the piston into
the cylinder.
a CAUTION
If the piston pin end is not at the proper position, you can
not insert the piston into the cylinder properly and the
piston ring will be damaged.
Locate the piston ring end to the locating pin and insert
the piston into the cylinder.
OK

NG
Ti g h t e n the cylinder nuts to the specified torque accord-

ing t o t h e specified tightening order as shown.
Tightening torque : 3 6 - 4 0 Nm
( 3 . 6 - 4 . 0 kg-m, 2 6 . 0 - 2 9 . 0 lb-ft)
F i t t h e exhaust valve w i t h stopper.

Install t h e spacer, spring cap and retainer.
Ti g h t e n t h e screws temporarily.
Tu r n t h e exhaust valve cap clockwise one turn.
Ti g h t e n t h e screws.
I n s p e c t the exhaust valves f o r smooth movement.
Install t h e n e w 0-rings.
Install t h e cylinder head.
NOTE: A p p l y Bond " 1 2 0 7 B " to the stud bolt threads when

assembling t h e removed stud bolts into t h e cylinder.
Ti g h t e n the cylinder head nuts to the speicfied torque ac-

cording t o t h e specified tightening order as s h o w n .
( 2 . 6 - 3 . 0 kg-m, 1 9 . 0 - 2 1 . 5 lb-ft)
Reassemble the engine mounting bracket. ( 5 - 2 )

Reassemble the spark plug and spark plug cap.
C o n n e c t t h e radiator hose and tighten t h e clamps.
P o u r c o o l a n t ( r 2-5)
I n s p e c t coolant leak.
CLUTCH 7-1
CLUTCH
OIL
OIL
7-2 CLUTCH
CLUTCH PLATE REMOVAL

D r a i n t h e transmission oil. ( 2 - 5 )
Remove the cotter pin and rear brake pivot bolt.
( 7 - 1 4 - 11 )
R e m o v e the clutch release arm.
R e m o v e the kick starter lever.
R e m o v e the clutch cover bolts.
Loosen t h e bolts diagonally and remove them.

R e m o v e the clutch springs and washers.
Remove the pressure plate.
R e m o v e the rack and bearing f r o m t h e pressure plate.
R e m o v e the drive and driven plates.
CLUTCH PLATE INSPECTION

Drive Plate
a Measure the drive plate thickness and c l o w w i d t h .
Service limit
Thickness 2.4 mm ( 0 . 0 9 in)
Claw width 15.3 m m ( 0 . 6 0 in)
I n s p e c t the drive plates for wear, distortion and discolo-

ration.
Driven Plate
M e a s u r e the driven plate distortion.
Service limit : 0 . 1 0 mm ( 0 . 0 4 in)
I n s p e c t the driven plates f o r w e a r and discoloration.
Clutch Spring
M e a s u r e the clutch spring free length.
Service limit : 4 2 . 3 m m ( 1 . 6 7 in)
NOTE.
spring is beyond the service limit.
CLUTCH 7-3
RACK A N D PINION INSPECTION

I n s p e c t the clutch release rack and pinion for wear and
damage.
Inspect the clutch release arm for smooth movement and
oil leakage around t h e oil seal.
CLUTCH PLATE REASSEMBLING

A p p l y transmission oil to the drive and driven plates and
fit them.
F i t the bearing, rack and pressure plate.
F i t the clutch springs, washers and bolts.
Ti g h t e n t h e bolts diagonally.
A l i g n the clutch release rack teeth w i t h the pinion gear.

Replace t h e gasket w i t h a n e w one.
F i t the cover.
Ti g h t e n t h e bolts diagonally.
Reassemble t h e rear brake pedal. ( 1 4 - 1 1 )
F i t the clutch release arm. Inspect the clutch cable play.

( 2-7)
Reassemble the k i c k starter lever.
Fill the transmission with specified transmission oil to the
correct level. ( 2 - 5 )
PRIMARY DRIVEN GEAR ASSY REMOVAL

Drain t h e transmission oil. ( c 2 - 5 )
D r a i n coolant. Disconnect the radiator hose. ( 1 1 - 2 )
Remove t h e c o t t e r p i n a n d r e a r brake p i v o t b o l t .
r=17
Remove t h e kick starter lever.
Remove the clutch cover bolts. Remove the clutch cover.
/-4
R e m o v e the bolts and pressure plate. ( :,-- 7-3)

R e m o v e t h e clutch plates. ( 7 - 3 )
F l a t t e n t h e lock washer.
H o l d the clutch sleeve hub with the special tool and loos-
en the nut.
09920-53710 C l u t c h sleeve hub holder
R e m o v e t h e clutch sleeve hub.

R e m o v e the primary drive gear and primary driven gear
assy.
R e m o v e t h e bearing.
.PRIMARY DRIVEN GEAR ASSY INSPECTION

I n s p e c t t h e clutch sleeve hub and primary driven gear
assy f o r w e a r and crack.
I n s p e c t t h e needle bearing f o r damage.
PRIMARY DRIVEN GEAR ASSY REASSEMBLY

F i t t h e washer and needle bearing.
F i t the primary driven gear assy.
F i t t h e washer, clutch sleeve hub and lock washer.
Ti g h t e n the clutch sleeve hub nut w i t h the special tool
to t h e specified torque.
09920-53710 C l u t c h sleeve hub holder
( 6 . 0 - 8 . 0 kg-m, 4 3 . 5 - 5 8 . 0 lb-ft)
CLUTCH 75
B e n d t h e lock washer t o secure the nut.

Reassemble the clutch plates and pressure plate.
F i t the dowel pins. Replace the 0-ring w i t h a n e w one.
F i t the clutch cover and bolts. Tighten the clutch cover
bolts diagonally.
Reassemble t h e kick starter lever.
Reassemble the clutch release arm.
Reassemble t h e rear brake pedal. ( 1 4 - 1 1 )
Reassemble the radiator hose and refill coolant. ( r 1 1-2)
Refill t h e transmission oil. ( 2 - 5 )
KICKSTARTER 81
KICK STARTER
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13338
8-2 KICK STARTER
KICK STARTER REMOVAL

D r a i n t h e transmission oil. I r 2-5)
D r a i n coolant. Disconnect the radiator hose. I E r 1 1-2)
Remove t h e c o t t e r p i n a n d rear brake p i v o t bolt.
14- 1 1 )
R e m o v e t h e kick starter lever.
Remove the clutch cover bolts. Remove the clutch cover.
R e m o v e the clutch. ( c1T- 7-3)
R e m o v e the kick idle gear circlip w i t h snap ring pliers.
Remove t h e kick idle gear.
U n h o o k the kick return spring.
R e m o v e t h e kick starter shaft.
Remove the following parts from the kick starter shaft.

Spacer, kick return spring, washer, spring, kick starter.
Remove the circlip with snap ring pliers. Remove the kick
drive gear.
KICK STARTER INSPECTION

I n s p e c t the oil seal for oil leakage and oil seal lip damage.
I n s p e c t the return spring f o r damage.

I n s p e c t the kick drive gear teeth f o r damage.
I n s p e c t t h e k i c k drive gear ratchet p a r t f o r w e a r and
damage.
I n s p e c t the kick shaft and drive gear for contact surface
wear.
KICKSTARTER 8-3
I n s p e c t the kick idle gear teeth f o r damage.

I n s p e c t the kick idle gear and drive shaft contact surface
for wear.
KICK STARTER REASSEMBLY

F i t the kick drive gear and washer to the kick shaft. Fit
the circlip firmly w i t h snap ring pliers.
F i t the return spring i n t o the kick shaft hole.
F i t the spacer.
F i t the kick starter to t h e kick starter shaft.
NOTE: B e sure to align the punch marks on the kick starter

and kick starter shaft w h e n fitting t h e kick starter.
F i t the kick starter assy to the crankcase. Hook the return

spring.
Reassemble the kick idle gear.
Reassemble the clutch. ( 7 - 5 )
Reassemble the clutch cover. (car 7-5)
Reassemble the kick starter lever.
Reassemble the clutch release arm.
Reassemble the rear brake pedal. ( r 1 4 - 11 )
C o n n e c t the radiator hose. Refill coolant. 1 1-2)
Refill t h e transmission oil. ( 2 - 5 )
I n s p e c t the clutch lever play.

I n s p e c t f o r coolant and transmission oil leaks.
I n s p e c t the kick starter for smooth movement.
TRANSMISSION AND CRANKSHAFT 9-1
TRANSMISSION AND CRANKSHAFT
8
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OIL
OIL
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9-2 TRANSMISSION AND CRANKSHAFT
D i s m o u n t the engine. ( 5 - 1 )
R e m o v e t h e cylinder and piston. ( 6 - 2 )
R e m o v e t h e clutch. ( r 7 - 2 )
R e m o v e the kick starter. ( 117 8-2)
R e m o v e the magneto rotor and stator. ( 1 2 - 4)
R e m o v e t h e exhaust valve actuator.
GEARSHIFT LINKAGE REMOVAL

R e m o v e the gearshifting shaft.
R e m o v e the t w o screws. Remove t h e p a w l lifter.
R e m o v e t h e driven gear. Be careful t h a t t h e pins and
springs d o n o t f l y o f f .
R e m o v e t h e gearshift cam bolt.
PRIMARY DRIVE GEAR

R e m o v e t h e primary drive gear w i t h the special tool.
09910-20115 Con-rod holder.
CRANKCASE SEPARATION
R e m o v e t h e crankcase fitting s c r e w s .
1- "
TRANSMISSIONAND CRANKSHAFT 9-3
Separate the crankcase with the special tool.

09920-13120 C r a n k c a s e separating tool
NOTE:
S e t the crankcase separating tool to the clutch side of
the crankcase.
Separate the crankcase gradually while hitting the crank-
case boss and countershaft softly with a plastic hammer.
TRANSMISSION REMOVAL
Remove the gearshift fork shaft and forks.
Remove the gearshift cam.
Remove the drive shaft assy and countershaft assy.
CRANKSHAFT REMOVAL
Remove the crankshaft by hitting with a plastic hammer.
GEARSHIFT LINKAGE INSPECTION

Inspect the gearshift shaft for bends and damage.
Inspect the return spring for damage.
Inspect the pawls, springs and pins for damage.

94 TRANSMISSION AND CRANKSHAFT
TRANSMISSION INSPECTION
Inspect the gear teeth, dogs, and gearshift grooves for
abnormal wear and damage.
Inspect the bushes and splines for abnormal wear and
discoloration.
Inspect the gearshift cam groove for abnormal wear and

damage.
Inspect the gearshift forks and shafts for wear and

damage.
nommillmoommilmom
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Measure the gearshift fork thickness w i t h a varnier

caliper.
Standard: 4 . 6 - 4 . 7 mm ( 0 . 1 8 - 0 . 1 9 in)
Measure the gearshift fork groove width with a varnier

caliper.
Standard: 4 . 8 - 4 . 9 mm ( 0 . 1 8 9 - 0 . 1 9 3 in)
TRANSMISSION AND CRANKSHAFT 9.5
Measure t h e gearshift fork t o groove clearance w i t h a

thickness gauge.
Service limit: 0 . 5 0 rnm ( 0 . 0 2 0 in)
CRANKSHAFT INSPECTION
a M e a s u r e the crankshaft runout w i t h V-blocks and dial
gauge.
Service limit : 0 . 0 5 mm ( 0 . 0 0 2 in)
M e a s u r e the crankshaft web to web width with a varni-

er caliper.
Standard : 5 7 . 9 - 5 8 . 1 m m ( 2 . 2 8 - 2 . 2 9 in)
imon
OIL S E A L INSPECTION, R E M O VA L A N D I N S TA L -
LATION
I n s p e c t the oil seal lips f o r wear and damage.
R e m o v e the oil seal w i t h t h e special tool.

0 9 9 1 3 - 5 0 1 2 1 O i l seal remover
F i t a n e w oil seal w i t h the special tool.
0 9 9 1 4 - 7 9 6 1 0 B e a r i n g / O i l seal installer
A p p l y grease t o t h e oil seal lip.
NOTE: B e sure to check the direction of the bearing oil seals

Left Right
before f i t t i n g them.
BEARING INSPECTION, R E M O VA L A N D I N S TA L -
LATION
I n s p e c t t h e bearings f o r play, discoloration, w e a r and
seizure.
M o v e t h e inner race b y finger and inspect f o r smooth
inc yement.
R e m o v e t h e retainers.
R e m o v e the bearing w i t h t h e special tools.
1 Bearing puller
-t)9923-74510 Bearing puller
09930-30102 Rotor remover slide shaft
F i t t h e bearing w i t h the special tool.
0 9 9 1 4 - 7 9 6 1 0 B e a r i n g / O i l seal installer
TRANSMISSION AND CRANKSHAFT 9-7
A p p l y thread lock " 1 3 0 3 " to the bearing retainer screws.
CRANKSHAFT INSTALLATION
F i t the crankshaft into t h e right crankcase half.
TRANSMISSION REASSEMBLY
_ 111 1- a
Ula.411
NOTE: S e a t the circlip in the groove and locate its end as

shown in t h e illustration.
Thrust
A p p l y transmission oil to the following parts: drive shaft,

counter shaft, transmission gears, bearings, gearshift
forks, gearshift shafts, gearshift cam.
Reassemble the drive shaft and countershaft with gears
installed.
Reassemble the gearshift cam, s h i f t forks and shafts.
tv
confirm t h a t the driveshaft and countershaft turn w i t h o u t
resistance.
F i t t h e n e w gasket and d o w e l pins.
CRANKCASE REASSEMBLY
F i t t h e l e f t crankcase half on t h e right crankcase half.
Ti g h t e n t h e crankcase bolts.
lv
the crankshaft into t h e bearing. I f it is hard to tighten the
bolts, separate the crankcase a n d confirm t h a t the trans-
r ' c s i o n parts are assembled correctly.
I n s p e c t t h e crankshaft f o r smooth movement.

A p p l y grease to 0-ring. Fit the 0-ring and spacer to the
countershaft.
TRANSMISSIONAND CRANKSHAFT 9-9
PRIMARY DRIVE GEAR

Ti g h t e n the primary drive gear bolt to the specified torque.
Tightening torque: 6 0 - 8 0 N . m
( 6 . 0 - 8 . 0 kg-m, 4 3 . 5 - 5 8 . 0 lb-ft)
GEARSHIFT LINKAGE REASSEMBLY

F i t the spring pin and pawl to the driven gear. Wider side
of p a w l CID should be positioned outside.
Reassemble the driven gear and p a w l lifter.

A p p l y thread Jock " 1 3 0 3 " t o the bolt and s c r e w s and
tighten them.
F i t t h e gearshift r e t u r n s p r i n g t o t h e gearshift s h a f t
properly.
A l i g n t h e center lines o f drive and driven gears.

Reassemble the exhaust valve actuator.
Reassemble the stator and magneto rotor. ( r 12-5)
Reassemble the kick starter. I 8 - 3 )
Reassemble the clutch. ( 7 - 3 )
Reassemble the piston and cylinder. ( r 6-5)
R e m o u n t the engine. ( :7
FUEL SYSTEM 10-1
FUEL SYSTEM
-
10-2 FUEL SYSTEM
CARBURETOR
Carburetor Removal
T u r n the fuelcock to the " O F F " position and disconnect
the fuel hose.
Loosen the carburetor clamp screws and remove the car-
buretor.
Remove two screws from the carburetor top cap. Remove
the throttle valve.
D i s c o n n e c t the throttle cable f r o m t h e throttle valve. II
R e m o v e the drain plug and screws.

R e m o v e the carburetor float chamber.
Remove the caps and floats.

Remove the needle valve assy.
Remove the pin and disassemble the needle valve assy.
Remove the main jet, and pilot jet.
R e m o v e t h e choke konb.
Clean t h e carburetor body w i t h pressurized air.
FUEL SYSTEM 103
Carburetor Inspection
I n s p e c t the following parts f o r damage.
Jet needle, throttle valve, f l o a t
I n s p e c t t h e following jets f o r clogging.
Main jet, p i l o t jet, starter jet
I n s p e c t t h e needle valve f o r wear.
Measure the float height with a varnier caliper. To meas-

ure t h e float height, place t h e carburetor upside d o w n
with t h e floats a n d main jets removed.
Standard float height: 1 6 . 0 mm ( 0 . 6 3 in)
rburetor Reassembly
Reverse t h e sequence o f removal.
-
Reed vale Removal
R e m o v e t h e carburetor. ( 1 0 - 2 )
R e m o v e t h e four bolts.
R e m o v e t h e intake pipe and read valve.
Reed Valve Inspection

I n s p e c t t h e reed valves f o r damage.
l n s p e t t h e reed valve stoppers f o r damage.
'NOTE: B e careful n o t to damage the removed reed vale

a S S y.
Reed Valve Reassembly

verse t h e sequence o f removal.
COOLINGSYSTEM 11-1
COOLING SYSTEM
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11-2 COOLING SYSTEM
COOLANT REPLACEMENT
AWARNING
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.
Place t h e motorcycle on a block.

R e m o v e t h e radiator cap.
R e m o v e t h e drain plug and drain coolant.
Ti g h t e n t h e drain plug.
P o u r specified coolant through the radiator inlet hole up
to the b o t t o m o f filler hole. ( - = 2-6)
Coolant capacity: 8 5 0 ml ( 1 . 8 US pt)
Ti g h t e n t h e radiator cap firmly.
R u n t h e engine a f e w minutes and inspect the coolant
level. ( 2 - 5 )
RADIATOR CAP INSPECTION

I n s p e c t the radiator cap for function w i t h a radiator cap
pressure gauge:
Radiator cap valve release pressure:
9 5 - 1 2 5 kPa ( 0 . 9 5 - 1 . 2 5 k g / c m
NOTE: A p p l y water to radiator cap seal before fitting the

radiator cap t o t h e pressure gauge.
RADIATOR
Removal
R e m o v e the seat and fuel tank.
Drain coolant.
D i s c o n n e c t the radiator hoses and over f l o w t u b e .
R e m o v e the radiator fitting bolts. Remove the radiator.
lssembly
Weverse the sequence o f removal.
COOLING SYSTEM 11-3
WATER PUMP
Removal
D r a i n the coolant. ( 1 1 - 2 )
R e m o v e t h e bolts and w a t e r pump cover.
R e m o v e the gasket and d o w e l pin.

I n s p e c t the impeller f o r damage.
R e m o v e t h e clutch cover. I E_T- 7-3)

R e m o v e the circlip w i t h snap ring pliers.
R e m o v e t h e w a t e r p u m p driven gear and w a t e r p u m p
shaft.
Inspect the water pump driven gear and shaft for damage.
I n s p e c t t h e bearing f o r smooth inner race movement.

I n s p e c t the oil seal f o r damage.
R e m o v e the oil seal.
R e m o v e the bearing w i t h t h e special tools.
0 9 9 2 1 - 2 0 2 0 0 B e a r i n g remover
0 9 9 3 0 - 3 0 1 0 2 R o t o r remover slide shaft
Reassembly
F i t the bearing and circlip. A p p l y transmission oil to the
bearing.
A p p l y thread lock " 1 3 0 3 " t o t h e outer surface o f the
oil seal. F i t the oil seal.
A p p l y grease t o the oil seal lip.
I n s e r t the water pump shaft. Fit the water pump driven
gear and circlip.
114 COOLING SYSTEM
Reassemble t h e clutch cover. ( 7 - 5 )

Reassemble the w a t e r pump impeller.
F i t the d o w e l pins and a n e w gasket.
Fill t h e radiator w i t h coolant. ( 1 1 - 2 )
ELECTRICAL SYSTEM 121
ELECTRICAL SYSTEM
12
3 . 0 - 4 . 0 kg-nn
12-2 ELECTRICAL SYSTEM
ELECTRICAL CIRCUIT
Engine s t o p s w i t c h
B
Magneto Ignition coil
r r
BR
I. - - 1 r - - -
IN
Color code:
B : Black
B/R : B l a c k w i t h red tracer
B/W : B l a c k w i t h w h i t e tracer
BY B l a c k w i t h y e l l o w tracer
G : Green
: Red
R/W : R e d w i t h w h i t e tracer
WIBI: W h i t e w i t h blue tracer
IGNITION COIL INSPECTION

Checking with Electro Tester
S e t the p o w e r s w i t c h t o " O F F " position.
: o n n e c t the coil test leads w i t h the yellow tip attached
to the terminal of ignition coil and the black tip to the coil
mounting bracket (ground). Connect the high tension lead
with the red l e a d attached to the spark plug cord and
he black g lead to the coil mounting bracket (ground).
S e t the t e s t selector knob t o " I G . C O I L " position.
S w i t c h on t h e power.
N o t e the spark in t h e spark plug w i n d o w. I t should be
strong and continuous, not intermittent, across pressset
8 mm (0.3 in) gap. A l l o w the spark to jump the test gap
for at least five minutes continuously, t o insure proper
operation u n d e r t h e temperature conditions o f actual
riding.
0 9 9 0 0 - 2 8 1 0 6 E l e c t r o tester
ELECTRICALSYSTEM 12-3
Checking with Pocket Tester

Measure the ignition coil electrical resistance with the pocket
tester.
09900-25002 P o c k e t tester
Primary Terminal Ground Approx. 0 - 1 i'2

Secondary Plug capGround Approx. 5 - 8 il
COI UNIT INSPECTION

Indicator light
Checking with Electro Tester Push
4 , - - - ,
C o n n e c t the test leads to a CDI unit and the electro tester. Main switch ON
S e t the selector knob to P.E.I. position and switch on the

power. Electro-testet
If t h e i n d i c a t o r l i g h t c o m e s o n , t h e C U u n i t w o r k s PEI test lead
properly.
09900-28106 E l e c t r a Tester
3900-70210 C D I unit test lead
Checking with Pocket Tester
Measure resistance between the lead wires w i t h the pock-
et tester l x 1kf1 range).
09900-25002 P o c k e t tester
A CAUTION
Using a insulation-resistance meter (so-called megger) for

this purpose can damage circuit elements in the COI unit.
Use a circuit tester of the type used by radio repairmen.
A High-grade circuit tester or an ohmmeter is preferred.
Unit: A p p r o x . k9,
Posit've (I) probe pin Wire color
-------,.. B/R R/W R G B/Y W/BI B/W G : Green
R : Red
B/R ---------,.., 170 125 120 0 OFF 125 B/R : Black w i t h Red tracer
, R/W 14 11 6.2 14 OFF 6.2 B/W : Black w i t h W h i t e tracer
'a R 7 7 7 OFF 3
BlY : Black w i t h Ye l l o w tracer
R/W : Red w i t h W h i t e tracer
Q) G 2.8 2.8 3.2
'--------....,.. 2.8 OFF 0 W/BI : W h i t e w i t h Blue tracer
>/ BY 0 170 125 125 OFF 125
c' W/BI 8 8 7 2.6 8.2 2.6
a)
z
BIW 2.8 2.8 3,2 0 2.8 OFF
-------,....
12-4 ELECTRICAL SYSTEM
STATOR COIL INSPECTION

Measure the startor coils electrical resistance.
Black/RedRed/White 1 0 0 - 2 0 0 '2
RedGreen 8 0 - 2 0 0 c2
MAGNETO ROTOR A N D S TATO R REMOVAL A N D

RESSEMBLY
R e m o v e t h e bolts and magneto cover.
R e m o v e t h e s c r e w s a n d s t a t o r. D i s c o n n e c t t h e lead
wires.
Loosen t h e n u t w i t h a special tool.

0 9 9 3 0 - 4 0 11 3 R o t o r holder
Remove the magneto rotor with the special tool. Remove

the key.
-
Magneto Rotor and Stator Reassembly

A l i g n the line on the stator and triangle mark on the crank-
case t o set the ignitio timing correctly.
ELECTRICAL SYSTEM 12.5
F i t the k e y into t h e crankshaft.

F i t t h e magneto rotor.
A p p l y thread lock super " 1 3 3 3 8 " to the n u t and tight-
en the nut to the specified torque w i t h the special tool.
0 9 9 3 0 - 4 0 11 3 R o t o r holder
Tightning torque: 3 0 - 4 0 (\lrn
( 3 . 0 - 4 . 0 kg-m, 2 1 . 5 - 2 9 . 0 lb-ft)
Reassemble t h e magneto cover.

FRONT AND REAR WHEELS 111
FRONT AND REAR WHEELS
--4111;
1303 0 . 7 1.0 kg-m
13
.; e "
4 . 0 kg-nn
13-2 FRONT AND REAR WHEELS
FRONT WHEEL DISASSEMBLY AND REASSEMBLY

Front wheel Removal
Place the motorcycle on a block t o lift ff o n t wheel o f f
the ground.
Loosen t h e f o u r axle shaft holder nuts.
Loosen t h e axle shaft and remove it.
R e m o v e t h e f r o n t wheel.
Front Wheel Reassembly

Reassemble the spacer, f r o n t wheel and axle shaft.
Ti g h t e n t h e axle the s h a f t t o the specified torque.
( 5 . 0 - 8 . 0 kg-m, 3 6 . 0 - 5 8 . 0 lb-ft)
F i t the axle holder and tighten t h e nuts temporarily.
Remove the block from under the chassis tube and move
the f r o n t f r o k up and d o w n several times.
Ti g h t e n t h e axle holder nuts t o the specified torque.
( 1 . 5 - 2 . 5 kg-m, 1 1 . 0 - 1 8 . 0 lb-ft)
NOTE: T o tighten the axle holder, tighten the upper nuts

first and then tighten the lower nuts so that the lower side
o f the holder has clearance.
REAR W H E E L R E M O V A L A N D R E A S S E M B LY
Rear Wheel Removal
Place the motorcycle on a block to lift the rear wheel o ff
the ground.
R e m o v e the c o t t e r pin and axle nut.
Loosen the chain adjuster lock nuts and chain adjusters.
R e m o v e the rear wheel.
Rear Wheel Reassembly

Reassemble t h e rear wheel and axle shaft.
A d j u s t the drive chain slack. ( 2 - 8 )
Ti g h t e n t h e axle n u t t o t h e specified torque.
Tightening torque: 8 5 - 1 1 5 N.m
( 8 . 5 - 1 1 . 5 kg-m, 6 1 . 5 - 8 3 . 0 lb-ft)
Replace the cotter w i t h a n e w one.
FRONT AND REAR WHEEL INSPECTION

Axle Shaft Inspection
Support the axle shaft with V-blocks and measure the axle
shaft runout.
Service limit: 0 . 2 5 mm ( 0 . 0 1 0 in)
Wheel Rim Inspection

Measure t h e wheel rim r u n o u t w i t h a dial gauge.
Service limit: 2 . 0 mm ( 0 . 0 8 in) a x i a l and radial
FRONTAND REARWHEELS 13-3
Wheel Bearing Inspection

Tu r n the inner race by finger and inspect it for smooth
movement.
I n s p e c t the clearance between the outer race and wheel
hub.
I n s p e c t for bearing damage.
WHEEL BEARING REMOVAL A N D REASSEMBLY

Front Wheel Bearing Removal
F i t the bearing remover into t h e wheel bearing.
09941-50110 Bearing remover.
I n s e r t the wedge bar into the slit of the bearing remover
from the opposite side.
H i t the wedge bar with a hammer and remove the bear-
ing and spacer.
Rear Wheel Bearing Removal

R e m o v e the dust seal.
R e m o v e the circlip w i t h snap ring pliers.
F i t the bearing remover into t h e wheel bearing.
09941-50110 Bearing remover
I n s e r t the wedge bar into the slit of the bearing remover
from t h e opposite side.
H i t the wedge bar with a hammer and remove the bearing.
Front Wheel Bearing Reassembly

A p p l y grease t o the bearings.
Reassemble the spacer and bearings with the special tool.
J9941 -34513 B e a r i n g installer set
NOTE:
Reasemble the left side (disc side) bearing first and then
reassemble the right side bearing.
P o s i t o n the bearing so sealed side faces out.
A f t e r reassembling the bearings, inspect the bearings for
smooth movement.
13-4 FRONT AND REAR WHEELS
Rear Wheel Bearing Reasembly

A p p l y grease t o the bearings.
Reassemble the spacer and bearings with the special tool.
0 9 9 4 1 - 3 4 5 1 3 B e a r i n g installer set jlo 01
NOTE: A f t e r reassembling the bearings, inspect the bear-

ings f o r smooth movement. lok_)111
F i t t h e circlips.
DISC PLATE REPLACEMENT

A p p l y thread lock super " 1 3 0 3 " t o the bolts.
Ti g h t e n t h e screws to t h e specified t o r q u e
Tightening torque: 7 - 1 0 N.m
( 0 . 7 - 1 . 0 kg-m, 5 . 0 - 7 . 0 lb-ft)
REAR SPROCKET RREPLACEMENT

Ti g h t e n t h e nuts to t h e specified torque.
( 3 . 0 - 4 . 0 kg-m, 2 1 . 5 - 2 9 . 0 lb-ft)
FRONTAND REARBRAKES 141
FRONT AND REAR BRAKES
0 . 5 - 0 . 8 kg-m
4E1 c(c. rc 1 . 5 - 2 . 0 kg-m
o
S
Tr ,
0 . 8 - 1 . 2 kg-m
1 . 5 - 2 . 0 kg-m
1. 5
, 6
1 . 5 - 2 . 0 kg-rn
1 . 5 - 2 . 0 kg-m
4
c#
14
1 . 5 - 2 . 0 kg-m
41
.,e
1 . 5 - 2 . 0 kg-m .
1 4trz, 0 . 6 - 0 . 9 kg-m 2 . 0 - 2 . 5 kg-m '
z
,- 1111 T .--
2 . 0 - 2 . 5 kg-m ( -
<
'
1 . 5 - 2 . 0 kg-m
40
14-2 FRONT AND REAR BRAKES
BRAKE FLUID AIR BLEEDING
AWARNING
Brake fluid can be hazardous to humans and pet. Brake
fluid is harmful or fatal if swallowed, and harmful if it
comes in contact with your skin or eyes.
Keep both fluid away from children. Call your doctor im-
mediately if brake fluid is swallowed and induce vomit-
ing. Flush eyes or skin with water if brake fluid gets in
eyes or comes in contact with skin.
AWARNING
The use of any fluid DOT4 brake fluid from a sealed con-
liner can damage the brake system and lead to an ac-
cident.
Use only DOT4 brake fluid from sealed container. Never

AlkWARNING'
Spilled brake fluid can damage painted surface and plas-
tic parts.
Be careful not to spill any brake fluid when servicing brake

fluid. Wipe spilled fluid up immediately.
R e m o v e t h e reservoir cap.
C o n n e c t a transparent tube to the bleeder valve and set
the other end i n t o a receptacle.
Pour brake fluid u p t o the FULL line.
P u m p the brake lever/pedal until air bubles stop coming
out f r o m t h e reservoir.
P u m p t h e brake lever/pedal i n t h e squeezed position.
Open t h e bleeder valve and tighten t h e bleeder valve.
Release the brake lever/pedal. Repeat this sequence un-
til air bubbles stop coming o u t from the bleeder valve.
NOTE:
D o n o t release t h e brake lever/pedal while t h e bleeder
valve is opened.
Replenish brake fluid t o the UPPER line when the brake

fluid level drops b e l o w LOWER line.
Ti g h t e n t h e air bleeder valve.
FRONT AND REAR BRAKES 14-3
Ti g h t e n the air bleeder valve.

Tightening torque: 6 - 9 N.m
1 0 . 6 - 0 . 9 kg-m, 4 . 5 - 6 . 5 lb-ft)
P o u r brake fluid u p t o the UPPER line.
Reassemble the reservoir cap.
BRAKE FLUID REPLACEMENT

R e m o v e the reservoir cap.
C o n n e c t a transparent tube to the bleeder valve and set
the o t h r end into a receptacle.
L o o s e n the bleeder valve and pump the brake lever/pe-
dal until brake fluid stops coming o u t from t h e bleeder
valve.
P o u r brake fluid i n t o the reservoir.
Bleed air from t h e brake system. I L
- Reassemble the reservoir cap.
BRAKE PADS REPLACEMENT

Front Brake Pads
R e m o v e the pad mounting bolts.
R e m o v e t h e caliper mounting bolts and caliper.
R e m o v e the brake pads.
NOTE: R e p l a c e the t w o brake pads as a set.
F i t the n e w brake pads into the caliper and tighten t h e

pad mounting bolts temporarily.
Ti g h t e n t h e caliper mounting bolts.
11 . 5 - 2 . 0 kg-m, 1 1 . 0 - 1 4 . 5 lb-ft)
Tighten the brake pad mounting bolts.
( 1 . 5 - 2 . 0 kg-m, 1 1 . 0 - 1 4 . 5 lb-ft)
OTE: P u m p the brake lever several times to seat the brake

pads a f t e r reassembling.
Rear Brake Pads

R e m o v e the t w o bolts and t h e caliper cover.
R e m o v e the pad mounting bolts.
14 4 FRONT AND REARBRAKES
R e m o v e t h e brake pads.
NOTE: R e p l a c e the t w o pads as a set.
F i t t h e brake pads into t h e caliper.

Ti g h t e n t h e brake pad mounting bolts.
( 1 . 5 - 2 . 5 kg-m, 11 . 0 - 1 8 . 0 lb-ft)
Reassemble t h e caliper cover.
NOTE: Pump the brake pedal several times to seat the brake
pads a f t e r reassembling.
BRAKE DISC INSPECTION
M e a s u r e t h e f r o n t and rear brake disc thickness.
Service limit
Front 2.5 mm (0.10 in)
Rear 4.0 mm (0.16 in)
M e a s u r e t h e f r o n t and rear brake disc runout.

Service limit: 0 . 3 mm (0.01 in)
CALIPER
ILWARNING
The use of any brake fluid except DOT4 brake fluid from
a sealed container can damage the brake system and lead
to an accident.

FRONTAND REARBRAKES 14-5
AWARNING
comes in contact with your skin or eyes
mediately if brake fluid is swallowed, and induce vomit-
eyes or comes in contact with skin.
A CAUTION

tic parts.
i Wipe spilled fluid up immediately.
Front Caliper Removal and Disassembly

Place a drain pan under the caliper and remove the un-
ion bolt.
R e m o v e t h e pad mounting bolts.
R e m o v e t h e caliper mounting bolts.
R e m o v e t h e brake pads and spring f r o m t h e caliper.
R e m o v e t h e caliper braket from t h e caliper.
R e m o v e t h e boots f r o m the caliper bracket.
W r a p the caliper w i t h a rag to prevent brake fluid scat-
ter and piston pop-out.
A p p l y low-pressure air into the caliper through the hole
to remove the pistons.
A WARNING
Fingers can get caught between piston and caliper body
when removing the piston.
not place your fingers on the piston when removing
the piston.
R e m o v e t h e piston seals ( j and dust seals .

Rear Caliper Removal and Disassembly

Place a block under the chassis tubes.
Place a rag u n d e r t h e brake hose union b o l t t o c a t c h
spilled brake fluid.
Disconnect t h e brake hose.
R e m o v e the brake pad mounting bolts.
R e m o v e the c o t t e r pin and axle nut.
D r a w o u t the axle shaft.
Slide o f f the caliper bracket w i t h the caliper.
Remove the brake pads and spring f r o m t h e caliper.
W r a p the caliper w i t h a rag t o prevent brake fluid scat-
ter and piston pop-out.
a A p p l y low-pressure air into the caliper through the hole
to remove t h e piston.
AWARNING
Fingers can get caught between piston and caliper body
when removing the piston.
Do not place your fingers on the piston when removing
1the piston.
Remove t h e piston seal and d u s t seal.
Caliper Inspection
Measure the caliper cylinder bore with a small bore gauge.
Front: 2 7 . 0 0 0 - 2 7 . 0 5 0 m m ( 1 . 0 6 3 0 - 1 . 0 6 5 0 in)
Rear: 2 7 . 0 0 0 - 2 7 . 0 5 0 m m ( 1 . 0 6 3 0 - 1 . 0 6 5 0 in)
I n s p e c t the caliper cylinder f o r scuffing.
Measure the caliper piston diameter with a micrometer.

Front: 2 6 . 9 0 0 - 2 6 . 9 5 0 m m ( 1 . 0 5 9 1 - 1 . 0 6 1 0 in)
Rear: 2 6 . 9 0 0 - 2 6 . 9 5 0 m m ( 1 . 0 5 9 1 - 1 . 0 6 1 0 in)
I n s p e c t the caliper piston f o r scuffing.
Caliper Cleaning
Flush t h e Caliper ports w i t h pressurized air.
Wa s h t h e caliper piston and cylinder w i t h fresh brake
fluid.
NOTE: D o n o t use gasoline or other cleaning solvents to

wash t h e caliper parts.
Front Caliper Reassembly

A p p l y brake fluid t o the piston seals and f i t t h e piston
seals Cf) and d u s t seals ( f .
F i t t h e pistons into t h e caliper.
A p p l y silicone grease t o t h e caliper axles.
9 9 0 0 0 - 2 5 1 0 0 S u z u k i silicone grease
F i t the boots and caliper brackets.
F i t t h e spring a n d brake pads. Ti g h t e n t h e brake p a d
mounting bolts temporarily.
Ti g h t e n the caliper mounting bolt to the specified torque.
Tighteing torque: 1 5 - 2 0 N
1 1 . 5 - 2 . 0 kg-m, 1 1 . 0 - 1 4 . 5 lb-ft)
Ti g h t e n the brake pad m o u n t i n g bolts t o t h e specified
torque.
( 1 . 5 - 2 . 0 kg-m, 1 1 . 0 - 1 4 . 5 lb-ft)
Ti g h t e n the brake hose union bolt to the specified torque.
( 1 . 5 - 2 . 0 kg-m, 1 1 . 0 - 1 4 . 5 lb-ft)
Refill brake fluid a n d bleed air f r o m the brake system.
( 14-2)
Rear Caliper Reassembly

A p p l y brake fluid to the piston seal and fit the piston seal
and dust seal .
F l i t the piston into the caliper.
F i t the spring and pads. Tighten the brake pad mounting
bolts temporaly.
A p p l y silicone grease t o t h e caliper axle.
9 9 0 0 0 - 2 5 1 0 0 S u z u k i silicone grease.
F i t the caliper to t h e bracket.
S l i d e the bracket into t h e s w i n g arm.
Reassemble t h e axle shaft. ( r 13-2)
Ti g h t e n the brake hose union bolt.
( 1 . 5 - 2 . 0 kg-m, 1 1 . 0 - 1 4 . 5 lb-ft)
Refill brake fluid a n d bleed air from t h e brake system.
( ,==r 14-2)
MASTER CYLINDER
A WARNING
comes in contact with your skin or eyes.
meiately if brake fluid is swallowed, and induce vomit-
eyes comes in contact with skin.
A WARNING
The use of any fluid except DOT4 brake fluid from a sealed
container can damage the brake system and lead to an
accident.

ACALITION
tic parts.
Be careful not to spill any fluid when filling the brake fluid
reservoir. Wipe spilled fluid up immediately.
Front Master Cylinder Removal and Disassembly

D r a i n brake fluid. ( 1 4
Loosen t h e brake hose adaptor and disconnect t h e
brake hose.
NOTE: H o l d the brake hose with a wrench to prevent

the brake hose from twisting when loosening the adaptor.
Remove the master cylinder cap.

Remove the master cylinder holder bolts.
Remove the n u t s and brake lever.
Remove the brake lever return spring.
R e m o v e t h e dust seal b o o t
R e m o v e t h e circlip '
R e m o v e the washer , piston a n d spring .
Rear Master Cylinder Removal and Disassembly

D r a i n brake fluid.( 7
R e m o v e t h e rear brake pedal. ( 1 4 - 1 1 )
Place a rag under t h e hose (reservoir) t o catch spilled
brake fluid. Remove the clamp and disconnect the hoe
(reservoir). Remove t h e union bolt.
R e m o v e the master cylinder clamp bolts.
R e m o v e t h e dust seal b o o t
R e m o v e the circlip (
R e m o v e t h e push rod (3).
R e m o v e the piston/primary cap r
Master Cylinder Inspection

M e a s u r e t h e cylinder bore w i t h a small bore gauge.
Front: 1 1 . 0 0 0 - 1 1 . 0 4 3 mm ( 0 . 4 3 3 1 - 0 . 4 3 4 8 in)
Rear: 1 4 . 0 0 0 - 1 4 . 0 4 3 m m ( 0 . 5 5 1 2 - 0 . 5 5 2 9 in)
Measure the cylinder piston diameter with a micrometer.

Front: 1 0 . 9 5 7 - 1 0 . 9 8 4 mm ( 0 . 4 3 1 4 - 0 . 4 3 2 4 in)
Rear: 1 3 . 9 5 7 - 1 3 . 9 8 4 mm ( 0 . 5 4 9 5 - 0 . 5 5 0 6 in)
I n s p e c t the cylinder bore and piston f o r scuffing.
I n s p e c t t h e piston rod and spring f o r damage.
Master Cylinder Cleaning

F l u s h t h e master cylinder ports w i t h pressurized air.
W a s h t h e master cylinder b o r e a n d piston w i t h fresh
brake fluid.
NOTE: D o n o t use gasoline or other cleaning solvents to

wash t h e master cylinder parts.
Front Master Cylinder Reassembly

F i t the spring, piston and washer.
F i t t h e circlip w i t h snap ring pliers.
F i t t h e dust seal boot.
Reassemble the brake lever.
Ti g h t e n the master cylinder clamp bolts to the specified
torque.
Tightening torque: 5 - 8 N.m
( 0 . 5 - 0 . 8 kg-m, 3 . 5 - 5 . 0 lb-ft)
l
Tightening torque: ?
CI) 1 5 - 2 0 N.m ( 1 . 5 - 2 . 0 kg-m, 1 1 . 0 - 1 4 . 5 lb-ft)
1 5 - 2 0 INI.m ( 1 . 5 - 2 . 0 kg-m, 1 1 . 0 - 1 4 . 5 lb-ft)
NOTE: H o l d the brake hose w i t h a wrench to prevent the

brake hose f r o m t w i s t i n g w h e n tightening the adaptor.
Refill brake fluid and bleed air from t h e brake system.

( ETT
Reassemble t h e reservoir cap.

Rear Master Cylinder Reassembly
F i t the piston/primary cup and push rod.
F i t t h e circlip w i t h snap ring pliers.
F i t the boot.
Ti g h t e n the master cylinder clamp bolts to the specified
Tightening torque: 8 - 1 2 N.m
( 0 . 8 - 1 . 2 kg-m, 6 . 0 - 8 . 5 lb-ft)
Reassemble the rear brake pedal.( 1 4 - 1 1 )

Ti g h t e n the brake hose union bolt to the specified torque.
Tiqhtening torque: 2 0 - 2 5 N.m
( 2 . 0 - 2 . 5 kg-m, 1 4 . 5 - 1 8 . 0 lb-ft)
Al CAUTION
Improper brake hose routing can damage the brake hose.
Set the brake hose so it touches the stopper and tighten

the union bolt. Ensure the brake hose has enough clear-
ance to the rear suspension spring.
C o n n e c t the hose (reservoir) and clamp it.

Refill b r a k e fluid a n d bleed air f r o m t h e brake system.
( 1 4 - 2 )
BRAKE PEDAL REMOVAL AND REASSEMBLY

Removal
R e m o v e t h e cotter pin behind t h e frame.
L o o s e n and remove the brake pedal p i v o t bolt.
R e m o v e t h e return spring.
R e m o v e the cotter pin and pin.
Reassembly
Reassemble the pin, w a s h e r and c o t t e r pin.
a F i t t h e return spring.
A p p l y grease to the brake pedal pivot bolt. Tighten the
bolt.
F i t t h e washer and cotter pin.
A d j u s t the brake pedal height. ( 2 - 1 2)
1
FRONT FORK AND STEERING 15-1
FRONT FORK AND STEERING
4
2 . 0 - 3 . 0 kg-m
2 . 0 - 3 . 0 kg-m
2 . 5 - 3 . 5 kg-m
Ipsro
\\, e
3.0 kg-m
15
0 . 9 - 1 . 1 kg-m s
5 . 0 - 5 . 5 kg-m
152 FRONT FORK AND STEERING
FRONT FORK DISASSEMBLY

Front Fork Dismounting
Place a block under the chassis tubes.
R e m o v e t h e f r o n t wheel. ( 1 3 - 2 )
R e m o v e t h e caliper. ( 1 4 - 5 )
R e m o v e t h e protecter.
L o o s e n t h e f r o n t f o r k cap bolt ,D
L o o s e n t h e upper bracket clamp bolts ,
L o o s e n t h e l o w e r bracket clamp bolts .
R e m o v e t h e f r o n t forks.
R e m o v e t h e f r o n t fork cap bolt from t h e outer tube.
Clean t h e f r o n t forks.
Front Fork Disassembling

R e m o v e the damping force adjuster (I), nut (
seat stopper 14).
R e m o v e t h e spacer.
D r a i n t h e oil b y inverting the f r o n t fork.
Ti g h t e n t h e f r o n t fork cap bolt temporarily t o the rod.
Tu r n o u t the compression damping force to the softest

position.
M o v e the front fork cap bolt up and down several times.
Invert the front fork and drain the oil. Repeat this proce-
dure until t h e rod moves smoothly w i t h o u t resistance.
R e m o v e t h e bolt fixing t h e piston rod w i t h t h e special

tools.
0 9 9 4 0 - 5 4 8 2 1 F r o n t fork assembling tool

09940-32760 A t t a c h m e n t
R e m o v e t h e piston rod.
R e m o v e the d u s t seal ( ! .
R e m o v e the snap ring (
NOTE: B e careful not to damage the inner tube when remov-

ing t h e snap ring.
H o l d the bracket o f the inner tube w i t h a vise and pull

the Outer tube t o remove the oil seal.
Remove the metal r

screw driver.
NOTE: B e careful not to damage the inner tube when remov-

ing the metal.
Remove the slide metal , washer ) , oil seal (" a n d dust

seal f r o m t h e inner tube.
Front Fork Inspection

M e a s u r e the f r o n t fork spring free length.
Service limit : 5 1 2 mm ( 2 0 . 2 in)
' )il)!):If)1911400,iiiii)Viai
15-4 FRONT FORK AND STEERING
I n s p e c t t h e inner tube f o r distortion and scratches.

I n s p e c t the inner tube and outer tube sliding surface for
scuffting or flaws.
I n s p e c t the inner rod f o r wear and distortion.
Front Fork Reassembling

C o v e r the inner tube with a vinyl film to prevent dust seal
lip and oil seal lip damage.
A p p l y silicone grease t o d u s t seal lip and oil seal lip.
F i t the dust seal, snap ring, oil seal, washer and slide me-
tal o n t o t h e inner tube.
F i t the metal on t h e inner tube.
NOTE: B e careful n o t damage the m e t a l surfaces.
I n s e r t t h e inner tube into t h e outer tube.

F i t the oil seal w i t h t h e special tool.
0 9 9 4 0 - 3 2 7 2 0 F r o n t fork oil seal installer
F i t the snap ring into t h e groove.

F i t t h e dust seal.
I n s e r t the piston rod into t h e outer tube.
Ti g h t e n the piston rod bolt with the special tools to the
specified torque.
0 9 9 4 0 - 5 4 8 2 1 F r o n t fork assembling tool
09940-32760 A t t a c h m e n t
Tightening torque : 5 0 - 5 5 N-m
( 5 . 0 - 5 . 5 kg-m, 3 6 . 0 - 4 0 . 0 lb-ft)
Fill w i t h f o r k oil and adjust the oil level. ( r 4-10)
H o o k a w i r e t o t h e lock n u t t o pull u p the piston rod.
1
FRONT FORK AND STEERING 155
Insert the spring and spacer.
NOTE: Insert t h e spring s o smaller diameter side c o m e s

upside.
Pull up the piston rod, Reassemble the spacer guide, nut,

damping force adjuster and cap. Remove the wire.
Front Fork Mounting

A d j u s t the f r o n t fork height. ( 4 - 1 1 )
Ti g h t e n t h e bolts t o t h e specified torque.
Tightening torque
N.m kg-m lb-ft
, 25-35 2.5-3.5 18.0-25.5
20-30 2.0-3.0 14.5-21.5
20-30 2.0-3.0 14.5-21.5
Reassemble the protecter.
Reassemble t h e caliper. ( , - 1 4 - 7 )
Reassemble the f r o n t wheel. ( EJ
STEERING
Steering Removal
Remove the f r o n t wheel. ( c r 13-2)
R e m o v e the caliper. ( c 1 4 - 5 )
Remove the f r o n t fender.
R e m o v e the f r o n t number plate.
Remove the handlebar clamp bolts and remove the han-
dlebar.
R e m o v e the f r o n t fork. ( r 15-2)

Remove t h e upper bracket.
Remove the steering stem head nut.
R e m o v e the steering n u t w i t h t h e special tool.
0 9 9 4 0 - 1 4 9 3 0 S t e e r i n g nut socket wrench
Remove the l o w e r bracket.

15-6 FRONT FORK AND STEERING
Steering Inspection
I n s p e c t t h e bearing races f o r wear.
I n s p e c t t h e needle bearings f o r wear.
I n s p e c t the steering stem f o r distortion.
i,40100.q.,
Steering Bearing Replacement

NOTE: R e p l a c e the outer race a n d bearing as a set.
R e m o v e the upper and l o w e r outer races w i t h the spe-

cial fools.
0 9 9 4 1 - 5 4 9 11 Steering race remover

09941-74910 Steering bearing installer
R e m o v e t h e lower bearing w i t h t h e special tool.
0 9 9 4 1 - 8 4 5 1 0 B e a r i n g inner race remover
F i t t h e l o w e r bearing w i t h t h e special tool.
0 9 9 4 1 - 7 4 9 1 0 S t e e r i n g bearing installer
F i t the upper and lower outer races with the special tool.
0 9 9 4 1 - 3 4 5 1 3 S t e e r i n g outer race and swing arm

bearing installer
Steering Reassembly
A p p l y grease t o t h e bearings.
F i t the steering stem, upper bearing, dust seal and steer-
ing stem nut.
Ti g h t e n the steering s t e m n u t t o t h e specified torque.
Tightening torque : 4 0 - 5 0 N-rn
( 4 . 0 - 5 . 0 kg-m, 2 9 . 0 - 3 6 . 0 lb-ft)
M o v e the steering stem right and l e f t several times t o

seat the bearings.
T u r n back the steering stem n u t b y lis t o 1/2 turn.
F i t the steering stem head nut and tighten it temporarily.
R e m o u n t the f r o n t fork. ( L-J- 15-5)
Ti g h t e n t h e steering s t e m h e a d n u t t o t h e specified
to
Tightening torque : 8 0 - 1 0 0 Nm
( 8 . 0 - 1 0 . 0 kg-m, 5 8 . 0 - 7 2 . 5 lb-ft)
Reassemble the f r o n t wheel. ( 1 3 - 2 )

Reassemble the handlebar.
R o c k the front fork forward and backward to ensure that

the steering has no play.
I n s p e c t the steering f o r smooth m o v e m e n t so t h a t the
handlebar can move right and left under its own weight.
REARSUSPENSION 16-1
REAR SUSPENSION
4 . 8 - 7 , 2 kg-m
t r
8 . 0 - 1 2 . 0 kg-m
8 . 0 - 1 2 . 0 kg-m
6 . 0 - 1 0 . 0 kg-m
,F
16
Ctrl
16-2 REAR SUSPENSION
REAR SHOCK ABSOBER

Rear Schock Absorber Removal
Place a block under chassis tubes.
R e m o v e t h e seat.
R e m o v e t h e frame covers.
R e m o v e the screws and bolts.
R e m o v e t h e frame side tube.

R e m o v e t h e air cleaner.
Remove the rear shock absorber mounting bolts and nuts.

Remove the rear shock absorber.
L o o s e n the lock nut and turn the adjuster w i t h the spe-

cial t o o l .
09910-60611 U n i v e r s a l clamp wrench

REAR SUSPENSION 16-3
Rear Shock Absorber Inspecion

I n s p e c t the rear suspension f o r oil leak.
I n s p e c t the damper rod for bends and smooth movement.
I n s p e c t the stopper rubber for deterioration and damage.
I n s p e c t the bearing f o r play and smooth movement.
Rear Shock Absorber Disposal

High pressure nitrogen gas is sealed in the rear shock ab-
sorber unit. Be sure to relese gas before disposing the rear
shock absorber unit.
R e m o v e the valve cap.
Press t h e valve w i t h a screwdriver.
A WARNING
Releasing high pressure gas from the rear shock absorb-
er unit can be hazardous.
Place a rag over the valve and push the valve with a screw-
driver to release nitrogen gas. Do not use your finger to
push the valve, and direct the valve away from your face
-
and body.
Bearing Replacement.
R e m o v e the d u s t seals.
R e m o v e t h e circlip.
S e t a pipe, washer, bolt (M10) and nut (M10) as shown.
Ti g h t e n the n u t and remove t h e bearing.
A p p l y grease t o the bearing.

S e t pipes, washers, bolt (M10) and nut (M10) as shown.
Ti g h t e n t h e n u t and f i t t h e bearing.
F i t t h e cirolip.
A p p l y grease to the dust seal and fit i t as grooved side
faces outside.
Rear Shock Absorber Reassembly

F i t t h e spring, adjuster and lock nut.
A d j u s t t h e spring s e t length.
Standard : 243 mm (9.6 in)
Range : 2 3 8 - 2 4 8 . 5 mm 1 9 . 4 - 9 . 8 in)
Ti g h t e n the upper and lower mounting bolts and nuts to

the specified torque.
Tightening torque : 4 0 - 6 0 Nrn

14.0-6.0 kg-m, 2 9 . 0 - 4 3 . 5 lb-ft)
Reassemble t h e air cleaner.

Reassemble t h e frame side tube.
Reassemble the frame cover and seat.
Tu n e t h e rear suspension. ( _1.7- 4-13)
-
Swing Arm Removal
R e m o v e t h e rear wheel. r 13
Remove the brake pedal. ( r r 1 4 - 11 )
Remove the rear brake hose f r o m t h e guides.
Remove the rear caliper. ( 1 4 - 6 )
Remove the drive chain.
R e m o v e t h e chain guide.
R e m o v e t h e rear cushion rod bolt.

R e m o v e t h e s w i n g arm pivot bolt.
R e m o v e t h e s w i n g arm.
R e m o v e t h e covers and bushings.
0 0 0 0 tee4
t t
Swing Arm Inspection
M e a s u r e the pivot shaft runout with a dial gauge and V-
blocks.
Service limit : 0 . 6 mm ( 0 . 0 2 in)
I n s p e c t t h e s w i n g arm f o r cracks and damage.

I n s p e c t the bearings, bushings and oil seals for damage.
I n s e r t the bushings into the bearings and inspect them
for play and s m o o t h movement.
Bearing Replacement
Remove the bearings and oil seals with the special tools.
F i t the bearings with the special tool and a pipe, 2 4 mm
(0.9 in) in diameter and 7 . 5 m m ( 0 . 3 in) in length.
0 9 9 1 4 - 7 9 6 1 0 B e a r i n g / o i l seal installer
F i t the oil seals w i t h the special tool and t h e spacer.
Swing Arm Reassembly

Reassemble t h e bushings and covers.
F i t t h e s w i n g arm t o the frame.
Ti g h t e n t h e s w i n g arm pivot shaft n u t t o the specified
torque.
( 5 . 0 - 8 . 0 kg-m, 3 6 . 0 - 5 8 . 0 lb-ft)
Ti g h t e n the rear cushion rod nut to the specified torque.

Tightening torque : 8 0 - 1 2 0 Nm
( 8 . 0 - 1 2 . 0 kg-m, 5 8 . 0 - 8 7 . 0 lb-ft)
Reassemble t h e chain guide.

Reassemble the rear caliper. ( i = 14-7)
F i t the rear brake hose guides.
Reassemble t h e brake pedal. ( i r 1 4 - 11 )
Reassemble the rear wheel. ( 1 3 - 2 )
REAR SUSPENSION LINKAGE

Rear Suspension Linkage Removal
R e m o v e the s w i n g arm. ( 1 6-4)
Remove the s w i n g arm linkage bolts.
near Suspension Linkage inspection

I n s p e c t the cushion lever rod and cushion.
I n s p e c t the spacers f o r damage.
I n s p e c t the bearings f o r damage.
Insert the spacers into the bearings and inspect them for
smooth movement.
Cushion Lever Bearing Replacement

R e m o v e t h e circlips.
R e m o v e the bearings w i t h t h e special tool.
F i t the bearings with the special tool and a pipe, 2 8 w i n
11.1 i n ) in diameter and 4 m m ( 0 . 2 in) in length.
0 9 9 1 4 - 7 9 6 1 0 B e a r i n g / o i l seal installer
F i t t h e circlips.
Rear Suspension Linkage Reassembling

Reassemble the rear suspension linkage.
Ti g h t e n t h e nuts t o t h e specified torque.
Tightening torque:
A: 4 8 - 7 2 Nm ( 4 . 8 - 7 . 2 kg-m, 3 4 . 5 - 5 2 . 0 lb-ft)
B: 4 8 - 7 2 Nrn ( 4 . 8 - 7 . 2 kg-m, 3 4 . 5 - 5 2 . 0 lb-ft)
C: 8 0 - 1 2 0 Nm ( 8 . 0 - 1 2 . 0 kg-m, 5 8 . 0 - 8 7 . 0 lb-ft)
D: 6 0 - 1 0 0 Nm ( 6 . 0 - 1 0 . 0 kg-m, 4 3 . 5 - 7 2 . 5 lb-ft)
E: 8 0 - 1 2 0 Nm ( 8 . 0 - 1 2 . 0 kg-m, 5 8 . 0 - 8 7 . 0 lb-ft)
Reassemble the s w i n g arm. 1 6
0.1
1
SERVICE DATA 17-1
SERVICE DATA
CYLINDER + PISTON + PISTON RING Unit: mm (in)

ITEM STANDARD LIMIT
Piston to cylinder clearance 0 . 0 4 5 - 0.055 0.120
(0.0017-0.0022) (0.0047)
Cylinder bore 67.000-67,015
(2.6387-2.6384)
Measure at 20 (0.8) from the top surface
Piston diam. 66.950 - 66.965 66.880
(2.6358 -2.6364) (2.6331)
Measure at 24 (0.9) from the skirt end
Cylinder distortion 0.05
(0.002)
Cylinder head distortion 0.05
(0.002)
Piston ring free end gap N 6.4 5.1
Approx. (0.25) (0.20)
Piston ring end gap 0.20 - 0.40 0,85
(0.008 - 0.016) (0.033)
Piston ring to groove clearance 0.010-0.050
(0.0004-0.0020)
Piston pin bore 1 8 . 0 0 0 - 18.006 18.030
(0.7087 - 0.7089) (0.7098)
Piston pin 0.D. 17.995-18.000 17.980
(0.7085 - 0.7087) (0.6724)
CONROD + CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 2 3 . 0 0 3 - 2 3 . 0 11 23.040
(0.9056-0,9059) (0.9071)
Crank web to web width 58.00.1
(2.283
Crankshaft runout 0.05
(0.002)
CLUTCH Unit: mm (in)

ITEM STANDARD LIMIT
1 cable play 2-3
(0.08-0.12)
Drive plate thickness 2.7-2,9 2.4 17
(0.106-0.114) (0.095)
Drive plate claw width 15.8-16.0 15.3
(0.62-0.63) (0.60)
Driven plate distortion 0.10
(0.004)
Clutch spring free length 42.3
(1.67)
17-2 SERVICE DATA
RADIATOR
STANDARD LIMIT
ITEM
110 kPa(1.1 kigicm', 1 6 psi)
1 pressure
Unit: mm (in) Except ratio
TRANSMISSION
STANDARD LIMIT
ITEM
2.652 (61/23)
Primary reduction ratio
3.846 (50/13)
Final reduction ratio
Gear ratios Low 2.285 (32/14)
2nd 1.733 (26/15)
3rd 1.375 (22116)
4th 1.090 (24/22)
Top 0.863 (19/22)
0.10-0.30 0.50
Shift fork to groove clearance No. & (0.004-0.012) (0.020)
- 4.8-4.9
Shift fork groove width No. & (0.189-0.193)
4.6-4.7
Shift fork thickness No. & No. (0.181-0.185)
DRIVE CHAIN
STANDARD LIMIT
ITEM
D.I.D.: D.I.D 5 2 0 V S
Drive chain Type TAKASAGO: RK520SMO
Links 114
323.8
20-pitch length (12.75)
45-55
Drive chain slack
(1.8-2.0)
ITEM SPECIFICATION
MIKUNI NTM38SS
Carburetor type
38 mm
Bore size
28C20
I.D. No.
16.0:
Float height
(M.J. #370
Main jet
(J.Ni 6AEL1-60-3rd
Jet needle
(N.J.) (R-1)
Needle jet
(CA.) 3.5
Cut-away - .. 4 - -
P (P.J.) # 5 0
SERVICE DATA 17.3
ITEM SPECIFICATION
By-pass (B.P.) 0.7 mm (0.028 in)
Pilot outlet (P.O.) 0.6 mm (0.024 in)
Air screw (A.S.) 1
Throttle cable play 0 . 5 - 1 . 0 mm ( 0 . 0 2 - 0 . 0 4 in)
ELECTRICAL Unit: mm (in)
ITEM SPECIFICATION NOTE
Ignition timing 75' - 1 r
Spark plug Type NGK: B8EGV UK, Australia
Type NGK: BR8EV Canada, France
0.5-0.6
Gap (0.020-0.024)
Spark performance Over 8 (0.3) at 1 atm.
Ignition coil resistance Primary 0-1 Q Terminal Ground
Secondary , 5 - 8 kii. Plug capGround
Magneto coil resistance 80-200 Q RG
1 1 0 0 - 2 0 0 c2 R/WB/W
BRAKE + WHEEL Unit: mm (in)

ITEM STANDARD LIMIT
Brake lever play 0.1-0.3
(0.004-0.01)
Rear brake pedal height 5
(0.2)
Brake disc thickness 3.0 - 2.5
Front
( 0 . 11 8 (0.10)
Rear 4.5 0.2 4.0
(0.177 0.008) (0.16)
Brake disc runout 0.30
Front&Rear
(0.01)
Master cylinder bore 11 . 0 0 0 - 11 . 0 4 3
Front
(0.4331-0.4348)
Rear 14.000-14.043
(0.5512-0.5529)
Master cylinder piston diam. 10.957-10.984
Front
(0.4314-0.4324)
Rear 13.957-13.984
(0.5495-0.5506)
Brake caliper cylinder bore 27.000-27.050
Front
(1.0630-1.0650)
Rear 27.000-27.050
(1.0630-1.0650)
Brake caliper piston diem'. 26.900-26.950
Front
(1.0591-1.0610)
Rear 26.900-26.950
_ (1.0591-1.0610)
Wheel rim runout 2.0
Axial
(0.08)
Radial 2.0
(0.08)
17-4 SERVICE DATA
ITEM STANDARD LIMIT

Wheel axle runout 0.25
Front
(0.010)
0.25
Rear
(0.010)
Tire size Front 80/100-21 51M
Rear 100/90-19 62M
Tire tread depth 4.0
Front
(0.16)
4.0
Rear
(0.16)
SUSPENSION Unit: m m (in)

ITEM S T A N D A R D LIMIT NOTE
Front fork stroke 310
(12.2)
Front fork spring free length 512
(20.2)
Front fork oil level 135
(5.3)
Front fork air pressure 0 kPa
(0 k g / c m
Rear shock absorber gas 1000 kPa
pressure (10 kg/crin
Rear shock absorber spring 243
pre-set length (9.6)
Rear wheel travel 324
(1.28)
Swingarrn pivot shaft runout 0.6
(0.02)
TIRE PRESSURE
Front 7 0 - 11 0 kPa
& 0 . 7 - 1 . 1 kg/cm'
Rear 1 0 - 1 6 psi
FUEL + OIL + COOLANT

Fuel type Unleaded gasoline m i n u m u m 9 5 o c t a n e
(RON)
Fuel tank capacity 11.0 L
(2.9 US gal)
Engine oil type MOTUL CENTURY 3 0 0 2 T
SHELL SUPER M
B.P. RACING
CASTROL R 3 0
CASTROL I T S ( A 5 4 5 )
CASTROL A 7 4 7
BELL-RAY M C - 1 0 0
Transmission oil-type SAE 1 0 W / 4 0
SERVICE DATA 17-5

Transmission oil-capacity 650 mi
Change (0.7 US qt)
750 ml
Overhaul
(0.8 US qt)
Front fork oil type SUZUKI fork oil SS-05 or an equivalent fork oil
Front fork oil capacity 619 ml
(each leg) (20.9 US oz)
Coolant type Use an anti-freeze&summer coolant compat-
ible with aluminum radiator, mixed with dis-
tilled water only, at the ratio of 50 : 50.
Coolant 850 ml
(1.8 US pt)
Rear shock absorber oil 262 mil
capacity (8.9 US oz)
I Brake fluid type DOTLI-I-
18-1 SPECIAL TOOLS
SPECIAL TOOLS
09900-00401 09900-06107 09900-06108 09900-09003 09900-20101

Hexagon w r e n c h Snap ring pliers Snap ring pliers Impact dirver set Varnier calipers
set (150 mm)
09900-20203 09900-20205 09900-20508 09900-20602 09900-20605

Micrometer Micrometer Cylinder gauge Dial gauge Dial gauge
(50 ( 0 - 2 5 mm) set
09900-20803 09900-25002 09900-28106 09900-70210 09913-50121

Thickness gauge Pocket tester Electro tester CDU u n i t t e s t 011 seal remover
lead
09914-79610 09920-13120 09900-53710 09923-73210 09923-74510

Bearing/Oil seal Crankcase Clutch sleeve h u b Bearing puller Bearing puller
installer separating tool holder
sn,
09924-84510 09930-30102 0 9 9 3 0 - 3 0 11 3 0 9 9 3 0 - 4 0 11 3 09940-14930

Bearing installer Rotor remover Flywheel r o t o r Rotor holder Steering n u t
set slide s h a f t remover socket w r e n c h
09940-32760 09940-32720 09941-34513 0 9 9 4 1 - 5 0 11 0 0 9 9 4 1 - 5 4 9 11

09940-54821 Front f o r k oil Bearing installer Wheel bearing Bearing outer
Front f o r k seal installer set remover race remover
assembling tool
SPECIALTOOLS 18-2
09941-74910 09 94 1-845 10 0 9 9 4 3 - 7 4 111

Steering bearing Beaing inner Front f o r k oil level
installer race remover gauge
18
1
I
191 WIRE, CABLE AND HOSE ROUTING
WIRE, CABLE AND HOSE ROUTING
Engine kill s w i t c h lead w i r e
Magneto lead w i r e
CDI u n i t lead w i r e
Engine kill s w i t c h lead w i r e
Radiator o v e r f l o w h o s e

Exhaust valve breather hose
WIRE, CABLE AND HOSE ROUTING 19-2
CLAMP
Do not bend t h e hoses
Carburetor over f l o w h o s e
Do n o t clamp this hose
Fuel hose
Carburator air vent hose (L)
Carburator air vent hose (RI
Carburator o v e r f l o w h o s e
CLAMP
CLAMP
CLAMP
Breather hose
19
19-3 WIRE, CABLE AND HOSE ROUTING
Rear shock absorber spring
163rrinn
(0.63 0.12 in)
t
Master cylinder
Caliper
WIRE, CABLE AND HOSE ROUTING 1 9
Throttle cable
\ C l u t c h cable
Front brake hose
Throttle cable
Clutch cable
I
19-5 WIRE, CABLEAND HOSE ROUTING
Radiator
hose
\ \
Exhaust valve
breather hose
WIRE, CABLE AND HOSE ROUTING 19-6
I
20-1 SPECIFICATIONS
SPECIFICATIONS
DIMENSIONS A N D DRY M A S S
Overall l e n g t h 2 1 6 5 mrn ( 8 5 . 3 in)
Overall w i d t h 815 m m (32.1 in)
Overall height 12 5 0 mm (49.2 in)
Wheelbase 1 4 6 5 mm (57.7 in)
Ground clearance 360 m m ( 1 4 . 2 in)
Seat h e i g h t 960 m m ( 3 7 . 8 in)
Dry mass 98 k g ( 2 1 6 lbs)
ENGINE
Type Two-stroke water-cooled
Intake s y s t e m Crankcase reed valve
Number o f c y l i n d e r 1
Bore 67.0 m m ( 2 . 6 3 8 in)
Stroke 70.8 m m ( 2 . 7 8 7 in)
Piston displacement 249 c m
Corrected compression ratio 8.6110.2 : 1 (Low/High)
Carburetor M U N I NITM38SS, single
Air cleaner Polyurethane f o a m element
Starter system Primary k i c k
Lubrication system Fuel/oil premixture o f 2 0 : 1
TRANSMISSION
Clutch Wet multi-plate t y p e
Transmission 5-speed constant mesh
Gearshift p a t t e r n 1-down, 4 - u p
Primary r e d u c t i o n 2.652 ( 6 i / 2 3 )
Final reduction 3.846 ( 5 0 / 1 3 )
Gear ratios, L o w 2.285 ( 3 2 / 1 4 )
2nd 1.733 ( 2 6 / 1 5 )
3rd 1.375 ( 2 2 / 1 6 )
4th 1.090 ( 2 4 / 2 2 )
Top 0.863 (19/22)
Drive c h a i n DAIDO O L D . 5 2 0 V S or TA K A S A G O
RK520SMO 11 4 links
SPECIFICATIONS 20-2
CHASSIS
Front suspension Telescopic, pneumatic/coil spring, oil damped
compression damping force 2 1 - w a y adjustable
rebound damping force 2 1 - w a y adjustable.
Rear s u s p e n s i o n New link suspension system, spring pre-load ful-
ly adjustable, compression damping force
18-way adjustable, rebound damping force
21-way adjustable.
Steering a n g l e 4 5 ' (right & left)
Caster 62 3 0 '
Trail 113 m m ( 4 . 4 in)
Turning r a d i u s 2.3 m ( 7 . 5 ft)
Front b r a k e Disc brake, hydraulically operated
Rear brake Disc brake, hydraulically operated
Front t i r e s i z e 80/100-21 5 1 M
Rear t i r e size 11 0 / 1 0 0 - 1 8 6 4 M
Front f o r k s t r o k e 3 1 0 nn nn ( 1 2 . 2 in)
Rear wheel travel 324 m m ( 1 2 . 8 in)
ELECTRICAL
Ignition t y p e SUZUKI " P E I "
Ignition t i m i n g 7 . 5 BT.D.C. a t 9 0 0 0 r p m
Spark plug NGK B8EGV U K , Australia
NGK BR8EV F o r Canada and France
CAPACITIES
Fuel t a n k 11.0 L ( 2 . 9 US gal)
Front f o r k o i l 619 ml ( 2 0 . 9 US oz)
Transmission oil 6 5 0 ml ( 0 . 7 US/Imp qt)
Coolant 8 5 0 ml ( 0 . 9 US qt)
20
INDEX
ITEM PAGE
AIR CLEANER 2-4
BEARING INSPECTION, R E M O VA L A N D INSTALLATION 9-6
BRAKE DISC INSPECTION 14-4
BRAKE FLUID A I R BLEEDING 14-2
BRAKE FLUID REPLACEMENT 14-3
BRAKE PADS REPLACEMENT 14-3
BRAKE PEDAL R E M O VA L A N D REASSEMBLY 14-11
BRAKES 2-10
BREAK-IN 1-4
CALIPER 14-4
CARBURETOR 10-2
CDI U N I T INSPECTION 12-3
CLUTCH 2-7
CLUTCH PLATE INSPECTION 7-2
CLUTCH PLATE REASSEMBLING 7-3
CLUTCH PLATE R E M O VA L 7-2
CON-ROD INSPECTION 6-5
COOLANT 2-5
COOLANT REPLACEMENT 11-2
CRANKCASE REASSEMBLY 9-8
CRANKCASE SEPARATION 9-2
CRANKSHAFT INSPECTION 9-5
CRANKSHAFT INSTALLATION 9-7
CRANKSHAFT REMOVAL 9-3
CYLINDER HEAD INSPECTION 6-3
CYLINDER HEAD R E M O VA L 6-2
CYLINDER HEAD, CYLINDER A N D PISTON 2-8
CYLINDER INSPECTION 6-3
CYLINDER REASSEMBLING 6-6
CYLINDER R E M O VA L 6-2
DISC PLATE REPLACEMENT 13-4
DRIVE CHAIN A N D SPROCKETS 2-8
DRIVE CHAIN GUIDE, BUFFER, TENSIONER ROLLER 2-10
ELECTRICAL CIRCUIT 12-2
ENGINE DISMOUNTING A N D MOUNTING 5-1
ENGINE MOUNTING 5-2
EXHAUST VA LV E 2-8
EXHAUST VA LV E INSPECTION 6-5
EXHAUST VA LV E REASSEMBLING 6-6
EXHAUST VA LV E REMOVAL 6-3
FRONT A N D REAR WHEEL INSPECTION 13-2
FRONT FORK 2-12
FRONT FORK DISASSEMBLY 15-2
FRONT FORK DISMOUNTING 15-2
FRONT FORK INSPECTION 15-3
FRONT FORK MOUNTING 15-5
FRONT FORK REASSEMBLING 15-4
FRONT WHEEL DISASSEMBLY A N D REASSEMBLY 13-2
FUEL 1-2
FUEL LINE 2-7
GEARSHIFT LINKAGE INSPECTION 9-3
GEARSHIFT LINKAGE REASSEMBLY 9-9
ITEM P A G E
GEARSHIFT LINKAGE REMOVAL 9 - 2
IGNITION COIL INSPECTION 1 2 - 2
INSPECTION BEFORE PRACTICE 2 - 1
INSPECTION BEFORE RACE 2 - 1
KICK STARTER INSPECTION 8 - 2
KICK STARTER REASSEMBLY 8 - 3
KICK STARTER REMOVAL 8 - 2
LOCATION OF PARTS 1 - 1
LUBRICATION 2 - 1 4
MACHINE TUNING, CARBURETOR 4 - 1
MACHINE TUNING, FORNT FORK 4 - 9
MACHINE TUNING, REAR SUSPENSION 4 - 1 2
MAGNETO ROTOR A N D S TATO R R E M O VA L A N D REASSEMBL 1 2 - 4
MASTER CYLINDER 1 4 - 8
OIL SEAL INSPECTION, R E M O VA L A N D INSTALLATION 9 - 5
OPERATING INSTRUCTIONS 1 - 3
PERIODIC MAINTENANCE CHART 2 - 2
PISTON A N D PISTON RING INSPECTION 6 - 4
PISTON RING A N D PISTON REASSEMBLING 6 - 5
PRIMARY DRIVEN GEAR A S S Y INSPECTION 7 - 4
PRIMARY DRIVEN GEAR A S S Y REASSEMBLY 7 - 4
PRIMARY DRIVEN GAER A S S Y R E M O VA L 7 - 3
RACK A N D PINION INSPECTION 7 - 3
RADIATOR 1 1 - 2
RADIATOR CAP INSPECTION 1 1 - 2
REAR SHOCK ABSORBER DISPOSAL 1 6 - 3
REAR SHOCK ABSORBER INSPECTION 1 6 - 3
REAR SHOCK ABSORBER REASSEMBLY 1 6 - 4
REAR SHOCK ABSORBER REMOVAL 1 6 - 2
REAR SUSPENSION 2 - 1 2
REAR SUSPENSION LINKAGE 1 6 - 6
REAR SUSPENSION LINKAGE REASSEMBLING 1 6 - 7
REAR WHEEL R E M O VA L A N D REASSEMBLY 1 3 - 2
REED VA LV E 1 0 - 3
SERVICE D ATA 1 7 - 1
SPARK PLUG 2 - 3
SPECIAL TOOLS A N D MATERIAL 1 8 - 1
STATOR COIL INSPECTION 1 2 - 4
STEERING 2 - 1 3
STEERING BEARING REPLACEMENT 1 5 - 6
STEERING REASSEMBLY 1 5 - 7
STEERING R E M O VA L 1 5 - 5
SWING A R M 1 6 - 4
THROTTLE CABLE 2 - 7
TIGHTENING TORQUE 2 - 1 5
TRANSMISSION 1 - 4
TRANSMISSION INSPECTION 9 - 4
TRANSMISSION OIL 2 - 5
TRANSMISSION REASSEMBLY 9 - 7
TRANSMISSION R E M O VA L 9 - 3
TROUBLESHOOTING, ENGINE 3 - 1
TROUBLESHOOTING, CHASSIS 3 - 4
ITEM PAGE
WATER PUMP
11-3
WHEEL BEARING R E M O VA L A N D REASSEMBLY 13-3
WHEELS A N D TIRES 2-13
WIRE, CABLE A N D HOSE ROUTING 19-1
r',57
Failure to : s e safety precautions may increase your-

risk o f
W e a r a helmet. eye protection, and bright protective
fl - c o n s u m i n g alcohol or other drugs.

1 e
ty
r v i c e
P e a s e
manual contains important safe-
read i t carefully.
x.;
Part No. 99011-28C52-01A
Al October, 1990 C ) E N
Printed in Japan
- -4

RM250 Owners Service Manual 1991

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RM250 Owners Service Manual 1991

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TABLE OF C O N T E N T S

ENGINE DISMOUNTING A N D MOUNTING 5

Gasoline: Unleaded gasoline minimun 9 5 octane (RON).

W H AT TO CHECK CHECK FOR

INSPECTION BEFORE RACE

W H AT TO CHECK CHECK FOR

All items o f inspection

PERIODIC MAINTENANCE CHART

NOTE: R =Replace, C =Clean, T = Tighten, IInspect and clean, adjust lubricate

Inspect the porcelain t i p color.

Porcelain tip color Cause

Standard Spark plug

B8EGV ... UK, Australia

Tighten the spark plug with specified tighteing torque af-

Tightening torque: 2 5 - 3 0 N.m

Remove outer element and inner elemtnefrom the ele-

Be sure to check the element seals properly after installing

Install the air cleaner cap.

NOTE.' R u n n i n g the engine without the air cleaner cap can

Remove the radoator cap.

Improperly tightening the radiator cap cannot obtain the

num alloy. Using non-recommended coolant may corrode alu-

Cooling System Inspection

Remove the throttle housing cover.

CYLINDER HEAD, CYLINDER AND PISTON

Remove the exhaust valve. ( 6

DRIVE CHAIN AND SPROCKETS

Drive Chain Adjustment

NOTE: P u l l the upper drive chain tight and lock it by placing

20th Pitch Length

Drive Chain Lubrication

Clean the drive chain with non-flammable cleaning solvent.

A d j u s t the drive chain slack.

DRIVE CHAIN GUIDE, BUFFER, TENSIONER ROLLER

Inspect the chain guide defence 2 f o r wear.

Drive Chain Guide Buffer

Drive Chain Tensioner Roller

Use only DOT4 brake fluid from a sealed container. Never

Front Brake Lever Adjustment

Brake lever play: 0 . 1 - 0 . 3 mm ( 0 . 0 0 4 - 0 . 0 1 2 in)

Tighten t h e lock nut.

Brake Pedal Height Adjustment

Spoke Nipple and Rim lock

No. ITEM LUBRICANT FREQUENCY COMMENTS

The following materials are necessary:

PART N.m kg-m lb-ft

26-30 2.6-3.0 19.0-21.5

For other bolts and n u t s n o t listed in t h e table, refer to this chart.

Fuel deterioration Replace

Insufficient Fuel deterioration Replace

Complaint Possible Cause Remedy

Complaint Possible Cause Remedy

Overheating Low coolant level Replenish

Complaint Possible Cause Remedy

Poor braking B r a k e pads w o r n Replace

MACHINE TUNING PRINCIPLES OF CARBURETOR TUNING

TUNING PARTS THROTTLE VA LV E OPENING

NEEDLE CLIP POSITION -------------

PILOT JET A N D PILOT 7 1 . 111111111

The pilot air screw is located in the inlet air pas-

The pilot jet meters the fuel supplied t o the pi-

Needle Clip Position Main Jet

To adjust the air/fuel mixture w i t h the jet nee-

Charging the needle itself also controls air/fuel