Suzuki AY50 Service Manual
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Suzuki AY50 Service Manual

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  • Page 2 FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI AY50/50W and procedures for its inspection/service and overhaul of its main com- GENERAL INFORMATION ponents. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to fa-...
  • Page 132 ELECTRICAL SYSTEM STATOR COIL Measure the resistance between the lead wire and ground using a pocket tester. If the resistance is incorrect, replace the stator coil. ! 09900-25002: Pocket tester " Tester knob indication: × 1 Ω range Standard resistance 0.1 –...
  • Page 214 AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) 11-1 AY50K1/WRK1 (’01-MODEL) AY50K2/WRK2 (’02-MODEL) This chapter describes specification, service data and servicing procedures which differ from those of the AY50Y/WRY (’00-MODEL). NOTE: * Any differences between AY50Y/WRY (’00-MODEL) and AY50K1/WRK1 (’01-MODEL) in specifications and service data are clearly indicated with the asterisk marks (*). * Please refer to the chapters 1 through 10 for details which are not given in this chap- ter.
  • Page 215 (4Ah)/10HR ..P-53 Air cleaner ....Polyurethane foam element 12 V 10.8 kC Starter system..... Electric and kick (3Ah)/10HR ..The others Lubrication system ..SUZUKI “CCI” Generator ....Magneto Fuse ......10 A TRANSMISSION Headlight ..... * 12 V 35/35 W Brake light/Taillight ..
  • Page 216 Battery ......12 V 14.4 kC Air cleaner ....Polyurethane foam element (4Ah)/10HR ..P-53 Starter system..... Electric and kick 12 V 10.8 kC Lubrication system ..SUZUKI “CCI” (3Ah)/10HR ..The others Generator ....Magneto TRANSMISSION Fuse ......10 A Clutch ......
  • Page 217 11-4 AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) SERVICE DATA AY50K1 CYLINDER + PISTON + PISTON RING Unit: mm ITEM STANDARD LIMIT Piston to cylinder 0.06 – 0.07 0.120 clearance Cylinder bore 41.005 – 41.020 41.075 Measure at 20 mm from the top surface Piston diam.
  • Page 218 AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) 11-5 TRANSMISSION Unit: mm Except ratio ITEM STANDARD LIMIT Reduction ratio P-22 * Variable 2.768 – 1.005 ——— P-02, 39 Variable 2.768 – 0.871 ——— P-04,26,34,53 Variable 2.975 – 1.140 ——— Final reduction ratio P-02, 22, 39 14.960 (51/15 ×...
  • Page 219 11-6 AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) ELECTRICAL Unit: mm ITEM SPECIFICATION NOTE Spark plug NGK: BPR6HS Type DENSO: W20FPR-U P-02, 22, 39 BOSCH: WR7BC 0.6 – 0.7 NGK: BPR7HS Type DENSO: W22FPR P-04, 26, 34, 53 0.6 – 0.7 Spark performance Over 8 at 1 atm.
  • Page 220 An unleaded gasoline is recommended. Fuel tank capacity 6.8 L Engine oil type Use SUZUKI CCI SUPER OIL. If they are not avail- able, use a good quality 2-stroke oil rated FC un- der JASO classification. Engine oil tank capacity 1.2 L...
  • Page 221 11-8 AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) AY50WRK1 CYLINDER + PISTON + PISTON RING Unit: mm ITEM STANDARD LIMIT Piston to cylinder 0.035 – 0.045 0.120 clearance Cylinder bore 41.010 – 41.025 41.105 Measure at 20 mm from the top surface Piston diam.
  • Page 222 AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) 11-9 THERMOSTAT + RADIATOR + ENGINE COOLANT TEMP. SWITCH + ENGINE COOLANT ITEM STANDARD/SPECIFICATION LIMIT Thermostat valve opening *Approx. 65°C ——— temperature Thermostat valve lift *Over 3 mm at 80°C ——— Radiator reservoir cap valve 100 kPa (1.0 kgf/cm ———...
  • Page 223 11-10 AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) SPECIFICATION ITEM P-02 P-22 ← Carburetor type KEIHIN PWS14 ← Bore size 14 mm I.D. No. 35E9 *35EA Idle r/min. 1 700 ± 200 r/min. 1 900 ± 200 r/min. ← Float height 5.1 ± 0.5 mm Main jet (M.J.) *#62...
  • Page 224 AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) 11-11 WATTAGE Unit: W ITEM SPECIFICATION Headlight Brake light/Taillight 21/5 Turn signal light Speedometer light 1.2 × 2 Fuel meter light Turn signal indicator light Oil level indicator light Water temp. indicator light *High beam indicator light *1.7 Trunk light BRAKE + WHEEL...
  • Page 225 An unleaded gasoline is recommended. Fuel tank capacity 6.8 L Engine oil type Use SUZUKI CCI SUPER OIL. If they are not avail- able, use a good quality 2-stroke oil rated FC un- der JASO classification. Engine oil tank capacity 1.2 L...
  • Page 226 AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) 11-13 THERMOSTAT (For AY50WRK1) REMOVAL • Remove the trunk. • Drain engine coolant. * Do not open the engine coolant reservoir cap when the engine is hot, as you may be injured by escaping hot liquid or vapor. * The engine must be cool before servicing the cooling system.
  • Page 227 11-14 AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) Immerse the thermostat into a container of water and keep it sus- pended as shown. Slowly heat the container and check the temperature on the ther- mometer when the thermostat valve begins to open. "...
  • Page 228 INSTALLATION Install the engine coolant temp. switch in the reverse order of removal. Pay attention to the following points: • Apply SUZUKI BOND No. 1215 to the thread portion of the engine coolant temp. switch. $ 99000-31110: SUZUKI BOND No.1215 •...
  • Page 229 11-16 AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) REGULATOR/RECTIFIER Measure the voltage between the terminals using the multi circuit tester, as indicated in the table below. If the voltage is not within the specified value, replace the regulator/rectifier with a new one. # 09900-25008: Multi circuit tester set % Tester knob indication: Diode test (&...
  • Page 230 AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) 11-17 WIRING DIAGRAM AY50K1 For P-02...
  • Page 231 11-18 AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) For P-39...
  • Page 232 AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) 11-19 For the others...
  • Page 233 11-20 AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) AY50WRK1 For P-02...
  • Page 234 AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) 11-21 For P-18...
  • Page 235 11-22 AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) For the others...
  • Page 236 NOTE: Please refer to the chapters 1 through 11 for details which are not given in this chapter. CONTENTS SPECIFICATIONS ................12- 2 AY50 AND AY50S................12- 2 AY50W AND AY50WS..............12- 3 SERVICE DATA ..................12- 4 AY50 AND AY50S................12- 4 AY50W AND AY50WS..............12- 8 WIRING DIAGRAM................12-13...
  • Page 237 Corrected compression ratio........ 6.5 : 1 Carburetor............KEIHIN PWS14 Air cleaner............Polyurethane foam element Starter system............Electric and Kick Lubrication system ..........SUZUKI “CCI” Idle speed ............1 900 ± 200 r/min DRIVE TRAIN Clutch..............Dry shoe, automatic, centrifugal type Gearshifting............
  • Page 238 AY50K3/SK3/WK3/WSK3 (’03-MODEL) 12-3 ELECTRICAL Ignition type............Electronic ignition (CDI) Ignition timing ............14° B.T.D.C. at 4 000 rpm Spark plug ............NGK BPR6HS or DENSO W20FPR-U Battery..............12V 10.8 kC (3Ah)/10HR Generator ............Flywheel magneto Fuse ..............10A Headlight ............. 12V 35/35W Brake light/Taillight ..........
  • Page 239 Corrected compression ratio........ 8.0 : 1 Carburetor............KEIHIN PWS14 Air cleaner............Polyurethane foam element Starter system............Electric and Kick Lubrication system ..........SUZUKI “CCI” Idle speed ............1 900 ± 200 r/min DRIVE TRAIN Clutch..............Dry shoe, automatic, centrifugal type Gearshifting............
  • Page 240 AY50K3/SK3/WK3/WSK3 (’03-MODEL) 12-5 ELECTRICAL Ignition type............Electronic ignition (CDI) Ignition timing ............14° B.T.D.C. at 4 000 rpm Spark plug ............NGK BPR6HS or DENSO W20FPR Battery..............12V 10.8 kC (3Ah)/10HR Generator ............Flywheel magneto Fuse ..............10A Headlight ............. 12V 35/35W Brake light/Taillight ..........
  • Page 241 12-6 AY50K3/SK3/WK3/WSK3 (’03-MODEL) SERVICE DATA AY50 AND AY50S CYLINDER + PISTON + PISTON RING Unit: mm ITEM STANDARD LIMIT Piston to cylinder clearance 0.06 – 0.07 0.120 Cylinder bore 41.005 – 41.020 41.075 Measure at 20 mm from the top surface Piston diam.
  • Page 242 AY50K3/SK3/WK3/WSK3 (’03-MODEL) 12-7 TRANSMISSION Unit: mm Except ratio ITEM STANDARD LIMIT Reduction ratio Variable 2.768 – 1.005 — Final reduction ratio 14.960 (51/15 × 66/15) — Drive belt width 16.9 15.9 18.4 17.4 Driven face spring free length 104.5 CARBURETOR ITEM SPECIFICATION Carburetor type...
  • Page 243 12-8 AY50K3/SK3/WK3/WSK3 (’03-MODEL) WATTAGE Unit: W ITEM SPECIFICATION Headlight Brake light/Taillight 21/5 Turn signal light Speedometer light 1.2 × 2 Fuel meter light Turn signal indicator light Oil level indicator light High beam indicator light Trunk light BRAKE + WHEEL Unit: mm ITEM STANDARD...
  • Page 244 An unleaded gasoline is recommended. Fuel tank capacity 6.8 L Engine oil type Use SUZUKI CCI SUPER OIL. If they are not avail- able, use a good quality 2-stroke oil rated FC under JASO classification. Engine oil tank capacity 1.2 L...
  • Page 245 12-10 AY50K3/SK3/WK3/WSK3 (’03-MODEL) AY50W AND AY50WS CYLINDER + PISTON + PISTON RING Unit: mm ITEM STANDARD LIMIT Piston to cylinder clearance 0.035 – 0.045 0.120 Cylinder bore 41.010 – 41.025 41.105 Measure at 20 mm from the top surface Piston diam. 40.970 –...
  • Page 246 AY50K3/SK3/WK3/WSK3 (’03-MODEL) 12-11 THERMOSTAT + RADIATOR + ENGINE COOLANT TEMP. SWITCH + ENGINE COOLANT ITEM STANDARD/SPECIFICATION LIMIT Thermostat valve opening temper- Approx. 65 °C — ature Thermostat valve lift Over 3 mm at 80 °C — Radiator reservoir cap valve open- 100 kPa (1.0 kgf/cm —...
  • Page 247 12-12 AY50K3/SK3/WK3/WSK3 (’03-MODEL) ELECTRICAL Unit: mm ITEM SPECIFICATION NOTE Spark plug NGK: BPR6HS Type DENSO: W20FPR 0.6 – 0.7 Spark performance Over 8 at 1 atm. Ignition coil resistance Plug cap – Secondary 4 – 10 kΩ B/W lead wire terminal 0.2 –...
  • Page 248 AY50K3/SK3/WK3/WSK3 (’03-MODEL) 12-13 BRAKE + WHEEL Unit: mm ITEM STANDARD/SPECIFICATION LIMIT Brake disc thickness Front 4.0 ± 0.2 Rear 4.0 ± 0.2 Brake disc runout Front & — 0.30 Rear Master cylinder bore Front 11.000 – 11.043 — Rear 12.000 – 12.043 —...
  • Page 249 An unleaded gasoline is recommended. Fuel tank capacity 6.8 L Engine oil type Use SUZUKI CCI SUPER OIL. If they are not avail- able, use a good quality 2-stroke oil rated FC under JASO classification. Engine oil tank capacity 1.2 L...
  • Page 250 AY50K3/SK3/WK3/WSK3 (’03-MODEL) 12-15 WIRING DIAGRAM AY50 AND AY50S P-02...
  • Page 251 12-16 AY50K3/SK3/WK3/WSK3 (’03-MODEL) P-19...
  • Page 252 AY50K3/SK3/WK3/WSK3 (’03-MODEL) 12-17 AY50W AND AY50WS P-02...
  • Page 253 12-18 AY50K3/SK3/WK3/WSK3 (’03-MODEL) P-19...
  • Page 254 AY50K3/SK3/WK3/WSK3 (’03-MODEL) 12-19 OIL HOSE ROUTING Filter Clip Oil hose Clip Clip to the oil tank Face the arrow mark on the filter, to the oil pump, when installing the filter. Clamp Oil hose Clip Clip Oil hose Oil hose Oil hose Clip Oil pump...
  • Page 255 This chapter describes specifications, service data and servicing procedures which differ from those of the AY50K3/WRK3 (’03-MODEL). NOTE: Please refer to the chapters 1 through 12 for details which are not given in this chapter. CONTENTS SPECIFICATIONS ................13-2 AY50 .....................13-2 AY50W ..................13-3 SERVICE DATA ...................13-4 AY50 .....................13-4 AY50W ..................13-8...
  • Page 256 Corrected compression ratio ............... 6.5 : 1 Carburetor ................... KEIHIN PWS14 Air cleaner ................... Polyurethane foam element Starter system..................Electric and kick Lubrication system ................SUZUKI “CCI” Idle speed ................... 1 900 ± 200 r/min DRIVE TRAIN Clutch ....................Dry shoe, automatic, centrifugal type Gearshifting..................
  • Page 257 Carburetor ..................KEIHIN PWS14 Air cleaner ..................Polyurethane foam element Starter system ..................Electric and kick Lubrication system ................SUZUKI “CCI” Idle speed ................... 1 900 ± 200 r/min DRIVE TRAIN Clutch ....................Dry shoe, automatic, centrifugal type Gearshifting ..................
  • Page 258 13-4 AY50K4/WK4 (’04-MODEL) SERVICE DATA AY50 CYLINDER + PISTON + PISTON RING Unit: mm ITEM STANDARD LIMIT Piston to cylinder clearance 0.06 – 0.07 0.120 Cylinder bore 41.005 – 41.020 41.075 Measure at 20 mm from the top surface. Piston diam.
  • Page 259 AY50K4/WK4 (’04-MODEL) 13-5 TRANSMISSION Unit: mm (Except ratio) ITEM STANDARD LIMIT Reduction ratio Variable 2.768 – 1.005 — Final reduction ratio 14.960 (51/15 × 66/15) — Drive belt width 16.9 15.9 18.4 17.4 Driven face spring free length 104.5 CARBURETOR ITEM SPECIFICATION Carburetor type...
  • Page 260 13-6 AY50K4/WK4 (’04-MODEL) WATTAGE Unit: W ITEM SPECIFICATION Headlight Brake light/Taillight 21/5 License plate light Turn signal light Speedometer light 1.2 × 2 Fuel meter light Turn signal indicator light Oil level indicator light High beam indicator light Trunk light BRAKE + WHEEL Unit: mm ITEM...
  • Page 261 An unleaded gasoline is recommended. Fuel tank capacity 6.8 L Engine oil type Use SUZUKI CCI SUPER OIL. If they are not avail- able, use a good quality 2-stroke oil rated FC under JASO classification. Engine oil tank capacity 1.2 L...
  • Page 262 13-8 AY50K4/WK4 (’04-MODEL) AY50W CYLINDER + PISTON + PISTON RING Unit: mm ITEM STANDARD LIMIT Piston to cylinder clearance 0.035 – 0.045 0.120 Cylinder bore 41.010 – 41.025 41.105 Measure at 20 mm from the top surface. Piston diam. 40.970 – 40.985 40.890 Measure at 23 mm from the skirt end.
  • Page 263 AY50K4/WK4 (’04-MODEL) 13-9 THERMOSTAT + RADIATOR + ENGINE COOLANT TEMP. SWITCH + ENGINE COOLANT ITEM STANDARD/SPECIFICATION LIMIT Thermostat valve opening temper- Approx. 65 °C — ature Thermostat valve lift Over 3 mm at 80 °C — Radiator reservoir cap valve open- 100 kPa (1.0 kgf/cm —...
  • Page 264 13-10 AY50K4/WK4 (’04-MODEL) ELECTRICAL Unit: mm ITEM SPECIFICATION NOTE Spark plug NGK: BPR6HS Type DENSO: W20FPR 0.6 – 0.7 Spark performance Over 8 at 1 atm. Ignition coil resistance Plug cap – Secondary 4 – 10 kΩ B/W lead wire terminal 0.2 –...
  • Page 265 AY50K4/WK4 (’04-MODEL) 13-11 BRAKE + WHEEL Unit: mm ITEM STANDARD/SPECIFICATION LIMIT Brake disc thickness Front 4.0 ± 0.2 Rear 4.0 ± 0.2 Brake disc runout Front & — 0.30 Rear Master cylinder bore Front 11.000 – 11.043 — Rear 12.000 – 12.043 —...
  • Page 266 An unleaded gasoline is recommended. Fuel tank capacity 6.8 L Engine oil type Use SUZUKI CCI SUPER OIL. If they are not avail- able, use a good quality 2-stroke oil rated FC under JASO classification. Engine oil tank capacity 1.2 L...
  • Page 267 Prepared by 7th Ed. February, 2004 1st Ed. March, 1997 Part No. 99500-10457-01E Printed in Japan...

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