Suzuki Ozark Service Manual
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Suzuki Ozark Service Manual

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FOREWORD
This manual contains an introductory description on
the SUZUKI LT-F250 and procedures for its inspec-
tion, service, and overhaul of its main components.
Other information considered as generally known is
not included.
Read the GENERAL INFORMATION section to
familiarize yourself with the vehicle and its mainte-
nance. Use this section as well as other sections as
a guide for proper inspection and service.
This manual will help you know the vehicle better so
that you can assure your customers of fast and reli-
able service.
* This manual has been prepared on the basis
of the latest specifications at the time of publi-
cation. If modifications have been made since
then, differences may exist between the con-
tent of this manual and the actual vehicle.
* Illustrations in this manual are used to show
the basic principles of operation and work
procedures. They may not represent the
actual vehicle exactly in detail.
* This manual is written for persons who have
enough knowledge, skills and tools, including
special tools, for servicing SUZUKI vehicles.
If you do not have the proper knowledge and
tools, ask your authorized SUZUKI motorcy-
cle dealer to help you.
Inexperienced mechanics or mechanics
without the proper tools and equipment
may not be able to properly perform the
services
described
Improper repair may result in injury to the
mechanic and may render the vehicle
unsafe for the rider.
© COPYRIGHT SUZUKI MOTOR CORPORATION 2001
in
this
manual.
GROUP INDEX

GENERAL INFORMATION

PERIODIC MAINTENANCE

ENGINE
DRIVE TRAIN

FUEL SYSTEM

LUBRICATION SYSTEM

CHASSIS

ELECTRICAL SYSTEM

SERVICING INFORMATION

1
2
3
4
5
6
7
8
9

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Questions and answers

julian
January 28, 2025

where is the neutral safety switch

2
1 comments:
Mr. Anderson
February 10, 2025

The neutral safety switch on a Suzuki Ozark is located on the pull start side of the motor, just to the rear of the motor. It is covered by a small oval cover with wires running into it.

This answer is automatically generated

0
Brian Bresee
April 12, 2025

Where is the pulse coil on a 2007 Suzuki Ozark 250

0

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Summary of Contents for Suzuki Ozark

  • Page 1: General Information

    FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI LT-F250 and procedures for its inspec- tion, service, and overhaul of its main components. GENERAL INFORMATION Other information considered as generally known is not included. Read the GENERAL INFORMATION section to...

  • Page 3: Table Of Contents

    SUPPLEMENTS LT-F250K3 (’03-MODEL) LT-F250K4 (’04-MODEL) LT-F250K5 (’05-MODEL) LT-F250K6 (’06-MODEL) LT-F250K7 (’07-MODEL) LT-F250K8 (’08-MODEL) LT-F250K9 (’09-MODEL)
  • Page 4 HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily.
  • Page 5 Apply molybdenum oil solution. (mixture of engine oil and SUZUKl Measure in voltage range. MOLY PASTE in a ratio of 1 : 1) Apply SUZUKI SUPER GREASE “A”. 99000-25030 (USA) Measure in resistance range. 99000-25010 (Others) Apply SUZUKI SILICONE GREASE.
  • Page 6  ...

  • Page 7: General Information

    GENERAL INFORMATION 1-1 GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE ..............1- 2 GENERAL PRECAUTIONS ..............1- 2 SUZUKI LT-F250K2 (2002-MODEL) ..........1- 4 SERIAL NUMBER LOCATION ............1- 4 FUEL AND OIL RECOMMENDATION ..........1- 4 FUEL ....................1- 4 ENGINE OIL .................1- 5 REAR DRIVE GEAR OIL .............1- 5 BRAKE FLUID ................1- 5...

  • Page 8: Warning/Caution/Note

    1-2 GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. ...
  • Page 9 GENERAL INFORMATION 1-3  * If parts replacement is necessary, replace the parts with SUZUKI Genuine Parts or their equiv- alent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order.

  • Page 10: Suzuki Lt-F250K2 (2002-Model)

    ) method or 91 octane or higher rated by the Research Method. • SUZUKI recommends that customers use alcohol-free unleaded gasoline whenever possible. • Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted. • Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10% etha- nol.

  • Page 11: Engine Oil

    Use unleaded gasoline that is graded 91 octane or higher by the Research Method. ENGINE OIL (For USA) SUZUKI recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or oils that meet API service classifications SF or SG and that have a viscosity rating of SAE 10W-40. If engine oil with a rating of SAE 10W-40 is not available, select an alter- native according to the chart.

  • Page 12: Information Labels

    1-6 GENERAL INFORMATION INFORMATION LABELS APPLIED SPECIFICATION LABEL or PLATE NAME E-03 E-17 E-24 E-28 E-33 — — Certification plate — — — — Information label — — Gearshift pattern label — — — Gearshift pattern label Tire air pressure label —...

  • Page 13: Specifications

    GENERAL INFORMATION 1-7 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ............1 800 mm (70.9 in) ..E-03, 28, 33 1 870 mm (73.6 in) ..E-17, 24 Overall width ............1 045 mm (41.1 in)..E-03, 28, 33 1 070 mm (42.1 in)..E-17, 24 Overall height ............
  • Page 14 1-8 GENERAL INFORMATION CHASSIS Front suspension ..........Independent, double wishbone, coil spring, oil damped Rear suspension ..........Swingarm type, coil spring, oil damped Steering angle............Inside 41.5° Outside 29° Caster ..............9° 30’ Trail ..............42 mm (1.65 in) Turning radius ............2.6 m (8.5 ft) Front brake............Disc brake, twin Rear brake ............Drum brake Front tire size ............AT22 ×...

  • Page 15: Country And Area Codes

    GENERAL INFORMATION 1-9 COUNTRY AND AREA CODES The following codes stand for the applicable countries and areas. CODE COUNTRY OR AREA E-03 E-17 Sweden E-24 Australia E-28 Canada E-33 California (USA)
  • Page 16  ...

  • Page 17: Periodic Maintenance

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE ..........2- 2 PERIODIC MAINTENANCE CHART ...........2- 2 MAINTENANCE AND TUNE-UP PROCEDURES .......2- 3 AIR CLEANER ................2- 3 EXHAUST PIPE NUTS AND MUFFLER BOLTS ......2- 4 VALVE CLEARANCE ..............2- 5 SPARK PLUG ................2- 6 FUEL HOSE .................2- 7 THROTTLE CABLE PLAY ............2- 8 ENGINE IDLE SPEED ..............2- 8...

  • Page 18: Periodic Maintenance Schedule

    2-2 PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the vehicle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometers, miles and months, and are dependent on whichever comes first. NOTE: More frequent servicing may be performed on vehicles that are use under severe conditions.

  • Page 19: Maintenance And Tune-Up Procedures

    PERIODIC MAINTENANCE 2-3 MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item mentioned in the Periodic Maintenance chart. AIR CLEANER Clean every 3 months. If the air cleaner is clogged with dust, intake resistance will be increased, with a resultant decrease in power output and an increase in fuel consumption.

  • Page 20: Exhaust Pipe Nuts And Muffler Bolts

    2-4 PERIODIC MAINTENANCE  * Inspect the air cleaner element for tears. A torn ele- ment must be replaced. * If driving under dusty conditions, clean the air cleaner element more frequently. The surest way to accelerate engine wear is to operate the engine with- out the element or with torn element.

  • Page 21: Valve Clearance

    PERIODIC MAINTENANCE 2-5 VALVE CLEARANCE Inspect initially at 1 month and every 6 months there- after. Excessive valve clearance results in valve noise and insufficient valve clearance results in valve damage and reduced power. Check the intake and exhaust valve clearances at the distances indicated above and adjust the valve clearances to specification, if necessary.

  • Page 22: Spark Plug

    2-6 PERIODIC MAINTENANCE  Securely tighten the locknut after completing adjust- ment. • Install the spark plug and TDC plug.  TDC plug: 23 N·m (2.3 kgf-m, 16.5 lb-ft) • Apply grease to the O-rings and install the O-rings valve inspection caps.

  • Page 23: Fuel Hose

    PERIODIC MAINTENANCE 2-7 SPARK PLUG GAP Measure the spark plug gap using a thickness gauge. If the spark plug gap is out of specification, adjust the gap.  Standard Spark plug gap: 0.6 – 0.7 mm (0.024 – 0.028 in) ...

  • Page 24: Throttle Cable Play

    2-8 PERIODIC MAINTENANCE THROTTLE CABLE PLAY Inspect initially at 1 month and every 3 months there- after. Adjust the throttle cable play A as follows. • Loosen the locknut 1 of the throttle cable. • Turn the adjuster 2 in or out to obtain the correct play. ...
  • Page 25 PERIODIC MAINTENANCE 2-9 ENGINE OIL REPLACEMENT • Place an oil pan under the drain plug 1, and then drain out the engine oil by removing the engine oil drain plug 1 and engine oil filler cap 2. • Reinstall the drain plug 1 and the gasket. Tighten the engine oil drain plug 1 to the specicied torque, and then pour the new oil through the oil filler hole.

  • Page 26: Final Bevel Gear Oil

    2-10 PERIODIC MAINTENANCE  When reassembling the oil filter, make sure that the oil filter is installed as shown above. If the filter is installed improperly, serious engine damage may result. FINAL BEVEL GEAR OIL Inspect every 6 months. Replace every 2 years. To change the final bevel gear oil, locate the vehicle on a level position and carry out the following steps.

  • Page 27: Spark Arrester

    PERIODIC MAINTENANCE 2-11 SPARK ARRESTER Clean every 6 months. • Remove the bolt 1. • Extract the spark arrester pipe 2 from the muffler. • Clean the spark arrester pipe 2 by brush. • Reinstall the spark arrester pipe 2. ...

  • Page 28: Brakes

    2-12 PERIODIC MAINTENANCE BRAKES Inspect initially at 1 month and every 3 months there- after. BRAKE PADS • Remove the front wheels. (7-10) The extent of brake pad wear can be checked by observing the limit line 1 on the side of brake pads. When the wear reaches the limit line, replace the pads with new ones.

  • Page 29: Brake Fluid

    PERIODIC MAINTENANCE 2-13 • Turn the adjuster 1 until the play A is 20 – 30 mm (0.8 – 1.2 in). Rear brake lever • After adjusting the brake pedal, check the rear brake lever play. The brake lever play B as measured at the lever holder should be between 3 –...
  • Page 30 2-14 PERIODIC MAINTENANCE AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion absorb a large proportion of the pressure developed by the master cylin- der and thus interferes with the full braking performance of the brake caliper.

  • Page 31: Brake Hose

    PERIODIC MAINTENANCE 2-15 BRAKE HOSE Inspect every 6 months. Replace every 4 years. • Check the brake hoses for leakage, cracks, wear and dam- age. If any damages are found, replace the brake hoses with new ones. TIRES Inspect every 3 months. 4.0 mm TIRE TREAD CONDITION Operating the vehicle with excessively worn tires will decrease...

  • Page 32: Steering

    2-16 PERIODIC MAINTENANCE  To minimize the possiblility of tire damage from over-inflation, we strongly recommended that a man- ual type air pump be used rather than a high pressure air compressor as found in service stations. When fill- ing air into the tires, never exceed 70 kPa (0.7 kgf/cm², 10 psi).

  • Page 33: Suspensions

    PERIODIC MAINTENANCE 2-17 SUSPENSIONS Inspect every 6 months. • Support the vehicle using a jack and wooden blocks. • Remove the front and rear wheels. (7-10) • Inspect the suspension arm and bushing for scratches, wear, or damage. If any damages are found, replace the suspen- sion arm or bushing with a new one.

  • Page 34: Chassis Bolts And Nuts

    2-18 PERIODIC MAINTENANCE CHASSIS BOLTS AND NUTS Tighten initially at 1 month and every 3 months there- after. Check that all chassis nuts and bolts are tightened to their specified torque. (Refer to page 2-19 and 2-20 for the locations of the following nuts and bolts.) Item N·m kgf-m...
  • Page 35 PERIODIC MAINTENANCE 2-19...
  • Page 36 2-20 PERIODIC MAINTENANCE...

  • Page 37: General Lubrication

    PERIODIC MAINTENANCE 2-21 GENERAL LUBRICATION Lubricate every 3 months. Proper lubrication is important for smooth operation and long life of each working part of the vehicle. Major lubrication points are indicated below.  1Brake lever holder 5Brake cam Grease  2Throttle lever and cable 6Brake cable Motor oil...

  • Page 38: Compression Pressure Check

    2-22 PERIODIC MAINTENANCE COMPRESSION PRESSURE CHECK The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership shoud include compression readings for each maintenance service. ...

  • Page 39: Oil Pressure Check

    PERIODIC MAINTENANCE 2-23 OIL PRESSURE CHECK Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts.  Oil pressure: Above 50 kPa (0.5 kgf/cm², 7.1 psi) at 3 000 r/min., oil temp. at 60°C (140°F) Below 80 kPa (0.8 kgf/cm², 11.4 psi) Low or high oil pressure can indicate any of the following conditions: LOW OIL PRESSURE...

  • Page 40: Initial Engagement And Clutch Lock-Up Inspection

    2-24 PERIODIC MAINTENANCE INITIAL ENGAGEMENT AND CLUTCH LOCK-UP INSPECTION The LT-F250 is equipped with a centrifugal type automatic clutch. To insure proper performance and longevity of the clutch assemblies, it is essential that the clutches engage smoothly and gradually. Before checking the initial engagement and clutch lock-up, two inspection checks must be performed to thor- oughly check the operation of the drive train.
  • Page 41 ENGINE 3-1 ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ...3- 2 ENGINE LEFT SIDE ..............3- 2 ENGINE RIGHT SIDE ..............3- 2 ENGINE CENTER ................3- 2 ENGINE REMOVAL AND INSTALLATION .........3- 3 ENGINE REMOVAL ..............3- 3 ENGINE INSTALLATION .............3- 8 ENGINE DISASSEMBLY ..............3-12 ENGINE TOP SIDE ..............3-12 ENGINE BOTTOM SIDE ..............3-15...

  • Page 42: Engine Components Removable With Engine In Place

    3-2 ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and installed without removing the engine from the frame. Refer to the page listed in each section for removal and installation instructions. ENGINE LEFT SIDE PARTS REMOVAL INSTALLATION...

  • Page 43: Engine Removal And Installation

    ENGINE 3-3 ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal procedure. •...
  • Page 44 3-4 ENGINE • Turn the fuel valve to the “ON” position and remove the carbu- retor. Carburetor removal 5-7 • Disconnect the engine ground lead wire 1. • Disconnect the neutral switch lead wire coupler 2. • Disconnect the signal generator lead wire coupler 3 and gen- erator lead wire coupler 4.
  • Page 45 ENGINE 3-5 • Remove the reverse gearshift arm 1. • Remove the spark plug cap. • Remove the right footrest 2. • Remove the brake pedal 3. • Remove the muffler 4.
  • Page 46 3-6 ENGINE • Remove the exhaust pipe. • Remove the breather hose 1. • Remove the starter motor cover 2. • Remove the starter motor lead wire. • Remove the engine mounting bracket A.
  • Page 47 ENGINE 3-7 • Remove the engine mounting bolts and nuts. • Disconnect the propeller shaft. • Remove the engine from the right side.

  • Page 48: Engine Installation

    3-8 ENGINE ENGINE INSTALLATION Remount the engine in the reverse order of engine removal. Pay attention to the following points: NOTE: * The engine mounting nuts are self-locking. * Once the nut has been removed, it is no longer of any use. Be sure to use new nuts, and then tighten them to the specified torque.
  • Page 49 Muffler connecting bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) Muffler mounting bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) • Apply SUZUKI SUPER GREASE “A” to the O-rings and install the brake pedal.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
  • Page 50 3-10 ENGINE • Apply THREAD LOCK SUPER “1342” to the bolts A and tighten each bolt to the specified torque.  Footrest bolt: 8 mm: 26 N·m (2.6 kgf-m, 19.0 lb-ft) 10 mm: 55 N·m (5.5 kgf-m, 40.0 lb-ft)  99000-32050: THREAD LOCK “1342” •...
  • Page 51 ENGINE 3-11 • Adjust the gearshift lever height A.  Gearshift lever height A: 0 – 10 mm (0 – 0.4 in) • After installing the engine, route the wire harness, cables and hoses properly. (9-12) • Adjust the following items. * Engine oil 2-9 * Engine idle speed 2-8 * Throttle cable play 2-8...

  • Page 52: Engine Disassembly

    3-12 ENGINE ENGINE DISASSEMBLY ENGINE TOP SIDE SPARK PLUG • Remove the spark plug.  09930-10121: Spark plug wrench set STARTER MOTOR • Remove the starter motor. RECOIL STARTER • Remove the recoil starter. • Remove the valve timing inspection plug 1. •...
  • Page 53 ENGINE 3-13 CAM CHAIN TENSION ADJUSTER • After removing the spring holder bolt 1, remove the cam chain tension adjuster. CYLINDER HEAD COVER • Remove the cylinder head cover. CAMSHAFT • Remove the C-ring 1. • Flatten the lock washer. •...
  • Page 54 3-14 ENGINE • Remove the cam chain tensioner by removing the bolt. CYLINDER HEAD • Remove the cylinder head nuts. • Remove the cylinder head bolts diagonally. • Remove the cylinder head. CYLINDER • Remove the cylinder nuts. • Remove the cam chain guide 1. •...

  • Page 55: Engine Bottom Side

    ENGINE 3-15 PISTON • Remove the piston by removing the piston pin circlip 1. NOTE: Place a rag under the piston so as not to drop the piston pin cir- clip into the crankcase. ENGINE BOTTOM SIDE NEUTRAL SWITCH • Remove the neutral switch. •...

  • Page 56: Starter Idle Gear

    3-16 ENGINE • Remove the generator roter cover. STARTER IDLE GEAR • Remove the starter idle gear. OIL FILTER • Remove the oil filter cover. • Remove the oil filter and O-ring 1. CLUTCH COVER • Remove the clutch adjuster cap 1. •...

  • Page 57: Clutch

    ENGINE 3-17 • Remove the clutch release ball assembly 1 and ball guide 2. CLUTCH NOTE: Slightly loosen the clutch spring bolts by holding the clutch shoe nut to facilitate later disassembly. • While holding the generator rotor with the special tool, remove the clutch shoe nut.
  • Page 58 3-18 ENGINE • Install the generator rotor attachment to the crankshaft end.  09930-31921: Rotor remover attachment • Remove the generator rotor with the special tool.  09930-35010: Rotor remover • Remove the key 1. • Remove the starter driven gear 2. CAM CHAIN •...

  • Page 59: Gearshift 3-19

    ENGINE 3-19 • Remove the clutch release arm 1. • Remove the clutch springs and bolts. • Remove the clutch release plate 2. • Remove the clutch sleeve hub nut with the special tool.  09920-53730: Clutch sleeve hub holder •...

  • Page 60: Oil Pump Drive Gear

    3-20 ENGINE • Remove the shift cam shaft 1. • Remove the gearshift cam plate and stopper. OIL PUMP DRIVE GEAR • Remove the oil pump drive gear 1 and pin 2. OIL PUMP • Remove the circlip. • Remove the oil pump driven gear 1. •...
  • Page 61 ENGINE 3-21 • Remove the left crankcase bolts. • Remove the right crankcase bolts. • Separate the crankcase with the special tool. NOTE: * The crankcase separator plate is parallel with the end face of the crankcase. * The crankshaft must remain in the left crankcase half. ...
  • Page 62 3-22 ENGINE • Remove the gearshift cam and forks. • Remove the shift cam lock shaft 1. • Remove the reverse driven gear 2 and reverse dog 3. • Remove the crankshaft with the special tool.  09920-13120: Crankcase separator DRIVE BEVEL GEAR •...
  • Page 63 ENGINE 3-23 • Fit the special tool onto the driveshaft.  09930-73150: Output shaft holder • Remove the secondary drive bevel gear and nut by holding the special tool with a vise. • Remove the driveshaft and countershaft.

  • Page 64: Engine Components Inspection And Servicing

    3-24 ENGINE ENGINE COMPONENTS INSPECTION AND SERVICING CYLINDER HEAD COVER DISASSEMBLY  Be sure to identify each removed part as to its loca- tion, and lay the parts out in groups designated as “Exhaust”, “Intake”, so that each will be restored to the original location during assembly.

  • Page 65: Cylinder Head

    ENGINE 3-25 ROCKER ARM I.D. When checking the valve rocker arm, the inside diameter of the valve rocker arm and wear of the camshaft contacting surface should be checked.  Rocker arm I.D. Standard: 12.000 – 12.018 mm (0.4724 – 0.4731 in) ...
  • Page 66 3-26 ENGINE • Remove the oil seal with long-nose pliers. • Remove the valve spring seat. NOTE: Removal of valves completes ordinary disassembling work. If valve guides have to be removed for replacement after inspect- ing the related parts, carry out the steps shown in the valve guide servicing.
  • Page 67 ENGINE 3-27 VALVE FACE WEAR Visually inspect each valve face for wear or damage. If any abnormal wear is found, replace the respective valve with a new one. Measure the valve head thickness T. If the valve head thickness is not within the specified value, replace the value with a new one.
  • Page 68 3-28 ENGINE • Re-finish the valve guide holes in the cylinder head with the reamer and handle.  09916-34561: Valve guide reamer (11.3 mm) 09916-34542: Reamer handle • Install a ring onto each valve guide. Be sure to use new rings. •...
  • Page 69 ENGINE 3-29 VALVE SEAT SERVICING The valve seats for intake and exhaust valves are machined to two different angles. The seat contact surface is cut at 45°. INTAKE EXHAUST 15° N-212 N-121 Valve seat 45° N-608 N-122 NOTE: The valve seat contact area must be inspected after each cut. ...
  • Page 70 3-30 ENGINE TOP NARROWING CUT The contact area too high and too • If the contact area W is too high on the valve, or if it is too wide on face of valve wide, use the 15° cutter to lower and narrow the contact area. FINAL SEAT CUT The contact area too low and too •...
  • Page 71 ENGINE 3-31 • After the desired seat position and width is achieved, use the 45° cutter very lightly to clean up any burrs caused by the pre- vious cutting operations.  Do not use lapping compound after the final cut is made.
  • Page 72 3-32 ENGINE  Valve spring free length (IN & EX) 236 – 287 N Service Limit : 41.0 mm (1.63 in)  Valve spring tension (IN & EX) 36.8 mm Standard: 236 – 287 N/36.8 mm (24.1 – 29.3 kgf/36.8 mm, 53.1 –...

  • Page 73: Camshaft

    To properly measure the oil clearance with plastigauge, all gas- ket material must be removed from fitting surfaces of cylinder head and cover. Do not apply SUZUKI BOND “1216B” until after the oil clearance has been determined. • Tighten the cylinder head cover bolts evenly and diagonally to the specified torque.

  • Page 74: Cam Chain Tension Adjuster

    3-34 ENGINE If the camshaft journal oil clearance measured exceeds the limit, measure the outside diameter of camshaft. Replace either the cylinder head set or the camshaft if the clear- ance is incorrect.  Camshaft journal O.D. Standard: 21.959 – 21.976 mm (0.8645 –...

  • Page 75: Cylinder

    ENGINE 3-35 CYLINDER CYLINDER DISTORTION Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance reading at several places as indicated. If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder. ...

  • Page 76: Piston Ring Groove Width

    3-36 ENGINE PISTON RING TO GROOVE CLEARANCE Using a thickness gauge, measure the side clearances of the 1st and 2nd rings. If any of the clearances exceeds the limit, replace both piston and piston rings.  Piston ring to groove clearance Service Limit (1st) : 0.18 mm (0.0071 in) (2nd): 0.15 mm (0.0059 in) ...
  • Page 77 ENGINE 3-37 Oversize piston ring The following oversize piston rings are used. They bear the fol- lowing identification numbers. SIZE 0.5 mm O.S. 0.5 mm O.S. Oversize oil ring The following oversize oil ring is available as optional parts. They bear the following identification mark. SIZE COLOR 0.5 mm O.S.

  • Page 78: Conrod/Crankshaft

    3-38 ENGINE CONROD/CRANKSHAFT CONROD SMALL END I.D. Using a caliper gauge, measure the conrod small end inside diameter.  Conrod small end I.D. Service Limit: 16.040 mm (0.6315 in)  09900-20605: Dial calipers (10 – 34 mm) 09900-22401: Small bore gauge (10 – 18 mm) If the conrod small end inside diameter exceeds the above men- tioned limit, replace the conrod.

  • Page 79: Clutch

    ENGINE 3-39 CLUTCH CLUTCH DRIVE PLATES NOTE: Wipe off engine oil from the clutch drive plates with a clean rag. • Measure the thickness of drive plates with a vernier calipers. • If each drive plate is not within the standard range, replace it with a new one.
  • Page 80 3-40 ENGINE CLUTCH SHOES Inspect the clutch shoes for chips, cracks, uneven wear, and heat discoloration. Also, check the depth of the grooves on the clutch shoes. If there is no groove at any part of the shoes, replace the shoes as a set. NOTE: The clutch shoes must always be changed as a set.
  • Page 81 ENGINE 3-41 • Apply THREAD LOCK SUPER “1303” to the bolts, and then tighten them to the specified torque with a offset wrench.  Starter clutch bolt: 26 N·m (2.6 kgf-m, 19.0 lb-ft)  99000-32030: THREAD LOCK SUPER “1303”  09930-44520: Rotor holder •...

  • Page 82: Transmission

    3-42 ENGINE TRANSMISSION DISASSEMBLY • Insert the special tool between the 2nd drive gear and 4th drive gear. • Remove the 2nd drive gear by a hydraulic press.  09950-81910: Remover • Disassemble the transmission as shown. 1 Reverse driven gear 2 Reverse gear dog 3 1st driven gear 4 5th driven gear...
  • Page 83 ENGINE 3-43 REASSEMBLY Assemble the transfer in the reverse order of disassembly. Pay attention to the following points: NOTE: * Always use new snap rings. * Before installing the gears, coat lightly engine oil to the shafts and gears.  * Never reuse a snap ring.
  • Page 84 3-44 ENGINE • When installing the bushings, align the shaft hole with the bushing hole.

  • Page 85: Gearshift Fork

    ENGINE 3-45 GEARSHIFT FORK SHIFT FORK TO GROOVE CLEARANCE Using a thickness gauge, check the shifting fork clearance in the groove of its gear. The clearance for each of the three shifting forks plays an impor- tant role in the smoothness and positiveness of shifting action. If the clearance exceeds the limit, replace the fork or its gear, or both.

  • Page 86: Generator Cover

    3-46 ENGINE GENERATOR COVER DISASSEMBLY • Remove the generator stator. • Remove the oil seal. REASSEMBLY • Install the oil seal with the special tool.  Replace the removed oil seal with a new one. • Install the generator stator.

  • Page 87: Clutch Cover

    ENGINE 3-47 CLUTCH COVER DISASSEMBLY • Remove the clutch release outer guide. • Remove the bearing with the special tool.  09921-20240: Bearing remover set NOTE: If there is no abnormal noise, the bearing removal is not neces- sary. INSPECTION Rotate the balls by hand to inspect for an abnormal noise and a smooth rotation.

  • Page 88: Crankcase

    3-48 ENGINE CRANKCASE Play Play BEARING INSPECTION Rotate the bearing inner race by finger to inspect for abnormal play, noise and smooth rotation while the bearings are in the crankcase. Replace the bearing in the following procedure if there is any- thing unusual.
  • Page 89 THREAD LOCK to the screws.  09900-32050: THREAD LOCK “1342” OIL SEAL • Remove the oil seal. • Apply SUZUKI SUPER GREASE “A” to the oil seal.  Replace the removed oil seal with a new one.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A”...

  • Page 90: Crankshaft

    3-50 ENGINE CRANKSHAFT DISASSEMBLY Crankshaft (R) Crank Pin " Bearing Conrod Crankshaft (L) REASSEMBLY • Determine the width between the webs referring to the figure when rebuilding the crankshaft.  Crank web to web width Standard: 53.0 ± 0.1mm (2.087 ± 0.004 in)

  • Page 91: Recoil Starter

    ENGINE 3-51 RECOIL STARTER 1 Ratchet set 2 Reel 3 Spiral spring 4 Rope assembly DISASSEMBLY • After removing the nut 1, take out the recoil starter related parts from the housing. 1 Nut 6 Spring 2 Friction plate 7 Spacer 3 Ratchet guide 8 Pin 4 Ratchet...
  • Page 92 Wear hand and eye protection when installing the reel, since the spring may quickly unwind and cause an injury. • Apply SUZUKI SUPER GREASE “A” to the spiral spring.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) •...
  • Page 93 ENGINE 3-53 • Pull the rope and check that the ratchet is pushed out.

  • Page 94: Drive Train

    3-54 ENGINE DRIVE TRAIN SECONDARY BEVEL GEARS CONSTRUCTION 1 Bearing 2 Shim 3 Secondary bevel drive gear 4 Washer 5 Washer 6 Secondary bevel driven gear 7 Shim 8 Bearing 9 Secondary bevel gear shaft 0 Bearing A Oil seal B O-ring C Water proof cover D Snap ring...
  • Page 95 ENGINE 3-55 SECONDARY DRIVEN BEVEL GEAR REMOVAL The following components must be removed in the described order before removing the secondary driven bevel gear. NOTE: Refer to the following pages for the details of each step. • Remove the rear wheel. (7-10) •...
  • Page 96 3-56 ENGINE INSPECTION Inspect the removed parts for the following abnormalities. * Drive and driven bevel gears damage or wear * Improper tooth contact * Abnormal noise of bearings * Bearing damage or wear * Oil seal damage or wear SECONDARY DRIVEN BEVEL GEAR REASSEMBLY •...
  • Page 97 • Apply grease to the seal lip groove and install it.  99000-25160: WATER RESISTANCE GREASE  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Apply grease to the O-ring and install the water proof cover.

  • Page 98: Secondary Gear Shims Adjustment

    3-58 ENGINE SECONDARY GEAR SHIMS ADJUSTMENT • Remove the secondary bevel gear cover. • Hold the bearings with the special tool.  09921-21910: Bearing holder • Set a dial gauge on the driven bevel gear as shown. For driven bevel gear ( 3-60) Measure the backlash by turning the driven bevel gear shaft in each direction, reading the total backlash on the dial gauge.
  • Page 99 ENGINE 3-59 TOOTH CONTACT After backlash adjustment is carried out, the tooth contact must be checked. Pay attention to the following procedures: • Remove the driven bevel gear. • Clean and degrease several teeth of the drive and driven bevel gears. •...

  • Page 100: Reassembly Information

    3-60 ENGINE REASSEMBLY INFORMATION List of shims B available for the driven bevel gear side. Shim thickness Part No. 0.60 mm (0.0236 in) 09181-25051 09181-25052 0.65 mm (0.0256 in) 0.70 mm (0.0276 in) 09181-25053 09181-25054 0.75 mm (0.0295 in) 09181-25055 0.80 mm (0.0315 in) 0.85 mm (0.0335 in) 09181-25056...

  • Page 101: Engine Reassembly

    ENGINE 3-61 ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassembly. Pay special attention to the following points: NOTE: Apply engine oil to each running and sliding part before reas- sembling. ENGINE BOTTOM SIDE DRIVE TRAIN • Install the driveshaft and countershaft. •...
  • Page 102 3-62 ENGINE CRANKSHAFT • When mounting the crankshaft in the crankcase, it is neces- sary to pull its left end into the crankcase with the special tool. NOTE: Use the proper bars.  09910-32812: Crankshaft installer • Install the reverse dog and washer 1. •...
  • Page 103 ENGINE 3-63 • Install the transmission related parts. NOTE: Each fork has own embossed letters. 1 05G-1B (For reverse/1st gear) 2 05G-2B (For 2nd/3rd gear) 3 19B-3J (For 4th/5th gear) • Install the reverse idle gear shaft 4. • Install the snap ring 5, washer 6 and spacer 7. ...
  • Page 104 • Fit the dowel pins onto the left half on the crankcase. • Apply engine oil to the conrod big end and gears. • Apply SUZUKI BOND “1207B/1215” to the mating surface of the right crankcase.  99104-31140: SUZUKI BOND “1207B” (USA)
  • Page 105 ENGINE 3-65 • Assemble the crankcase within few minutes. NOTE: Fit the clamp to the bolt A. OIL PUMP • Install the oil pump. • Install the washer 1 and pin 2. • Install the oil pump driven gear by installing the snap ring. OIL PUMP DRIVE GEAR •...
  • Page 106 3-66 ENGINE GEARSHIFT • Install the spring 1, washer 2 and gearshift cam stopper 3. NOTE: Fit the spring end to the stopper properly. • Install the the gearshift cam plate 4. • Apply THREAD LOCK “1342” to the bolt and install the gear- shift cam plate guide.
  • Page 107 ENGINE 3-67 CLUTCH • Install the clutch drive plates and driven plates one by one onto the clutch sleeve hub 1. DRIVE PLATE ...6 pcs DRIVEN PLATE ..5 pcs • Install the clutch pressure plate 2. • Install the washer 3 onto the countershaft. •...
  • Page 108 3-68 ENGINE • Install the washer and clutch sleeve hub nut. NOTE: The convex side of the washer faces outside. INSIDE OUTSIDE Washer • Tighten the clutch sleeve hub nut to the specified torque with the special tool.  Clutch sleeve hub nut: 70 N·m (7.0 kgf-m, 50.5 lb-ft) ...
  • Page 109 ENGINE 3-69 CAM CHAIN • Install the cam chain. GENERATOR • Install the starter driven gear 1. • Install the key 2. NOTE: Degrease the tapered portion of the generator rotor assembly and also the crankshaft. Use nonflammable cleaning solvent to wipe off the oily or greasy matter to make these surfaces com- pletely dry.
  • Page 110 3-70 ENGINE • Install the clutch shoe and washer. • Before installing the clutch shoe nut, apply engine oil to the thread and inside surface of the nut. • Install the clutch shoe nut.  Apply engine oil to the clutch shoe nut. •...
  • Page 111 ENGINE 3-71 • Install the clutch cover. OIL FILTER • Before installing the oil filter, fit the new O-rings and apply engine oil lightly to them. • Install the spring 1 and oil filter.  Use a new O-ring to prevent oil leakage. STARTER IDLE GEAR •...
  • Page 112  99000-31110: SUZUKI BOND “1215” (Others) • Install the secondary bevel gear cover. STARTER CUP • Apply SUZUKI SUPER GREASE “A” to the O-ring and lip of the oil seal. • Install the starter cup.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A”...

  • Page 113: Engine Top Side

    ENGINE 3-73 NEUTRAL SWITCH • Install the springs and switch contacts. • Install the neutral switch. ENGINE TOP SIDE PISTON • Install the piston rings in the order of oil ring, 2nd ring and 1st ring. • The first member to go into the oil ring groove is a spacer 1. After placing the spacer, fit the two side rails 2.
  • Page 114 3-74 ENGINE • Position the gaps of the three rings as shown. Before inserting the piston into the cylinder, check that the gaps are so • 2nd ring located. • Upper side • Lower side rail rail • 1st ring •...
  • Page 115 ENGINE 3-75 • Hold each piston ring with properly position, insert the piston into the cylinder. • Tighten the cylinder base nuts temporarily. NOTE: Fit the clamp to the bolt B.  When installing the cylinder and cylinder head, pull the cam chain upward, or the chain will be caught between the crankcase and cam drive sprocket.
  • Page 116 3-76 ENGINE • Install the cam chain tensioner. CAMSHAFT • Align the line A on the generator rotor with the index mark B on the crankcase.  Pull the cam chain upward, or the chain will be caught between crankcase and cam drive sprocket. •...
  • Page 117 • Clean the mating surface of the cylinder head and head cover before matching. • Install the dowel pins to the cylinder head. • Apply SUZUKI BOND “1216B” to the mating surface of the cylinder head cover. • Fit the camshaft end cap 1.
  • Page 118 3-78 ENGINE 1216 CAM CHAIN TENSION ADJUSTER After removing the spring holder bolt and spring, unlock the ratchet mechanism 1 and push in the push rod 2 all the way. NOTE: Before installing the cam chain tension adjuster, unlock the ratchet mechanism 1 and move the push rod 2 in place to see if it slides smoothly.
  • Page 119 ENGINE 3-79 • Apply grease to the new O-rings and install the valve inspec- tion caps.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the valve timing inspection plug. RECOIL STARTER • Apply a small quantity of THREAD LOCK “1342” to the bolts.
  • Page 120 • Tighten the locknut 4 by holding the adjuster.  Locknut 4: 23 N·m (2.3 kgf-m, 16.5 lb-ft) • Apply SUZUKI SUPER GREASE “A” to the O-ring and install the clutch adjuster cap.  99000-25030: SUZUKI SUPER GREASE “A” (USA)
  • Page 121 DRIVE TRAIN 4-1 DRIVE TRAIN CONTENTS REAR DRIVING SYSTEM ..............4- 2 REAR DRIVE REMOVAL .............4- 3 REAR DRIVE DISASSEMBLY .............4- 5 REAR DRIVE INSPECTION ............4- 9 REAR DRIVE REASSEMBLY ............4-11 REAR DRIVE INSTALLATION ............4-16 SHIM ADJUSTMENT ..............4-18 REASSEMBLY INFORMATION ..........4-21...

  • Page 122: Rear Driving System

    4-2 DRIVE TRAIN REAR DRIVING SYSTEM 1 Rear drive gear case cover 2 Shim, LH 3 Bevel ring gear 4 Shim, RH 5 Rear drive gear case 6 Shim 7 Bevel pinion gear 8 Pinion gear shaft coupling joint 9 Propeller shaft 0 Universal joint...

  • Page 123: Rear Drive Removal

    DRIVE TRAIN 4-3 REAR DRIVE REMOVAL • Remove the rear wheels. (7-10) • Disconnect the rear brake cables and brake drum air vent hose. • Remove the left wheel hub. (7-11) • Remove the rear drive gear case under cover. •...
  • Page 124 4-4 DRIVE TRAIN • Remove the rear drive gear case together with the propeller shaft. • Remove the propeller shaft from the rear drive gear case. • Remove the axle housing bolts and nuts. • Remove the rear axle together with the axle housing.

  • Page 125: Rear Drive Disassembly

    DRIVE TRAIN 4-5 REAR DRIVE DISASSEMBLY REAR DRIVE GEAR CASE • Remove the rear drive gear case cover bolts diagonally and evenly. • Pry the cover at the arrows as shown by tapping with a plastic mallet. • Remove the ring gear and shims. •...
  • Page 126 4-6 DRIVE TRAIN • Remove the bearing and oil seal out of the cover with a suit- able tool. NOTE: If there is no abnormal condition, the bearing/oil seal removal is not necessary.  The removed bearing and oil seal must be replaced with the new ones.
  • Page 127 DRIVE TRAIN 4-7 • Unstake the bearing locknut with a small chisel or drill. • Remove the bearing locknut with the special tool.  09921-21820: Bearing lock nut wrench  The removed locknut must be replaced with a new one. •...
  • Page 128 4-8 DRIVE TRAIN • Remove the pinion gear pilot bearing with the special tools.  09921-20210: Bearing puller 09930-30104: Sliding shaft NOTE: If there is no abnormal condition, the bearing removal is not nec- essary.  The removed bearing must be replaced with a new one.

  • Page 129: Rear Drive Inspection

    DRIVE TRAIN 4-9 REAR DRIVE INSPECTION PROPELLER SHAFT Inspect the splines of the propeller shaft for wear or damage. Also, inspect the boot for cuts or damage. If any defects are found, replace the propeller shaft and its boot with the new ones. UNIVERSAL JOINT Inspect the universal joint and outer surface of the bearing for scuffing, wear and damage.
  • Page 130 4-10 DRIVE TRAIN Check the outer race play and smooth rotation of the bearing by hand while it is on the pinion gear shaft. Inspect the pinion gear for wear or damage. If the pinion gear is damaged, inspect the ring gear also. If any defects are found, replace the bearing and gear with the new ones.

  • Page 131: Rear Drive Reassembly

    • Apply grease to the new oil seal lips.  09913-70210: Bearing installer set  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) NOTE: The marked side on the oil seal should be positioned outside.
  • Page 132 • Fix the bearing race with the snap ring. • Apply grease to the bearing.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the new dust seal with the special tool and then apply grease to the seal lip.
  • Page 133 • Install the new oil seal to the gear case with the special tool. • Apply grease to the new oil seal lip groove.  09913-85210: Bearing/oil seal installer  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) NOTE: After the backlash and tooth contact have been checked or adjusted, install the oil seal.
  • Page 134 • Apply grease to the splines of the pinion gear shaft and install the pinion gear shaft coupling joint by tapping with a plastic mallet.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Apply 4 – 5 gram of water resistance grease to the outside of seal lip groove.
  • Page 135 DRIVE TRAIN 4-15 UNIVERSAL JOINT • Apply grease to the bearing and its dust seal lip.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the universal joint and bearings with the special tool.

  • Page 136: Rear Drive Installation

    • Coat a new O-ring with grease and install it into the groove in the gear case.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Apply grease to the splines of the axle.
  • Page 137 DRIVE TRAIN 4-17 • Tighten the axle housing mounting bolts to the specified torque.  Axle housing mounting bolt: 60 N·m (6.0 kgf-m, 43.5 lb-ft) • Tighten the shock absorber mounting bolt to the specified torque.  Shock absorber mounting bolt: 50 N·m (5.0 kgf-m, 36.0 lb-ft) •...

  • Page 138: Shim Adjustment

    4-18 DRIVE TRAIN SHIM ADJUSTMENT BACKLASH • Install the pinion gear assembly, removed shim and new bearing locknut. (4-13) • Tighten the bearing locknut to the specified torque. (4-13) NOTE: At this time, it is not necessary to stake the bearing locknut. (4-13) •...
  • Page 139 DRIVE TRAIN 4-19 • Install the gear case cover and tighten its bolts to the speci- fied torque in a crisscross pattern. (4-14) NOTE: * Do not install the new O-ring to the gear case cover at this time. * Do not apply a thread lock to the case cover bolts at this time. ...
  • Page 140 4-20 DRIVE TRAIN TOOTH CONTACT After backlash adjustment and left shim selection are carried out, the tooth contact must be checked. Pay attention to the fol- lowing procedures: • Remove the ring gear. • Clean and degrease several teeth on the ring gear and pinion Incorrect gear, and then apply a coating of machinist’s layout dye or paste to several teeth of the pinion gear.

  • Page 141: Reassembly Information

    DRIVE TRAIN 4-21 REASSEMBLY INFORMATION 4 – 5 gram 100 N . m (10.0 kgf . m, 72.5 lb-ft) Pinion gear shim Left side of ring gear shim Right side of ring gear shim 27 N·m (2.7 kgf-m, 19.5 lb-ft) 25 N·m (2.5 kgf-m, 18.0 lb-ft) Mating surfaces...
  • Page 142 4-22 DRIVE TRAIN...
  • Page 143 FUEL SYSTEM 5-1 FUEL SYSTEM CONTENTS FUEL TANK ..................5- 2 CONSTRUCTION .................5- 2 FUEL LINE INSPECTION ............5- 3 REMOUNTING ................5- 3 FUEL VALVE ..................5- 4 REMOVAL AND INSPECTION ............5- 4 FUEL STRAINER .................5- 4 REMOUNTING ................5- 4 CARBURETOR ...................5- 5 CONSTRUCTION .................5- 5 SPECIFICATIONS ...............5- 6 I.D.

  • Page 144: Fuel Tank

    5-2 FUEL SYSTEM FUEL TANK CONSTRUCTION 1 Fuel tank 2 Fuel cap 3 Breather hose 4 Gasket 5 Seal washer 6 Fuel valve 7 Fuel hose...

  • Page 145: Fuel Line Inspection

    FUEL SYSTEM 5-3 FUEL LINE INSPECTION Inspect the fuel lines, fuel tank and fuel tank cap for damage and fuel leakage. If any damages are found, replace the defective parts with the new ones. • Remove the front fender. (7-5) •...

  • Page 146: Fuel Valve

    5-4 FUEL SYSTEM FUEL VALVE REMOVAL AND INSPECTION • Remove the fuel tank. (5-3) • Remove the fuel valve.  Gasoline is highly flammable and explosive. Keep heat, sparks and flames away from gasoline. FUEL STRAINER If the fuel strainer is dirty with sediment or rust, fuel will not flow smoothly and loss in engine power may result.

  • Page 147: Carburetor

    FUEL SYSTEM 5-5 CARBURETOR CONSTRUCTION 1 Diaphragm K Spring 2 Air vent hose L Holder 3 Ring M Cap 4 Piston valve N Pilot jet 5 Air jet O Needle jet 6 Throttle lever cap 7 O-ring 8 Top cover 9 Spring 0 Stopper plate A Spring...

  • Page 148: Specifications

    5-6 FUEL SYSTEM SPECIFICATIONS SPECIFICATION ITEM E-03, 24, 28 E-17 E-33 ← ← Carburetor type MIKUNI BS29 ← ← Bore size 29 mm I.D. No. 05G0 05G2 05G1 ← ← Idle r/min 1 500 ± 100 r/min Float height 17.1± 1.0 mm ←...

  • Page 149: Removal

    FUEL SYSTEM 5-7 REMOVAL • Remove the fuel tank side covers. (7-5) • Disconnect the fueI hose 1 and vacuum hose 2. • Loosen the carburetor clamp screws • Remove the carburetor side cap 3. • Remove the O-ring 4. •...

  • Page 150: Disassembly

    5-8 FUEL SYSTEM DISASSEMBLY • Remove the fuel hose 1, air vent hose 2 and vacuum hose • Remove the coasting enrichment valve cover 4, spring 5. • Remove the coasting enrichment valve 6. • Remove the carburetor top cap. ...
  • Page 151 FUEL SYSTEM 5-9 • Remove the stopper plate 1. • Remove the following parts. 2 Jet needle 3 Washer 4 Spring • Remove the diaphragm by removing the ring 5 . • Remove the throttle stop screw holder 6. • Remove the float chamber 7. •...
  • Page 152 5-10 FUEL SYSTEM • Remove the O-ring 1.  Replace the removed O-ring with a new one to prevent fuel leakage. • Remove the float pin 2, float 3 and needle valve 4. • Remove the following parts. 1 Main jet 2 Needle jet holder, O-ring and needle jet 3 Pilot jet 4 Pilot screw...
  • Page 153 FUEL SYSTEM 5-11 PILOT SCREW REMOVAL (For E-33) Because harsh cleaning solvents can damage the O-ring seals in the pilot system, the pilot system components should be removed before cleaning. • Use a 1/8" size drill bit with a drill-stop to remove the pilot screw plug.

  • Page 154: Cleaning

    5-12 FUEL SYSTEM CLEANING  Some carburetor cleaning chemicals, especially dip- type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical man- ufacturer’s instructions on proper use, handling and storage. • Clean all jets with a spray-type carburetor cleaner and dry them using compressed air.

  • Page 155: Inspection

    FUEL SYSTEM 5-13 INSPECTION Check the following items for any damage or clogging. If any damages are found, replace the damaged parts with new ones. * Pilot jet * Valve seat * Main jet * Piston valve * PiIot air jet * Starter jet * Needle jet air bleeding hole * O-ring * Float...

  • Page 156: Reassembly

    5-14 FUEL SYSTEM REASSEMBLY Reassemble the carburetor in the reverse order of disassembly. Pay attention to the following points: NEEDLE JET • Install the needle jet with the bigger I.D. portion of the needle jet facing upward. PILOT SCREW • After cleaning, install the pilot screw 1 to the original setting by turning the screw in until it lightly seats, and then backing it out the same number of turns counted during disassembly.
  • Page 157 E on the piston vaIve faces the air cIeaner box. THROTTLE STOP SCREW • Apply the SUZUKI SUPER GREASE “A” to thread part of the throttle stop screw, then install the throttle stop screw to the carburetor.

  • Page 158: Remounting

    5-16 FUEL SYSTEM REMOUNTING Remount the carburetor assembly in the reverse order of removal. Pay attention to the following points: • Align the lug on the carburetor with the intake pipe’s cutout. • Make sure that the carburetor hoses are routed properly. (9-17) After the carburetor assembly has been remounted onto the engine perform the following adjustments:...

  • Page 159: Lubrication System

    LUBRICATION SYSTEM LUBRICATION SYSTEM CONTENTS LUBRICATION SYSTEM ..............6- 2 ENGINE LUBRICATION CIRCUIT ..........6- 2 ENGINE LUBRICATION FLOW CHART ........6- 4 OIL PRESSURE ..................6- 5 OIL FILTER ..................6- 5 OIL STRAINER ...................6- 5 OIL PUMP ...................6- 5...
  • Page 160 6-2 LUBRICATION SYSTEM LUBRICATION SYSTEM ENGINE LUBRICATION CIRCUIT OIL PUMP OIL FILTER LUBRICATION OIL RETURNED OIL...
  • Page 161 LUBRICATION SYSTEM 6-3 EXHAUST SIDE INTAKE SIDE LUBRICATION OIL RETURNED OIL...
  • Page 162 6-4 LUBRICATION SYSTEM ENGINE LUBRICATION FLOW CHART...
  • Page 163 LUBRICATION SYSTEM 6-5 OIL PRESSURE (2-23) OIL FILTER (2-9) OIL STRAINER (3-21, 63, 64) OIL PUMP (3-20, 3-65)
  • Page 164  ...
  • Page 165 CHASSIS 7-1 CHASSIS CONTENTS EXTERIOR PARTS ........................7- 2 CONSTRUCTION ......................7- 2 REMOVAL ........................7- 4 REMOUNTING ........................7- 9 FRONT AND REAR WHEELS ....................7-10 CONSTRUCTION ......................7-10 REMOVAL ........................7-10 INSPECTION AND DISASSEMBLY ................7-11 REMOUNTING AND REMOUNTING ................7-12 TIRES ............................

  • Page 166: Exterior Parts

    7-2 CHASSIS EXTERIOR PARTS CONSTRUCTION 1 Front carrier 2 Front fender 3 Fuel tank side cover 4 Front inner fender 5 Front grip bar 6 Center cover 7 Seat...
  • Page 167 CHASSIS 7-3 1 Rear carrier 2 Rear fender 3 Footrest mud guard 4 Footrest ITEM N·m kgf-m lb-ft 40.0 19.0 20.5 40.0...

  • Page 168: Removal

    7-4 CHASSIS REMOVAL SEAT • Remove the seat by pulling the lever. FRONT CARRIER • Remove the front carrier 1. FRONT GRIP BAR • Remove the bolts. • Remove the front grip bar 1.
  • Page 169 CHASSIS 7-5 FUEL TANK SIDE COVER • Remove the seat. (7-4) • Remove the fuel tank side covers by removing the fasteners. FRONT FENDER • Remove the seat. (7-4) • Remove the fuel tank side covers. (See above) • Remove the fasteners which connect the front fender and mud guard.
  • Page 170 7-6 CHASSIS • Remove the front inner fenders. • Disconnect the headlight couplers. • Remove the fasteners. • Remove the fuel tank cap. • Remove the front fender. NOTE: When removing the front fender, take the front fender backward with the forehead of the front fender opened out. •...
  • Page 171 CHASSIS 7-7 FOOTREST MUD GUARD • Remove the fuel tank side cover. (7-5) • Remove the footrest mud guard 1. NOTE: The fastener A on the rear fender consists of screw, washer and nut. FOOTREST • Remove the seat. (7-4) •...
  • Page 172 7-8 CHASSIS REAR FENDER • Remove the seat. (7-4) • Remove the fuel tank side covers. (7-5) • Remove the rear carrier. (7-7) • Remove the battery 1. • Remove the rear fender mounting bolts. • Disconnect the CDI unit coupler. •...

  • Page 173: Remounting

    CHASSIS 7-9 REMOUNTING Remount the exterior parts in the reverse order of removal. Pay attention to the following points: REAR CARRIER • Apply THREAD LOCK SUPER “1303” and “1322” to the rear carrier mounting bolts 1.  99000-32030: THREAD LOCK SUPER “1303” (USA) ...

  • Page 174: Front And Rear Wheels

    7-10 CHASSIS FRONT AND REAR WHEELS CONSTRUCTION 1 Front brake disc 2 Dust seal 3 Bearing 4 Spacer 5 Wheel hub 6 Bearing 7 Dust seal A Front brake disc bolt B Wheel set nut C Front wheel hub nut D Rear wheel hub nut ITEM N·m...

  • Page 175: Inspection And Disassembly

    CHASSIS 7-11 REAR WHEEL HUB • Remove the rear wheel. (7-10) • Remove the cotter pin and loosen the wheel hub nut by apply- ing the rear brake. • Remove the wheel hub nut and washer and then remove the wheel hub 1.

  • Page 176: Remounting And Remounting

    When installing each wheel, make sure the arrow A on the tire points in the direction of rotation. FRONT WHEEL HUB • Apply SUZUKI SUPER GREASE “A” to the hub bearing and the lip of the dust seals before installing them.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A”...
  • Page 177 • Install the dust seals 1 into the front wheel hub with stamped mark facing to outside by using the special tool.  09913-70210: Bearing installer set • Apply SUZUKI SUPER GREASE “A” to the dust seal’s lip.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) •...
  • Page 178 7-14 CHASSIS REAR WHEEL HUB • Apply small amount of SUZUKI SUPER GREASE “A” to the left wheel hub’s spline.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)  Do not apply grease to the right wheel hub.

  • Page 179: Tires

    CHASSIS 7-15 TIRES TIRE REPLACEMENT • Remove the front and rear wheels. (7-10) • After removing the air valve cap, release the tire pressure by depressing the valve. • Dismount the bead from the rim completely as shown. • Separate the tire from the rim by using a set of tire levers and rim protectors.
  • Page 180 7-16 CHASSIS • When installing each tire, make sure the arrow A on the tire points in the direction of rotation. Also, make sure the outer side of the wheel rim is facing outward. NOTE: For inspecting the tire refer to page 2-15. Inspect the valve core, before installation.

  • Page 181: Front Brake

    CHASSIS 7-17 FRONT BRAKE CONSTRUCTION 1 Master cylinder reservior cap A Master cylinder mounting bolt 2 Diaphragm B Brake hose union bolt 3 Master cylinder clamp C Air bleeder valve 4 Boot D Brake caliper mounting bolt 5 Piston/cup set E Brake pad mounting pin 6 Cup F Caliper holder pin...

  • Page 182: Brake Pad Replacement

    7-18 CHASSIS BRAKE PAD REPLACEMENT • Remove the front wheel. (7-10) • Remove the brake caliper mounting bolts 1 and brake pad mounting pins 2. • Remove the brake pads.  * Do not operate the brake lever during or after brake pad removal.

  • Page 183: Brake Fluid Replacement

    CHASSIS 7-19 BRAKE FLUID REPLACEMENT • Place the vehicle on a level surface and keep the handlebar straight. • Remove the master cylinder reservoir cap and diaphragm. • Suck up the old brake fluid as much as possible. • Fill the reservoir with new brake fluid. ...
  • Page 184 7-20 CHASSIS • Remove the spring 1. • Place a rag over the brake caliper piston to prevent the piston from popping out and then force out the piston using com- pressed air.  Do not use high pressure air to prevent brake caliper piston damage.

  • Page 185: Brake Caliper Inspection

    CHASSIS 7-21 BRAKE CALIPER INSPECTION BRAKE CALIPER Inspect the brake caliper cylinder wall for nicks, scratches or other damage. If any damages are found, replace the brake cal- iper with a new one. BRAKE CALIPER PISTON Inspect the brake caliper piston for any scratches or other dam- age.

  • Page 186: Brake Caliper Reassembly And Remounting

    • Tighten the pin 2 to the caliper holder 1 to the specified torque.  Caliper holder pin: 18 N·m (1.8 kgf-m, 13.0 lb-ft) • Apply SUZUKI SILICONE GREASE to the brake caliper holder pin 2.  99000-25100: SUZUKI SILICONE GREASE...
  • Page 187 CHASSIS 7-23 • Apply SUZUKI SILICONE GREASE to the brake caliper holder slide pin.  99000-25100: SUZUKI SILICONE GREASE • Install the pin 1, washer 2 and caliper holder 3 to the cali- per. • Apply THREAD LOCK SUPER “1360” to the pin 1.

  • Page 188: Brake Disc Removal And Disassembly

    7-24 CHASSIS BRAKE DISC REMOVAL AND DISASSEMBLY • Remove the front wheel. (7-10) • Remove the front wheel hub. (7-10) • Remove the brake disc. BRAKE DISC INSPECTION • Remove the front wheel. (7-10) • Remove the caliper. (7-19) Inspect the brake disc for cracks or damage and measure the thickness using the micrometer.

  • Page 189: Master Cylinder Removal And Disassembly

    CHASSIS 7-25 MASTER CYLINDER REMOVAL AND DISASSEMBLY • Place a rag underneath the brake hose union bolt on the mas- ter cylinder to catch any spilt brake fluid. Remove the brake hose union bolt and disconnect the brake hose.  Immediately wipe off any brake fluid contacting any part of the vehicle.

  • Page 190: Master Cylinder Inspection

    7-26 CHASSIS • Remove the piston/secondary cup, primary cup and spring. 7 Secondary cup 8 Piston 9 Primary cup 0 Spring MASTER CYLINDER INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or damage. If any damages are found, replace the master cylinder with a new one.
  • Page 191 CHASSIS 7-27 • Align the master cylinder holder’s mating surface 1 with the punched mark 2 on the handlebars and tighten the upper clamp bolt first.  Master cylinder clamp bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) A Master cylinder B Master cylinder upper clamp bolt C Handlebar D Clearance...

  • Page 192: Front Suspension

    7-28 CHASSIS FRONT SUSPENSION CONSTRUCTION 1 Front shock absorber 2 Upper wishbone arm 3 Bushing 4 Lower wishbone arm 5 Steering knuckle 6 Snap ring 7 Knuckle end A Shock absorber mounting upper nut B Shock absorber mounting lower bolt C Wishbone arm pivot nut D Steering knuckle nut E Tie rod end nut...

  • Page 193: Removal And Disassembly

    CHASSIS 7-29 REMOVAL AND DISASSEMBLY • Remove the wheel hub. (7-10) • Remove the brake hose clamp 1. • Disconnect the brake hose at the hose clamp. • Remove the front disc cover 2. • Remove the cotter pin and tie rod end nut. ...

  • Page 194: Inspection

    7-30 CHASSIS • Remove the cotter pins and nuts. • Remove the steering knuckle 1 with a commercially available ball bearing joint remover 2. INSPECTION FRONT SHOCK ABSORBER Inspect the shock absorber for oil leakage or damage. If any damages are found, replace the front shock absorber with a new one.
  • Page 195 CHASSIS 7-31 KNUCKLE END Inspect the knuckle end boot for wear or damage. If any dam- ages are found, replace the knuckle end with a new one. Inspect the knucle end for smooth movement. If there are any abnormalities, replace the tie rod end with a new one. •...

  • Page 196: Reassembly And Remounting

    7-32 CHASSIS BRAKE DISC COVER Inspect the brake disc cover for damage. If any damages are found, replace the brake disc cover with a new one. REASSEMBLY AND REMOUNTING Reassemble and remount the front suspension in the reverse order of removal and disassembly. Pay attention to the following points: •...
  • Page 197 CHASSIS 7-33 • Degrease the tapered portion of knuckle and also knuckle end with nonflammable cleaning solvent. • Install the wishbone arms to the knuckle and tigten the knuckle nuts to the specified torque.  Knuckle nut: 45 N·m (4.5 kgf-m, 32.5 lb-ft) •...
  • Page 198 7-34 CHASSIS • Tighten the tie rod end nut to the specified torque.  Tie rod end nut: 35 N·m (3.5 kgf-m, 25.5 lb-ft) • Install the cotter pin.  Replace the removed cotter pin with a new one.

  • Page 199: Steering

    CHASSIS 7-35 STEERING CONSTRUCTION 1 Steering head cover 2 Handlebars 3 Handlebar upper clamp 4 Handlebar lower clamp 5 Brake cable guide 6 Steering shaft holder 7 Steering shaft 8 Dust seal 9 Bushing 0 Dust seal A O-ring B Dust seal C Tie rod D Tie rod end A Handlebar clamp bolt...

  • Page 200: Removal

    7-36 CHASSIS REMOVAL • Remove the front fender and center cover. (7-5) • Remove the master cylinder assembly from the handlebars. (7-25) • Remove the throttle lever case 1. • Disconnect the rear brake cable 2 and remove the handlebar switch 3.
  • Page 201 CHASSIS 7-37 • Remove the cotter pins and tie rod end nuts.  Replace the removed cotter pins with new ones. • Remove the cotter pin and steering shaft nut 1, washer 2 and dust seal 3.  Replace the removed cotter pins with new ones. •...

  • Page 202: Inspection And Disassembly

    7-38 CHASSIS • Remove the steering shaft 1. • Remove the dust seals 2 from the steering shaft. • Remove the steering shaft holder half 3. • Remove the steering shaft. • Remove the dust seal 4 from the steering shaft. INSPECTION AND DISASSEMBLY Inspect the removed parts for the following abnormalities.
  • Page 203 CHASSIS 7-39 TIE ROD END Inspect the tie rod ends for smooth movement. If there are any abnormalities, replace the tie rod end with a new one. Inspect the tie rod end boot for wear or damage. If any damages are found, replace the tie rod end with a new one.

  • Page 204: Reassembly And Remounting

    Pay attention to the following points: STEERING SHAFT • Apply SUZUKI SUPER GREASE “A” to the O-ring, dust seals and steering shaft before remounting the steering shaft.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) •...
  • Page 205 CHASSIS 7-41 • Apply SUZUKI SUPER GREASE “A” to the steering shaft holders and dust seals before remounting the steering shaft holders.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)  To prevent the entry of dirt, the dust seal end A must face forward when installed to the steering shaft.
  • Page 206 7-42 CHASSIS HANDLEBARS When installing the lower handlebar holder 1 to the steering shaft, the higher mating portion must face to forward. • Set the handlebars to match its punched mark 2 to the mat- ing face of the handlebar clamps. •...

  • Page 207: Toe-In Adjustment

    CHASSIS 7-43 TOE-IN ADJUSTMENT Adjust the toe-in as follows: • Place the vehicle on level ground and set the handlebars straight. Make sure all the tires are inflated to the standard pressure. (2-15) • Place 75 kg (165 lbs) of weight on the seat. Forward •...

  • Page 208: Front Wheel, Front Brake, Front Suspension And Steering Reassembling Information

    7-44 CHASSIS FRONT WHEEL, FRONT BRAKE, FRONT SUSPENSION AND STEERING REASSEMBLING INFORMATION...

  • Page 209: Rear Brake

    CHASSIS 7-45 REAR BRAKE CONSTRUCTION 1 Dust seal 7 Bearing A Brake panel bolt 2 Drum cover 8 Brake camshaft B Brake cam lever nut 3 Brake drum 9 O-ring 4 Brake shoe 0 O-ring 5 O-ring A Brake panel 6 Snap ring B Brake cam lever ITEM...

  • Page 210: Removal And Disassembly

    7-46 CHASSIS REMOVAL AND DISASSEMBLY • Remove the rear wheel. (7-10) • Remove the rear hub. (7-11) • Disconnect the brake cables. • Remove the drum cover bolts. • Remove the drum cover 1 by using the slotted screwdriver. • Remove the brake drum 2. •...
  • Page 211 CHASSIS 7-47 • Remove the O-ring 1. • Disconnect the brake breather hose 2. • Remove the brake panel. • Remove the O-ring 3. • Remove the brake cam lever 4. • Remove the washer 5 and spring 6. • Remove the brake camshaft 7 and O-rings 8 from the brake panel.

  • Page 212: Inspection

    7-48 CHASSIS INSPECTION BRAKE DRUM Measure the brake drum I.D. to determine the extent of wear. If the measurement value exceeds the service limit, replace the brake drum with a new one.  Brake drum I.D. Service Limit: 140.7 mm (5.54 in) BRAKE SHOE Inspect the brake shoes for wear or damage.

  • Page 213: Reassembly And Remounting

    REASSEMBLY AND REMOUNTING • Install the new dust seal 2 to the drum cover 3 by using the removed dust seal 1. • Apply SUZUKI SILICONE GREASE to the dust seal lips. Dust seal  99000-25100: SUZUKI SILICONE GREASE Drum cover...
  • Page 214 7-50 CHASSIS • Apply SUZUKI SUPER GREASE “A” to the O-rings and brake camshaft. • Install the new O-rings and brake camshaft to the anchor panel.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) ...
  • Page 215 • Install the new O-ring to the brake panel.  Replace the removed O-ring with a new one. • Apply SUZUKI SUPER GREASE “A” to the anchor pin and brake camshaft sliding surface lightly.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A”...
  • Page 216 7-52 CHASSIS • Install the brake drum.  Do not apply grease to the spline portion of brake drum. NOTE: Before installing the brake drum, make sure that the brake drum is clean and free of any greasey matter. • Install the drum cover and tighten the bolts. NOTE: When installing the drum cover, make sure that the O-ring must be fitted into the groove on the brake panel securely.

  • Page 217: Rear Suspension

    CHASSIS 7-53 REAR SUSPENSION CONSTRUCTION 1 Rear shock absorber 2 Swingarm 3 Bushing A Rear shock absorber mounting upper bolt B Rear shock absorber mounting lower nut C Swingarm pivot nut ITEM N·m kgf-m lb-ft 40.0 41.0 61.5...

  • Page 218: Removal

    7-54 CHASSIS REMOVAL • Remove the rear wheel. (7-10) • Remove the rear brake. (7-46) • Remove the rear drive gear case, drive shaft and rear axle housing. (4-3) • Remove the rear shock absorbers 1. • Disconnect the brake breather hose from the swingarm. •...

  • Page 219: Reassembly And Remounting

    CHASSIS 7-55 REASSEMBLY AND REMOUNTING Reassembly and remount the rear swingarm and suspension in the reverse order of removal and disassembly. Pay attention to the following points: • Install the swingarm and rear shock absorber. • Tighten the swingarm pivot bolts and shock absorber mount- ing bolts temporarily.

  • Page 220: Rear Axle

    7-56 CHASSIS REAR AXLE CONSTRUCTION 1 Rear axle 2 Rear axle housing...

  • Page 221: Removal

    CHASSIS 7-57 REMOVAL • Remove the trailer towing. (E17, E24 ONLY) • Remove the right and left rear wheels. (7-10) • Remove the rear wheel right and left hubs. (7-11) • Remove the rear brake. (7-46) • Support the rear drive gear case with a jack or wooden block. •...

  • Page 222: Inspection

    REASSEMBLY AND REMOUNTING Reassembly and remounting the rear axle in reverse order of removal and disassembly. Pay attemtion to the following points: • Apply SUZUKI SUPER GREASE “A” to the rear drive case spline.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A”...
  • Page 223 CHASSIS 7-59 • Tighten the rear axle housing bolts/nuts 1 and rear shock absorber mounting bolt 2 to the specified torque.  Rear shock absorber mounting nut (lower): 60 N·m (6.0 kgf-m, 43.5 lb-ft) • Tighten the axle housing mounting nuts 3. •...

  • Page 224: Rear Wheel, Rear Brake, Rear Suspension, Rear Swingarm And Rear Axle Shaft Reassembling Information

    7-60 CHASSIS REAR WHEEL, REAR BRAKE, REAR SUSPENSION, REAR SWIN- GARM AND REAR AXLE SHAFT REASSEMBLING INFORMATION...

  • Page 225: Reverse Lock Release Cable

    CHASSIS 7-61 REVERSE LOCK RELEASE CABLE REMOVAL AND INSTALLATION • Take the boot 1 off. • Loosen the locknut 2. • Remove the clip 3 and pin 4. • Loosen the locknuts 5 and remove the reverse lock release cable. •...
  • Page 226  ...

  • Page 227: Electrical System

    ELECTRICAL SYSTEM 8-1 ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ..............8- 2 CONNECTORS ................8- 2 COUPLERS ..................8- 2 CLAMPS ..................8- 2 FUSES ..................8- 2 SEMI-CONDUCTOR EQUIPPED PARTS ........8- 2 BATTERY ..................8- 3 CONNECTING THE BATTERY ...........8- 3 WIRING PROCEDURE ..............8- 3 USING THE MULTI CIRCUIT TESTER ........8- 3 LOCATION OF ELECTRICAL COMPONENTS .........8- 4 CHARGING SYSTEM .................8- 6...

  • Page 228: Cautions In Servicing

    8-2 ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTORS • When disconnecting a connector, be sure to hold the termi- nals; do not pull the lead wires. • When connecting a connector, push it in so it is firmly attached. • Inspect the connector for corrosion, contamination and any breakage in the cover.

  • Page 229: Battery

    ELECTRICAL SYSTEM 8-3 BATTERY • The MF battery used in this vehicle does not require mainte- nance (e.g., electrolyte level inspection, distilled water replen- ishment). • During normal charging, no hydrogen gas is produced. How- ever, if the battery is overcharged, hydrogen gas may be pro- duced.

  • Page 230: Location Of Electrical Components

    8-4 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS Battery Ignition switch Parking brake switch Emergency switch (E-17) Handlebar switch (L) Brake light pedal switch Horn button (E-17, 24) Starter motor...
  • Page 231 ELECTRICAL SYSTEM 8-5 Horn (E-17, 24) Generator Ignition coil Neutral switch Neutral switch diode Regulator/rectifier Fuse Neutral relay Starter relay CDI unit...

  • Page 232: Charging System

    8-6 ELECTRICAL SYSTEM CHARGING SYSTEM Ignition switch Fuse Battery Generator Regulator/rectifier TROUBLESHOOTING Battery runs down quickly. Accessories Check accessories which use excessive • Remove accessories are installed amounts of electricity. No accessories Check the battery for current leaks. Current leaks •...
  • Page 233 ELECTRICAL SYSTEM 8-7 Measure the continuity of the generator coil. No continuity • Faulty generator coil or 8-9) disconnected lead wires Continuity Measure the generator no-load voltage. Incorrect • Faulty generator 8-9) Correct Inspect the regulator/rectifier. Incorrect • Faulty regulator/rectifier 8-10) Correct Incorrect...

  • Page 234: Inspection

    8-8 ELECTRICAL SYSTEM INSPECTION BATTERY CURRENT LEAKAGE • Remove the seat. (7-4) • Turn the ignition switch to the “OFF” position. • Disconnect the - battery lead wire. Measure the current between - battery terminal and the - bat- tery lead wire using the multi circuit tester. If the reading exceeds the specified value, leakage is evident.
  • Page 235 ELECTRICAL SYSTEM 8-9 GENERATOR COIL RESISTANCE • Remove the fuel tank left side cover. (7-5) • Disconnect the generator coupler. Measure the resistance between the three lead wires. If the resistance is not specified value, replace the stator coil with a new one. Also, check that the generator core is insulated.
  • Page 236 8-10 ELECTRICAL SYSTEM REGULATOR/RECTIFIER • Remove the regulator/rectifier. Measure the voltage between the terminals using the multi cir- cuit tester, as indicated in the table below. If the voltage is not within the specified value, replace the regu- lator/rectifier with a new one. ...

  • Page 237: Starter System

    ELECTRICAL SYSTEM 8-11 STARTER SYSTEM Engine Emergency Ignition Starter stop switch switch (E-17) switch button Fuse Neutral relay Starter motor Neutral Reverse indicator indicator light light B/Bl Starter relay Neutral switch Parking brake switch TROUBLESHOOTING Starter motor will not run. Check if the starter motor runs when its terminal is connected The transmission is in neutral.

  • Page 238: Starter Motor Removal And Disassembly

    8-12 ELECTRICAL SYSTEM Check the starter relay. Incorrect • Faulty starter relay 8-15) Correct • Improper starter relay contact The starter motor runs when the transmission is in neutral, but does not run when the transmission is in any position other than neutral, with the parking brake lever grasp firmly. Incorrect •...

  • Page 239: Starter Motor Inspection

    ELECTRICAL SYSTEM 8-13 • Disassembly the starter motor, as shown. Housing end (outside) Brush holder Brush spring O-ring Brush terminal set Starter motor case Washer set Armature Housing end (inside) O-ring STARTER MOTOR INSPECTION CARBON BRUSHES Inspect the carbon brushes for abnormal wear, cracks, or smoothness in the brush holder.

  • Page 240: Starter Motor Reassembly And Remounting

    Replace the removed O-rings with new ones to pre- vent oil leakage and moisture. • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) •...

  • Page 241: Starter Relay Inspection

    ELECTRICAL SYSTEM 8-15 • Apply SUZUKI SUPER GREASE “A” to the O-ring .  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) STARTER RELAY INSPECTION • Remove the seat. (7-4) • Remove the fuel tank left side cover. (7-5) •...

  • Page 242: Neutral Relay Inspection

    8-16 ELECTRICAL SYSTEM Measure the relay coil resistance between the terminals using the multi circuit tester. If the resistance is not within the specified value, replace the starter relay with a new one.  09900-25008: Multi circuit tester set  Tester knob indication: Resistance (Ω) ...

  • Page 243: Ignition System

    ELECTRICAL SYSTEM 8-17 IGNITION SYSTEM Emergency Engine switch Ignition stop switch (E-17) switch Fuse CDI unit Wave form Ignition power arrangment source circuit circuit DC-DC Ignition converter coil Battery Driver Generator Spark plug Neutral Neutral Parking relay switch brake switch TROUBLESHOOTING Make sure the transmission is in the neutral position and the engine stop switch is in the “RUN”...
  • Page 244 8-18 ELECTRICAL SYSTEM Measure the ignition coil primary peak voltage. ( 8-19) Inspect the spark plug. Correct NOTE: The ignition coil peak voltage 2-6) inspection method is applicable only with the multi circuit tester and the peak volt adaptor. Correct Incorrect Incorrect •...

  • Page 245: Inspection

    ELECTRICAL SYSTEM 8-19 INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the fuel tank left side cover. (7-5) • Remove the left front inner fender. (7-5) • Remove the spark plug cap. • Connect a new spark plug to spark plug cap and ground it to the cylinder head.
  • Page 246 8-20 ELECTRICAL SYSTEM IGNITION COIL RESISTANCE • Remove the left front inner fender. (7-5) • Disconnect the ignition coil lead wires and spark plug cap, and remove the ignition oil. Measure the ignition coil resistance in both the primary and sec- ondary windings using the multi circuit tester.
  • Page 247 ELECTRICAL SYSTEM 8-21 • Repeat the above procedure a few times and measure the highest pickup coil peak voltage.  Tester knob indication: Voltage ()  Pickup coil peak voltage: More than 4.0 V If the peak voltage measured on the CDI unit coupler is lower than the standard value, measure the peak voltage on the gen- erator coupler as follows.

  • Page 248: Lamps

    8-22 ELECTRICAL SYSTEM LAMPS HEADLIGHT A Headlight mounting bolt B Headlight beam adjusting screw ITEM N·m kgf-m lb-ft Headlight bulb: 12 V 30/30 W (Right & Left) If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.

  • Page 249: Brake Light/Taillight

    ELECTRICAL SYSTEM 8-23 BRAKE LIGHT/TAILLIGHT Brake light/taillight: 12 V 21/5 W If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure. BULB REPLACEMENT • Remove the socket. •...

  • Page 250: Indicator Light

    8-24 ELECTRICAL SYSTEM INDICATOR LIGHT High beam indicator light (E-17) INSPECTION ITEM Steering RE: Reverse indicator light O/Bl Bl/R stem head cover NU: Neutral indicator light O/Bl Bl/B HI: High beam indicator light (E-17) WIRE COLOR : Yellow : Black with White tracer Bl/B : Blue with Black tracer Bl/R...

  • Page 251: Diode

    ELECTRICAL SYSTEM 8-25 DIODE • Remove the fuel tank left side cover. (7-5) • Remove the neutral switch diode. Measure the voltage between the terminals using the multi cir- cuit tester as indicated in the table below.  09900-25008: Multi circuit tester set ...

  • Page 252: Switches

    8-26 ELECTRICAL SYSTEM SWITCHES Measure each switch for continuity using a multi circuit tester. If any abnormality is found, replace the respective switch assemblies with a new one.  09900-25008: Multi circuit tester set NEUTRAL SWITCH IGNITION SWITCH Color Color Position Position Neutral...

  • Page 253: Battery

    ELECTRICAL SYSTEM 8-27 BATTERY SPECIFICATIONS Type designation YTX12-BS Capacity 12V, 36.0 kC (10 Ah)/10HR a Anode plates e Stopper b Separator (fiberglass plate) f Filter c Cathode plates g Terminal d Upper cover breather h Safty valve INITIAL CHARGING FILLING ELECTROLYTE •...
  • Page 254 8-28 ELECTRICAL SYSTEM NOTE: If air bubbles do not rise from any one of the filler ports, tap the bottom of the electrolyte container two or three times. Never remove the electrolyte container from the battery while there is still electrolyte in the container. •...

  • Page 255: Servicing

    ELECTRICAL SYSTEM 8-29 SERVICING Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, clean the battery terminals with sandpaper.
  • Page 256  ...

  • Page 257: Servicing Information

    SERVICING INFORMATION 9-1 SERVICING INFORMATION CONTENTS TROUBLESHOOTING ................9- 2 ENGINE ..................9- 2 DRIVE TRAIN ................9- 5 CARBURETOR ................9- 5 CHASSIS ..................9- 6 BRAKES ..................9- 7 ELECTRICAL ................9- 8 BATTERY ..................9- 9 WIRING DIAGRAM ................9-10 WIRING HARNESS, CABLE, AND HOSE ROUTING .......9-12 WIRING HARNESS ROUTING ............9-12 CABLE ROUTING ................9-14 FUEL HOSE ROUTING ...............9-16...

  • Page 258: Troubleshooting

    9-2 SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. 1. Worn cylinder. Replace. 2. Worn piston ring. Replace. 3. Worn valve guide or improper valve seating. Repair or replace.
  • Page 259 SERVICING INFORMATION 9-3 Complaint Symptom and possible causes Remedy Engine is noisy. Noise seems to come from the crankshaft 1. Worn or burnt bearing. Replace. 2. Big-end bearing worn or burnt. Replace. 3. Thrust clearance too large. Replace. Noise seems to come from transmission 1.
  • Page 260 9-4 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine idles poorly. 1. Valve clearance out of adjustment. Adjust. 2. Poor seating of valves. Replace. 3. Defective valve guides. Replace. Replace. 4. Worn rocker arm or arm shaft. 5. Defective generator. Replace.

  • Page 261: Drive Train

    SERVICING INFORMATION 9-5 DRIVE TRAIN Complaint Symptom and possible causes Remedy Power will not trans- 1. Broken drive and driven bevel gear teeth. Replace. mit from the engine to 2. Broken propeller shaft serration. Replace. the rear wheel. 3. Worn or broken rear axle serration. Replace.

  • Page 262: Chassis

    9-6 SERVICING INFORMATION CHASSIS Complaint Symptom and possible causes Remedy Handling is too heavy 1. Improper front wheel alignment. Adjust. or stiff. 2. Insufficiently lubricated. Lubricate. 3. Low air pressure in front tires. Adjust. 4. Tie rod ends tending to seize. Replace.

  • Page 263: Brakes

    SERVICING INFORMATION 9-7 BRAKES Complaint Symptom and possible causes Remedy Poor braking. 1. Insufficient brake fluid. Refill to level mark. (FRONT) 2. Air in brake fluid circuit. Bleed air out. 3. Worn pads. Replace. 4. Worn disc. Replace. Poor braking. 1.

  • Page 264: Electrical

    9-8 SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coil. Replace. sparking. 2. Defective spark plug. Replace. 3. Defective generator. Replace. 4. Defective CDI unit. Replace. 5. Defective pickup coil. Replace. Spark plug is wet or 1.

  • Page 265: Battery

    SERVICING INFORMATION 9-9 BATTERY Complaint Symptom and possible causes Remedy Sulfation or spots on 1. Cracked battery case. Replace. surfaces of cell 2. Battery has been left in a run-down condition for a long Replace. plates. time. Battery runs down 1.

  • Page 266: Wiring Diagram

    9-10 SERVICING INFORMATION WIRING DIAGRAM E-03, 24, 28 and 33...
  • Page 267 SERVICING INFORMATION 9-11 E-17...

  • Page 268: Wiring Harness, Cable, And Hose Routing

    9-12 SERVICING INFORMATION WIRING HARNESS, CABLE, AND HOSE ROUTING WIRING HARNESS ROUTING Clamp Ignition switch Handlebar switch Brake light lever switch Horn button (E-17, 24) Emergency switch (E-17) Battery Horn (E-17, 24) Wiring harness Wiring harness Brake light/Taillight Fix the clamp Clamp Clamp to the frame.
  • Page 269 SERVICING INFORMATION 9-13 Clamp Emergency switch Horn button Front brake switch (E-17, 24) Ignition switch Ignition switch lead wire Forward Handlebar switch (L) Brake lever switch Steering Emergency switch Parking brake switch upper bracket (E-17) Horn button (E-17, 24) Starter cable Starter motor Clamp lead wire...

  • Page 270: Cable Routing

    9-14 SERVICING INFORMATION CABLE ROUTING Starter cable Brake hose Parking brake cable Reverse cable Throttle cable Pass the starter cable Pass the throttle cable and reverse cable in front behind the brake hose. of the wiring harness. Pass the parking brake cable in front of the steering stem shaft.
  • Page 271 SERVICING INFORMATION 9-15 Rear brake cable Throttle cable Parking brake cable Reverse cable Clamp Starter cable Starter cable Clamp the starter cable with the wiring harness. Parking brake cable Starter cable Tighten the nut after adjusting Reverse cable the reverse cable play. Clamp...

  • Page 272: Fuel Hose Routing

    9-16 SERVICING INFORMATION FUEL HOSE ROUTING Fuel valve vacuum hose Fuel tank Fuel valve Clip Carburetor Clip Fuel hose Install the curve of the fuel hose to the fuel valve.

  • Page 273: Carburetor Hose Routing

    SERVICING INFORMATION 9-17 CARBURETOR HOSE ROUTING Upper Lower 5 mm Upper Air vent 1. Install the clip to the air vent hose cap hose cap. 2. Insert the tip of air vent hose from the right side to the air Lower vent hose cap and clip.

  • Page 274: Front Brake Hose Routing

    9-18 SERVICING INFORMATION FRONT BRAKE HOSE ROUTING...

  • Page 275: Rear Brake Breather Hose Routing

    SERVICING INFORMATION 9-19 REAR BRAKE BREATHER HOSE ROUTING...

  • Page 276: Special Tools

    9-20 SERVICING INFORMATION SPECIAL TOOLS 09900-00410 09900-06106 09900-06107 09900-06108 09900-09004 Hexagon wrench set Snap ring pliers Snap ring pliers Snap ring pliers Impact driver set 09900-20202 09900-20203 09900-20205 09900-20508 Micrometer Micrometer Micrometer Cylinder gauge set 09900-20101 (1/100 mm, (1/100 mm, (1/1000 mm, (1/100 mm, Vernier calipers...
  • Page 277 SERVICING INFORMATION 9-21 09915-64510 Compression gauge 09913-85210 09915-74532 Bearing/oil seal 09918-02410 09915-74511 Oil pressure gauge 09916-10911 installer (Adaptor) Oil pressure gauge adaptor Valve lapper set 09916-14910 09916-21111 09916-24450 09916-22480 09916-14510 Valve lifter attach- 09916-24900 Solid pilot Solid pilot Valve lifter ment Valve seat cutter set (N-100-5.52)
  • Page 278 9-22 SERVICING INFORMATION 09930-10121 Spark plug wrench 09930-30721 09930-35010 09930-31921 09930-44520 Rotor remover Rotor remover Rotor remover Rotor holder 09930-73150 09950-81910 Output shaft holder Remover NOTE: When ordering a special tool, please confirm whether it is available or not.

  • Page 279: Tightening Torque

    SERVICING INFORMATION 9-23 TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lb-ft Cylinder head cover bolt Cam chain sprocket bolt Cylinder head nut (8 mm) 16.5 Cylinder head nut (6 mm) Cylinder base nut (6 mm) Cam chain tension adjuster bolt Cam chain tension adjuster spring holder bolt Spark plug 13.0 Valve clearance adjuster locknut...

  • Page 280: Drive Train

    9-24 SERVICING INFORMATION DRIVE TRAIN ITEM N·m kgf-m lb-ft Front propeller shaft flange coupling bolt 32.5 Rear drive shaft housing nut 16.5 Rear propeller shaft flange coupling bolt 21.5 Rear drive gear case bolt 16.5 Rear drive gear oil filler plug 24.0 Rear drive gear oil drain plug 24.0...

  • Page 281: Tightening Torque Chart

    SERVICING INFORMATION 9-25 TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt A (mm) N·m kgf-m lb-ft N·m kgf-m lb-ft 0.15 0.23 0.45 0.55...

  • Page 282: Service Data

    9-26 SERVICING INFORMATION SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. ——— (1.3) ——— (1.1) Valve clearance (when cold) 0.03 – 0.08 ——— (0.001 – 0.003) 0.08 – 0.13 ——— (0.003 – 0.005) Valve guide to valve stem 0.010 –...
  • Page 283 SERVICING INFORMATION 9-27 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 33.780 – 33.820 33.480 (1.3299 – 1.3315) (1.3181) 32.990 – 33.030 32.690 (1.2988 – 1.3004) (1.2870) Camshaft journal oil clearance 0.036 – 0.066 0.150 (0.0014 – 0.0026) (0.0059) Camshaft journal holder I.D.
  • Page 284 9-28 SERVICING INFORMATION ITEM STANDARD LIMIT Piston ring thickness 0.97 – 0.99 ——— (0.038 – 0.039) 1.17 – 1.19 ——— (0.046 – 0.047) Piston pin bore 16.002 – 16.008 16.030 (0.6300 – 0.6302) (0.6311) Piston pin O.D. 15.992 – 16.000 15.980 (0.6296 –...
  • Page 285 SERVICING INFORMATION 9-29 DRIVE TRAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3.250 (65/20) ——— Secondary reduction ratio 1.235 (21/17) ——— Final reduction ratio 3.200 (32/10) ——— Transmission 3.083 (37/12) ——— gear ratio 1.933 (29/15) ——— 1.388 (25/18) ———...
  • Page 286 9-30 SERVICING INFORMATION ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Spark plug NGK: DR7EA Type DENSO: X22ESR-U 0.6 – 0.7 (0.024 – 0.028) Spark performance Over 8 (0.3) at 1 atm. Ignition coil resistance Terminal – 0.05 – 1.0 Ω Primary Terminal Plug cap –...
  • Page 287 SERVICING INFORMATION 9-31 BRAKE + WHEEL Unit: mm (in) ITEM STANDARD/SPECIFICATION LIMIT Rear brake cable play 3 – 5 ——— (0.12 – 0.20) Rear brake pedal free travel 20 – 30 ——— (0.79 – 1.18) Brake disc thickness 3.3 – 3.7 Front (0.130 –...
  • Page 288 9-32 SERVICING INFORMATION FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the research method. Gasoline containing MTBE (MethyI Tertiary E-03, 28, 33 ButyI Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible.

  • Page 289: Lt-F250K3 ('03-Model)

    LT-F250K3 (’03-MODEL) 10-1 LT-F250K3 (’03-MODEL) This chapter describes specifications, service data and servicing procedures which differ from those of the LT-F250K2 (’02-MODEL). NOTE: * Any differences between LT-F250K2 (’02-MODEL) and LT-F250K3 (’03-MODEL) in specifica- tions and service data are clearly indicated with the asterisk mark (*). * Please refer to the chapters 1 through 9 for details which are not given in this chapter.
  • Page 290 10-2 LT-F250K3 (’03-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length............1 800 mm (70.9 in) ..E-03, 28, 33 1 870 mm (73.6 in) ..E-17, 24 Overall width ............1 045 mm (41.1 in)..E-03, 28, 33 1 070 mm (42.1 in)..E-17, 24 Overall height............1 070 mm (42.1 in) Wheelbase ............1 140 mm (44.9 in) Front track............
  • Page 291 LT-F250K3 (’03-MODEL) 10-3 CHASSIS Front suspension..........Independent, double wishbone, coil spring, oil damped Rear suspension ..........Swingarm type, coil spring, oil damped Steering angle ............. Inside 41.5° Outside 29° Caster..............9° 30’ Trail ..............42 mm (1.65 in) Turning radius ............. 2.6 m (8.5 ft) Front brake............
  • Page 292 10-4 LT-F250K3 (’03-MODEL) SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.3) — (1.1) Valve clearance (when cold) 0.03 – 0.08 — (0.001 – 0.003) 0.08 – 0.13 — (0.003 – 0.005) Valve guide to valve stem 0.010 –...
  • Page 293 LT-F250K3 (’03-MODEL) 10-5 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 33.780 – 33.820 33.480 (1.3299 – 1.3315) (1.3181) 32.990 – 33.030 32.690 (1.2988 – 1.3004) (1.2870) Camshaft journal oil clearance 0.036 – 0.066 0.150 (0.0014 – 0.0026) (0.0059) Camshaft journal holder I.D.
  • Page 294 10-6 LT-F250K3 (’03-MODEL) ITEM STANDARD LIMIT Piston ring thickness 0.97 – 0.99 — (0.038 – 0.039) 1.17 – 1.19 — (0.046 – 0.047) Piston pin bore 16.002 – 16.008 16.030 (0.6300 – 0.6302) (0.6311) Piston pin O.D. 15.992 – 16.000 15.980 (0.6296 –...
  • Page 295 LT-F250K3 (’03-MODEL) 10-7 DRIVE TRAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3.250 (65/20) — Secondary reduction ratio 1.235 (21/17) — Final reduction ratio 3.200 (32/10) — Transmission gear 3.083 (37/12) — ratio 1.933 (29/15) — 1.388 (25/18) —...
  • Page 296 10-8 LT-F250K3 (’03-MODEL) ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Spark plug NGK: DR7EA Type DENSO: X22ESR-U 0.6 – 0.7 (0.024 – 0.028) Spark performance Over 8 (0.3) at 1 atm. Ignition coil resistance Terminal – 0.05 – 1.0 Ω Primary Terminal Plug cap –...
  • Page 297 LT-F250K3 (’03-MODEL) 10-9 BRAKE + WHEEL Unit: mm (in) ITEM STANDARD/SPECIFICATION LIMIT Rear brake cable play 3 – 5 — (0.12 – 0.20) Rear brake pedal free travel 20 – 30 — (0.79 – 1.18) Brake disc thickness 3.3 – 3.7 Front (0.130 –...
  • Page 298 10-10 LT-F250K3 (’03-MODEL) FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro-...
  • Page 299 LT-F250K3 (’03-MODEL) 10-11 TIGHTENING TORQUE CHASSIS ITEM N·m kgf-m lb-ft Handlebar clamp bolt 16.5 Steering shaft holder bolt 16.5 Steering shaft nut 35.5 Steering knuckle nut (Upper & Lower) 32.5 Tie rod end nut *6.0 *43.5 Tie rod locknut 21.0 Front shock absorber mounting nut (Upper) 41.0 bolt (Lower)
  • Page 300 10-12 LT-F250K3 (’03-MODEL) CLUTCH 1 Clutch drive plate : 7 pcs 2 Clutch driven plate (t = 1.2 mm) : 6 pcs...

  • Page 301: Lt-F250K4 ('04-Model)

    LT-F250K4 (’04-MODEL) 11-1 LT-F250K4 (’04-MODEL) This chapter describes specifications, service data and servicing procedures which differ from those of the LT-F250K3 (’03-MODEL). NOTE: * Any differences between LT-F250K3 (’03-MODEL) and LT-F250K4 (’04-MODEL) in specifica- tions and service data are clearly indicated with the asterisk mark (*). * Please refer to the chapters 1 through 10 for details which are not given in this chapter.
  • Page 302 11-2 LT-F250K4 (’04-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..................1 800 mm (70.9 in) ….. E-28, 33 1 870 mm (73.6 in) ….. E-17, 24 Overall width ..................1 045 mm (41.1 in)……E-28, 33 1 070 mm (42.1 in)……E-17, 24 Overall height ..................
  • Page 303 LT-F250K4 (’04-MODEL) 11-3 CAPACITIES Fuel tank, including reserve .............. 10.6 L (2.8/2.3 US/Imp gal) reserve ................2.6 L (0.7/0.6 US/Imp gal) Engine oil, oil change................. 2 200 ml (2.3/1.9 US/Imp qt) filter change ..............2 300 ml (2.4/2.0 US/Imp qt) overhaul ................
  • Page 304 11-4 LT-F250K4 (’04-MODEL) SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.3) — (1.1) Valve clearance (when cold) 0.03 – 0.08 — (0.001 – 0.003) 0.08 – 0.13 — (0.003 – 0.005) Valve guide to valve stem 0.010 –...
  • Page 305 LT-F250K4 (’04-MODEL) 11-5 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 33.780 – 33.820 33.480 (1.3299 – 1.3315) (1.3181) 32.990 – 33.030 32.690 (1.2988 – 1.3004) (1.2870) Camshaft journal oil clearance 0.036 – 0.066 0.150 (0.0014 – 0.0026) (0.0059) Camshaft journal holder I.D.
  • Page 306 11-6 LT-F250K4 (’04-MODEL) ITEM STANDARD LIMIT Piston ring thickness 0.97 – 0.99 — (0.038 – 0.039) 1.17 – 1.19 — (0.046 – 0.047) Piston pin bore 16.002 – 16.008 16.030 (0.6300 – 0.6302) (0.6311) Piston pin O.D. 15.992 – 16.000 15.980 (0.6296 –...
  • Page 307 LT-F250K4 (’04-MODEL) 11-7 DRIVE TRAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3.250 (65/20) — Secondary reduction ratio 1.235 (21/17) — Final reduction ratio 3.200 (32/10) — Transmission gear 3.083 (37/12) — ratio 1.933 (29/15) — 1.388 (25/18) —...
  • Page 308 11-8 LT-F250K4 (’04-MODEL) ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Spark plug NGK: DR7EA Type DENSO: X22ESR-U 0.6 – 0.7 (0.024 – 0.028) Spark performance Over 8 (0.3) at 1 atm. Ignition coil resistance Terminal – 0.05 – 1.0 Ω Primary Terminal Plug cap –...
  • Page 309 LT-F250K4 (’04-MODEL) 11-9 BRAKE + WHEEL Unit: mm (in) ITEM STANDARD/SPECIFICATION LIMIT Rear brake cable play 3 – 5 — (0.12 – 0.20) Rear brake pedal free travel 20 – 30 — (0.79 – 1.18) Brake disc thickness 3.3 – 3.7 Front (0.130 –...
  • Page 310 11-10 LT-F250K4 (’04-MODEL) FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl E-28, 33 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro-...
  • Page 311 LT-F250K4 (’04-MODEL) 11-11 TIGHTENING TORQUE DRIVE TRAIN ITEM N·m kgf-m lb-ft Rear axle housing/swingarm (RH) *6.0 *43.5 Rear axle housing/final gear case (RH) *5.0 *36.0 Swingarm (LH)/final gear case (LH) *5.0 *36.0 CHASSIS ITEM N·m kgf-m lb-ft Handlebar clamp bolt *2.6 *19.0 Steering shaft holder bolt...
  • Page 312 11-12 LT-F250K4 (’04-MODEL) ENGINE ITEM N·m kgf-m lb-ft Cylinder head cover bolt Cam chain sprocket bolt Cylinder head nut (8 mm) 16.5 Cylinder head nut (6 mm) Cylinder base nut (6 mm) Cam chain tension adjuster bolt Cam chain tension adjuster spring holder bolt Spark plug 13.0 Valve clearance adjuster locknut...
  • Page 313 LT-F250K4 (’04-MODEL) 11-13 CLUTCH SLEEVE HUB NUT TIGHTNING TORQUE REASSEMBLY • Hold the clutch sleeve hub using the special tool, and then tighten the specified torque.  Clutch sleeve hub nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft)  09920-53730: Clutch sleeve hub holder •...
  • Page 314 11-14 LT-F250K4 (’04-MODEL) DRIVE TRAIN UNIVERSAL JOINT Grease nipple Grease nipple...
  • Page 315 LT-F250K4 (’04-MODEL) 11-15 GEARSHIFT LINKAGE...

  • Page 316: Lt-F250K5 ('05-Model)

    LT-F250K5 (’05-MODEL) 12-1 LT-F250K5 (’05-MODEL) This chapter describes specifications, service data and servicing procedures which differ from those of the LT-F250K4 (’04-MODEL). NOTE: * The specifications and service data are the same as LT-F250K4 (’04-MODEL). * Please refer to the chapters 1 through 11 for details which are not given in this chapter. CONTENTS SPECIFICATIONS ..................12- 2 SERVICE DATA ...................12- 4...
  • Page 317 12-2 LT-F250K5 (’05-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..................1 800 mm (70.9 in)....E-28, 33 1 870 mm (73.6 in)....E-17, 24 Overall width ..................1 045 mm (41.1 in)....E-28, 33 1 070 mm (42.1 in)....E-17, 24 Overall height ..................
  • Page 318 LT-F250K5 (’05-MODEL) 12-3 CAPACITIES Fuel tank, including reserve .............. 10.6 L (2.8/2.3 US/Imp gal) reserve ................2.6 L (0.7/0.6 US/Imp gal) Engine oil, oil change ................ 2 200 ml (2.3/1.9 US/Imp qt) filter change..............2 300 ml (2.4/2.0 US/Imp qt) overhaul................
  • Page 319 12-4 LT-F250K5 (’05-MODEL) SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.3) — (1.1) Valve clearance (when cold) 0.03 – 0.08 — (0.001 – 0.003) 0.08 – 0.13 — (0.003 – 0.005) Valve guide to valve stem 0.010 –...
  • Page 320 LT-F250K5 (’05-MODEL) 12-5 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 33.780 – 33.820 33.480 (1.3299 – 1.3315) (1.3181) 32.990 – 33.030 32.690 (1.2988 – 1.3004) (1.2870) Camshaft journal oil clearance 0.036 – 0.066 0.150 (0.0014 – 0.0026) (0.0059) Camshaft journal holder I.D.
  • Page 321 12-6 LT-F250K5 (’05-MODEL) ITEM STANDARD LIMIT Piston ring thickness 0.97 – 0.99 — (0.038 – 0.039) 1.17 – 1.19 — (0.046 – 0.047) Piston pin bore 16.002 – 16.008 16.030 (0.6300 – 0.6302) (0.6311) Piston pin O.D. 15.992 – 16.000 15.980 (0.6296 –...
  • Page 322 LT-F250K5 (’05-MODEL) 12-7 DRIVE TRAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3.250 (65/20) — Secondary reduction ratio 1.235 (21/17) — Final reduction ratio 3.200 (32/10) — Transmission gear 3.083 (37/12) — ratio 1.933 (29/15) — 1.388 (25/18) —...
  • Page 323 12-8 LT-F250K5 (’05-MODEL) ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Spark plug NGK: DR7EA Type DENSO: X22ESR-U 0.6 – 0.7 (0.024 – 0.028) Spark performance Over 8 (0.3) at 1 atm. Ignition coil resistance Terminal – 0.05 – 1.0 Ω Primary Terminal Plug cap –...
  • Page 324 LT-F250K5 (’05-MODEL) 12-9 BRAKE + WHEEL Unit: mm (in) ITEM STANDARD/SPECIFICATION LIMIT Rear brake cable play 3 – 5 — (0.12 – 0.20) Rear brake pedal free travel 20 – 30 — (0.79 – 1.18) Brake disc thickness 3.3 – 3.7 Front (0.130 –...
  • Page 325 12-10 LT-F250K5 (’05-MODEL) FUEL + OIL SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl E-28, 33 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro- sion inhibitor is permissible.
  • Page 326 LT-F250K5 (’05-MODEL) 12-11 TIGHTENING TORQUE CHASSIS ITEM N·m kgf-m lb-ft Handlebar clamp bolt 19.0 Steering shaft holder bolt 16.5 Steering shaft nut 35.5 Steering knuckle nut (Upper & Lower) * 29 * 2.9 * 21.0 Tie rod end nut 21.0 Tie rod locknut 21.0 Front shock absorber mounting...
  • Page 327 12-12 LT-F250K5 (’05-MODEL) WIRING DIAGRAM E-24, 28, 33...
  • Page 328 LT-F250K5 (’05-MODEL) 12-13 E-17...

  • Page 329: Lt-F250K6 ('06-Model)

    LT-F250K6 (’06-MODEL) 13-1 LT-F250K6 (’06-MODEL) This chapter describes service specifications, service data and servicing procedurers which dif- fer from those of the LT-F250K5 (’05-MODEL). NOTE: * Any differences between the LT-F250K5 (’05-MODEL) and LT-F250K6 (’06-MODEL) in spec- ifications are cleary indicated with an asterisk (*) mark. * Please refer to the capters 1 through 12 for details which are not given in this chapter.

  • Page 330: Specifications

    13-2 LT-F250K6 (’06-MODEL) E-17, 24, 28, 33 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..................1 800 mm (70.9 in)..... E-28, 33 1 870 mm (73.6 in)..... E-17, 24 Overall width ..................1 070 mm (42.1 in)..... E-17, 24 1 045 mm (41.1 in)..... E-28, 33 Overall height ..................

  • Page 331: Service Data

    LT-F250K6 (’06-MODEL) 13-3 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.3) — (1.1) Valve clearance (when cold) 0.03 – 0.08 — (0.001 – 0.003) 0.08 – 0.13 — (0.003 – 0.005) Valve guide to valve stem 0.010 –...
  • Page 332 13-4 LT-F250K6 (’06-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 33.780 – 33.820 33.480 (1.3299 – 1.3315) (1.3181) 32.990 – 33.030 32.690 (1.2988 – 1.3004) (1.2870) Camshaft journal oil clearance 0.036 – 0.066 0.150 (0.0014 – 0.0026) (0.0059) Camshaft journal holder I.D.
  • Page 333 LT-F250K6 (’06-MODEL) 13-5 ITEM STANDARD LIMIT Piston ring thickness 0.97 – 0.99 — (0.038 – 0.039) 1.17 – 1.19 — (0.046 – 0.047) Piston pin bore 16.002 – 16.008 16.030 (0.6300 – 0.6302) (0.6311) Piston pin O.D. 15.992 – 16.000 15.980 (0.6296 –...
  • Page 334 13-6 LT-F250K6 (’06-MODEL) DRIVE TRAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3.250 (65/20) — Secondary reduction ratio 1.235 (21/17) — Final reduction ratio 3.200 (32/10) — Transmission gear 3.083 (37/12) — ratio 1.933 (29/15) — 1.388 (25/18) —...
  • Page 335 LT-F250K6 (’06-MODEL) 13-7 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Spark plug NGK: DR7EA Type DENSO: X22ESR-U 0.6 – 0.7 (0.024 – 0.028) Spark performance Over 8 (0.3) at 1 atm. Ignition coil resistance Terminal – 0.05 – 1.0 Ω Primary Terminal Plug cap –...
  • Page 336 13-8 LT-F250K6 (’06-MODEL) BRAKE + WHEEL Unit: mm (in) ITEM STANDARD/SPECIFICATION LIMIT Rear brake cable play 3 – 5 — (0.12 – 0.20) Rear brake pedal free travel 20 – 30 — (0.79 – 1.18) Brake disc thickness 3.3 – 3.7 Front (0.130 –...
  • Page 337 LT-F250K6 (’06-MODEL) 13-9 FUEL + OIL SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl E-28, 33 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro- sion inhibitor is permissible.

  • Page 338: Specifications

    13-10 LT-F250K6 (’06-MODEL) E-04 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..................* 1 950 mm (76.8 in) Overall width ..................1 070 mm (42.1 in) Overall height ..................1 070 mm (42.1 in) Wheelbase ..................1 140 mm (44.9 in) Front track ...................

  • Page 339: Service Data

    LT-F250K6 (’06-MODEL) 13-11 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.3) — (1.1) Valve clearance (when cold) 0.03 – 0.08 — (0.001 – 0.003) 0.08 – 0.13 — (0.003 – 0.005) Valve guide to valve stem 0.010 –...
  • Page 340 13-12 LT-F250K6 (’06-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 33.780 – 33.820 33.480 (1.3299 – 1.3315) (1.3181) 32.990 – 33.030 32.690 (1.2988 – 1.3004) (1.2870) Camshaft journal oil clearance 0.036 – 0.066 0.150 (0.0014 – 0.0026) (0.0059) Camshaft journal holder I.D.
  • Page 341 LT-F250K6 (’06-MODEL) 13-13 ITEM STANDARD LIMIT Piston ring thickness 0.97 – 0.99 — (0.038 – 0.039) 1.17 – 1.19 — (0.046 – 0.047) Piston pin bore 16.002 – 16.008 16.030 (0.6300 – 0.6302) (0.6311) Piston pin O.D. 15.992 – 16.000 15.980 (0.6296 –...
  • Page 342 13-14 LT-F250K6 (’06-MODEL) DRIVE TRAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3.250 (65/20) — Secondary reduction ratio 1.235 (21/17) — Final reduction ratio 3.200 (32/10) — Transmission gear 3.083 (37/12) — ratio 1.933 (29/15) — 1.388 (25/18) —...
  • Page 343 LT-F250K6 (’06-MODEL) 13-15 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Spark plug NGK: DR7EA Type DENSO: X22ESR-U 0.6 – 0.7 (0.024 – 0.028) Spark performance Over 8 (0.3) at 1 atm. Ignition coil resistance Terminal – 0.05 – 1.0 Ω Primary Terminal Plug cap –...
  • Page 344 13-16 LT-F250K6 (’06-MODEL) BRAKE + WHEEL Unit: mm (in) ITEM STANDARD/SPECIFICATION LIMIT Rear brake cable play 3 – 5 — (0.12 – 0.20) Rear brake pedal free travel 20 – 30 — (0.79 – 1.18) Brake disc thickness 3.3 – 3.7 Front (0.130 –...
  • Page 345 LT-F250K6 (’06-MODEL) 13-17 FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Gasoline used should be graded 91 octane or higher. An unleaded gasoline is recommended. Fuel tank capacity including 10.6 L reserve (2.8/2.3 US/lmp gal) reserve 2.6 L (0.7/0.6 US/lmp gal) Engine oil type * SAE 10W-40, API SF/SG or SH/SJ with JASO MA Engine oil capacity...

  • Page 346: Speedometer/Odometer Gear

    13-18 LT-F250K6 (’06-MODEL) SPEEDOMETER/ODOMETER GEAR 1 Output shaft 2 Odometer driven gear 3 O-ring 4 Sleeve 5 Seal 6 Speedometer 7 Speedometer cable Speedometer cable Clamp ITEM N·m kgf-m lb-ft 10.0 72.5...

  • Page 347: Exterior Parts

    LT-F250K6 (’06-MODEL) 13-19 EXTERIOR PARTS CONSTRUCTION 1 Front carrier 2 Front fender 3 Fuel tank side cover 4 Front inner fender 5 Front grip bar 6 Center cover 7 Head lamp cover 8 Front fender mudguard...
  • Page 348 13-20 LT-F250K6 (’06-MODEL) 1 Rear carrier 2 Rear fender 3 Rear fender mudguard 4 Rear grip bar 5 Speed plate holder  ITEM N·m kgf-m lb-ft 20.5 40.0...
  • Page 349 LT-F250K6 (’06-MODEL) 13-21 STEERING Handlebars Steering head cover Rear view mirror...
  • Page 350 13-22 LT-F250K6 (’06-MODEL) LAMPS HEADLIGHT Headlight bulb (Right & Left) 12 V 35/35 W Position light bulb (Right & Left) 12 V 4 W  If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.
  • Page 351 LT-F250K6 (’06-MODEL) 13-23 HEADLIGHT AND POSITION LIGHT To replace the headlight and position light bulbs, follow the pro- cedure below. • Remove two screws 1 and the headlight assembly. • Disconnect the head light coupler 2 and position light coupler •...
  • Page 352 13-24 LT-F250K6 (’06-MODEL) TURN SIGNAL LIGHT/BRAKE LIGHT Front turn signal light bulb (Right & Left) 12 V 21 W Rear turn signal light bulb (Right & Left) 12 V 18 W Brake light bulb (Right & Left) 12 V 21/5 W ...
  • Page 353 LT-F250K6 (’06-MODEL) 13-25 BRAKE/TAILLIGHT Replace the brake/taillight bulb as follows: • Turn the socket counterclockwise. • Push the bulb in and turn it to the left. Remove the bulb. • To install a new bulb, push the bulb in firmly turn it to the right while pushing in.
  • Page 354 13-26 LT-F250K6 (’06-MODEL) LICENSE LIGHT License light bulb (Right & Left) 12 V 5 W  If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.

  • Page 355: Steering

    LT-F250K6 (’06-MODEL) 13-27 INSPECTION ITEM Steering RE: Reverse indicator light O/Bl Bl/R stem NU: Neutral indicator light O/Bl Bl/B head cover TU: Turn signal indicator light WIRE COLOR : Yellow : Black with White tracer Bl/B : Blue with Black tracer Bl/R : Blue with Red tracer O/Bl...

  • Page 356: Switches

    13-28 LT-F250K6 (’06-MODEL) SWITCHES Measure each switch for continuity using a multi circuit tester. If any abnormality is found, replace the respective switch assemblies with a new one.  09900-25008: Multi circuit tester set HORN BUTTON TURN SIGNAL SWITCH Color Color Position Position...

  • Page 357: Cable Routing

    LT-F250K6 (’06-MODEL) 13-29 CABLE ROUTING Speedometer cable must be Each cables must be passed passed behind the brake hose. in front of the harness. Speedometer cable must be passed behind the brake hose. Speedometer cable Clamp...

  • Page 358: Regulator/Rectifier Installation

    13-30 LT-F250K6 (’06-MODEL) REGULATOR/RECTIFIER INSTALLATION Regulator/rectifier Bracket...

  • Page 359: Wiring Diagram

    LT-F250K6 (’06-MODEL) 13-31 WIRING DIAGRAM...
  • Page 360  ...
  • Page 361 LT-F250K7 ( 07-MODEL) 14-1 LT-F250K7 ( 07-MODEL) NOTE: * The service data is the same as the K6-MODEL. CONTENTS SPECIFICATIONS ..................14- 2 INFORMATION LABEL INSTALLATION (For E-33) ........14- 3 FRONT BRAKE HOSE ROUTING .............. 14- 4...

  • Page 362: Lt-F250K7 ('07-Model)

    14- 2 LT-F250K7 (’07-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..................1 800 mm (70.9 in) Overall width..................1 045 mm (41.1 in) Overall height ..................1 070 mm (42.1 in) Wheelbase ..................1 140 mm (44.9 in) Front track ................... 790 mm (31.1 in) Rear track....................
  • Page 363 LT-F250K7 (’07-MODEL) 14- 3 CAPACITIES Fuel tank, including reserve............. 10.6 L (2.8/2.3 US/Imp gal) reserve................2.6 L (0.7/0.6 US/Imp gal) Engine oil, oil change ............... 2 200 ml (2.3/1.9 US/Imp qt) filter change ..............2 300 ml (2.4/2.0 US/Imp qt) overhaul ................
  • Page 364 14- 4 LT-F250K7 (’07-MODEL) INFORMATION LABEL INSTALLATION (For E-33) LABEL Frame LH side...
  • Page 365 LT-F250K7 (’07-MODEL) 14- 5 FRONT BRAKE HOSE ROUTING...
  • Page 366  ...
  • Page 367 LT-F250K8 ( 08-MODEL) 15-1 LT-F250K8 ( 08-MODEL) NOTE: * The service data is the same as the K7-MODEL. CONTENTS INFORMATION LABEL ................15- 2 CAMSHAFT DRIVE CHAIN ................ 15- 2...

  • Page 368: Lt-F250K8 ('08-Model)

    15- 2 LT-F250K8 (’08-MODEL) INFORMATION LABELS APPLIED SPECIFICATION LABEL or PLATE NAME E-04 E-17 E-24 E-28 E-33 Certification plate E Information label E Gearshift pattern label E Gearshift pattern label E/ F Tire air pressure label E Tire air pressure label and warning no-passenger label F Compliance label E General warning label F General warning and age, 16 label E...
  • Page 369 LT-F250K9 ('09 MODEL) 16-1 LT-F250K9 ('09 MODEL) CONTENTS PAGE...

  • Page 370: Swingarm

    16-2 LT-F250K9 ('09 MODEL) SPECIFICATIONS DIMENSIONS AND CURB MASS Overall length ..................1 870 mm (73.6 in)..... E-17, 24 1 800 mm (70.9 in)..... E-28, 33 Overall width..................1 070 mm (42.1 in)..... E-17, 24 1 045 mm (41.1 in)..... E-28, 33 Overall height ..................
  • Page 371 LT-F250K9 ('09 MODEL) 16-3 SERVICE DATA CARBRETOR SPECIFICATION ITEM * E-24 E-17 * E-28, 33 ← ← Carburetor type MIKUNI BS29 ← ← Bore size 29 mm I.D. No. 05G0 05G2 05G1 ← ← Idle r/min 1 500 ± 100 r/min Float height 17.1 ±...
  • Page 372 16-4 LT-Z250K9 ('09 MODEL) FUEL TANK CONSTRUCTION 1 Fuel tank 2 Fuel cap 3 Breather hose 4 Gasket 5 Gasket 6 Fuel valve 7 Fuel hose...
  • Page 373 LT-Z250K9 ('09 MODEL) 16-5 CARBURETOR PILOT SCREW REMOVAL (For E-28, 33) Because harsh cleaning solvents can damage the O-ring seals in the pilot system, the pilot system components should be removed before cleaning. • Use a 1/8” size drill bit with a drill-stop to remove the pilot screw plug.
  • Page 374 16-6 LT-Z250K9 ('09 MODEL) INFORMATION LABELS Information label (E-28) Certification label (E-33) Front of frame right side...

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Lt-f250 ozark 2002-2009250 ozark 2002-2009Lt-f250Lt-f250k3 2003Lt-z250k4 2004Lt-z250k5 2005 ... Show all

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