Page 1 RM-Z450 OWNER’S SERVICE MANUAL Part No. 99011-35G52-01A July, 2006...
Page 2 This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator. The manual contains important safety information and instructions which should be read carefully before operating the motorcycle.
Page 3 This manual is presented as a means whereby you carefully. To emphasize special information, the can maintain your RM-Z450 in top working condi- symbol ! and the words WARNING, CAUTION tion at all times. Your riding skill and the mainte- and NOTE have special meanings.
Page 4 You need to prepare for the unex- pected by wearing a helmet and other protective gear, and practicing safe riding techniques to minimize the damage to you and your machine. May all of your rides on your new Suzuki be winning rides!
Page 5: Serial Number Location
SERIAL NUMBER LOCATION The frame number 1 is stamped on the steering head as shown in the photograph. The engine serial num- ber 2 is stamped on the right side of the crankcase assembly. Write down the serial numbers here for your future reference. Frame No.
Page 6 WARNINGS FOR SERVICING ! WARNING ! WARNING Never run the engine indoors or in a Fuel can catch on fire if you do not handle garage. Exhaust gas contains carbon mon- it properly. Gasoline vapors can catch fire oxide, a gas that is colorless and odorless easily.
Page 7: Replacement Parts
NOTE: installing a circlip. Use of replacement parts which are not equivalent • Use special tools where specified. in quality to genuine SUZUKI parts can lead to per- • Use genuine SUZUKI parts and recommended formance problems and damage. oil.
Page 8 Apply THREAD LOCK SUPER “1360” Data beside it indicates specified or equivalent. torque. 99000-32130 Apply oil. Use engine oil or transmission Use SUZUKI FORK OIL SS-05 or oil unless otherwise specified. equivalent. 99000-99001-SS5 Apply molybdenum oil solution. Use SUZUKI REAR SUSPENSION OIL (Mixture of engine oil and SUZUKI SS-25 or equivalent.
Page 9: Table Of Contents
GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE TROUBLESHOOTING MACHINE TUNING ENGINE REMOVAL AND INSTALLATION CYLINDER HEAD, CYLINDER AND PISTON CLUTCH KICK STARTER GEARSHIFTING TRANSMISSION AND CRANKSHAFT LUBRICATION SYSTEM FUEL SYSTEM COOLING SYSTEM ELECTRICAL SYSTEM FRONT AND REAR WHEELS FRONT AND REAR BRAKES FRONT FORK AND STEERING REAR SUSPENSION SERVICING INFORMATION...
Page 10 GENERAL INFORMATION GENERAL INFORMATION CONTENTS LOCATION OF PARTS ................1- 2 ACCESSORY ....................1- 3 SIDE STAND ..................1- 3 FUEL AND OIL RECOMMENDATION ............1- 3 OPERATING INSTRUCTIONS ..............1- 4 STARTING THE ENGINE ..............1- 4 STOPPING THE ENGINE ..............1- 5 TRANSMISSION ...................
Page 11: Location Of Parts
GENERAL INFORMATION LOCATION OF PARTS 1 Clutch lever 2 Hot starter lever 3 Engine stop switch 4 Front brake lever 5 Throttle grip 6 Fuel tank cap 7 Carburetor starter knob 8 Gearshift lever 9 Front suspension compression damp- ing adjuster 0 Front suspension rebound damping adjuster A Kick starter lever...
Page 12: Accessory
Use only unleaded gasoline of at least 95 octane. (Research method) ....For other countries Engine oil: SUZUKI recommends the use of SUZUKI PERFOR- MANCE 4 MOTOR OIL or equivalent engine oil. Use of SF/SG or SH/SJ in API with MA in JASO. The rec- ommended viscosity is SAE 10W-40.
Page 13: Operating Instructions
GENERAL INFORMATION OPERATING INSTRUCTIONS CAUTION Leaving the engine at idling speed after riding will cause engine overheat as this competition motorcycle does not have the radiator cooling fan and coolant reservoir. Riding the motorcycle under severe conditions such as muddy or sandy terrain with high ambient temperature can shorten time to be overheated.
Page 14: Stopping The Engine
GENERAL INFORMATION When the engine is already warm or restarts: 1) Pull the hot starter lever 1. 2) Kick the engine over, leaving the throttle closed without using the starter knob. 3) Return the hot starter lever back immediately after the engine starts.
Page 15: Break-In (Running-In)
GENERAL INFORMATION BREAK-IN (RUNNING-IN) WHEN THE MOTORCYCLE IS NEW CLOSED CLOSED 1) Warm up the engine before starting off. 2) Ride for 60 minutes using less than 1/2 throttle opening. 3) Ride for 60 minutes using less than 3/4 throttle opening. FULL NOTE: OPEN...
Page 16: Exterior Parts
GENERAL INFORMATION EXTERIOR PARTS 5 N·m (0.5 kgf-m, 3.5 lb-ft) 5 N·m (0.5 kgf-m, 3.5 lb-ft)
Page 17 – MEMO –...
Page 18 PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE ................ 2- 3 INSPECTION BEFORE PRACTICE ............2- 3 INSPECTION BEFORE RACE (All items of inspection before practice on previous page plus) ..2- 4 PERIODIC MAINTENANCE CHART ............ 2- 5 SPARK PLUG ....................2- 7 AIR CLEANER .....................
Page 19 PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS EXHAUST SILENCER ................2-26 SILENCER INSPECTION AND REPLACEMENT ........ 2-26 SILENCER REASSEMBLY ..............2-27 DRIVE CHAIN AND SPROCKETS ............. 2-27 DRIVE CHAIN SLACK ................2-27 DRIVE CHAIN ADJUSTMENT ............. 2-28 DRIVE CHAIN PLATE WEAR .............. 2-28 DRIVE CHAIN PLATE WEAR ..............
Page 20: Periodic Maintenance
PERIODIC MAINTENANCE PERIODIC MAINTENANCE INSPECTION BEFORE PRACTICE WHAT TO CHECK CHECK FOR Spark plug • Heat range, fouled electrode, tightness • Loose high-tension cord Air cleaner element • Dust • Lubrication Engine oil Oil level Coolant Coolant level Cooling system •...
Page 21: Inspection Before Race
PERIODIC MAINTENANCE INSPECTION BEFORE RACE (All items of inspection before practice on previous page plus) WHAT TO CHECK CHECK FOR Clutch Clutch disc plates wear and distortion Brake pads Wear Sprockets Wear Cleanliness Fuel tank Leakage Fuel hose • Damage •...
Page 22: Periodic Maintenance Chart
PERIODIC MAINTENANCE PERIODIC MAINTENANCE CHART It is very important to inspect and maintain the machine regularly. Follow the guideline in the chart. The life of parts varies depending on the riding conditions. Perform more often than shown in the chart if you use the motorcycle under severe conditions.
Page 23 PERIODIC MAINTENANCE Interval Every Every Every races race 3 races 6 races Remarks Service Every Every Every hours Item 2 hours 6 hours 12 hours Tire — — Inspect every 20 min. up to initial 2 hours Spoke nipple — —...
Page 24: Spark Plug
PERIODIC MAINTENANCE SPARK PLUG • Remove the seat. (!5-2) • Remove the radiator covers and fuel tank. (!5-2) • Disconnect the spark plug cap. • Remove the spark plug. " 09816-00141: Spark plug wrench NOTE: Remove the dirt around the spark plug before removing the spark plug to prevent dirt from entering the combustion cham- ber.
Page 25: Air Cleaner
PERIODIC MAINTENANCE AIR CLEANER AIR CLEANER ELEMENT REMOVAL • Remove the left frame cover. • Remove the wing nut 1. • Remove the element 2 from the element holder. WASHING • Fill a washing pan large enough to hold the element with a non-flammable cleaning solvent A.
Page 26: Engine Oil And Oil Filter
PERIODIC MAINTENANCE NOTE: Follow the instructions below to keep the air cleaner element dry when cleaning the motorcycle. • Cover the element with vinyl bag. • Install the left frame cover. • Cover the inlet hole on the frame cover in order to prevent water from coming into the air cleaner box.
Page 27: Inspection Before Engine Oil Level Check
2-10 PERIODIC MAINTENANCE INSPECTION BEFORE ENGINE OIL LEVEL CHECK • Before starting the engine, check that there is sufficient oil for operating the engine. CAUTION If the engine is started with insufficient or no oil, the engine components will possibly be damaged. NOTE: The oil level measurement may become inaccurate unless the motorcycle is held upright as the motorcycle inclination affects...
Page 28: Engine Oil Level Inspection
PERIODIC MAINTENANCE 2-11 ENGINE OIL LEVEL INSPECTION • During inspection, hold the motorcycle in an upright position on a level surface. NOTE: The oil level measurement may become inaccurate unless the motorcycle is held upright as the motorcycle inclination affects the oil level.
Page 29: Engine Oil Filter Change
2-12 PERIODIC MAINTENANCE ENGINE OIL FILTER CHANGE • Drain the engine oil as described in the engine oil replace- ment procedure. • Remove the oil filter cap 1 and spring 2 with oil filter 3. • Apply engine oil lightly to the gasket of the new oil filter before installation.
Page 30: Oil Strainers
PERIODIC MAINTENANCE 2-13 OIL STRAINERS OIL STRAINER (No.1) REMOVAL • Drain engine oil. (!2-11) • Remove the engine oil strainer cap. CAUTION Do not lie the motorcycle to prevent dirty engine oil into the oil circuit when removing the oil strainer (No.1).
Page 31: Engine Coolant
2-14 PERIODIC MAINTENANCE ENGINE COOLANT ENGINE COOLANT LEVEL CHECK % WARNING You can be injured by scalding fluid or steam if you open the radiator cap when the engine is hot. Do not open the radiator cap when the engine is hot. Wait until engine cools.
Page 32: Engine Coolant Replenishment
PERIODIC MAINTENANCE 2-15 ENGINE COOLANT REPLENISHMENT • Use an anti-freeze and Summer engine coolant which is com- patible with aluminum radiator, mixed with distilled water at the ratio of 50:50. NOTE: The radiator, cylinder and cylinder head are made of aluminum alloy.
Page 33: Clutch Cable
2-16 PERIODIC MAINTENANCE CLUTCH CABLE Adjust the clutch cable play as follows: MAJOR ADJUSTMENT • Loosen the lock-nut 1. • Turn adjuster 2 so the clutch lever has 10 – 15 mm (0.4 – 0.6 in) play at the clutch lever end before pressure is felt. •...
Page 34: Throttle Cable
THROTTLE CABLE OIL SUPPLY • Remove the throttle case 1. • Apply oil to the throttle cable. • Apply SUZUKI SUPER GREASE “A” to the throttle cable spool. ' 99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
Page 35: Hot Starter
2-18 PERIODIC MAINTENANCE HOT STARTER Adjust the hot starter cable play as follows: • Loosen the lock-nut 1. • Turn adjuster 2 so the hot starter lever clearance A mea- sured at the lever holder obtains 2 – 3 mm (0.08 – 0.12 in) when squeezing the lever until pressure is felt.
Page 36: Engine Idle Speed
PERIODIC MAINTENANCE 2-19 ENGINE IDLE SPEED • Adjust the throttle cable play. (!2-16) • Warm up the engine. NOTE: Make this adjustment when the engine is hot. • Connect the multi-circuit tester to the high-tension cord. • Start the engine, turn the throttle stop screw 1 and set the engine idle speed as follows.
Page 37: Fuel Hose
2-20 PERIODIC MAINTENANCE FUEL HOSE • Inspect the fuel hose for damage and fuel leakage. If any defects are found, the fuel hose must be replaced. • Replace the fuel hose every four years. FUEL FILTER • Drain the fuel. •...
Page 38: Valve Clearance
PERIODIC MAINTENANCE 2-21 VALVE CLEARANCE • Remove the seat. (!5-2) • Remove the radiator covers and fuel tank. (!5-2) • Disconnect the spark plug cap. (!2-7) • Remove the spark plug. (!2-7) • Remove the cylinder head cover and its cylinder head cover gasket.
Page 39: Valve Clearance Adjustment
2-22 PERIODIC MAINTENANCE VALVE CLEARANCE ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim. • Remove the intake or exhaust camshafts. (!6-4) • Remove the tappet 1 and shim 2 by fingers or magnetic hand.
Page 40 PERIODIC MAINTENANCE 2-23 (INTAKE SIDE)
Page 41 2-24 PERIODIC MAINTENANCE (EXHAUST SIDE)
Page 42: Cylinder Head, Cylinder And Piston
PERIODIC MAINTENANCE 2-25 CYLINDER HEAD, CYLINDER AND PISTON CYLINDER HEAD INSPECTION • Remove the cylinder head. (!6-4) • Decarbonize the combustion chambers. • Inspect for pinholes, cracks and other damage. • If any defects are found, replace the cylinder head with a new one.
Page 43: Exhaust Silencer
2-26 PERIODIC MAINTENANCE EXHAUST SILENCER SILENCER INSPECTION AND REPLACEMENT • Remove the baffle mounting bolts. • Remove the baffle 1 and inner plate 2. • Inspect the glass wool 3 for clogging with carbon deposit or tar. • Replace the glass wool 3 with a new one if necessary.
Page 44: Silencer Reassembly
• Install the baffle and diffuser. • Tighten four bolts. NOTE: Apply SUZUKI BOND to the circumference of the silencer pipe and diffuser. ( 99000-31140: SUZUKI BOND “1207B” or equivalent • The baffle mounting bolt is of flanged type which tightens the body 3, baffle 1 and inner plate 2 together.
Page 45: Drive Chain Adjustment
2-28 PERIODIC MAINTENANCE DRIVE CHAIN ADJUSTMENT • Loosen the axle nut 1. • Loosen the lock-nuts 2 and adjust the drive chain slack to the specification by turning the adjusters 3. Make sure that the right and left adjuster plates 4 are at the same position on scales 5.
Page 46: Drive Chain Lubrication
PERIODIC MAINTENANCE 2-29 DRIVE CHAIN LUBRICATION • Remove the chain clip and joint from the drive chain and remove the drive chain. • Clean the drive chain with kerosine. CAUTION Do not use trichloroethylene, gasoline or any similar solvent. These fluids will damage the O-ring seals. Use only kerosine to clean the drive chain.
Page 47: Drive Chain Guide, Buffer And Tensioner Roller
2-30 PERIODIC MAINTENANCE DRIVE CHAIN GUIDE, BUFFER AND TENSIONER ROLLER DRIVE CHAIN GUIDE INSPECTION • Inspect the drive chain guide 1 for bends and damage. NOTE: The drive chain can hit a bent guide causing noise and drive chain wear. •...
Page 48: Brakes
PERIODIC MAINTENANCE 2-31 BRAKES BRAKE FLUID LEVEL • Inspect the brake fluid level in both front and rear reservoirs. If the brake fluid level is lower than LOWER mark A, replenish the reservoir with the specified brake fluid to the UPPER line. (!16-14) Inspect brake pad wear and brake fluid leakage if the brake fluid level decreases.
Page 49: Brake Pad
2-32 PERIODIC MAINTENANCE BRAKE PAD Wear limit • Inspect the brake pads for wear. If the brake pads are worn, replace them with new ones. (!16-5) NOTE: * Pump the brake lever and pedal several times to restore the Wear limit brake pads after replacing the brake pads.
Page 50: Front Fork
PERIODIC MAINTENANCE 2-33 FRONT FORK • Move the front fork up and down several times and inspect for smooth movement. • Inspect for damage and oil leaks. • Inspect the bolts and nuts for tightness. • If any defects are found, replace the front fork with a new one. •...
Page 51: Spoke Nipple And Rim Lock Inspection
2-34 PERIODIC MAINTENANCE SPOKE NIPPLE AND RIM LOCK INSPECTION • Inspect the spokes for tension by squeezing the spoke nip- ples. • Retighten the spoke nipples with a spoke nipple wrench so as all spokes have same tension. $ Spoke nipple: 6 N·m (0.6 kgf-m, 4.5 lb-ft) CAUTION Improperly tightening the spoke nipples can damage the wheel.
Page 52: Lubrication
A. Lightweight oil such as WD-40 or penetrating oil B. Aerosol type Chain Lube C. SUZUKI SUPER GREASE “A” (or equivalent grease) or Water-proof wheel bearing grease Follow the schedule closely. The disassembly necessary to lubricate many components is in itself valuable preventative maintenance.
Page 53: Compression Pressure Check
2-36 PERIODIC MAINTENANCE COMPRESSION PRESSURE CHECK The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to replace the cylinder is often based on the results of a compression test. COMPRESSION PRESSURE SPECIFICATION (Automatic decomp. actuated) Standard 430 –...
Page 54: Oil Pressure Check
PERIODIC MAINTENANCE 2-37 OIL PRESSURE CHECK Check the oil pressure periodically. This will give a good indication of the condition of the moving parts. # Oil pressure: 50 kPa (0.5 kgf/cm², 7.1 psi) at 1 950 r/min, oil temp. at 50 °C (122 °F) Low or high oil pressure can indicate any of the following conditions: LOW OIL PRESSURE * Clogged oil filter...
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Page 56: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING CONTENTS ENGINE ......................3- 2 CARBURETOR .................... 3- 6 RADIATOR (COOLING SYSTEM) .............. 3- 6 CHASSIS ..................... 3- 7 BRAKES ...................... 3- 8 ELECTRICAL ....................3- 9...
Page 57: Engine
TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. • Valve clearance out of adjustment Adjust • Worn valve guides or poor seating of valves Repair or Replace • Mistiming valves Adjust •...
Page 58 TROUBLESHOOTING Complaint Symptom and possible causes Remedy Noisy engine Excessive valve chatter • Too large valve clearance Adjust • Weakened or broken valve springs Replace • Worn tappet or cam surface Replace • Worn and burnt camshaft journal Replace Noise seems to come from piston •...
Page 59 TROUBLESHOOTING Complaint Symptom and possible causes Remedy Engine lacks power. Defective engine internal parts • Loss of tappet clearance Adjust • Weakened valve springs Replace • Valve timing out of adjustment Adjust • Worn piston ring or cylinder Replace • Poor seating of valves Repair •...
Page 60 TROUBLESHOOTING Complaint Symptom and possible causes Remedy Slipping clutch • Weakened clutch springs Replace • Worn or distorted pressure plate Replace • Worn or distorted clutch plates Replace • Insufficient throttle cable play Adjust Dragging clutch • Some clutch spring weakened while others are not Replace •...
Page 61: Carburetor
TROUBLESHOOTING CARBURETOR Complaint Symptom and possible causes Remedy Starting difficulty. • Improperly working starter knob — • Improperly working hot starter lever — • Clogged starter jet passage Clean • Maladjusted pilot screw Adjust • Maladjusted throttle stop screw Adjust •...
Page 62: Chassis
TROUBLESHOOTING CHASSIS Complaint Symptom and possible causes Remedy Heavy steering • Overtightened steering stem nut Adjust • Broken bearing in steering stem Replace • Distorted steering stem Replace • Not enough pressure in tires Adjust Wobbly handlebars • Loss of balance between right and left front forks Adjust •...
Page 63: Brakes
TROUBLESHOOTING BRAKES Complaint Symptom and possible causes Remedy Insufficient brake • Leakage of brake fluid from hydraulic system Repair or replace power • Worn pads Replace • Oil adhesion of engaging surface of pads Clean disc and pads • Worn disc Replace •...
Page 64: Electrical
TROUBLESHOOTING ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor • Defective ignition coil Replace sparking • Defective spark plug Replace • Defective CDI unit Replace • Defective magneto Replace • Open-circuited wiring connections Check and repair Spark plug soon •...
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Page 66: Machine Tuning
MACHINE TUNING MACHINE TUNING CONTENTS CARBURETOR TUNING ................4- 2 PRINCIPLES OF CARBURETOR TUNING .......... 4- 2 SLOW SYSTEM ..................4- 3 MAIN SYSTEM ..................4- 5 INTERMEDIATE SYSTEM ..............4- 5 CARBURETOR TUNING IN PRACTICE ..........4- 7 FRONT FORK TUNING ................4-10 COMPRESSION DAMPING FORCE ADJUSTMENT ......
Page 67: Carburetor Tuning
Riders who are not familiar with the operation and jetting procedures of the KEIHIN carburetor should have their local authorized Suzuki dealer perform these alterations. Mechanically experienced riders can alter the carburetor settings based on the following information and specifications.
Page 68: Slow System
MACHINE TUNING As shown below, each of the asterisk (*) marked parts is located between the air/fuel passage and has its own air/fuel mixture adjustable range in terms of the throttle valve opening. The chart indicates that the car- buretor can supply correct air/fuel mixture to the engine in any range because of the overlapping adjustable range of the each part.
Page 69 MACHINE TUNING PILOT SCREW (P.S.) The pilot screw controls volume of the air/fuel mixture in slow range. Pilot screw specifications indicate the number of turns out from the lightly seated position. Air/fuel mixture Pilot screw turn out Lean 1 turn out 1 and 1/4 turns out 1 and 1/2 turns out 1 and 3/4 turns out...
Page 70: Main System
MACHINE TUNING MAIN SYSTEM MAIN JET (M.J.) The main jet, like the slow jet, meters fuel flow. Each jet size is indicated by a number. Larger number means a larger bore diameter and fitting a larger number main jet enriches the air/fuel mixture.
Page 71 MACHINE TUNING Jet needle clip position To adjust the air/fuel mixture with the jet needle, change position of the needle clip which is set in the 5th groove. The lower Lean groove the clip is moved to, the higher the jet needle rises and the larger the clearance with the main nozzle becomes, resulting in a richer air/fuel mixture ratio.
Page 72: Carburetor Tuning In Practice
MACHINE TUNING CARBURETOR TUNING IN PRACTICE In the previous section, basic principles of carburetor tuning have been discussed. Described in this section are the bases for carburetor tuning required when coping with variations in air (oxygen) concentration. VARIATION IN AIR (OXYGEN) CONCENTRATION AND CARBURETOR CONDITIONS As the air, affected by the temperature, altitude and humidity, gets expanded or compressed, air (oxygen) concentration varies accordingly.
Page 73 MACHINE TUNING JUDGING AIR/FUEL MIXTURE INCLUDED PARTS AND OPTIONAL PARTS For proper carburetor tuning, it is necessary to Main jet know how to judge the air/fuel mixture made in the Air/fuel carburetor; whether too rich, too lean or properly SIZE P/NO.
Page 74 MACHINE TUNING 2 Adjustment of main system Jet needle With the throttle opened 3/4 to full, make main sys- Air/fuel SIZE P/NO. tem adjustment monitoring the air/fuel mixture con- mixture dition after completion of slow system settings. Lean NKZV 13383-35GK0 * Make sure to adjust the main system before NKYV 13383-35GJ0...
Page 75: Front Fork Tuning
4-10 MACHINE TUNING FRONT FORK TUNING The front fork compression and rebound damping force, and oil level are adjustable for rider’s preference, rider’s weight and course condition. NOTE: * Break-in new front forks before attempting adjustment. * Be sure to adjust both right and left front forks equally. * Inspect the following items before attempting adjustment.
Page 76: Oil Quantity Minor Adjustment
Operating the motorcycle with the fork oil quantity unevenly adjusted can cause handling instability. Never mix different types of fork oil. Different oils may cause chemical reaction and deteriorate. # 99000-99001-SS5: SUZUKI FORK OIL SS-05 or equivalent...
Page 77: Oil Change (Only For Outer Tube Oil Chamber)
4-12 MACHINE TUNING OIL CHANGE (Only for outer tube oil chamber) • Remove the front forks. ("17-4) • Thoroughly clean the fork before disassembly. CAUTION The fork oil quantity must be adjusted equally on both fork legs to provide equal performance. Scratches or other damage on the inner tube or on the oil seal lip will cause oil leak.
Page 78 MACHINE TUNING 4-13 • Slide down the outer tube. • Pour the specified amount of fork oil into the outer tube. # 99000-99001-SS5: SUZUKI FORK OIL SS-05 or equivalent Identification Oil quantity Parts No. Spring rate (Slit mark Oil quantity...
Page 79: Spring Change
4-14 MACHINE TUNING SPRING CHANGE • Remove the front forks. ("17-4) • Thoroughly clean the fork before disassembly. CAUTION The fork oil quantity must be adjusted equally on both fork legs to provide equal performance. Scratches or other damage on the inner tube or on the oil seal lip will cause oil leakage.
Page 80 US/Imp oz) 320 – 414 ml 385 ml (10.82/11.27 – 51171-35G30 (13.01/13.56 13.99/14.58 US/Imp oz) US/Imp oz) 315 – 408 ml 380 ml (10.65/11.09 – Hard 51171-35G40 (12.84/13.38 13.79/14.37 US/Imp oz) US/Imp oz) # 99000-99001-SS5: SUZUKI FORK OIL SS-05 or equivalent...
Page 81: Front Fork Tuning Procedure
4-16 MACHINE TUNING FRONT FORK TUNING PROCEDURE Test ride the motorcycle and find out how the front suspension reacts on various types of surface. According to the symptom noticed, adjust the front fork to the best setting for rider and race track conditions. To adjust, attempt changing fork oil capacity and compression and rebound damping force following the instructions below.
Page 82: Rear Suspension Tuning
MACHINE TUNING 4-17 REAR SUSPENSION TUNING The rear suspension compression and rebound damping force, and spring pre-load are adjustable for rider’s preference, rider’s weight and course condition. NOTE: * Break-in the rear suspension when riding with a new rear cushion unit. ("1-6) * Inspect the following items before attempting adjustment.
Page 83: Rebound Damping Force Adjustment
4-18 MACHINE TUNING REBOUND DAMPING FORCE ADJUSTMENT NOTE: To set the adjuster, you must gently turn the adjust screw clock- Soft Hard wise until it stops, then back it out the recommended number of turns. Do not force the adjust screw past the stopped position, or you may damage the adjuster.
Page 84: Rear Suspension Tuning Procedure
MACHINE TUNING 4-19 REAR SUSPENSION TUNING PROCEDURE • Adjust the rear suspension according to the rider’s weight and preference by referring to the table below. Spring Part No. Spring rate Marking paint Set-length adjustable range 51 N/mm 62211-37FJ0 Silver (5.1 kgf/mm) Soft 53 N/mm 247 –...
Page 85 4-20 MACHINE TUNING After the sag measurement has been set 104 mm (4.09 in), test ride the motorcycle and adjust the suspen- sion for the rider and track conditions referring to the guide below. SYMPTOM SECTION ADJUSTMENT PROCEDURE Feels too hard overall •...
Page 86: Suspension Balance
MACHINE TUNING 4-21 SUSPENSION BALANCE Balancing the front to rear suspension properly is the most critical adjustment for suspension performance. If the front forks are adjusted harder than the rear suspension, such as changing to heavier front fork oil, stiffer compression and rebound setting, air pressure build up in the forks and so on, the front forks will collapse less on bumps.
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Page 88: Engine Removal And Installation
ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL AND INSTALLATION CONTENTS ENGINE REMOVAL AND INSTALLATION ..........5- 2 REMOVAL ..................... 5- 2 INSTALLATION ..................5- 6...
Page 89: Engine Removal And Installation
ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL AND INSTALLATION REMOVAL • Drain engine oil. (!2-11) • Drain engine coolant. (!13-3) • Remove the seat 1. • Remove the radiator covers 2, left and right. • Remove the right frame cover 3. •...
Page 90 ENGINE REMOVAL AND INSTALLATION • Remove the exhaust pipe 5 and exhaust pipe gasket 6. • Remove the muffler 7. • Remove the front protectors, left and right. • Remove the radiator mounting bolts, left and right. • Disconnect the radiator hose 8, 9. •...
Page 91 ENGINE REMOVAL AND INSTALLATION • Disconnect the magneto lead wire coupler A and clamp. • Disconnect the clutch cable B. • Remove the carburetor. (!12-5) • Disconnect the spark plug cap. • Remove the cotter pin C, washer D and clip E. •...
Page 92 ENGINE REMOVAL AND INSTALLATION • Remove the drive chain clip M and release the drive chain. • Remove the circlip N and engine sprocket O. # 09900-06107: Snap ring pliers • Remove the front engine brackets P, left and right. •...
Page 93 ENGINE REMOVAL AND INSTALLATION INSTALLATION Install the engine in the reverse order of removal. Pay attention to the following points: • Fit the swingarm in its position and hold it with the swingarm pivot shaft. • Mount the engine on the frame. •...
Page 94 • Install the gearshift lever in the correct position. $ Gearshift lever bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Apply grease to the brake pedal pivot bolt. % 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the brake pedal and brake pedal spring. (!19-23)
Page 95 ENGINE REMOVAL AND INSTALLATION • Install the clip D, washer E and cotter pin F. CAUTION Replace the cotter pin F with a new one. • Install the kick starter lever in the correct position. (!8-7) $ Kick starter lever bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) •...
Page 96 ENGINE REMOVAL AND INSTALLATION • Tighten the connector clamp bolt K temporarily. NOTE: When install the connector clamp, fit the convex part of the con- nector clamp onto the concave part of muffler. • Check the clearance between exhaust pipe and radiator hose. •...
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Page 98 CYLINDER HEAD, CYLINDER AND PISTON CYLINDER HEAD, CYLINDER AND PISTON CONTENTS CONSTRUCTION ..................6- 2 CYLINDER HEAD, CYLINDER AND PISTON ........6- 2 ENGINE TOP SIDE ..................6- 3 CYLINDER HEAD COVER REMOVAL ..........6- 3 CAMSHAFTS (AUTOMATIC DECOMP.) AND CAM CHAIN TENSION ADJUSTER REMOVAL ........
Page 99: Construction
CYLINDER HEAD, CYLINDER AND PISTON CONSTRUCTION CYLINDER HEAD, CYLINDER AND PISTON 14 N . m (1.4 kgf-m, 10.0 lb-ft) 46 N . m (4.6 kgf-m, 33.5 lb-ft) 10 N . m (1.0 kgf-m, 11 N . m 7.0 lb-ft) (1.1 kgf-m, 8.0 lb-ft) 10 N .
Page 100: Engine Top Side
CYLINDER HEAD, CYLINDER AND PISTON ENGINE TOP SIDE CYLINDER HEAD COVER REMOVAL • Remove the seat. (!5-2) • Remove the radiator covers and fuel tank. (!5-2) • Disconnect the spark plug cap and remove the spark plug. (!2-7) • Remove the cylinder head cover 1 and cylinder head cover gasket.
Page 101: Cylinder Head Removal
CYLINDER HEAD, CYLINDER AND PISTON • Remove the cam chain tension adjuster cap bolt 3 and spring. • Remove the cam chain tension adjuster 4 and its gasket. • Remove the camshaft journal holders 5. NOTE: Loosen the camshaft journal holder bolts diagonally. •...
Page 102: Cylinder Removal
CYLINDER HEAD, CYLINDER AND PISTON • Remove the cylinder head base bolts 3. • Loosen the cylinder base bolt 4. • Remove the cylinder head bolts and washers. NOTE: When loosening the cylinder head bolts, loosen each bolt little by little diagonally. •...
Page 103: Piston And Piston Ring Removal
CYLINDER HEAD, CYLINDER AND PISTON • Remove the cylinder gasket 2 and dowel pins. PISTON AND PISTON RING REMOVAL • Remove the cylinder. (!6-5) • Place a clean rag over the cylinder base to prevent the piston pin circlip 1 from dropping into the crankcase. •...
Page 104: Cam Chain, Cam Chain Tensioner And Cam Chain Guide Removal
CYLINDER HEAD, CYLINDER AND PISTON CAM CHAIN, CAM CHAIN TENSIONER AND CAM CHAIN GUIDE REMOVAL • Remove the cylinder head. (!6-4) • Remove the magneto cover and magnet rotor. (!14-10 to -11) • Remove the cam chain No.1 guide 1. •...
Page 105: Engine Top Components Inspection And Service
CYLINDER HEAD, CYLINDER AND PISTON ENGINE TOP COMPONENTS INSPECTION AND SERVICE AUTOMATIC DECOMP. INSPECTION • Check the decomp. cam moves smoothly and shaft 1 rotates together. • If any abnormal condition are found, replace the camshaft assembly. CAMSHAFT INSPECTION CAUTION The camshaft assembly can not be disassembled.
Page 106 CYLINDER HEAD, CYLINDER AND PISTON CAM WEAR • Measure the cam height H using the micrometer. • Replace a camshaft if the cams are worn to the service limit. " Cam height H Service Limit IN.: 33.27 mm (1.310 in) EX.: 33.39 mm (1.315 in) # 09900-20202: Micrometer (25 –...
Page 107: Cam Chain Tension Adjuster Inspection
6-10 CYLINDER HEAD, CYLINDER AND PISTON • If the camshaft journal oil clearance measured exceeds the limit, measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal. • Replace the camshaft or the cylinder head depending upon which one exceeds the specification.
Page 108: Cam Chain Tensioner Inspection
CYLINDER HEAD, CYLINDER AND PISTON 6-11 CAM CHAIN No.1 GUIDE, CAM CHAIN No.2 GUIDE AND CAM CHAIN TENSIONER INSPECTION • Inspect the contacting surface of the cam chain guides and cam chain tensioner. • If it is worn or damaged, replace it with a new one. CYLINDER HEAD AND VALVE INSPECTION VALVE DISASSEMBLY •...
Page 109 6-12 CYLINDER HEAD, CYLINDER AND PISTON • Remove the valve spring retainer 4 and valve spring 5. • Remove the valve 6 from the combustion chamber side. • Remove the valve stem seal 7 and spring seat 8. CAUTION Do not reuse the removed valve stem seal. •...
Page 110 CYLINDER HEAD, CYLINDER AND PISTON 6-13 VALVE STEM RUNOUT • Support the valve using V-blocks and check its runout using the dial gauge as shown. • If the runout exceeds the service limit, replace the valve. " Valve stem runout (IN & EX): Service Limit:0.05 mm (0.002 in) # 09900-20607: Dial gauge (1/100 mm) 09900-20701: Magnetic stand...
Page 111 6-14 CYLINDER HEAD, CYLINDER AND PISTON VALVE STEM WEAR • If the valve stem is worn down to the limit, as measured with a micrometer, replace the valve. • If the stem is within the limit, then replace the guide. •...
Page 112 CYLINDER HEAD, CYLINDER AND PISTON 6-15 • Cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 – 150 °C (212 – 302 °F) with a hot plate. CAUTION Do not use a burner to heat the valve guide hole to prevent cylinder head distortion.
Page 113 6-16 CYLINDER HEAD, CYLINDER AND PISTON • If the seat width W measured exceeds the standard value or seat width is not uniform, refuse the seat using the seat cutter. " Valve seat width W: Standard: 0.9 – 1.1 mm (0.035 – 0.043 in) VALVE SEAT SERVICING The valve seats 1 for both the intake valve 2 and exhaust valve 3 are machined to three different angles.
Page 114 CYLINDER HEAD, CYLINDER AND PISTON 6-17 • Clean and assemble the head and valve components. Fill the intake and exhaust ports with gasoline to check for leaks. • If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from sealing.
Page 115 6-18 CYLINDER HEAD, CYLINDER AND PISTON • Install the valve spring with the small-pitch portion A facing cylinder head. A Small-pitch portion B Large-pitch portion C UPWARD D Paint • Put on the valve spring retainer 2, and using the valve lifter, press down the spring, fit the valve cotter halves to the stem end, and release the lifter to allow the valve cotter 3 to wedge in between retainer and stem.
Page 116: Oil Seal Inspection
• Remove the retainer 1 and plug 2. • Remove the oil seal 3. OIL SEAL INSTALLATION • Apply SUZUKI SUPER GREASE “A” to the oil seal clip. ' 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Fit a new oil seal with special tools.
Page 117: Cylinder Inspection
6-20 CYLINDER HEAD, CYLINDER AND PISTON CYLINDER INSPECTION CYLINDER DISTORTION • Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance read- ing at several places indicated. • If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder.
Page 118: Piston And Piston Ring Inspection
CYLINDER HEAD, CYLINDER AND PISTON 6-21 PISTON AND PISTON RING INSPECTION PISTON DIAMETER • Using a micrometer, measure the piston outside diameter at 15 mm (0.59 in) A from the piston skirt end. • If the measurement is less than the limit, replace the piston. "...
Page 119: Piston Ring Groove Width
6-22 CYLINDER HEAD, CYLINDER AND PISTON PISTON RING-TO-GROOVE CLEARANCE • Decarbonize the piston ring and piston ring groove. • Measure the side clearances of the 1st piston ring using the thickness gauge. • If any of the clearances exceed the limit, replace both the pis- ton and piston ring.
Page 120: Crankshaft And Conrod Inspection
CYLINDER HEAD, CYLINDER AND PISTON 6-23 CRANKSHAFT AND CONROD INSPECTION For inspection other than the following, refer to page 10-7. CONROD SMALL END I.D. • Using a small bore gauge, measure the inside diameter of the conrod small end. • If the inside diameter of the conrod small end exceeds the limit, replace the conrod.
Page 121: Cam Chain, Cam Chain Tensioner And Cam Chain Guide Installation
6-24 CYLINDER HEAD, CYLINDER AND PISTON CAM CHAIN, CAM CHAIN TENSIONER AND CAM CHAIN GUIDE INSTALLATION Install the cam chain and cam chain tensioner in the reverse order of removal. Pay attention to the following points: • Install the cam chain tensioner 1. $ Cam chain tensioner bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft) •...
Page 122: Piston And Piston Ring Installation
CYLINDER HEAD, CYLINDER AND PISTON 6-25 PISTON AND PISTON RING INSTALLATION Install the piston and piston ring in the reverse order of removal. Pay attention to the following points: PISTON RING • Install the piston rings in the order of oil ring and 1st ring. •...
Page 123 6-26 CYLINDER HEAD, CYLINDER AND PISTON PISTON • Install the piston with the punch mark 1 facing towards the exhaust side. • Before installing the piston pin, apply MOLYBDENUM OIL SOLUTION onto its surface. % MOLYBDENUM OIL SOLUTION • Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into crankcase.
Page 124: Cylinder And Cylinder Head Installation
• Thoroughly wipe off oil from the fitting surface of the crank- case. • Apply SUZUKI BOND “1215” to the crankcase as shown. ) 99000-31110: SUZUKI BOND “1215” or equivalent • Install the dowel pins into the crankcase and then install the cylinder gasket 1.
Page 125 6-28 CYLINDER HEAD, CYLINDER AND PISTON CYLINDER HEAD • Install the dowel pins into the cylinder and then install the cyl- inder head gasket 1 onto the cylinder. CAUTION Use a new gasket to prevent gas leakage. • Place the cylinder head 2 on the cylinder. CAUTION Do not drop the cam chain into the crankcase.
Page 126: Camshaft (Automatic Decomp.) And Cam Chain Tension Adjuster Installation
CYLINDER HEAD, CYLINDER AND PISTON 6-29 CAMSHAFT (AUTOMATIC DECOMP.) AND CAM CHAIN TENSION ADJUSTER INSTALLATION Install the camshaft and cam chain tension in the reverse order of removal. Pay attention to the following points: CAMSHAFT (AUTOMATIC DECOMP.) • Place a wrench over the crankshaft and turn it counter-clock- wise to align the TDC mark A with the center of the groove B of the timing inspection hole.
Page 127 6-30 CYLINDER HEAD, CYLINDER AND PISTON • Pull the exhaust side of the cam chain taut to install the camshaft sprocket (exhaust side). • Turn the exhaust camshaft so that the timing mark C is aligned with the gasket surface of the cylinder head.
Page 128 CYLINDER HEAD, CYLINDER AND PISTON 6-31 CAM CHAIN TENSION ADJUSTER • Retract the push rod by pushing the stopper 1. • Install a new gasket 2. CAUTION Use a new gasket to prevent oil leakage. • Install the cam chain tension adjuster 3 with “UP” mark faced upward.
Page 129: Clutch
• Install the new gasket to the cylinder head cover. CAUTION Use the new gaskets to prevent oil leakage. • Apply SUZUKI BOND to the end caps of the cylinder head cover gasket as shown. * 99000-31140: SUZUKI BOND “1207B” or equivalent •...
Page 130 CLUTCH CLUTCH CONTENTS CONSTRUCTION ..................7- 2 CLUTCH ....................7- 2 CLUTCH PLATE ..................7- 3 REMOVAL ..................... 7- 3 INSPECTION ..................7- 5 RELEASE BEARING REPLACEMENT ..........7- 6 INSTALLATION ..................7- 7 PRIMARY DRIVEN GEAR AND CLUTCH SLEEVE HUB ......7- 9 REMOVAL .....................
Page 131: Construction
CLUTCH CONSTRUCTION CLUTCH 10 N . m (1.0 kgf-m, 7.0 lb-ft) 90 N . m 9.0 kgf-m, 65.0 lb-ft Drive No. 1 plate (Black paint) Drive No. 2 plate (Green paint) Driven No. 1 plate (Silver) Driven No. 2 plate (Gray)
Page 132: Clutch Plate
CLUTCH CLUTCH PLATE REMOVAL • Drain engine oil. (!2-11) • Remove the brake pedal. (!16-18) • Remove the clutch cover 1 and its gasket. • Hold the clutch housing with the special tool. CAUTION Be careful not to damage the clutch housing or clutch plates.
Page 133 CLUTCH • Remove the clutch drive plates 4 and driven plates 5. NOTE: Mark the paint mark A to the clutch driven No. 2 plate. Mark the paint mark. A Clutch driven No. 2 plate B Clutch driven No. 1 plate C Direction of outside •...
Page 134: Inspection
CLUTCH INSPECTION DRIVE PLATE • Measure the drive plate thickness. # Drive plate thickness Service Limit: 2.77 mm (0.109 in) " 09900-20101: Vernier calipers • Inspect the drive plates for wear, distortion and discoloration. • If the drive plate thickness is found to have reached the limit, replace it with a new one.
Page 135: Release Bearing Replacement
CLUTCH PUSH ROD • Inspect the push rod for wear and damage. • If any defects are found, replace the push rod with a new one. RELEASE BEARING • Inspect the release bearing for play, discoloration, wear and seizure. • Move the inner race by finger and inspect for smooth move- ment.
Page 136: Installation
CLUTCH INSTALLATION Install the clutch plates in the reverse order of removal. Pay attention to the following points: • Install the spring washer seat 1 and spring washer 2 onto the clutch sleeve hub correctly. • Apply engine oil to the drive plates 3 and driven plates 4. •...
Page 137 CLUTCH • Install the clutch springs and clutch spring set bolts. • Hold the clutch housing with the special tool. CAUTION Be careful not to damage the clutch housing or clutch plates. " 09920-53740: Clutch sleeve hub holder • Tighten the clutch spring set bolts to the specified torque. NOTE: Tighten the clutch spring set bolts diagonally.
Page 138: Primary Driven Gear And Clutch Sleeve Hub
CLUTCH PRIMARY DRIVEN GEAR AND CLUTCH SLEEVE HUB REMOVAL • Remove the clutch cover. (!7-3) • Remove the pressure plate and clutch plates. (!7-3, -4) • Flatten the lock washer 1. • Hold the clutch sleeve hub with the special tool and loosen the nut 2.
Page 139: Inspection
7-10 CLUTCH INSPECTION • Inspect the clutch sleeve hub and primary driven gear for wear and cracks. • If necessary, replace the sleeve hub or driven gear. • Inspect the needle bearings and spacer for damage and wear. • If any defects are found, replace the bearing or spacer. INSTALLATION Install the primary driven gear and clutch sleeve hub in the reverse order of removal.
Page 140 CLUTCH 7-11 • Tighten the clutch sleeve hub nut with the special tool to the specified torque. " 09920-53740: Clutch sleeve hub holder % Clutch sleeve hub nut: 90 N·m (9.0 kgf-m, 65.0 lb-ft) • Make sure the clutch sleeve hub for smooth movement. •...
Page 141: Clutch Release Camshaft
7-12 CLUTCH CLUTCH RELEASE CAMSHAFT REMOVAL • Disconnect the clutch cable 1. NOTE: Loosen the clutch cable adjuster when disconnecting. • Remove the clutch cover and its gasket. (!7-3) • Remove the pressure plate and push rod. (!7-3) • Pull the clutch release camshaft 2 out of crankcase. INSPECTION CLUTCH RELEASE CAMSHAFT •...
Page 142: Installation
Pay attention to the following points: • Apply SUZUKI MOLY PASTE to the clutch release camshaft. & 99000-25140: SUZUKI MOLY PASTE or equivalent • Apply SUZUKI SUPER GREASE “A” to the oil seal lips. ' 99000-25010: SUZUKI SUPER GREASE “A” or equivalent •...
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Page 144: Kick Starter
KICK STARTER KICK STARTER CONTENTS CONSTRUCTION ..................8- 2 KICK STARTER ..................8- 2 KICK STARTER ................... 8- 3 REMOVAL ..................... 8- 3 INSPECTION ..................8- 4 INSTALLATION ..................8- 5...
Page 145: Construction
KICK STARTER CONSTRUCTION KICK STARTER 23 N·m (2.3 kgf-m, 16.5 lb-ft) 10 N·m (1.0 kgf-m, 7.0 lb-ft)
Page 146: Removal
KICK STARTER KICK STARTER REMOVAL • Drain engine oil. (!2-11) • Drain engine coolant. (!13-3) • Remove the brake pedal. (!16-18) • Disconnect the radiator hose 1. • Remove the right front protector 2. • Remove the kick starter lever 3. •...
Page 147: Inspection
KICK STARTER • Remove the following parts from the kick starter shaft 8: Return spring 9 Kick starter C Spring guide 0 Snap ring D Shim A Shim E Spring B Kick starter drive gear F " 09900-06107: Snap ring pliers •...
Page 148: Installation
KICK STARTER INSTALLATION Install the kick starter in the reverse order of removal. Pay atten- tion to the following points: • Install the kick starter guide 1. # Kick starter guide bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Install the kick starter drive gear 2 and shim 3 to the kick starter shaft.
Page 149 KICK STARTER • Install the shim 8 and spring 9 to the kick starter shaft. • Install the kick starter shaft assembly to the crankcase. NOTE: Securely engage the stopper portion C of the kick starter with the stopper guide D. •...
Page 150 KICK STARTER • Install the kick starter lever so that its punch mark F aligns with the truncated spline G. • Tighten the kick starter lever bolt to the specified torque. # Kick starter lever bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) •...
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Page 152: Gearshifting
GEARSHIFTING GEARSHIFTING CONTENTS CONSTRUCTION ..................9- 2 GEARSHIFT LINKAGE ................. 9- 2 GEARSHIFT LINKAGE ................9- 3 REMOVAL ..................... 9- 3 INSPECTION ..................9- 4 INSTALLATION ..................9- 5...
Page 153: Construction
GEARSHIFTING CONSTRUCTION GEARSHIFT LINKAGE 10 N . m (1.0 kgf-m, 7.0 lb-ft) 24 N . m (2.4 kgf-m, 17.5 lb-ft)
Page 154: Removal
GEARSHIFTING GEARSHIFT LINKAGE REMOVAL • Drain engine oil. (!2-11) • Drain engine coolant. (!13-3) • Remove the gearshift lever 1. NOTE: Mark the gearshift shaft head at which the gearshift lever slit set for correct reinstallation. • Remove the right crankcase cover and clutch assembly. (!7-9, 8-3) •...
Page 155: Inspection
GEARSHIFTING • Remove the gearshift pawls 8, pins 9 and springs 0. • Remove the gearshift cam driven gear pin A and gearshift cam stopper plate B. • Remove the gearshift cam stopper C, spring D and washer INSPECTION • Inspect the gearshift shaft 1 for bends and damage. •...
Page 156: Installation
GEARSHIFTING INSTALLATION Install the gearshift in the reverse order of removal. Pay atten- tion to the following points: • Install the washer 1, spring 2 and gearshift cam stopper 3. NOTE: Install the spring 2 to the hole A. # Shift cam stopper bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) •...
Page 157 GEARSHIFTING • With the pawls held in pushed position, install the pawl lifter • Install the gearshift cam driven gear and pawl lifter. • Apply THREAD LOCK SUPER to the screws. • Tighten the screws. $ 99000-32030: THREAD LOCK SUPER “1303” or equivalent •...
Page 158 GEARSHIFTING • Align the mark on the gearshift shaft head with the gearshift lever matching surface. • Tighten the gearshift lever bolt to specified torque. # Gearshift lever bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) INSPECTION AFTER INSTALLATION • Engine oil level and oil leakage (!2-11) •...
Page 159 – MEMO –...
Page 160 TRANSMISSION AND CRANKSHAFT 10-1 TRANSMISSION AND CRANKSHAFT CONTENTS CONSTRUCTION ..................10- 2 TRANSMISSION AND CRANKSHAFT ..........10- 2 ENGINE BOTTOM SIDE ................10- 3 PRIMARY DRIVE GEAR REMOVAL ..........10- 3 CRANKCASE SEPARATION ............. 10- 4 TRANSMISSION REMOVAL .............. 10- 4 CRANKSHAFT REMOVAL ..............
Page 161: Construction
10-2 TRANSMISSION AND CRANKSHAFT CONSTRUCTION TRANSMISSION AND CRANKSHAFT 90 N . m (9.0 kgf-m, 65.0 lb-ft)
Page 162: Engine Bottom Side
TRANSMISSION AND CRANKSHAFT 10-3 ENGINE BOTTOM SIDE • Remove the engine. (!5-2 to -5) NOTE: The following parts must be removed before disassembling the engine bottom side (crankcase). • Remove the cylinder head, cylinder and piston. (!6-4 to -6) • Remove the magneto cover. (!14-10) •...
Page 163: Crankcase Separation
10-4 TRANSMISSION AND CRANKSHAFT CRANKCASE SEPARATION • Remove the engine sprocket spacer 1 and two O-rings 2. • Remove the oil strainer cap 3 and oil strainer (No.1). (!2-13) • Remove the crankcase bolts and engine oil drain plug 4. •...
Page 164: Crankshaft Removal
TRANSMISSION AND CRANKSHAFT 10-5 • Remove the gearshift fork shaft 4. • Remove the gearshift cam 5. • Remove the gearshift forks 6. • Remove the countershaft assembly 7 and driveshaft assem- bly 8. CRANKSHAFT REMOVAL • Remove the crankshaft with the special tool. CAUTION Be careful not to damage the thread part of the crank- shaft.
Page 165: Transmission Inspection
10-6 TRANSMISSION AND CRANKSHAFT TRANSMISSION INSPECTION • Inspect the gear teeth, dogs, and gearshift grooves for abnor- mal wear and damage. • Inspect the bushings and splines for abnormal wear and dis- coloration. • If necessary, replace defective parts with a new one. •...
Page 166: Conrod Inspection
TRANSMISSION AND CRANKSHAFT 10-7 • Measure the gearshift fork groove width with a vernier cali- pers. # Gearshift fork groove width Standard: 4.95 – 5.05 mm (0.195 – 0.199 in) " 09900-20101: Vernier calipers CONROD INSPECTION • For conrod inspection other than the following, refer to page 6-??.
Page 167: Oil Seal Inspection
Oil seal 2: $ 22 Attachment Oil seal 3: $ 17 Attachment • Apply grease to each oil seal lip. % 99000-25010: SUZUKI SUPER GREASE “A” or equivalent NOTE: Be sure to check the direction of the crankshaft bearing oil seal 4 before fitting them.
Page 168: Bearing Inspection
TRANSMISSION AND CRANKSHAFT 10-9 BEARING INSPECTION • Inspect the bearings for play, discoloration, wear and seizure. • Move the inner race by finger and inspect for smooth move- ment. • If it does not move smoothly, replace the bearing with a new one.
Page 169 10-10 TRANSMISSION AND CRANKSHAFT • Remove the bearings 2, 8. " 09921-20240: Bearing remover set Bearing 2, 8: Remover 20 mm • Remove the bearing 4. " 09941-64511: Bearing/Oil seal remover 09930-30104: Sliding shaft • Remove the bearing 9. " 09921-20200: Bearing remover 09930-30104: Sliding shaft •...
Page 170 TRANSMISSION AND CRANKSHAFT 10-11 INSTALLATION • Press the new bearings with the special tools. Bearing 1: $ 55 Attachment Bearing 2, 8: $ 42 Attachment Bearing 3, 6: $ 72 Attachment Bearing 4: $ 40 Attachment Bearing 5: $ 52 Attachment Bearing 7: $ 37 Attachment Bearing 9: $ 15 Attachment "...
Page 171: Crankshaft Installation
10-12 TRANSMISSION AND CRANKSHAFT CRANKSHAFT INSTALLATION • Fit the crankshaft into the left crankcase with the special tools. NOTE: Use the attachment (inner driver attachment 3) for crankshaft bearing inside diameter. " 09910-32812: Crankshaft installer 1 09911-11310: Crankshaft installer attachment 2 09913-70210: Bearing installer set (Inner driver attachment 35 mm 3)
Page 172: Transmission Installation
TRANSMISSION AND CRANKSHAFT 10-13 TRANSMISSION INSTALLATION 28.5 mm (1.12 in) NOTE: Install the snap ring in the groove and locate its end as shown in the illustration. Thrust Sharp edge • Apply engine oil to the following parts: driveshaft, counter- shaft, transmission gears, bearings.
Page 173 10-14 TRANSMISSION AND CRANKSHAFT • Install the gearshift forks 3, 4. • Install the gearshift cam 5 and gearshift shaft 6. NOTE: Turn the gearshift cam to the neutral position and confirm that the driveshaft and countershaft turn without resistance. •...
Page 174: Crankcase Installation
TRANSMISSION AND CRANKSHAFT 10-15 CRANKCASE INSTALLATION • Fit the dowel pins and gasket 1. CAUTION Replace the gasket 1 with a new one. • Fit the right crankcase on the left crankcase. • Install the bracket A to the bolt. (!19-24) •...
Page 175: Primary Drive Gear Installation
10-16 TRANSMISSION AND CRANKSHAFT • Apply grease to Oil seal lip and O-rings 5. % 99000-25010: SUZUKI SUPER GREASE “A” or equivalent CAUTION Replace the O-rings with new ones. • Fit the O-rings 5 and spacer 6 to the driveshaft.
Page 176 TRANSMISSION AND CRANKSHAFT 10-17 • Connect the crankcase breather hose 4. • Install the oil pump No.1, No.2 and oil pump idle gear. (!11-6) • Install the gearshift linkage. (!9-5) • Install the kick idle gear and kick starter shaft. (!8-5) •...
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Page 178: Lubrication System
LUBRICATION SYSTEM 11-1 LUBRICATION SYSTEM CONTENTS ENGINE LUBRICATION SYSTEM ............11- 2 ENGINE LUBRICATION SYSTEM CHART ........11- 2 ENGINE OIL LEVEL INSPECTION ............. 11- 3 ENGINE OIL CHANGE ................ 11- 3 ENGINE OIL FILTER CHANGE ............11- 3 OIL PRESSURE CHECK ..............11- 3 OIL STRAINERS REMOVAL ..............
Page 179: Engine Lubrication System
11-2 LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM CHART CAM SPROCKET & CAM CHAIN CAMSHAFT BEARINGS IN & EX CAM FACES CONROD SMALL END CAMSHAFT CYLINDER WALL JOURNALS OIL NOZZLE CYLINDER HEAD CYLINDER RIGHT CRANKCASE CLUTCH CRANKSHAFT RIGHT CRANKCASE COUNTER SHAFT RIGHT END COVER...
Page 180: Engine Oil Level Inspection
LUBRICATION SYSTEM 11-3 ENGINE OIL LEVEL INSPECTION (!2-11) ENGINE OIL CHANGE (!2-11) ENGINE OIL FILTER CHANGE (!2-12) OIL PRESSURE CHECK (!2-37) OIL STRAINER REMOVAL (!2-13) OIL STRAINER INSPECTION (!2-13) OIL STRAINER INSTALLATION (!2-13) OIL SEAL REMOVAL • Remove the snap ring 1. "...
Page 181: Oil Seal Installation
• Fit the new oil seal with the special tools. " 09913-70210: Bearing installer set Oil seal: # 22 Attachment • Apply SUZUKI SUPER GREASE to the oil seal lip. $ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the snap ring 1.
Page 182: Oil Pump No.1 And No.2 Inspection
LUBRICATION SYSTEM 11-5 • Remove the oil pump No.2 shaft 2, pin 3, inner rotor 4 and outer rotor 5. OIL PUMP No.1 AND No.2 INSPECTION • Check the oil pump with each part for any defects or wear. • Replace the defective parts with a new one.
Page 183: Oil Pump No.1 And No.2 Installation
11-6 LUBRICATION SYSTEM OIL PUMP No.1 AND No.2 INSTALLATION OIL PUMP No.1 Install the oil pump No.1 in the reverse order of removal. Pay attention to the following points: • Install the oil pump No.1 cover 2, oil pump No.1 plate 3 and pin 4 to oil pump driven gear shaft 1.
Page 184 LUBRICATION SYSTEM 11-7 OIL PUMP No.2 Install the oil pump No.2 in the reverse order of removal. Pay attention to the following points: • Install the pin 2 to oil pump No.2 shaft 1. • Install the inner rotor 3 to oil pump No.2 shaft 1. NOTE: Fit the slot A of the inner rotor to the pin 2.
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Page 186: Fuel System
FUEL SYSTEM 12-1 FUEL SYSTEM CONTENTS FUEL TANK AND FUEL VALVE ............... 12- 2 CONSTRUCTION ................12- 2 REMOVAL ................... 12- 2 CLEANING AND INSPECTION ............12- 3 INSTALLATION ................... 12- 3 CARBURETOR ..................12- 4 CONSTRUCTION ................12- 4 REMOVAL ...................
Page 187: Fuel Tank And Fuel Valve
12-2 FUEL SYSTEM FUEL TANK AND FUEL VALVE CONSTRUCTION REMOVAL " WARNING Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Remove the seat. (!5-2) • Remove the fuel tank. (!5-2) • Drain fuel. • Remove the fuel valve 1. •...
Page 188: Cleaning And Inspection
FUEL SYSTEM 12-3 CLEANING AND INSPECTION If the fuel strainer is dirty with sediment, fuel will not flow smoothly and loss in engine power may result. Clean the fuel strainer with compressed air. INSTALLATION Install the fuel tank and fuel valve in the reverse order of removal.
Page 189: Carburetor
12-4 FUEL SYSTEM CARBURETOR CONSTRUCTION 1 Clip 2 Jet needle 3 Throttle valve Throttle position sensor 5 Slow air jet 6 Starter jet 7 Pilot screw 8 Slow jet 9 Main jet 0 Float valve A Float B Leak jet C Throttle stop screw...
Page 190: Removal
FUEL SYSTEM 12-5 REMOVAL " WARNING Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Remove the seat and radiator covers. (!5-2) • Turn the fuel valve to the OFF position. • Place a container beneath the drain hose, drain fuel from the float chamber by loosening the drain screw 1.
Page 191: Disassembly
12-6 FUEL SYSTEM • Remove the throttle pulley cover 6. • Loosen the lock-nuts 7. • Remove the throttle cables from the pulley. DISASSEMBLY • Remove the hot starter valve 1 and spring from the hot starter cable. • Remove the drain hose, fuel hose and air vent hoses. NOTE: Do not remove the throttle position sensor 2 unless it is neces- sary to replace it.
Page 192 FUEL SYSTEM 12-7 • Remove the throttle valve assembly 5. • Disassemble the throttle valve assembly. 6 Throttle valve A Spring 7 Bearing B Needle set screw 8 Jet needle C Floating valve 9 Clip D Seal 0 Collar • Remove the throttle shaft E with the link arm F, spring G, plastic washer H and steel washer I.
Page 193 12-8 FUEL SYSTEM • Remove the acceleration pump cover K. • Remove the spring L, O-rings M and diaphragm N. • Remove the float chamber O from the carburetor body. • Remove the drain plug P and leak jet Q. •...
Page 194 FUEL SYSTEM 12-9 • Remove the following parts. Z Main jet [ Main nozzle \ Buffer plate ] Starter jet ^ Slow jet • Remove the slow air jet a.
Page 195: Cleaning
12-10 FUEL SYSTEM CLEANING " WARNING Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and storage. • Clean all jets with a spray-type carburetor cleaner and dry them using compressed air.
Page 196 FUEL SYSTEM 12-11 FUEL LEVEL • Remove the drain hose and then install a proper cap 1 to the carburetor drain. • Remove the drain screw and than connect the special tool. $ 09913-14541: Fuel level gauge • Hold the carburetor in the proper angle with a stand. Lateral direction: Horizontal Carburetor set position...
Page 197: Reassembly
12-12 FUEL SYSTEM FLOAT HEIGHT • Tilt the carburetor until the float arm B just touches the float valve rod. • Measure the float height A. % Standard float height: 8.0 mm (0.315 in) $ 09900-20101: Vernier calipers • If necessary, slightly bend the float arm B to change the float height.
Page 198 Replace the O-rings with new ones. • Apply thin coat of the grease to the O-ring. CAUTION Replace the O-ring with a new one. & 09900-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the pilot screw 0. NOTE: Turn in the pilot screw 0 until it lightly seats, then back it out the counted number of turns.
Page 199 12-14 FUEL SYSTEM • Apply SUZUKI SILICONE GREASE to the throttle shaft. ' 99000-25100: SUZUKI SILICONE GREASE or equivalent • Hook the return spring onto the stopper of the throttle pulley. • Insert the throttle shaft and install the steel washer A, plastic washer B and link arm C.
Page 200 FUEL SYSTEM 12-15 CAUTION Replace the gasket with a new one. • Reassemble the hot start valve E to the hot start cable end. ACCELERATION PUMP TIMING If turn the stop screw of the acceleration pump, adjust the accel- eration pump timing after assemble the carburetor. •...
Page 201: Installation
12-16 FUEL SYSTEM INSTALLATION Install the carburetor in the reverse order of removal. Pay atten- tion to the following points: • Fit the projection on the carburetor body in the depression of the intake pipe. INSPECTION AFTER INSTALLATION • Wire, cable and hose routing (!19-18 to -22) •...
Page 202: Throttle Position Sensor
FUEL SYSTEM 12-17 THROTTLE POSITION SENSOR INSPECTION THROTTLE POSITION SENSOR INPUT VOLTAGE • Disconnect the throttle position sensor coupler 1. • Shift the transmission into neutral. B/Bl • Start the engine. • Measure the throttle position sensor input voltage using the multi circuit tester.
Page 203: Removal
12-18 FUEL SYSTEM REMOVAL • Remove the carburetor. (!12-5) • Remove the throttle position sensor using the special tool. $ 09930-11950: Torx wrench, T25 INSTALLATION • Install the throttle valve with the throttle position sensor. NOTE: Align the throttle shaft end A with the groove B of throttle posi- tion sensor.
Page 204 COOLING SYSTEM 13-1 COOLING SYSTEM CONTENTS CONSTRUCTION ..................13- 2 ENGINE COOLANT ................... 13- 3 REPLACEMENT .................. 13- 3 COOLING CIRCUIT ................... 13- 4 INSPECTION ..................13- 4 RADIATOR ....................13- 5 INSPECTION ..................13- 5 REMOVAL ................... 13- 6 INSTALLATION ...................
Page 205: Construction
13-2 COOLING SYSTEM CONSTRUCTION 10 N . m (1.0 kgf-m, 7.0 lb-ft) 11 N . m (1.1 kgf-m, 8.0 lb-ft)
Page 206: Engine Coolant
COOLING SYSTEM 13-3 ENGINE COOLANT REPLACEMENT $ WARNING Engine coolant may be harmful if swallowed or if it comes in contact with the skin or eyes. If engine cool- ant gets into the eyes or contacts the skin, flush the eyes or wash the skin thoroughly, with plenty of water.
Page 207: Cooling Circuit
13-4 COOLING SYSTEM COOLING CIRCUIT INSPECTION • Remove the radiator cap. $ WARNING * Engine coolant may be harmful if swallowed or if it comes in contact with the skin or eyes. If engine coolant gets into the eyes or contacts the skin, flush the eyes or wash the skin thoroughly, with plenty of water.
Page 208: Radiator
COOLING SYSTEM 13-5 RADIATOR INSPECTION RADIATOR • Visually inspect the radiators and hose for damage. • Fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver. RADIATOR CAP • Fit the cap to the radiator cap tester. •...
Page 209: Removal
13-6 COOLING SYSTEM REMOVAL $ WARNING * Engine coolant may be harmful if swallowed or if it comes in contact with the skin or eyes. If engine coolant gets into the eyes or contacts the skin, flush the eyes or wash the skin thoroughly, with plenty of water.
Page 210: Water Pump
COOLING SYSTEM 13-7 WATER PUMP REMOVAL $ WARNING Engine coolant may be harmful if swallowed or if it comes in contact with the skin or eyes. If engine cool- ant gets into the eyes or contacts the skin, flush the eyes or wash the skin thoroughly, with plenty of water.
Page 211: Inspection
13-8 COOLING SYSTEM • Remove the shim 3 and water pump shaft 4. • Remove the oil seal. CAUTION Replace the removed oil seal with a new one. NOTE: If there is no abnormal condition, the oil seal removal is not nec- essary.
Page 212 COOLING SYSTEM 13-9 • Press the oil seal with the suitable size socket wrench. • Apply SUZUKI SUPER GREASE to the oil seal lip. & 99000-25010: SUZUKI SUPER GREASE “A” or equivalent IMPELLER AND WATER PUMP SHAFT • Hold the water pump shaft with a wrench and tighten the impeller to the specified torque.
Page 213 13-10 COOLING SYSTEM WATER PUMP CASE • Install the dowel pins and oil filter 1. • Install the spring 2 and a new gasket 3. • Apply engine coolant to the gasket 3. CAUTION Use a new gasket to prevent engine oil/coolant leak- age.
Page 214: Electrical System
ELECTRICAL SYSTEM 14-1 ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ............... 14- 2 CONNECTOR ..................14- 2 COUPLER ................... 14- 2 SEMI-CONDUCTOR EQUIPPED PART ..........14- 2 USING THE MULTI-CIRCUIT TESTER ..........14- 2 SWITCH ....................14- 2 LOCATION OF ELECTRICAL COMPONENTS ........14- 3 CONSTRUCTION ..................
Page 215: Cautions In Servicing
14-2 ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTOR • When connecting a connector, be sure to push it in until a click is felt. Click • Inspect the connector for corrosion, contamination and break- age in its cover. COUPLER Click • With a lock type coupler, be sure to release the lock when dis- connecting, and push in fully to engage the lock when con- necting.
Page 216: Location Of Electrical Components
ELECTRICAL SYSTEM 14-3 LOCATION OF ELECTRICAL COMPONENTS 1 Engine stop switch 4 CDI unit 2 Ignition coil 5 Pick-up coil 3 Throttle position sensor 6 Magneto...
Page 217: Construction
14-4 ELECTRICAL SYSTEM CONSTRUCTION ELECTRICAL SYSTEM 80 N . m (8.0 kgf-m, 58.0 lb-ft) ELECTRICAL CIRCUIT Throttle position sensor Engine stop switch B/Br B/Br B/Br B/Bl B/Bl B/Bl Magneto W/Bl Ignition coil CDI unit Y Y Y Spark plug WIRE COLOR: G: Green B/Bl: Black with Blue tracer B/W: Black with White tracer...
Page 218: Troubleshooting
ELECTRICAL SYSTEM 14-5 TROUBLESHOOTING No spark or poor spark Step 1 1) Check the ignition system couplers for poor connections. Is there connection in the ignition system couplers? Go to Step 2. Poor connection of couplers Step 2 1) Measure the ignition coil primary peak voltage. ("14-8) Is the peak voltage OK? Go to Step 3.
Page 219 14-6 ELECTRICAL SYSTEM Step 7 1) Check the stator. Is the stator OK? Go to Step 8. Faulty stator Step 8 1) Measure the engine stop switch resistance. ("14-9) Is the resistance OK? • Faulty CDI unit • Open or short circuit in wire harness Faulty engine stop switch...
Page 220: Ignition System
ELECTRICAL SYSTEM 14-7 IGNITION SYSTEM IGNITION SYSTEM PEAK VOLTAGE INSPECTION • Disconnect the magneto lead wire coupler 1. • Connect the multi-circuit tester with peak volt adaptor as shown. • Measure the highest peak voltage by depressing the kick starter pedal several times forcefully. # Stator coil peak voltage + Black/Red –...
Page 221: Ignition System Coil Inspection
14-8 ELECTRICAL SYSTEM IGNITION SYSTEM COIL INSPECTION • Disconnect the magneto lead wire coupler 1. • Measure the exciter, charge and pick-up coils resistance. # Stator coil resistance 24 – 40 Ω Exciter Black/Red – Red/White 1.6 – 3.2 Ω Charge Yellow –...
Page 222: Ignition Coil Inspection
ELECTRICAL SYSTEM 14-9 IGNITION COIL INSPECTION • Remove the seat and fuel tank. ("5-2) • Disconnect the ignition coil lead wire coupler 1 and spark plug cap 2. • Measure the ignition coil resistance. # Ignition coil resistance White/Blue – 0.17 –...
Page 223: Magneto Rotor
14-10 ELECTRICAL SYSTEM MAGNETO ROTOR REMOVAL • Drain engine oil. ("2-11) • Remove the seat and fuel tank. ("5-2) • Disconnect the magneto lead wire coupler and clamp. • Remove the left front protector 1. • Remove the gearshift lever 2. ("9-3) •...
Page 224 ELECTRICAL SYSTEM 14-11 • Remove the magneto rotor nut with a special tool. ! 09930-44560: Rotor holder • Remove the magneto rotor with a special tool. ! 09930-35020: Rotor remover • Remove the magneto rotor key 5.
Page 225: Installation
14-12 ELECTRICAL SYSTEM INSTALLATION • Remove any grease from the tapered portion A of the mag- neto rotor and crankshaft B. • Fit the magneto rotor key 1 into the crankshaft. • Install the magneto rotor. • Tighten the magneto rotor nut to the specified torque with a special tool.
Page 226: Stator
ELECTRICAL SYSTEM 14-13 STATOR REMOVAL • Remove the magneto cover. ("14-10) • Remove the stator 1. • Remove the clamp 2 and pick-up coil 3. • Remove the grommet 4. INSTALLATION • Apply THREAD LOCK to the stator set bolts and tighten them. ( 99000-32050: THREAD LOCK “1342”...
Page 227 – MEMO –...
Page 228: Front And Rear Wheels
FRONT AND REAR WHEELS 15-1 FRONT AND REAR WHEELS CONTENTS CONSTRUCTION ..................15- 2 FRONT WHEEL ..................15- 3 REMOVAL ................... 15- 3 INSPECTION ..................15- 4 DUST SEAL AND BEARING REPLACEMENT ........15- 5 DISC PLATE REPLACEMENT ............15- 7 INSTALLATION ...................
Page 229: Construction
15-2 FRONT AND REAR WHEELS CONSTRUCTION 90 N . m (9.0 kgf-m, 65.0 lb-ft) 25 N . m (2.5 kgf-m, 18.0 lb-ft) 30 N . m (3.0 kgf-m, 21.5 lb-ft) 12 N . m (1.2 kgf-m, 8.5 lb-ft) 35 N . m (3.5 kgf-m, 25.5 lb-ft)
Page 230: Front Wheel
FRONT AND REAR WHEELS 15-3 FRONT WHEEL REMOVAL • Remove the front axle nut 1. • Loosen the left axle holder bolts 2. • Place the motorcycle on a block to lift front wheel off the ground. • Loosen the right axle holder bolts 3. •...
Page 231: Inspection
15-4 FRONT AND REAR WHEELS INSPECTION SPACER AND DUST SEAL • Inspect the right and left dust seals 1 and wheel spacers 2 for wear and cracks. • If any defects are found, replace the spacer together with the dust seal. NOTE: Apply grease to the spacer and dust seal before reassembling.
Page 232: Dust Seal And Bearing Replacement
FRONT AND REAR WHEELS 15-5 WHEEL BEARING • Turn the inner race by finger and inspect it for smooth move- ment. • Inspect for bearing damage. • If any defects are found, replace the bearing with a new one. DUST SEAL AND BEARING REPLACEMENT •...
Page 233 • Fit the dust seals and apply grease to their lips. NOTE: When installing the dust seal, place the manufacturer’s code indicated side of the dust seal outside. " 09913-70210: Bearing installer set Bearing: #40 Attachment $ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
Page 234: Disc Plate Replacement
FRONT AND REAR WHEELS 15-7 DISC PLATE REPLACEMENT • Remove the disc plate. • Apply THREAD LOCK SUPER to the bolts. % 99000-32110: THREAD LOCK SUPER “1322” or equivalent • Tighten the bolts to the specified torque. & Disc plate bolt: 12 N·m (1.2 kgf-m, 8.5 lb-ft) INSTALLATION •...
Page 235: Rear Wheel
15-8 FRONT AND REAR WHEELS REAR WHEEL REMOVAL • Loosen the rear axle nut 1. • Place the motorcycle on a block to lift the rear wheel off the ground. • Remove rear axle nut 1 and washer 2. • Remove the rear axle shaft 3 and chain adjuster washers 4. •...
Page 236: Inspection
FRONT AND REAR WHEELS 15-9 INSPECTION WHEEL SPACER AND DUST SEAL • Inspect the rear wheel spacers 1 and dust seals 2 for wear and cracks. • If any defects are found, replace the spacer together with the dust seal. NOTE: Apply grease on the spacer and dust seal before reassembling.
Page 237 • Remove the spacer 2 and bearing with the special tool. " 09921-20240: Bearing remover set (Remover 25 mm) • Apply grease to the wheel bearings. $ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Assemble the bearings with the special tools, using the suit- able spacer A match for the outside dimension of bearings.
Page 238: Disc Plate Replacement
When installing the dust seal, place the manufacturer’s code indicated side of the dust seal outside. " 09913-70210: Bearing installer set Oil seal: #42 Attachment $ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent DISC PLATE REPLACEMENT • Remove the disc plate.
Page 239: Rear Sprocket Replacement
15-12 FRONT AND REAR WHEELS REAR SPROCKET REPLACEMENT • Remove the rear sprocket. NOTE: Install the rear sprocket as the letter on the sprocket surface faces outside. • Tighten the nuts to the specified torque. & Rear sprocket nut: 30 N·m (3.0 kgf-m, 21.5 lb-ft) INSTALLATION Left Right...
Page 240: Front And Rear Brakes
FRONT AND REAR BRAKES 16-1 FRONT AND REAR BRAKES CONTENTS CONSTRUCTION ..................16- 2 BRAKE FLUID AIR BLEEDING ..............16- 3 BRAKE FLUID REPLACEMENT ............... 16- 4 BRAKE PADS REPLACEMENT ............... 16- 5 FRONT BRAKE PADS ................ 16- 5 REAR BRAKE PADS ................16- 5 BRAKE DISC INSPECTION ..............
Page 241: Construction
16-2 FRONT AND REAR BRAKES CONSTRUCTION 10 N·m (1.0 kgf-m, 7.0 lb-ft) 23 N·m 23 N·m (2.3 kgf-m, (2.3 kgf-m, 16.5 lb-ft) 16.5 lb-ft) 10 N·m 23 N·m (1.0 kgf-m, 7.0 lb-ft) (2.3 kgf-m, 16.5 lb-ft) 18 N·m (1.8 kgf-m, 13.0 lb-ft) 29 N·m (2.9 kgf-m, 21.0 lb-ft)
Page 242: Brake Fluid Air Bleeding
FRONT AND REAR BRAKES 16-3 BRAKE FLUID AIR BLEEDING "#WARNING Brake fluid can be hazardous to humans and pets. Brake fluid is harmful or fatal if swallowed, and harm- ful if it comes in contact with your skin or eyes. Keep brake fluid away from children.
Page 243: Brake Fluid Replacement
16-4 FRONT AND REAR BRAKES • Connect a transparent tube to the bleeder valve and set the other end into a receptacle. • Loosen the bleeder valve and pump the brake lever/pedal until air bubbles stop coming out from the reservoir. •...
Page 244: Brake Pads Replacement
FRONT AND REAR BRAKES 16-5 BRAKE PADS REPLACEMENT FRONT BRAKE PADS • Remove the cap 1 and pad mounting pin 2. • Remove the brake pads 3. NOTE: Replace the two brake pads as a set. • Fit the new brake pads into the caliper. •...
Page 245: Brake Disc Inspection
16-6 FRONT AND REAR BRAKES BRAKE DISC INSPECTION • Inspect the brake disc for damage. • Measure the front and rear brake disc thickness. & Brake disc thickness Service limit (Front): 2.5 mm (0.10 in) (Rear): 3.5 mm (0.14 in) •...
Page 246: Front Caliper Removal And Disassembly
FRONT AND REAR BRAKES 16-7 FRONT CALIPER REMOVAL AND DISASSEMBLY • Place a rag under the brake hose union bolt to catch spilled brake fluid. • Remove the union bolt 1. • Disconnect the brake hose. • Remove the caliper mounting bolts 2. •...
Page 247: Caliper Inspection
! Specification and classification: DOT 4 • Install the springs and boots. • Apply SUZUKI SILICONE GREASE to the caliper axles. ' 99000-25100: SUZUKI SILICONE GREASE or equivalent • Install the caliper bracket.
Page 248: Rear Caliper Removal And Disassembly
FRONT AND REAR BRAKES 16-9 • Tighten the caliper mounting bolts 1 to the specified torque. $ Brake caliper mounting bolt: 25 N·m (2.5 kgf-m, 18.0 lb-ft) • Tighten the brake pad mounting pin 2 to the specified torque. $ Brake pad mounting pin: 18 N·m (1.8 kgf-m, 13.0 lb-ft) •...
Page 249: Rear Caliper Reassembly And Installation
16-10 FRONT AND REAR BRAKES • Remove the caliper bracket 5 from the caliper. • Remove the boots 6 and 7. • Remove the spring 8. • Wrap the caliper with a rag to prevent brake fluid scatter and piston pop-out. •...
Page 250 FRONT AND REAR BRAKES 16-11 • Install the springs and boots. • Apply SUZUKI SILICONE GREASE to the caliper axles. ' 99000-25100: SUZUKI SILICONE GREASE or equivalent • Install the caliper bracket. • Install the brake pads. • Tighten the brake pad mounting pin temporarily.
Page 251: Master Cylinder
16-12 FRONT AND REAR BRAKES MASTER CYLINDER "#WARNING Brake fluid can be hazardous to humans and pets. Brake fluid is harmful or fatal if swallowed, and harm- ful if it comes in contact with your skin or eyes. Keep brake fluid away from children. Call your doctor immediately if brake fluid is swallowed, and induce vomiting.
Page 252: Master Cylinder Inspection
FRONT AND REAR BRAKES 16-13 • Remove the dust boot 5. • Remove the snap ring 6 with snap ring pliers. ( 09900-06108: Snap ring pliers • Remove the washer 7 and piston/cup set 8. MASTER CYLINDER INSPECTION • Inspect the cylinder bore and piston for scuffing, wear and damage.
Page 253: Front Master Cylinder Reassembly And Installation
• Apply grease to the brake lever pivot bolt and contact point between piston and brake lever. ) 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Tighten the pivot bolt and nut to the specified torque. $ Brake lever pivot nut: 6 N·m (0.6 kgf-m, 4.4 lb-ft) Brake lever pivot bolt: 6 N·m (0.6 kgf-m, 4.4 lb-ft)
Page 254: Rear Master Cylinder Removal And Disassembly
FRONT AND REAR BRAKES 16-15 REAR MASTER CYLINDER REMOVAL AND DISASSEMBLY • Drain brake fluid. (%16-4) • Remove the cotter pin, washer and then master cylinder rod pin 1. • Remove the master cylinder mounting bolts and master cylin- der 2. •...
Page 255: Master Cylinder Inspection
• Apply grease to the contact point between piston and push rod. ) 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Set the brake hose end between the hose stoppers, then tighten the brake hose union bolt 1 to the specified torque.
Page 256: Brake Lever
• Apply grease to the brake lever adjuster return spring, pivot bolt and contact point between piston and brake lever. ) 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Tighten the pivot bolt and nut to the specified torque.
Page 257: Installation
• Remove the master cylinder rod pin 4. • Remove the brake pedal pivot bolt 5 and return spring 6. INSTALLATION • Apply SUZUKI SUPER GREASE to the oil seal and brake pedal pivot bolt. ) 99000-25010: SUZUKI SUPER GREASE “A”...
Page 258: Front Fork And Steering
FRONT FORK AND STEERING 17-1 FRONT FORK AND STEERING CONTENTS CONSTRUCTION ..................17- 2 FRONT FORK, STEERING ..............17- 2 HANDLEBAR CONTROLS ..............17- 3 REMOVAL ................... 17- 4 DISASSEMBLY ................... 17- 5 INSPECTION ..................17- 9 REASSEMBLY ..................17-11 INSTALLATION ...................
Page 259: Construction
17-2 FRONT FORK AND STEERING CONSTRUCTION FRONT FORK, STEERING 25 N . m (2.5 kgf-m, 18.0 lb-ft) 100 N . m (10.0 kgf-m, 72.5 lb-ft) 23 N . m 30 N . m (3.0 kgf-m, 21.5 lb-ft) (2.3 kgf-m, 16.5 lb-ft) 35 N .
Page 260: Handlebar Controls
FRONT FORK AND STEERING 17-3 HANDLEBAR CONTROLS 25 N·m (2.5 kgf-m, 18.0 lb-ft) 6 N·m (0.6 kgf-m, 4.5 lb-ft) 6 N·m (0.6 kgf-m, 4.5 lb-ft)
Page 261: Removal
17-4 FRONT FORK AND STEERING REMOVAL • Place the motorcycle on a block to lift front wheel off the ground. • Remove the front wheel. (!15-3) • Remove the front number plate 1. • Remove the protector 2. • Remove the handlebar. NOTE: Mark the paint mark A to the matching surface of handlebar holder and handlebars before removing.
Page 262: Disassembly
FRONT FORK AND STEERING 17-5 DISASSEMBLY • Set rebound and compression damper settings to the mini- mum settings (softest) before disassembling. Record the set- ting before turning the adjuster. • Thoroughly clean the fork before disassembly. CAUTION Scratches or other damage on the inner tube or on the oil seal lip will cause oil leakage.
Page 263 17-6 FRONT FORK AND STEERING • Clamp the axle holder 2 with a vise. Protect the axle holder with a rag when using a vise. • Loosen the center bolt 3 completely with a 21 mm socket wrench. # WARNING Clamping the axle holder too tight can damage it which will affect riding stability.
Page 264 FRONT FORK AND STEERING 17-7 • With the outer tube compressed by hands, remove the special tool. CAUTION Removing the lock-nut 4 and pushing the inner rod thread into the damper rod will damage the inner rod oil seal. Do not remove the lock-nut 4 from the inner rod. •...
Page 265 17-8 FRONT FORK AND STEERING INNER TUBE • Separate the inner tube 1 out of the outer tube 2. • Remove the slide bushing 3 from the inner tube 1. • Remove the following parts from the inner tube 1. Guide bushing 4 Seal retainer 5 Oil seal 6...
Page 266: Inspection
FRONT FORK AND STEERING 17-9 • Drain the fork oil from the damper rod assembly by moving the inner rod several strokes. INSPECTION CENTER BOLT • Inspect the adjuster rod of the center bolt for damage. If it is damaged, replace it with a new one. COMPRESSION DAMPER UNIT •...
Page 267 17-10 FRONT FORK AND STEERING DAMPER ROD ASSEMBLY • Inspect the damper rod assembly for scratches or bending. If it has scratches or is bent, replace it with a new one. FORK SPRING • Measure the free length of front fork spring. •...
Page 268: Reassembly
FRONT FORK AND STEERING 17-11 REASSEMBLY NOTE: * Clean all fork parts before reassembling. * Replace the O-rings, oil seal and dust seal with new ones. * Apply specified front fork oil when installing the O-rings, slide bushing, guide bushing, damper unit and other sliding parts. INNER TUBE •...
Page 269 $ Fork oil quantity (Inside the damper rod): 193 ml (6.52/6.80 US/lmp oz) % 99000-99001-SS5: SUZUKI FORK OIL SS-05 or equivalent • With the damper rod held immovable in fully extended posi- tion, gently install the compression damper unit 4 to the sub-...
Page 270 FRONT FORK AND STEERING 17-13 • Hold the bottom (flat part) of the sub-tank. • Tighten the compression damper unit 4 to the specified torque. & Compression damper unit: 30 N·m (3.0 kgf-m, 21.5 lb-ft) • With the damper rod held in vertical position, slowly move the inner rod several strokes.
Page 271 17-14 FRONT FORK AND STEERING • With the damper rod in horizontal position, move the inner rod by hand to inspect it if operating smoothly. • If the inner rod is not extend, repeat the “COMPRESSION DAMPER UNIT” procedures (Pour the specified amount fork oil and discharge an excess of oil).
Page 272 FRONT FORK AND STEERING 17-15 • Clamp the axle holder with a vise. Protect the axle holder with a rag when using a vise. # WARNING Clamping the axle holder too tight can damage it which will affect riding stability. Do not clamp the axle holder too tight.
Page 273 • Pour the specified amount of fork oil into the outer tube. $ Oil quantity (When standard fork spring is used): 385 ml (13.01/13.56 US/lmp oz) % 99000-99001-SS5: SUZUKI FORK OIL SS-05 or equivalent • Raise the outer tube and temporarily tighten the fork cap bolt (sub-tank).
Page 274: Installation
FRONT FORK AND STEERING 17-17 INSTALLATION • Install the front fork with the line T aligned with the upper sur- face of the upper bracket. • Check that the air valve A is positioned at the front. • Tighten the fork lower clamp bolts to the specified torque. &...
Page 275: Steering
17-18 FRONT FORK AND STEERING STEERING REMOVAL HANDLEBARS • Place the motorcycle on a block to lift front wheel off the ground. • Remove the front number plate and protector. (!17-4) • Remove the clamps. • Remove the engine stop switch 1. •...
Page 276 FRONT FORK AND STEERING 17-19 • Remove the handlebar holder bolts and remove the handle- bars. NOTE: Mark the paint mark to the matching surface of handlebar holder and handlebars before removing. STEERING STEM • Remove the front wheel 1. (!15-3) •...
Page 277 17-20 FRONT FORK AND STEERING • Remove the handlebar holder set bolts and nuts. • Remove the steering stem nut with the special tools. " 09940-14911: Steering nut socket wrench 09940-14960: Attachment • Remove the steering stem lower bracket. NOTE: Hold the steering stem lower bradcet by hand to prevent it from falling.
Page 278: Inspection
FRONT FORK AND STEERING 17-21 INSPECTION STEERING STEM • Inspect the needle bearings for wear. • Inspect the steering stem for distortion. • Replace the defective parts with a new one. • Inspect the bearing outer races for wear. • If any defects are found, replace the bearing with a new one. •...
Page 279: Bearing Replacement
17-22 FRONT FORK AND STEERING BEARING REPLACEMENT • Remove the lower bearing. • Fit the lower bearing with the special tool. " 09925-18011: Steering bearing installer NOTE: Replace the outer race and bearing as a set. • Remove the upper outer race with the special tools. "...
Page 280: Installation
Install the steering in the reverse order of removal. Pay attention to the following points: STEERING STEM • Apply grease to the bearings. ( 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Fit the steering stem lower bracket, upper bearing and steer- ing stem nut.
Page 281 17-24 FRONT FORK AND STEERING • Install the front forks to the steering stem and tighten the lower clamp bolts temporarily. • Tighten the steering stem head nut to the specified torque. & Steering stem head nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft) •...
Page 282 FRONT FORK AND STEERING 17-25 • Apply grease to the throttle cable and their hole. ( 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Align the matching mark D on the handlebars with the throttle holder matching surface. • Tighten the screws securely.
Page 283 17-26 FRONT FORK AND STEERING ” mark on the left grip with the matching mark F • Align the “ on the left handlebar end. • Align the matching mark G on the handlebars with the clutch lever holder matching surface. •...
Page 284 REAR SUSPENSION 18-1 REAR SUSPENSION CONTENTS CONSTRUCTION ..................18- 2 REAR SUSPENSION ................18- 2 REAR SHOCK ABSORBER ..............18- 3 REMOVAL ................... 18- 3 SPRING REPLACEMENT ..............18- 4 INSPECTION ..................18- 5 BEARING REPLACEMENT ..............18- 6 OIL REPLACEMENT ................18- 7 DISASSEMBLY AND INSPECTION ...........
Page 285: Construction
18-2 REAR SUSPENSION CONSTRUCTION REAR SUSPENSION 80 N . m (8.0 kgf-m, 58.0 lb-ft) 60 N . m (6.0 kgf-m, 43.5 lb-ft) 80 N . m (8.0 kgf-m, 58.0 lb-ft) 80 N . m 60 N . m (8.0 kgf-m, (6.0 kgf-m, 58.0 lb-ft) 43.5 lb-ft)
Page 286: Rear Shock Absorber
REAR SUSPENSION 18-3 REAR SHOCK ABSORBER REMOVAL • Place a block under chassis tube. • Remove the seat. (!5-2) • Loosen the air cleaner clamp screw. • Remove the right frame cover. (!5-2) • Remove the muffler and rear frame assembly. •...
Page 287: Spring Replacement
18-4 REAR SUSPENSION • Remove the rear shock absorber lower mounting bolt and nut. NOTE: If necessary, move the swingarm up or down to facilitate this mounting bolt/nut removal. • Remove the rear shock absorber. SPRING REPLACEMENT • Loosen the lock-nut 1 with the special tool and turn it fully to the end of the thread.
Page 288: Inspection
REAR SUSPENSION 18-5 • Adjust the spring set length and tighten the locknut. # Standard spring set length: 7.3 mm (0.29 in) compressed from the free length Spring set length adjustable range: 247 – 263 mm (9.72 – 10.35 in) [at spring free length 265 mm (10.42 in)] a: Hardest spring setting b: Softest spring setting...
Page 289: Bearing Replacement
• Apply grease to the needle roller bearings and install them. • Apply grease to the dust seals and spacers. • Install the spacers A and B. A for Right side B for Left side % 99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
Page 290: Oil Replacement
REAR SUSPENSION 18-7 OIL REPLACEMENT TOOLS AND EQUIPMENT • Following tools and equipment are required to perform oil replacement. 1 Screwdriver or small punch 7 Rags 2 Vise* 8 Nitrogen tank 3 Drain Pan 9 Filler Hose and Nozzle 4 Oilcan 0 Regulator Assembly 5 Beaker A Owner’s Service Manual...
Page 291 Be sure to extend the rod after filling the oil. • Tilt the shock absorber unit as shown and pour the fresh rear suspension oil fully into the reservoir. 99000-99001-S25: SUZUKI REAR SUSPENSION OIL SS-25 or equivalent # Oil capacity: 395 ml (13.35/13.91 US/Imp oz) •...
Page 292 REAR SUSPENSION 18-9 • Replace the O-rings on the compression adjuster assembly with new ones. • Reinstall the compression adjuster assembly 1. $ Compression adjuster assembly: 30 N·m (3.0 kgf-m, 21.5 lb-ft) • Fill the rear shock absorber unit with nitrogen gas to 784 kPa (8.0 kgf/cm , 113.8 psi).
Page 293: Disassembly And Inspection
18-10 REAR SUSPENSION DISASSEMBLY AND INSPECTION • Clean and dry the rear shock absorber. • Remove the spring from the rear shock absorber. (!18-4) • Turn the rebound damping force adjuster to the softest posi- tion. • Press the valve with a screwdriver to bleed out nitrogen gas. (!18-7) •...
Page 294: Reassembly
• Fit the stopper to the shock absorber body. • Fill the specified rear suspension oil in the rear shock absorber. (!18-8) 99000-99001-S25: SUZUKI REAR SUSPENSION OIL SS-25 or equivalent # Oil capacity: 395 ml (13.35/13.91 US/Imp oz) • Reinstall the compression adjuster assembly. (!18-9) •...
Page 295: Installation
18-12 REAR SUSPENSION INSTALLATION Install the rear shock absorber in the reverse order of removal. Pay attention to the following points: • Tighten the rear shock absorber lower mounting bolt and nut to the specified torque. NOTE: If necessary, move the swingarm up or down to facilitate this mounting bolt/nut tightening.
Page 296: Swingarm
REAR SUSPENSION 18-13 SWINGARM REMOVAL • Place the motorcycle on a block to lift rear wheel off the ground. • Remove the rear wheel. (!15-8) • Remove the chain guide. • Remove the rear brake hose guide. • Remove the rear master cylinder mounting bolts. •...
Page 297 18-14 REAR SUSPENSION • Down the rear brake pedal, remove the pivot shaft. • Remove the swingarm. • Remove the chain buffer. • Remove the plates. • Remove the following parts from the swingarm. Spacer 1 Oil seal 2 Washer 3 Thrust bearing 4 Dust seal 5 Spacer 6...
Page 298: Inspection
REAR SUSPENSION 18-15 INSPECTION PIVOT SHAFT • Measure the pivot shaft runout with the dial gauge and V-blocks. • If any the runout exceeds the limit, replace the pivot shaft with a new one. # Swingarm pivot shaft runout Service Limit: 0.3 mm (0.01 in) "...
Page 299: Bearing Replacement
• Remove the bearings with the special tool. " 09921-20240: Bearing remover set • Press the new bearings with the special tool. " 09924-84521: Bearing installer • Apply grease to the bearings. % 99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
Page 300: Installation
7 Spacer 4 Thrust bearing • Apply grease to the dust seals, bearings and oil seals. % 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Apply THREAD LOCK SUPER to the plate mounting screws. ' 99000-32110: THREAD LOCK SUPER “1322”...
Page 301: Rear Suspension Linkage
18-18 REAR SUSPENSION REAR SUSPENSION LINKAGE REMOVAL • Place a block under the chassis tubes. • Remove the lower drive chain control roller nut 1. • Remove the rear cushion rod bolt and nut. • Remove the cushion lever bolt and nut. •...
Page 302: Inspection
REAR SUSPENSION 18-19 INSPECTION • Inspect the cushion rod and cushion lever for damage. • Inspect the dust seals, oil seals and spacers for damage. • Replace the defective parts with a new one. • Insert the spacers into the bearings and inspect them for excessive play and smooth movement.
Page 303: Bearing Replacement
( 6: right side) * Position the needle roller bearing cages by referring to the illustration of page 18-22. • Apply grease to the needle roller bearings and install them. % 99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
Page 304: Installation
Pay attention to the following points: • Position the dust seals 1 so that the manufacturer’s code indicated side of the seals face outside. ( 2: inside) • Apply grease to the dust seals. % 99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
Page 305 18-22 REAR SUSPENSION • Tighten the cushion lever, cushion rod and swingarm nuts to the specified torque. Left Right 4 mm (0.16 in) 4 mm (0.16 in) 4 mm (0.16 in) 4 mm (0.16 in) $ Tightening torque: A: 60 N·m (6.0 kgf-m, 43.5 lb-ft) B: 60 N·m (6.0 kgf-m, 43.5 lb-ft) C: 80 N·m (8.0 kgf-m, 58.0 lb-ft) D: 80 N·m (8.0 kgf-m, 58.0 lb-ft)
Page 306 REAR SUSPENSION 18-23 Left Right CAUTION Improperly reassembled rear suspension linkage bolts can interfere with suspension move- ment and damage the rear suspension linkage. * Make sure that the rear shock absorber rebound damping adjuster on the bottom bracket of the rear shock absorber is located to the right side.
Page 307 – MEMO –...
Page 308: Servicing Information
SERVICING INFORMATION 19-1 SERVICING INFORMATION CONTENTS SERVICE DATA ..................19- 2 TIGHTENING TORQUE ................19-10 SPECIAL TOOLS ..................19-14 WIRING DIAGRAM ..................19-17 CABLE ROUTING ..................19-18 WIRE HARNESS ROUTING ..............19-20 FUEL HOSE ROUTING ................19-21 RADIATOR HOSE AND CARBURETOR HOSE ROUTING ..... 19-22 REAR BRAKE PEDAL SET-UP ..............
Page 309: Service Data
19-2 SERVICING INFORMATION SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.42) — (1.14) Tappet clearance (when cold) 0.09 – 0.16 — (0.004 – 0.006) 0.17 – 0.24 — (0.007 – 0.009) Valve guide to valve stem 0.010 –...
Page 310 SERVICING INFORMATION 19-3 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 33.57 – 33.62 33.27 (1.322 – 1.324) (1.310) 33.69 – 33.74 33.39 (1.326 – 1.328) (1.315) Camshaft journal oil clearance 0.032 – 0.066 0.150 IN. & EX. (0.001 –...
Page 311: Oil Pump
19-4 SERVICING INFORMATION CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end I.D. 19.010 – 19.018 19.040 (0.7484 – 0.7487) (0.7496) Conrod deflection — (0.12) Conrod big end side clearance 0.20 – 0.65 (0.008 – 0.026) (0.04) Conrod big end width 19.75 –...
Page 312 SERVICING INFORMATION 19-5 TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 2.583 (62/24) — Final reduction ratio 3.500 (49/14) — Gear ratios 2.000 (30/15) — 1.611 (29/18) — 1.363 (30/22) — 1.166 (28/24) —...
Page 313 19-6 SERVICING INFORMATION ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Ignition timing 15° B.T.D.C. at 1 950 r/min. Spark plug Type NGK: DIMR8A10 0.9 – 1.0 (0.035 – 0.039) Spark performance Over 8 (0.3) at 1 atm. 72 – 127 Ω Pick-up coil resistance R –...
Page 314 SERVICING INFORMATION 19-7 ITEM STANDARD LIMIT Wheel rim runout Axial — (0.08) Radial — (0.08) 1.60 × 21 Wheel rim size Front — 2.15 × 19 Rear — Wheel axle runout 0.25 Front — (0.010) 0.25 Rear — (0.010) TIRE ITEM STD/SPEC.
Page 315 19-8 SERVICING INFORMATION SUSPENSION Unit: mm (in) ITEM STANDARD LIMIT NOTE Front fork stroke — (12.2) Front fork inner tube — O.D. (18.5) Front fork spring free 494 ± 2.5 487 (19.17) length (19.45 ± 0.10) Front fork damping Rebound MAX –...
Page 316 (1.4/1.1 US/Imp qt) Air cleaner element oil type MOTUL AIR FILTER OIL or equivalent filter oil Front fork oil type SUZUKI FORK OIL SS-05 or an equivalent fork oil Front fork oil capacity 385 ml Outer tube oil (each leg) (13.01/13.55 US/Imp oz)
Page 317: Tightening Torque
19-10 SERVICING INFORMATION TIGHTENING TORQUE ENGINE PART N·m kgf-m lb-ft Cylinder head cover bolt (Initial) (Final) 10.0 Spark plug Cylinder head bolt (Initial) 18.0 (Final) 33.5 Cylinder head base bolt Cylinder base bolt Camshaft journal holder bolt Primary drive gear nut 65.0 Magneto rotor nut 58.0...
Page 318 SERVICING INFORMATION 19-11 PART N·m kgf-m lb-ft Engine mounting nut (upper) 40.0 32.5 Engine mounting nut (lower) 32.5 Engine mounting nut (front) 40.0 Engine mounting bracket nut (upper) 29.0 Engine mounting bracket nut (front) 29.0 Engine sprocket cover bolt Kick starter lever bolt 16.5 Fuel filter mounting bolt 0.44...
Page 319 19-12 SERVICING INFORMATION CHASSIS PART N·m kgf-m lb-ft Handlebar clamp bolt 18.0 Front fork upper clamp bolt (right and left) 16.5 Front fork lower clamp bolt (right and left) 16.5 Steering stem head nut 10.0 72.5 Front fork cap bolt 25.5 Lock-nut/center bolt 16.0...
Page 320 SERVICING INFORMATION 19-13 For other bolts and nuts not listed in the table, refer to this chart. Conventional or “4” marked bolt “7” marked or crown headed bolt Bolt Diameter A (mm) N·m kgf-m lb-ft N·m kgf-m lb-ft 0.15 0.23 0.45 0.55 16.5...
Page 321: Special Tools
19-14 SERVICING INFORMATION SPECIAL TOOLS 09900-20101 09900-00410 09900-06107 09900-06108 09900-09003 Vernier calipers Hexagon wrench set Snap ring pliers Snap ring pliers Impact driver set (150 mm) 09900-20202 09900-20204 09900-20205 09900-20102 Micrometer Micrometer Micrometer 09900-20530 Vernier calipers (25 – 50 mm) (75 –...
Page 322 SERVICING INFORMATION 19-15 09911-11310 09913-10750 Crankshaft installer Compression gauge 09913-14541 09913-50121 09913-70210 attachment adaptor Fuel level gauge Oil seal remover Bearing installer set 09915-64512 09915-74510 Compression gauge Oil pressure gauge 09916-10911 09916-14510 09916-14521 Valve lapper set Valve lifter Attachment 09916-34550 09916-34580 09916-44910 09916-34542...
Page 323 19-16 SERVICING INFORMATION 09940-14911 09930-30104 09940-14960 Rotor remover slide 09930-35020 09930-44560 Steering nut socket 09940-34581 shaft Rotor remover Rotor holder wrench Attachment F 09940-52861 09941-34513 09941-53630 09941-54911 09940-40211 Front fork oil seal Steering race Front fork top cap Bearing outer race Adapter installer set installer...
Page 324: Wiring Diagram
SERVICING INFORMATION 19-17 WIRING DIAGRAM IGNITION COIL CDI UNIT ENGINE STOP SWITCH Ground : Pickup THROTTLE coil POSITION SENSOR MAGNETO WIRE COLOR Black Blue Green Yellow B/Bl: Black with Blue tracer B/Br: Black with Brown tracer B/G: Black with Green tracer B/R: Black with Red tracer B/W:...
Page 325: Cable Routing
19-18 SERVICING INFORMATION CABLE ROUTING...
Page 326 SERVICING INFORMATION 19-19...
Page 327: Wire Harness Routing
19-20 SERVICING INFORMATION WIRE HARNESS ROUTING...
Page 328: Fuel Hose Routing
SERVICING INFORMATION 19-21 FUEL HOSE ROUTING : The clamp screw head should face..Down side. Down side. 4.4 N . m (0.44 kgf-m, 3.2 lb-ft) Backward. The chamfer side of washer faces outside.
Page 329: Radiator Hose And Carburetor Hose Routing
19-22 SERVICING INFORMATION RADIATOR HOSE AND CARBURETOR HOSE ROUTING Radiator (R) Pass the fuel hose above the intake pipe. Carburetor hose * Air vent hose (clear) 4pcs Fuel hose * Drain hose (black) 1pc Pass through the hose into the hose guide. Radiator (L) Radiator breather hose Forward left side.
Page 330: Rear Brake Pedal Set-Up
SERVICING INFORMATION 19-23 REAR BRAKE PEDAL SET-UP...
Page 331: Magneto Installation
19-24 SERVICING INFORMATION MAGNETO INSTALLATION...
Page 332: Clutch Cable Adjuster
SERVICING INFORMATION 19-25 CLUTCH CABLE ADJUSTER Quick adjuster Turn to tighten Tur urn to tighten n to tighten the clutch cab the clutch cable tension. le tension. the clutch cable tension. Tur urn to loosen Turn to loosen n to loosen the clutch cable tension.
Page 333: Front Brake Hose Routing
19-26 SERVICING INFORMATION FRONT BRAKE HOSE ROUTING Front brake hose Front brake master cylinder Front brake hose Hose guide Stopper Set the brake hose end between the hose stopper, then tighten the brake hose union bolt to the specified torque. Front fork protector Front brake hose Clamp...
Page 334: Rear Brake Hose Routing
SERVICING INFORMATION 19-27 REAR BRAKE HOSE ROUTING...
Page 335: Handlebar Set-Up
19-28 SERVICING INFORMATION HANDLEBAR SET-UP Assemble throttle cables as to show this drawing. Throttle cable Marking on drawing position. (Pull side) Match “ ” mark of grip (L) with marking. Upper side Throttle cable 30˚ (Return side) Marking on drawing position. Match slit of throttle case with marking.
Page 336: Rear Wheel Spokes Installation
SERVICING INFORMATION 19-29 REAR WHEEL SPOKES INSTALLATION...
Page 337: Front Number Plate Installation
19-30 SERVICING INFORMATION FRONT NUMBER PLATE INSTALLATION Number plate band Number plate band Handlebar Hot starter cable Clutch cable VIEW A IGNITION COIL INSTALLATION High-tension cord Cushion Tube Align the cushion edge with VIEW A High-tension cord Cushion the high-tension cord tube.
Page 338: Specifications
SERVICING INFORMATION 19-31 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ............2 185 mm (86.0 in) Overall width............830 mm (32.7 in) Overall height ............. 1 260 mm (49.6 in) Wheelbase ............1 480 mm (58.3 in) Ground clearance..........350 mm (13.8 in) Seat height ............
Page 339 19-32 SERVICING INFORMATION CHASSIS Front suspension ..........Telescopic, coil spring, oil damped Rear suspension ..........Link type, coil spring, oil damped Front suspension stroke........310 mm (12.2 in) Rear wheel travel ..........310 mm (12.2 in) Caster ..............25° 30’ Trail ..............
Page 340: Spare Parts List
SERVICING INFORMATION 19-33 SPARE PARTS LIST ITEM PART NAME PART NUMBER Q’TY PARTS SET, SPARE 19900-35G30 GASKET, MAGNETO COVER 11483-35G10 GASKET, CLUTCH COVER OUTER 11484-35G10 GASKET, EXHAUST, PIPE 14181-35G00 CONNECTOR, MUF JT 14771-29F00 FILTER COMP, ENGINE OIL 16510-35G00 O-RING, WATER POMP CASE 17431-35G10 LEVER, BRAKE 57310-37F00...
Page 341: Setting Data
19-34 SERVICING INFORMATION SETTING DATA DATE RACE/COURSE TEMP./HUMIDITY WEATHER COURSE COUDITION MAIN JET JET NEEDLE SLOW JET AIR SCREW FLOAT LEVEL SPARK PLUG OIL LEVEL COMP. ADJ. POSITION RE-BOUND ADJ. POSITION SPRING SPRING SPRING SET LENGTH COMP. ADJ. POSITION LOW COMP.
Page 342 WARNING Failure to follow these safety precautions may increase your risk of injury: ¹ ¹ Wear a helmet, eye protection, and bright protective clothing. ¹ Don’t ride after consuming alcohol or other drugs. This owner’s service manual contains important safety information.

Suzuki RM-Z450 Owner's Service Manual

Group Index 1

Periodic Maintenance 2

Troubleshooting

Machine Tuning

Cylinder Head, Cylinder and Piston

Clutch

Kick Starter

Gearshifting

Transmission and Crankshaft

Lubrication System

Fuel System

Cooling System

Electrical System

Front and Rear Wheels

Front and Rear Brakes

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

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Summary of Contents for Suzuki RM-Z450