Manual De Servicio Suzuki Gz 150 (ingles) 361t3h

GZ150

99500H33381H000

GZ150

FOREWORD

GROUP INDEX

This manual contains an introductory description on the SUZUKI Gw250 and procedures for its inspection /service and overhaul of its main components. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service. This manual will help you know the motorcycle better so that you can assure your customers of fast and reliable service.

8

* This manual has been prepared on the basis of the latest specifications at the time of publication. If modifications have been made since then, differences may exist between the content of this manual and the actual motorcycle. * Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual motorcycle exactly in detail. * This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you.

WARNING Inexperienced mechanics or mechanics without proper tools, not to able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider and enger. JIANGMEN DACHANGJIANG GROUP CO., LTD. NOVEMBER, 2011 (The First Edition)

GENERAL INFORMATION

1

PERIODIC MAINTENANCE

2

ENGINE

3

D SYSTEM AND FUEL SYSTEM

4

CHASSIS

5

ELECTRICAL SYSTEM

6

SERVICING INFORMATION

7

HOW TO USE THIS MANU A L T O LOCATE WHAT Y O U ARE LOOKING F O R : 1 . T h e t e xt o f t h is manual is d i vide d into sections. 2 . T h e section titl e s are l isted in the G R OUP IN D EX. 3 . Ho l d i ng the manual as shown a t the ri g ht wi l l a l l o w y ou to find the first page of t he s e ction e as i ly. 4 . The contents are listed on t h e first page of each sect i o n to he l p you find the item and page you n e ed.

C O MPO N ENT PARTS A ND WO RK T O B E DONE U n der t h e na m e of eac h syst e m o r unit , is its exp lo d e d vi ew. work in s truction s a n d oth e r s ervi ce in f o r ma t io n su ch as t h e tig h t e n in g torque, lu b ricating p o ints a n d l o cking a g e n t po in t s, are p rov id e d . Exam p le : Fr o nt w h eel 18~28N.m

50~80N.m

SYMBOL The following symbols are instructions and necessary information for maintenance. SYMBOL

OIL No.4

DEFINITION

SYMBOL

DEFINITION

Torque control required. Data beside it indicates specified torque.

A P P L Y O R US E F RONT DA M P ER OIL

APPLY oil. Use engine oil unless otherwise specified.

APPLY THREAD LOCK “1322”

APPLY MOLY PASTE. Mix engine oil and MOLY PASTE at a ratio of 1:1.

APPLY THREAD LOCK SUPER “1342”

APPLY SUPER GREASE “A”


APPLY SUPER GREASE “C”


APPLY SUPER SILICONE GREASE

APPLY OR USE BREAK FLUID

APPLY MOLY PASTE

MEASURE IN VOLTAGE RANGE

APPLY HEAT TRANSFER OIL

MEASURE IN RESISTANCE RANGE

APPLY SEALANT THREE BOND “1215”

MEASURE IN CURRENT RANGE.

APPLY SEALANT THREE BOND “1216”

MEASURE THE TESTING RANGE OF THE DIODE

APPLY SEALANT THREE BOND “1207B”

MEASURE THE BREAK OVER RANGE

Apply BOND No.4

USE SPECIAL TOOL

APPLY OR USE COOLANT

It refers to the date of maintenance.

Note: All symbols are shown in the table above, including those not used in this Service Manual.

GENERAL INFORMATION

1 1 CONTENTS WARNING/CAUTION/NOTICE/NOTE GENERAL PRECAUTIONS SERIAL NUMBER LOCATIONS FUEL AND OIL RECOMMENDATIONS BREAK-IN PROCEDURE SPECIFICATIONS

1-1 1-1 1-2 1-3 1-4 1-5

GENERAL INFORMATION

WARNING/CAUTION/NOTICE/NOTE Please read this manual and follow its instructions carefully. Toemphasize special information, the symbol and the words WARNING, CAUTION, NOTICE AND NOTE have special meanings.Pay particular attention to messages highlighted by these signal words:

WARNING Indicates a potential hazard that could result in death or serious injury.

CAUTION Indicates a potential hazard that could result in minor or moderade injury.

NOTICE Indicates a potential hazard that could result in vehicle or equipment damage. NOTE: Indicates special information to make maintenance easier or instructions clearer. Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARNINGS and CAUTIONS stated, you must use good judgment and basic mechanical safety principles. If you are unsure about how to perform a particular service operation, ask a more experienced mechanic for advice.

GENERAL PRECAUTIONS WARNING Proper service and repair procedures are important for the safety of the service mechanic and thesafety and reliability of the vehicle. ● When 2 or more persons work together, pay attention to safety of each other. ● When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoor. ● When working with toxic or flammable materials, make sure that the area you work in is wellventilated and that you follow all off the material manufacturer's instructions. ● Never use gasoline as a cleaning solvent. ● To avoid getting burned, do not touch the engine, engine oil or exhaust system during or for a while after engine operation. ● After servicing fuel, oil, exhaust or brake system, check all lines and fittings related to the system for leaks. ●

1-1

GENERAL INFORMATION

NOTICE If parts replacement is necessary, replace the parts with SUZUKI GENUINE PARTS or their equivalent. When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation . ● Be sure to use special tools when instructed. ● Make sure that all parts used in reassembly are clean, and also lubricated when specified. ● When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the specified type. ● When performing service to electrical parts, if the service procedures not require used of battery power, disconnect the positive terminal. ● When removing the battery, disconnect the negative cable first and then the positive cable. ● When reconnecting the battery, connect the positive cable first and then the negative cable, and replace the terminal cover on the positive terminal. ● Tighten cylinder head and case bolts and nuts, beginning with larger diameter and ending with smaller diameter, from inside to outside diagonally, to the specified tightening torque. ● Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, cotter pins, circlips, and certain other parts as specified, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces. ● Never reuse a circlip. When installing a new circlip, take care not to expend the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted. ● Do not use self-locking nuts a few times over. ● Use a torque wrench to tighten fasteners to the torque values when specified. Wipe off grease or oil if a thread is smeared with them. ● After reassembly, check parts for tightness and operation. ● ●

NOTE: ● ●

To protect environment, do not unlawfully dispose of used Engine oil and other fluids, batteries and tires. To protect Earth's natural resources, properly dispose of used vehicles and parts.

SERIAL NUMBER LOCATIONS The frame serial number ① is stamped on on the steering stem. The engine serial number ② is located on the right side of the crankcase. These numbers are required especially for ing the machine and ordering spare parts.

1

2

1-2

GENERAL INFORMATION

FUEL AND OIL RECOMMENDATION FUEL Use nonleaded gasoline with an octane rating of 90 or higher (Research method). Nonleaded gasoline can extend spark plug life and muffler life.

ENGINE OIL Oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil. Use oil with an API classification of SF/SG or SH/SJ, or with JASO classification of MA.

SAE 10W-40 10W-40

API SF/SG SH/SJ

JASO MA

API :American Petroleum Institute JASO: Japanese Automobile Standards Organization SAE ENGINE OIL VISCOSITY Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W40 engine oil is not available, select an alternative according to the chart. NOTE: Dispose used engine oil properly to avoid environment pollution. We suggest you to collect the used oil in a sealed container and take it to a nearby recycling facility. Do not place it into a trash bin and do not pour it onto the ground.

ENGINE OIL

TEMP.

JASO T903 The JASO T903 standard is an index to select engine oil for 4stroke motorcycle and ATV engines. Motorcycle and ATV engines lubricate clutch and transmission gears with engine oil. JASO T903 specifies performance requirements for motorcycle and ATV clutches and transmissions. There are two classes, MA and MB. The oil container shows the classification as follows. ① ②

---------MA

① Code number of oil sales company ② Oil classification Engine conserving Suzuki does not recommend the use of "ENERGY CONSERVING" oil. Some kinds of engine oil which have an API classifi-cation of SH or higher have an "ENERGY CONSERVING" indication in the API classification doughnut mark. Thus oil can affect engine life and clutch performance.

Not recommend

1-3

Recommend

GENERAL INFORMATION

BREAK-IN PROCEDURES Previous sections explains how important proper break-in is to achieving maximum life and perfor-mance from your new Suzuki motorcycle. The following guidelines explain proper break-in procedures. RECOMMENDED THROTTLE OPENING LIMIT Throttle opening must not reach maximum during new motorcycle brake-in period, it is suggested to be less than 3/4 of the maximum while snap-acceleration must be avoided in driving. VARY THE ENGINE SPEED The engine speed should be varied and not held at a constant speed. This allows the parts to be ''loaded'' with pressure, and then unloaded, allowing the parts to cool. This aids the mating process of the parts, It is essential that some stress be placed on the engine components during break-in to ensure this mating process. Do not, though, apply excessive load on the engine. BREAK-IN THE NEW TIRES New tires need proper break-in to assure maximum performance, just as the engine does. Wear in the tread surface by gradually increasing your cornering lean angles over the first 160 km before attempting maximum performance. Avoid hard acceleration, hard cornering, and hard braking for the first 160 km. WARNING ●

Fail to perform break-in of the tires could cause tires slip and loss of control . Use extra care when riding on new tires hard acceleration, hard cornering and hard braking for the first 160 km .

AVOID CONSTANT LOW SPEED Operating the engine at constant low speed (light load) can cause parts to glaze and not seat in. Allow thw engine to accelerate freely through the gears without exceeding the recommended maximum limit. Do not, however,use full throttle for the initial 500 km. ALLOW THE ENGINE OIL TO CIRCULATE BEFORE RIDING Allow sufficient idling time after warm or cold engine start up before applying load or revving the engine. This allows time for the lubricating oil to reach all critical engine components. OBSERVE YOUR FIRST AND MOST CRITICAL SERVICE The initial service (1000 km maintenance) is the most important service your motorcycle will receive. During break-in operation, all of the engine components will have mated together and seated. Maintenance required as part of the initial service includes correction of all adjustments, tightening of all fasteners and replacement of dirty oil. Timely performance of this service will help make sure you get the best service life and performance from the engine.

1-4

GENERAL INFORMATION

SPECIFICATIONS DIMENSIONS AND CURB WEIGHT 2250mm 900mm 1160mm 1460mm 150mm 150kg

Overall length Overall width Overall height Wheelbase Ground clearance Curb weight

ENGINE Type Number of cylinders Bore Stroke Piston displacement Compression ratio Fuel system Air cleaner Starter system Lubrication system

four-stroke, air-cooled, Single-cylinder vertical type 1 57.0mm 58.6mm 149ml 8.9: 1 Fuel injection paper filter Electric Pressure splash lubrication

TRANSMISSION Wet multi-plate 5-speed gear transmission 3.500 2.867 3.000 1.875 1.368 1.143 0.957 KMC 428H

Clutch Transmission Primary reduction Final reduction Gear ratios, low 2nd 3rd 4th 5th Drive chain

1-5

GENERAL INFORMATION

ELECTRICAL Ignition type Ignition timing Spark plug Battery Fuse Headlight Tail/Brake light Turn signal light Position light

Electronic ignition 13°B.T.D.C. Below 1 500 r/min CR6E 12V,6Ah 10A,20A 12V,35W/35W 12V,5W/21W 12V,10W 12V,5W

CHASSIS Front suspension Rear suspension

Telescopic, coil spring, oil dampened Swing arm, oil dampened spring 5-way adjustable 40° 32.5° 132 mm Disc Drum 90/90-18 51P 120/80-16 60P 120 mm

Steering angle Caster Trail Front brake Rear brake Front tire size Rear tire size Stroke of front absorber

CAPACITIES Fuel tank including reserve reserve Engine oil Front shock absorber oil

11.5 L 2L 1 000 ml 385±3 ml

1-6

PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE MAINTENANCE PROCEDURES BATTERY/FUSE AIR CLEANER ELEMENT EXHAUST PIPE AND MUFFLER BOLTS BOLTS/NUTS OF THE CYLINDER HEAD & CYLINDER VALVE CLEARANCE SPARK PLUG ENGINE OIL ENGINE OIL FILTER OIL SUMP FILTER CLUTCH CABLE THROTTLE BODY EVAPORATIVE EMISSION CONTROL SYSTEM FUEL HOSE FUEL FILTER DRIVE CHAIN BRAKES TIRES STEERING FRONT/REAR SUSPENSION ILLUMINATION AND SIGNAL CHASSIS AND ENGINE MOUNTING BOLTS AND NUTS COMPRESSION PRESSURE INSPECTION

2-1 2-3 2-3 2-4 2-4 2-5 2-5 2-6 2-6 2-7 2-7 2-7 2-8 2-8 2-8 2-9 2-9 2-10 2-13 2-13 2-13 2-14 2-14 2-16

2


PERIODIC MAINTENANCE The chart below lists recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in of kilometer, miles and time for your convenience. Clean after the first 1,000 km and every 2,000-3,000 km afterwards

NOTE: More frequent servicing may be performed on motorcycles that are used under severe conditions.

PERIODIC MAINTENANCE CHART INTERVAL

Km

1 000

4 000

8 000

month

3

6

12

Battery/fuse

Inspect

Inspect

Air cleaner element

Clean

Exhaust pipe and Muffler bolts

Inspect

Clean Inspect

Nuts of cylinder head and cylinder

Inspect

Inspect

2-5

Valve clearance (cold engine)

Inspect

Inspect

2-5

Inspect

Inspect

ITEM

Spark plug Engine oil Oil filter (filter element)

Fuel filter

2-4 2-4

2-6 2-6 2-7

Replace Clean every 12000 km

2-7

Inspect

Inspect

2-8

Inspect

Inspect

Throttle body Fuel hose

Replace

Initial replacement after the first 500 km, the second replacement at 1,000km total mileage, while further replacement for every 4,000 km.

Oil sump filter Clutch cable

2-3

Replace every 12 000 km

Replace

PAGE

Clean

2-8

Replace every four years Inspect

Inspect

Replace

Clean & lubricate for every 1,000 km

Drive chain

2-8

2-8 2-9

Brake

Inspect

Inspect

2-10

Tires

Inspect

Inspect

2-13

Steering

Inspect

Inspect

2-13

Inspect

2-13

Front and rear absorber Illumination and signal

Inspect

Inspect

2-14

Chassis and engine mounting bolts and nuts

Inspect

Inspect

2-14

Compression pressure

Inspect

2-1

2-16


LUBRICATION CHART The following is a basic lubrication requirement for a motorcycle operated in an economical manner and based on the mileage displayed by the odometer.

INTERVAL km ITEM Throttle cable

Initial and every 6 000 km

month

Every 12 000 km 12 _

6

Throttle grip

Engine oil _

Clutch cable

Engine oil

Grease _

Brake cable

Engine oil

_

Engine oil every 1000 km

Transmission Chain Brake pedal axle Brake camshaft

Grease or oil _

Steering stem bearing

_ Grease

Grease every 2 years or 20000 km

Swing arm bearings NOTE: “-"stands for not required

WARNING Do not apply too much lubrication grease on the brake cam to prevent the brake from slipping.

When driving on wet roads or under rainy conditions, lubricate the parts with engine oil or grease to avoid rust. Be sure to remove oily contamination or rust.

2-2


MAINTENANCE PROCEDURES This section introduces the maintenance and adjustment methods of each part during regular maintenance.

BATTERY/FUSE Inspect Initial 1 000 km and Every 4 000 km

BATTERY The battery is located below the saddle. This type of battery is totally sealed, thus eliminating the need for replenishing battery fluids. However, re-charging is required once the voltage falls below 12.5V. Follow the steps below on uninstalling the battery: ● ● ● ●

the motorcycle by side stand. Dismount the right cover. Dismount the “ _ ” negative wire. Dismount the “ + ” positive wire. Take out the battery.

Install the battery in the reverse order as described above.

NOTICE While installing the battery, fasten the wire to the positive terminal first, then the negative.

FUSE The fuse is located on the battery fasten belt. If the engine suddenly stops or the circuit breaks down, check the fuse first.

WARNING Do not to use fuse beyond the stipulated specification range. Otherwise it may seriously damage the electric system, or even cause fire, motorcycle burning, or engine power failure.

NOTICE Be sure to use fuse with an operating current of 15A. Do not use substitutes such as aluminum or iron wires. A fuse that melts frequently suggests malfunctioning of the electrical system, which should be checked.

2-3


AIR CLEANER ELEMENT Clean after the first 1 000 km and every 4 000 km afterwards If the air cleaner is clogged with dust, intake resistance will be increased with a resultant decrease in power output and an increase in fuel consumption. Check and clean the element in the following manner:

● ● ● ● ●

Remove the left frame cover. Remove the screws and take out the air cleaner element assembly. Use compressed air to remove the dust on the air filter assembly. Get rid of the dust in the air filter box and cover. Reinstall the cleaned or new air cleaner element in the reverse order of removal.

NOTICE Always use pressured air to blow from the inside of air cleaner element to the outside. If pressured air is blow in the opposite direction, dirt will be forced into the pores of the air cleaner element thus restricting air flow through the air cleaner element.

NOTICE If driving under dusty condition, clean the air cleaner element more frequently. The surest way to accelerate engine wear is to use the engine without the element or to use a ruptured element. Make sure that the air cleaner is in good condition at all times. Life of the engine depends largely on this component!

EXHAUST PIPE AND MUFFLER BOLTS Inspect Initial 1 000 km and Every 4 000 km ●

Tighten the exhaust pipe clamp bolts and muffler mounting bolt to the specified torque with a torque wrench.

Exhaust pipe c la m p b o l t s : 1 8~2 8 N·m

Muffler mounting bolt : 40~60N·m

2-4


NUTS OF THE CYLINDER HEAD & CYLINDER Inspect Initial 1 000 km and Every 4 000 km

NUTS OF THE CYLINDER HEAD ● ●

Take off the saddle and the fuel tank (refer to page 3-2). Tighten the four M10 nuts ① with the specified torque through a torque wrench under cool engine conditions.

Nuts o n th e cyl in d e r hea d : 2 8 ~32 N·m

NUTS OF THE CYLINDER ●

Tighten the nuts ② and ③ on side of the cylinder head with the specified torque.

Nu ts o n t he c y lin d e r : 8~1 2 N·m

VALVE CLEARANCE Inspect Initial 1 000 km and Every 4 000 km Too big valve clearance will result in valve noise; and too small valve clearance will lead to valve damage and power output decrease. The valve clearance should be inspected at the mileages mentioned above, and adjusted by following order. ● ● ● ●

●

Remove the saddle and fuel tank. Remove the cap of the cylinder head cover. Remove spark plug, valve timing inspection plug and inlet/exhaust valve plug. Unscrew the plug of the generator cover, and rotate the generator rotor anticlockwise with a box wrench till the “T” scribed line on the generator rotor aligns with the center (the position pointed by the arrow) of the valve timing inspection plug hole on the crankcase, to set the piston at TDC of compression stroke. Insert the thickness gauge of the standard specification into the space between the valve end and the adjusting screw of the rocker arm.

09900-20803: Thickness gauge Valve clearance (when cold): Standard: IN:0.04-0.07mm EX:0.10-0.13mm

2-5


●

If the valve clearances are not between the dimensions above, it should be adjusted with special tools. 11F14-016 : Adjustment wrench

●

Remount the screw plugs on the spark plug and on the generator cover.

NOTE: The valve clearance should be inspected and adjusted when the engine is cold. The inspection and adjustment of both the inlet valve and the exhaust valve should be done when they are at the TDC of compression stroke.

SPARK PLUG Inspect Initial 1 000 km and Every 4 000 km.. Replace it every 12 000 km. Measure the spark plug gap with a thickness gauge. The standard spark plug gap is 0.7-0.8mm. If the measured spark plug gap is out of standard range, adjust or replace it with a new one. Whenever removing the carbon deposit, be sure to observe the operational color of the spark plug’s porcelain tip. This color tells you whether or not the standard spark plug is suitable for your type usage. A normal operating spark plug should be very light brown in color. If the spark plug is very white or glazed appearance, it has been operating much too hot. This spark plug should be replaced with the colder plug. KIND

TYPE

HOT TYPE

NGK CR5HSA

STANDARD

NGK CR6HSA

COLD TYPE

NGK CR7HSA

0.7-0.8mm

ENGINE OIL Inspect Initial 1 000 km and Every 4 000 km 2

Engine oil replacement should be made when the engine is warm as follows: ● ● ●

the motorcycle by side stand. Drain the oil by removing the drain plug ① and filler cap ② . Fit the drain plug ① securely and add fresh oil through the filler. The engine will hold about 1 000 ml of oil. * Use 10W/40 viscosity of oil under API classification of SF or SG. ● Start the engine and run it for 3 minutes. ● Stop the engine and wait 3 minutes. ● Hold the motorcycle vertically and check the engine oil level through the engine oil level check window. If the level is below the "L" mark, add oil until the level reaches the "F" mark.

2-6

1


ENGINE OIL FILTER Inspect Initial 1 000 km and Every 4 000 km The oil filter elements should be replaced according to the order below: ● ● ● ● ● ● ● ●

Unscrew the oil brain bolt to brain out the engine oil. Unscrew the two bolts of the oil filter cover. Unscrew the oil filter cover and take out the filter. Replace a new filter. Make sure the O-ring ① has been installed well before reassembling the new filter. Make sure the spring ② and the O-ring ③ have been installed correctly before reassembling the oil filter. Install the oil filter cover and fasten the bolts. Fill proper engine oil and inspect the dip stick.

NOTE: If the engine oil and the oil filter element are replaced at the same time, 1 100 ml of engine oil should be fed. If an overhaul of the engine, 1 350 ml of engine oil should be fed.

NOTICE The oil filter element should be installed in strict line with the requirements above; otherwise the engine will be seriously damaged.

OIL SUMP FILTER Clean Every 12 000 km Clean the sump filter screen to remove any foreign matter that may be collected there. Inspect the screen to insure that it is free of any sign of damage.

2-7

④

⑤

③

②

①


CLUTCH CABLE

4mm

Inspect Initial 1 000 km and Every 4 000 km

1

2

Clutch play should be 4mm as measured at the clutch level holder before the clutch begins to disengage. If the play in the clutch is incorrect, adjust it in the following way: ●

Loosen the lock nut ① and turn the clutch lever adjuster ② as far as it will go.

● ●

Loosen clutch cable adjuster lock nut ③. Turn the clutch cable adjuster ④ in or out to acquire the specified play. Tighten lock nut while holding the adjuster in position.

●

The clutch cable should be lubricated with a light weight oil whenever it is adjusted.

THROTTLE BODY Clean Every 8 000 km Clean the throttle body. (Refer to page 4-24)

FUEL HOSE Inspect the first 1 000km and every 4 000km afterward and replace every four years. Inspect whether the t of the fuel hose is damaged or fuel leakage. If it is, replace the fuel hose.

FUEL FILTER Inspect Initial 1 000 km and Every 4 000 km The fuel filter is installed under the fuel cock. The fuel filter element should be replaced or cleaned at regular intervals. During its replacement or cleaning, pay attention to its direction of installation.

2-8

3

4


DRIVE CHAIN Clean & lubricate for every 1,000 km Check (eyeballing) whether the drive chain has the following defects ( the motorcycle with the main stand to make the rear wheel leave the ground. Pull out the access hole plug at the neutral position, and rotate the rear wheel slowly by hand to check). 1. The chain pins are loose; 2. The roller is damaged; 3. The chain links are rusty; 4. The chain links are twisted or block; 5. The wear is excessively serious. If any defect above, please replace the drive chain. ● ●

Clean the driven chain with kerosene. If the drive chain is rusty too fast, the cleaning interval should be shortened. After being cleaned and dried, the drive chain should be applied with chain oil or SAE #90 gear oil for lubrication.

ADJUSTMENT ● ● ● ●

● ●

Loosen the rear wheel shaft nut ① . Loosen the regulator of drive chain ② to adjust the drive chain carefully. Loosen the regulator to make 10-20mm chain sag between the engine and the rear chain wheel. The mark ③ on both sides of the regulator should be on the same position for centering of the front wheel and the rear wheel. After adjustment of the drive chain, tighten the rear wheel shaft nut. After adjustment, inspect the rear brake gap (see page 212).

WEAR OF DRIVE CHAIN There are 21 pins on the drive chain. Measure their lengths. If their length is over 259.0mm, the drive chain should be replaced. Drive chain 20pitch length: Service limit: 259.0mm 09900-20101: Slide caliper

2-9

10~20mm


BRAKERS Inspect initial 1 000 km and every 4 000 km Replace brake hose every 4 years. Change brake fluid every 2 years.

FRONT BRAKE Brake fluid level the motorcycle body on the center stand, and place the handlebars straight. Check the brake fluid level by observing the lower limit line on the brake fluid reservoir. When the level is below the lower limit line, replenish with brake fluid that meets the following specification. Brake fluid specification: only use DOT3 or DOT4

NOTICE The brake system of this motorcycle is filled with a glycolbased brake fluid. Do not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will be caused. Do not use any brake fluid taken from old or used or unsealed containers. Never re-use the brake fluid left over from the last servicing and stored for long periods.

WARNI NG Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces. Check the brake hose for cracks and hose t for leakage before riding.

Brake disc Inspect the thickness ① of the brake disc by using caliper. If the thickness is less than 4.5mm, replace the disc immediately. TOOL

09900-20101 : Vernier caliper (1/50 mm,150 mm) Service limit

4.5mm

4.5 mm

Brake pads Inspect the brake pads by noting whether or not the friction pads are worn down to the grooved limit line② . If a pad is worn to the grooved wear line, it must be replaced. (Refer to page 5-15)

2-10


Air bleeding the brake fluid circuit Air trapped in the fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the caliper brake. The presence of air is indicated by "sponginess" of the brake lever and also by lack of braking force. Considering the danger to which such trapped air exposes the machine and rider, it is essential that, after remounting the brake and restoring the brake system to the normal condition, the brake fluid circuit be purged of air in the following manner: Fill up the master cylinder reservoir to the "HIGH"level line. Replace the reservoir cap to prevent entry of dirt. Attach a pipe to the caliper bleeder valve, and insert the free end of the pipe into a receptacle.

Bleeder valv e tightening torque : 7~9N·m Squeeze and release the brake lever several times in rapid succession, and squeeze the lever fully without releasing it. Loosen the bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle; this will remove the tension of the brake lever causing it to touch the handlebar grip. Then, close the valve, pump and squeeze the lever, and open the valve. Repeat this process until the fluid flowing into the receptacle no longer contains air bubbles. NOTE: Replenish the brake fluid reservoir as necessary while bleeding the brake system. Make sure that there is always some fluid visible in the reservoir.

Close the bleeder valve, and disconnect the pipe. Fill the reservoir to the "HIGH" level line.

NOTICE Handle the brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials, etc.

REAR BRAKE ●

Adjust the limit screw of the brake pedal to put the brake pedal at a position 62.5mm top the brake pedal. Finally fasten the nut. Height of the rear brake pedal H : 62.5mm

2-11


●

After adjusting the height of the rear brake pedal, adjust its stroke to realize a free stroke ① of 20-30mm. Free travel : 20-30mm

●

Adjust the free stroke of the rear brake pedal by turning the adjusting nut②. After adjustment, inspect the running state of the rear brake switch. If necessary, the rear brake switch should be adjusted.

BRAKE WEAR-OFF As shown in the right picture, the wear limitation of the brake shoe for a GZ150 motorcycle is carved on the brake drum. Under normal wear conditions, the extension line ③ of the brake cam shaft should be within the range of the angle carved on the brake drum. Inspect the wear situation of the brake shoe by following the order. ● ●

●

Inspect whether the brake system has been properly adjusted. After the adjustment, inspect whether the extension line ③ is within the range of the angle carved on the brake drum when the braking-system is working. If the extension line ③ is beyond the range of the angle carved on the brake drum, the brake shoe should also be replaced.

BRAKE LIGHT SWITCH Step on the rear brake pedal to inspect the brake light switch. If the brake light switch works inflexible, it may be adjusted by turning the adjusting nut of the brake switch.

2-12


TIRES Inspect Initial 1 000 km and Every 4 000 km There are multiple indicators ① of the wear sign position on the peripheral direction of the tyre. Inspect the wear signs (the bosses in the grooves) ② near the indicators ①, to make sure the tread depth is enough and, if they have been worn, replace the tyre. Eyeballing the worn conditions and the damages ③ (piercing or cracks) of the tires surfaces. Excessive wear of tires or too much damage on surfaces will lower the stability of riding. In this case, please replace the tires. TIRE PRESSURE Inspect the tyre pressure and check whether the valve cock has air leakage.

FRONT

SOLD RIDING 2 1.75 kgf/cm 175 Kpa

REAR

2.25 kgf/cm 225 Kpa

2

DUAL RIDING 1.75 kgf/cm 175 Kpa

2

2.25 kgf/cm 225 Kpa

2

Inspect Initial 1 000 km and Every 4 000 km Properly adjust the bearing of the steering to make the steering rotate flexibly and ensure safety during riding. Too tight steering will make the rotation of the steering inflexible. Too loose steering will result in vibration and further damage to the bearing. Inspect the steering to make sure it has no shaking. If the steering has shake, adjust it with the method stated in page 5-11.

FRONT/REAR SUSPENSION Inspect Every 8 000 km

FRONT SUSPENSION ●

Grasp the front brake, squeeze the front suspension to check its motion, check for leaks or damage. Replace damaged parts and tighten all bolts and nuts.

REAR SUSPENSION ● ●

② ①

STEERING

●

③

Press down the rear of the motorcycle repeatedly to check the performance of the rear suspension Check for leaks or damage; tighten all bolts and nuts.

2-13


ILLUMINATION AND SIGNAL Inspect Initial 1 000 km and Every 4 000 km Inspect the headlight, the left and right turn signal indicator lights, the taillights or the brake lights and the signal lights on the dashboard. If any problem, replace relevant light(s) in time (see page 6-9).

CHASSIS AND ENGINE MOUNTING BOLTS AND NUTS Inspect Initial 1 000 km and Every 4 000 km Check the tightening torque of the bolts and nuts for the motorcycle according to the table below: ITEM

N·m

Kg·m

1

Front axle bolt

50~80

5.0~8.0

2

Front axle limiting bolt

18~28

1.8~2.8

3

Handlebar lock-up bolt

12~20

1.2~2.0

L

18~28

1.8~2.8

R

18~28

1.8~2.8

4 Clamping bolt of the stem head

5 6

Steering bolt

50~80

5.0~8.0

7

Stem bolt (clamping bolt of the front absorber)

25~40

2.5~4.0

8

Brake pedal mounting bolt

18~28

1.8~2.8

9

Caliper mounting bolt

27~43

2.7~4.3

10

Brake hose union bolt

20~25

2.0~2.5

11

Bolts of the exhaust pipe

18~28

1.8~2.8

12

Rear shock absorber bolt/nut

22-35

2.2-3.5

13

Brake cam lever bolt/nut

8~12

0.8~1.2

14

Rear axle nut

50~80

5.0~8.0

15

Bolt/nut of the rear swing arm shaft

50~80

5.0~8.0

33-39

3.3-3.9

33-39

3.3-3.9

33-39

3.3-3.9

16 17

Engine mounting bolt/nut

18

2-14


5 4 1

5

3 2 4

6

9 10 8 7

12 12

11

13

14

15

18 17 16

17

2-15


COMPRESSION PRESSURE Inspect Every 8 000 km

INSPECTION NOTE: Before testing the compression pressure of the engine, be sure that the nuts and bolts of the cylinder head are securely tightened with specified torque, and the air valve clearance is correct. Keep the engine running idle for several minutes before carrying-out the test. 1

● ● ● ●

Remove spark plug. Fit the compression gauge ① and adapter ② to the plug hole, taking care to make the connection absolutely tight. Twist the throttle grip into wide-open position. Crank the engine several times with the starter motor, and read the highest gauge indication as the compression of the cylinder.

09915-64510 : Compression gauge ① 09915-63210 : Adapter ②

Compression pressure Standard

Limit

10-14 kgf/cm2

8 kgf/cm2

A low compression pressure may indication any of the following malfunctions: * Excessively worn cylinder wall. * Worn piston or piston rings. * Piston rings stuck in the grooves. * Poor seating of valves. * Defective cylinder head gasket. When the compression pressure noted is down to or below the limit indication above, the engine must be disassembled, inspected and repaired as required.

2-16

2

ENGINE CONTENTS REMOVING ENGINE PARTS WI TH ENGINE UN-REMOVED ENGINE REMOVAL AND REMOUNTING CYLINDER HERD AND VALVE CYLINDER AND PISTON & CAM CLUTCH AND GEAR SHIFT MECHANISM GENERATOR AND START CLUTCH CRANKSHAFT, TRANSMISSION AND KICK START DEVICE SECONDARY AIR SYSTEM

3-1 3-2 3-7 3-18 3-26 3-36 3-43 3-56

3

ENGINE

REMOVING ENGINE PARTS WITH ENGINE UN-REMOVED The following parts can be removed and remounted without removing the engine. Refer to sections about parts removing and remounting.

UPPER PART OF THE ENGINE Cam chain tensioner Cylinder head cover Cam shaft Cylinder head Cylinder Piston

3-7 3-8 3-8 3-8 3-18 3-18

RIGHT SIDE OF ENGINE 3-22 3-22 3-22 3-23 3-26

Engine oil filter Clutch cover Clutch Oil pump Gear shifting fork shaft

LIFT SIDE OF ENGINE Gear lever Chain wheel cover Start motor Primary decelerate gear Generator cover 2nd decelerate gear Generator rotor Start clutch Generator dtator

3-26 3-27 3-27 3-27 3-28 3-28 3-28 3-29 3-31

3-1

ENGINE

ENGINE REMOVAL AND REOUUNTING ENGINE REMOVAL Before taking the engine out of the frame, thoroughly clean the engine with a suitable cleaner. ● Remove

the seat by using the key.

● Take off the right ● Disconnect the

and left frame covers. and lead wires of battery.

NOTICE First, disconnect the

● Take

lead wire.

off the fuel tank bolts.

● Take

off the fuel tank put in hose, the pastern stopple fuel hose. ● Take off the hose of fuel cut-off valve and charcoal tin. ● Take off fuel air filter hose. ● Disconnection the couplers of the fuel gauge , take off fuel tank.

the hose fuel pump ①. the input hose fuel pump ②. ● Take off the fuel filter ③. ● Disconnection ● Disconnection

2

1

3

3-2

ENGINE

● Remove

the bolt of 3 way hose, take off the 3 way and hose.

● Disconnection ● Disconnection

the couplers of D ① and FIAV ②. the couplers of MAQS ③. 1 2

3

● Disconnection

the couplers of ETS.

● Disconnection

the PVC hose .

the electronegative hose ④. Loosen the throttle cable nuts ⑤ and ⑥ , remove the throttle.

● Remove

4 5

6

3-3

ENGINE

●Remove

the nuts and screw of the throttle body, and detach the throttle body from right side of the frame .

● Take

off the clutch cable by removing the clutch lever bolt and adjuster lock nut.

● Remove

the exhaust pipe bolts and muffler mounting bolt, then take off the muffler.

● Disconnect

the couplers of generator ① and gear position

indicator ②. 2

1

● Take

off the engine sprocket cover.

3-4

ENGINE

●Take

off the gear shifting pole. Remove the nut of rear under the engine . Mounting bolt (rear under) :33-39N•m

● Take

off the drive chain by removing the clip.

● Take ● Take

off the lead wire of starter motor. off the engine temperature sensor.

● Take off the breather pipe. ● Disconnect the ground wire

● Take ● Take

from the starter motor.

off the spark plug cap. off left and right decorate cover of the cylinder.

3-5

ENGINE

● Remove

engine mounting bolts.

Mounting bolt (top) : 33-39N•m Mounting bolt (front) : 33-39N•m Mounting bolt (rear) :33-39N•m

● Remove swing arm pivot nut and brackets. ● Use both hands, and lift the engine from the

frame.

Bolt of the rear swing arm shaft : 50-80N•m

NOTICE Be careful not to draw out the swing arm pivot shaft completely from the left side swing arm pivot hole. Insert the shaft or rod into the right side pivot hole from the right side of the frame to keep the alignment of the frame holes and swing arm pivot holes.

ENGINE REMOUNTING The engine can be mounted in the reverse order of removal. ●

Temporarily fasten the engine mounting bracket before inserting the engine mounting bolts.

NOTE: The engine mounting nuts are self-lock nuts. Once the nut has been removed, it is no longer of any use. Be sure to use new nuts and tighten them to the specified torque.

ENGINE OIL REPLACE ● Pour

1 000mL of engine oil SAE 10W/40 graded SF or SG into the engine after overhauling engine.

● Start

up the engine and allow it run for several seconds at idle speed. About one minute after stopping engine, check oil level. ● If the level is below the “L” mark, add oil with the level reaches the “F” mark.

● After

remounting the engine, inspections should be done for the following parts: * Clutch cable (see page 2-8) * Throttle cable (see page 2-9) * Idle speed (see page 2-9) * Drive chain (see page 2-10)

3-6

ENGINE

CYLINDER HEAD AND VALVE CYLINDER HEAD REMOVAL ● Remove the engine (see ● Drain out the engine oil.

page 3-2).

NOTE: If top end repair only is being performed, it is not necessary to remove the engine from the frame. As already noted, seat, fuel tank, frame covers etc. must be removed. ● Remove

the timing inspection screw plug of valve and the screw plug of the generator rotor.

● Remove

the bolt of chain tensioner and the tensioner.

● Remove

the access hole covers of the inlet valve and the exhaust valve as well as the spark plug.

●

Raise the piston to the TDC (see page 2-5).

NOTE: When take down the cylinder head cover, the piston must locate at the TDC of the compressions stroke.

3-7

ENGINE

● Loosen the cylinder head cover bolts in the order indicated ● in the illustration and remove brack comps of cylinder head

cap. Detach the cylinder head cover. NOTE: When removing cylinder head cover, piston must be at top dead center on compression stroke.

● Remove

camshaft sprocket bolts and detach the camshaft.

NOTICE Do not make sprocket, chain and bolts drop into the crankcase.

● Loosen

●

the nuts of the cylinder head and of the cylinder .

Loosen the six cylinder head nuts diagonally then detach the cylinder head.

NOTE: When unscrew the bolts of the cylinder head, the bolts should be diagonally loosened for two or three times.

DISASSEMBLY ●

Remove rock arm shaft set bolts.

3-8

Do not remove

ENGINE

● Pull

out the rocker arm shaft with pliers.

● Remove

rocker arm and spring and undee waher.

● Remove

the valve spring with specified tools.

11F14-003 : valve knocked-down tool

● Take

out the valve spring retainer, inner spring and outer spring. ● Pull out the valve from the other side.

● Remove

oil seal, using long-nose pliers. Take out the spring seat.

NOTICE Removed oil seal should be replaced with a new one.

3-9

ENGINE

● Remove

valve guide by using the special tool.

09916-44910 : Valve guide remover

NOTICE Only oversize valve guide is available as a spare part.

CYLINDER HEAD INSPECTION CYLINDER HEAD COVER ● After

removing sealant (SUZUKI BOND No.1215) from the fitting surface of the cylinder head cover, place the cylinder head cover on a surface plate and check for distortion with a thickness gauge. Check points are shown in Fig. 0.05mm

Service limit 09900-20803 : Thickness guage

SWING ARM SHAFT ●

Measure the outer diameter of the swing arm shaft. Standard

11.977-11.995mm

09900-20205 : Micrometer (0-25mm)

SWING ARM ●

Measure the inner diameter of the swing arm, and inspect the wear situation of the swing arm surface with the cam. Standard

12.000~12.018mm

09900-20605: Internal micrometer

CAMSHAFT ●

If the engine has abnormal sound, shaking or insufficient output power, should inspect the cam wear situation and the camshaft run-out. ● The wear of the camshaft always results in the poor operation of the inlet valve and the exhaust valve and further declined engine power. The wear loss of the camshaft is determined by the heights ① of the inlet cam and the exhaust cam. If the wear losses of the cams exceed the limit values, please replace the camshaft. 3-10

Inlet open (B.T.D.C.)

Inlet close (A.B.D.C.)

TDC

Exhaust open (B.B.D.C.)

Exhaust close (A.T.D.C.)

B.D.C. Valve timing diagram

ENGINE

CAM HEIGHT

Height ① (limit)

Inlet cam

33.350mm

Exhaust cam

33.000mm

09900-20202: Micrometer (25~50mm)

Measure the outside diameter of camshaft journal. Replace either the cylinder head set or the cam shaft if the O.D. is incorrect.

Standard

21.959-21.980mm

09900-20205: Micrometer (0~25mm)

Measure the runout with a dial gauge. Replace the camshaft if the runout exceeds the limit. 0.10mm

Service limit

09900-20701 : Magnetic stand 09900-20606 : Dial gauge (1/100mm) 09900-21304 : V-block (100mm)

VALVE SPRING ●

Measure the free lengths of the valve springs. IN

31.24 mm

EX

33.58 mm

Service limit

09900-20201: Slide caliper (150mm)

CYLINDER HEAD ●

Inspect whether the spark plug hole and the valve base have scratches. ● Inspect the cylinder head with a thickness gauge to see whether it has deformed. Service limit

0.05 mm

09900-20803: Thickness gauge

3-11

1

ENGINE

VALVES ● If

the valve stem is worn down to the limit, when measured with a micrometer, replace the valve. IN

4.975-4.990mm

EX

4.955-4.970mm

Standard

09900-20205 : Micrometer (0-25mm) the thickness ① and, if the thickness is found to have been reduced to the limit, replace the valve.

● Measure

Service limit

0.5 mm

NOTE: Visually inspect each valve for wear of its seating face. Replace any valve with an abnormally worn face.

●

the valve with “v” block, as shown, and check its runout with a dial gauge. The valve must be replace if the runout exceeds the limit. 09900-20701: Magnetic stand 09900-20606: Dial indicator 09900-21304: V-shaped block Service limit

0.5 mm

● As

shown in the right picture, valves with a Vshaped block and measure its run-out with a dial indicator. If the measured value exceeds the limit value, the valves should be replaced. 09900-20701: Magnetic stand 09900-20606: Dial indicator 09900-21304: V-shaped block Service limit

0.05 mm

THE VALVE STEM SEAL ●

Lubricate valve stem seal with oil, and press-fit the seal into position with a finger tip.

NOTICE Do not reuse the oil seals.

3-12

1

ENGINE

VALVE SEAT WIDTH ● Coat

the valve seat with prussian blue uniformly. Fit the valve and tap the coated seat with the valve face in a rotating manner, in order to obtain a clear impression of the seating . In this operation, use the valve lapper to hold the valve head.

● The

ring-like dye impression left on the valve face must be continuous any break. In addition, the width of the dye ring, which is the visualized seat “width”, must be within the specification.

VALVE SEAT SERVICING The inlet and exhaust valve seat should be machined into four different angles (the surface of valve seat should be cut into 45°angle). INTAKE SINDE

EXHAUST SINDE

N-122 45 o

N-122 45 o

N116 30 o

N126

60 o

N111

N-120 15 o

N-121 45 o

09916-20610 : Valve seat cutter (N121) 09916-20620 : Valve seat cutter (N122) 09916-20630 : Valve seat cutter (N126 ) 09916-24311 : Solid pilot (N-100-5.0) 09916-21110 : Valve seat cutter set

30o

NOTE: After cutting each time, the surfaces of the valve seats must be inspected.

3-13

60o

ENGINE

● Grind

the uneven or irregular surface with 45° tooling.

NOTE: Finish the air valve seat surface with 45 ° tooling after the valve is replaced.

● Grind

of s s at th se id e W alv v

the top surface of the original valve seat by 1/4 of its width with 30° tooling.

30 o

the bottom of the original valve seat by 1/4 of its width with 60° tooling.

f s so a t th se id e W alv v

● Grind

60 o

● Process

the valve seat surface to standard height with 45° tooling. ● Make sure all pitting and irregular surfaces have been cut. If necessary, adjust it again. Standard

0.9-1.1mm

0.9～1.1mm

● Apply a thin coat of Prussian blue onto the valve ● Press the valve onto the valve seat and make

seat. it rotate for couple times. After that, take out the valve and observe the contract surface of the valve seat. There should be clear traces on the contract surface. NOTE: The position of the valve seat has affect on the contract surface of the valve, which is of great significance for good sealing. ● If the contract surface of the valve is too high, cut it lower with a 30°angle milling cutter. ● If the contract surface of the valve is too low, adjust it with a 60°angle milling cutter. ● Cut the valve seat to the standard width with a 45° angle milling cutter. 3-14

45 o

30 o Contract surface of the valve is too high

Contract surface of the valve is too low

60 o

ENGINE

●

After cutting the valve seat, apply an abrasive coat onto the valve surface, and gently grind the valve. After grinding, clean all left abrasive of the cylinder head and the valve. Inspect the surface of the valve seat again.

NOTICE Too big grinding force will possibly result in deformation or damage to the valve seat. Please change the working angle of the grinding tool frequently, in order to avoid uneven grinding of the valve seat. If the abrasive enters into the space between the valve stem and the valve guide pipe, it will possibly result in damage.

CYLINDER HEAD ASSEMBLY

●

Clean the cylinder head thoroughly with a cleaning liquid and blow all ages with compressed air. ● Mount a new valve oil seal. ● Lubricate all valves with molybdenum grease. ● Insert the valves into air guide pipes and mount spring washers, springs and spring bases for the valves. 99000-25140: Molybdenum grease

3-15

ENGINE

NOTE: When a valve spring is mounted, the seal ring side should face the combustion chamber. In order to avoid oil seal damage, the valve oil seal should be mounted while the valve is rotating slowly. ● Mount

a valve lock clamp.

11F14-003 : Valve knocked-down tool

CYLINDER HEAD COVER REASSEMBLY ● Apply ● Place

SUZUKI MOLY PASTE to the rocker arms and shafts. the spring and the wave washer and arm in the exhaust side. ● Place the wave washer and arm in the inlet side. ● After inserting the shafts, tighten the set bolts.

M

99000-25140: SUZUKI MOLY PASTE

NOTICE Use a new O-ring on the rocker arm shafts to prevent oil leakage. Use a new gasket on the set bolts to prevent oil leakage.

REASSEMBLY ● Clean

feculence from the surface of the cylinder head.

dowel pins ① to cylinder head and then, attach new gasket to cylinder head.

● Fit

3-16

ENGINE

● Mount

the nuts of the cylinder head , and tighten them with the specified torques.

EX Copper washer

Copper washer

Cylinder head nut : 25~32N•m

Copper washer

● Mount

nuts of the cylinder head and cylinder, and tighten them with the specified torques. Cylinder head nut : 8~12N•m Cylinder nut : 8~12N•m

● Apply

THREAD LOCK SUPER “1303B” to the bolts and the tighten the cam sprocket.

NOTE: Do not rotate magneto rotor while doing this. When the sprocket is not positioned correctly, turn the sprocket. When installing the camshaft into the cam sprocket, pay attention not to dislodge the locating pin or it may fall into the crankcase. 1303B

99000-32030 : THREAD LOCK SUPER“1303B”

● Thoroughly

wipe off oil from the fitting surface of cylinder head. ● Fit two dowel pins to the cylinder head side. ● Uniformly apply SUZUKI BOND No.1215 to the cylinder head surface. 99000-31110 : SUZUKI BOND No.1215

● Mount

cylinder head cover and the bolts.

3-17

IN

Copper washer

ENGINE

CYLINDER AND PISTON CYLINDER DISASSEMBLY ● ● ●

Remove the cylinder head (see 3-6 Page ). Remove the washer and the pin. Remove the cylinder .

CYLINDER INSPECTION ● Remove the ● Inspect the

residual gasket of the cylinder surface. plainness of the cylinder with a ruler and a thickness gauge Service limit

0.05mm

09900-20803: Thickness gauge ● Inspect

whether the inner part of the cylinder is worn or damaged. ● Measure the inner diameter of the cylinder along directions X and Y respectively. Three horizontal planes vertical to the axis should be selected for measurement. Using the maximum valve as reference when judging whether the cylinder is worn. Servicing limit TOOL

57.135mm

09900-20508 : Cylinder gauge set

DISASSEMBLY AND INSPECTION OF THE PISTON DISASSEMBLY NOTE: Block the crankshaft plane with a piece of clean cloth lest the piston pin or other parts drop into the crankcase. ● Remove ● Remove

●

piston pin retainer with pliers. piston pin and piston.

Remove the piston ring.

NOTICE Be careful not to damage the piston ring during disassembly.

3-18

ENGINE

● Remove

the carbon in the piston ring slot with the old piston

ring.

INSPECTION ●

Push the piston ring into the slot, measure the clearance between the piston ring and the ring slot. Piston ring

Servicing limit

1st

0.180mm

2nd

0.150mm

09900-20803: Thickness gauge ● ●

Check for damage or wearing of the piston. Measure the piston O.D. at 8mm along the vertical direction of the piston pin. 8mm

Servicing limit

09900-20202 : Micrometer (25~50mm)

TOOL

●

Measure the hole inner diameter of the piston pin. Servicing limit

●

56.845mm

15.030mm

Measure the outer diameter of the piston pin. Servicing limit

TOOL

14.080mm

09900-20605 : Dial calipers 09900-20205 : Micrometer (0~25mm)

● Measure

the inner diameter of the smaller end of connecting

rod. Servicing limit

15.040

09900-20605 : Dial calipers

3-19

ENGINE

●

Put the piston ring horizontally on the cylinder bottom to measure the opening clearance. Piston ring

Servicing limit

1st

0.5mm

2nd

0.5mm

09900-20803: Thickness gauge NOTE: When using the piston head to jack the piston rings into the cylinder, make sure they enter evenly.

PISTON RING ASSEMBLY ●

Clean the piston ring slot completely and assemble the piston ring.

NOTE: Apply engine oil on all piston rings. Avoid damaging the piston and piston ring during assembly. Align the mark on the piston ring upward during assembly, pay attention to distinguish the marks of the top ring and the second ring. ● Keep

the opening of each ring cross at 120°, do not leave the oil ring opening on the same line. ● The piston ring must be able to rotate freely in the ring slot after installation.

3-20

ENGINE

PISTON REASSEMBLY The following are reminders for piston installation: ● Rub

a small quantity of SUZUKI MOLY PASTE onto the piston pin. ● Place a clean rag over the cylinder base to prevent piston pin circlip from dropping into crankcase, and then fit the piston pin circlip with long-nose pliers. M

99000-25140: SUZUKI MOLY PASTE

NOTICE Use a new piston pin circlip to prevent circlip failure which will occur with a bent one. ● When

fitting the piston, turn hole on the piston head to exhaust side.

CYLINDER Before mounting the cylinder, oil the big end and small end of the conrod and also the sliding surface of the piston. ●

Fit dowel pins ① to crankcase and then fit gasket.

NOTICE To prevent oil leakage, do not use the old gasket again, always use new one.

● Hold

each piston ring with the piston rings properly spaced and insert them into the cylinder. Check to insure that the piston rings are properly inserted into the cylinder.

NOTE: When mounting the cylinder, after attaching camshaft drive chain ② , keep the camshaft drive chain taut. The camshaft drive chain must not be caugth between cam drive chain sprocket and crankcase when crankshaft is rotated.

NOTE: There is a holder for the bottom end of the cam chain guide cast in the crankcase. Be sure that the guide is inserted properly or binding of the cam chain and guide may result. ●

Install the cylinder head (see page 3-13).

3-21

2

ENGINE

CLUTCH AND GEAR SHAFT MECHANISM CLUTCH COVER DISASSEMBLY ● Drain out the engine oil completely. ● Loosen the adjusting bolts ① and ② of the clutch. ● Make the cable and the release swing arm separate.

● Remove ● Remove

oil filter cover bolts and oil filter cover. oil filter.

● Remove

clutch cover bolts and clutch cover.

● Remove

the gasket and the positioning pin.

CLUTCH DISASSEMBLY ● Remove

clutch spring mounting bolts diagonally while holding the primary driven gear, and remove clutch pressure plate.

3-22

2

1

ENGINE

● Remove

clutch handspike and gear & plate.

● Remove

the clutch drive plate and driven plate.

● Flatten

the lock washer and remove the clutch sleeve hub nut by using the special tool.

11F14-005 : Clutch sleeve hub holder

● Put

the conrod holder for fixing the crank. Remove the primary drive gear nut. ● Remove the primary drive gear.

11F14-1019 : Conrod holder Clutch driven hub : 40~60N•m

● Remove

oil pump driven gear and primary drive gear.

3-23

ENGINE

INSPECTION ● If

the drive friction discs of the clutch have scratches or discoloration phenomenon, they should be replaced. ● Measure the thicknesses of the friction discs. Service limit

2.40mm Checking thickness

09900-20101: slide caliper (150mm)

● Measure

the thicknesses of the drive friction discs.

Service limit

11.40mm

09900-20101: slide caliper (150mm) NOTE: If the drive friction discs exceed the use limit, the whole set friction discs must be replaced.

Checking claw width

● Measure

each driven disc for distortion with a thickness gauge. Replace driven disc which exceed the limit. Service limit

0.10mm

09900-20803 : Thickness gauge Checking distortion

● Measure

the free lengths of the clutch springs

Service limit

29.45mm

09900-20101: slide caliper (150mm) NOTE: If one or more clutch springs exceed the use limit, the whole set springs must be replaced. ● Inspect

the release bearing for any abnormality, particularly crank, to decide whether it can be reused or should be replaced. ● Smooth engagement and disengagement of the clutch depends much on the condition of this bearing.

3-24

ENGINE

● Primary

driven gear is composed as shown.

① Primary driven gear

④ Rivet

② Damper

⑤ Clutch housing

③ Plate If the internal damper wears, play is generated between gear and housing, causing abnormal noise. If the play is extreme, replace the primary driven gear assembly with a new one.

REASSEMBLY ● Install ● Install

primary drive gear and oil pump driven gear. gasket and bush & primary driven gear & clutch sleeve hub. ● Install lock gasket, and tighten clutch sleeve hub nut using the special tool to the specified torque. Clutch sleeve hub nut : 30~50N•m 11F14-005 : Clutch sleeve hub holder ● Install drive plates and driven plates to ● Insert push rod in the countershaft. ● Tighten clutch spring bolts diagonally.

the sleeve hub.

● Install ● Install

the new gasket and pin. clutch cover, and tighten clutch cover bolts.

● Install ● Install

oil filter and oil filter cover. and adjust clutch cable, and add engine oil.

3-25

ENGINE

GEAR SHAFT MECHANISM DISASSEMBLY ● Remove

the bolts, the retainer rings and the gear shift pedal. ● Remove the clutch (see page 3-22).


● Loose

oil pump driven gear. the gear shift.

the bolt, remove cover board ① and ② . 2

NOTE: When removing cam driven gear, do not lose gear shifting pawl ④ , pin ⑤ and spring ⑥ . 99000-32050 : Apply thread lock super “1342”

1

INSPECTION ● Inspect

whether the gearshift shaft is bent, worn or damaged. ● Inspect whether the gearshift arm spring and the return spring are damaged or fatigued.

7

8 3 6 5 4

REASSEMBLY ● Gear

shafter can be mounted in the reverse order of removal.

3-26

ENGINE

GENERATOR AND START CLUTCH DISASSEMBLY OF THE GENERATOR COVER ●

Remove the generator connector ① , the gear switch connector ② , electron instrument connector ③.

●

Remove the engine sprocket cover.

●

Remove the bolts and the starter motor.

● Remove

the starter motor gear cover and generator wiring

harness.


the pin and the gasket. the primary decelerate gear and shaft.

3-27

1 2

ENGINE

● Remove ● Remove ● Remove

magneto cover bolts and detach magneto cover. the gear position switch. the bolts and drive sprocket wheel.

● Remove

the pin and the gasket.

● Remove

the second decelerate gear and shaft.

ROTOR DISASSEMBLY ● Remove

magneto rotor nut.

11F14-001 : Rotor holder

● Remove

magneto rotor and key.

11F14-005 : Rotor separator NOTE: Be careful when Remove the keys; avoid damaging the key slot and the crank.

3-28

ENGINE

DISASSEMBLY ● Inspect

if starter idle gear rotation in one direction is easy and difficult in another. ● Remove the starter idle gear.

●

Fix rotor with rotor holder and remove overriding clutch bolt. 11F14-001 : Rotor holder

NOTE: Unless necessary for inspection, please do not remove overriding clutch.

●

Remove the starter clutch.

STARTER CLUTCH INSPECTION ● Inspect

the starter clutch linear spacer ring for wear, damage and irregular motion. ● Clean starter clutch and coat spacer ring with engine oil. NOTE: In case starter clutch spring is removed, it must be replaced as a whole.

●

Install clutch housing/ starter clutch on rotor.

3-29

ENGINE

●

Fix the rotor with rotor holder. 11F14-001 : Rotor holder

● Clean hexagon-socket bolt thread and coat it with bond. ● Fit starter clutch screw and tighten it at tightening torque.

Starter clutch bolt : 10~15N·m 1 3 05

●

99000-32100 : THREAD LOCK SUPER

Install the gear on rotor by rotating it counter clockwise.

REASSEMBLY ●

Install the gear on rotor by rotating it counter clockwise.

● Make

the key slot of the rotor align with the key of the crank to install the rotor. ● Install the bolt of the rotor of the generator and tighten it with the specified torque.

Bol t s f o r t h e rotor : 5 0 ~70N·m 11F14-001 : Rotor holder

3-30

ENGINE

● Remove

the second decelerate gear and shaft.

STATOR DISASSEMBLY ● Remove

the bolts, cable guide, the stator and the induction

coil.

REASSEMBLY ● Install

the stator and the cable guide, apply the proper amount of anti-loosening glue of the screws and finally tighten the screws. ● Install the induction coil, apply proper amount of antiloosening glue on the screw heads and finally tighten the screws with the specified torque.

99000-32050 : Apply thread lock super “1342”

REASSEMBLY GENERATOR COVER ● Install

the new gasket and the pin.

● Install

the generator and tighten bolts.

3-31

ENGINE

● Install

●

Install the new gasket and the decelerate gear cover.

● Install

●

the primary decelerate gear and shaft.

the bolts and starter motor.

Install the engine sprocket cover.

the generator connector ① , the gear switch connector ② , electron instrument connector ③.

● Install

1 2

3-32

ENGINE

CRANKSHAFT, TRANSMISSION AND KICK STARTER CRANKCASE DISASSEMBLY ● Remove

cylinder head and cylinder. (Refer to page 3-5) Remove clutch and primary drive gear & oil pump. (Refer to page 3-16) Remove generator. (Refer to page 3-27)

● Remove

sump filter cap and neutral cam stopper..

● Remove

balance shaft nut with special tool.

● Remove

crankcase bolts.

● Separate

the crankcase into 2 parts, right and left with crankcase separating tool. Fit the crankcase separating tool, so that the tool plate is parallel with the end face of the crankcase. 11F14-004 : Crankcase separating tool

CAUTION Do not pry crankcase with screwdriver. 3-33

ENGINE

TRANSMISSION ● Remove

● Draw

gear shifting cam stopper spring.

out gear shifting fork shafts and take off forks.

● Remove

clusters of gears and gear shifting cam.

CRANKSHAFT AND BALANCE SHAFT ● Remove

crankshaft and balance shaft with crankcase.

INSPECTION ●

Measure the connecting rod large end side play with a thickness gauge.

Service limit

0.5mm

09900-20803 : Thickness gauge

3-34

ENGINE

● Place

crankshaft on a V-block and measure radial run-out of crankshaft with a dial gauge. Standard

0.05mm

09900-20606 : Dial gauge（1/100） 09900-20701 : Magnetic stand 09900-21304 : V-block（100mm） ● Rotate inner races of bearings with finger. ● Bearing rotation should be smooth and silent. ● Simultaneously inspect if bearing outer race

rotates in crankcase. ● In case of difficult rotation of bearing inner race or rotation of outer race, replace bearing with a new one.

● Inspect

balance shaft drive gear for wear and damage. replacing balance shaft drive gear, align the hole of the gear with the heave of crankshaft.

● When

● Inspect

balance shaft gear for wear and damage. replacing balance shaft gear, do not lose the spring when remove circlip .

● When

● Using

a thickness gauge, check the shifting fork clearance in the groove of its gear. If the clearance limit is exceeded by any of the three gears, determine whether the gear or the gear shifting fork should be replaced by measuring the thickness and groove width. Standard

0.10~0.30mm

Service limit

0.50mm Checking clearance

09900-20803 : Thickness gauge 3-35

ENGINE

Standard

No.1&No.2

4.80-4.90mm

No.3

5.30-5.40mm

09900-20101 : Vernier calipers Checking groove width

No.1&No.2

5.00-5.10mm

No.3

5.50-5.60mm

Standard

09900-20101 : Vernier calipers Checking thickness

● Inspect gearshift cam guide slot. ● In case of damage of gearshift

cam guide slot, replace

gearshift cam with a new one.

● Inspect

all bushes, gear inner faces, and gear faces for abnormal wear or poor lubrication.

GEARSHIFT BEARING REPLACING ● Inspect

bearings for easy rotation by rotating each of them and simultaneously inspect if bearing outer race rotates in crankcase. Replace it in case of rotation.

3-36

ENGINE


main shaft bearing from right crankcase. auxiliary shaft needle bearing from right crankcase with special tool. 09923-73210 : Bearing puller 09930-30102 : Rotor remover slide shaft


auxiliary shaft bearing from left crankcase. main shaft bearing from left crankcase with special

tool. 09923-73210 : Bearing puller 09930-30102 : Rotor remover slide shaft

● Mount

new bearings with special tool.

09940-53311 : Bearing installer 09924-84510 : Bearing installer 09913-75820 : Bearing installer 09913-80112 : Bearing installer

3-37

ENGINE

REASSEMBLY CRANKSHAFT AND BALANCE SHAFT

● Decide

the width between the webs referring to the figure below when rebuilding the crankshaft. STD

52.9~53.1mm

● When

mounting the crankshaft in the crankcase, it is necessary to pull its left end into the crankcase.

09910-32812 : Crankshaft installer 09910-20116 : Conrod holder

3-38

ENGINE

NOTICE Never fit the crankshaft into the crankcase by striking it with a plastic hammer. Always use the special tool, otherwise crankshaft alignment accuracy will be affected.

● When

installing the balance shaft into the crankcase. The sign “O” and sign of the balance shaft drive gear must like right picture.

TRANSMISSION

3-39

ENGINE

NOTICE Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded and a new circlip must be installed. When installing a new circlip, care must be taken not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always insure that it is completely seated in its groove and securely fitted.

● Press-fit

2nd drive gear onto the counter shaft. Before reassembling, coat the internal face of the 2nd drive gear with THREAD LOCK SUPER “1303” and install it so that the length A as shown in fig. 99000-32030 : APPLY THREAD LOCK SUPER “1303” Counter shaft length (Low to 2nd)

A 0 88.0± 0.2 mm

NOTE: this procedure may be performed only twice before shaft replacement is required.

GEAR SHIFTING CAM AND FORK

3-40

ENGINE

● Fit

the gear shifting cam on the crankcase. Position the cam as shown in Fig. so that the gear shifting fork can be installed easily.

NOTE: Two kinds of gear shifting forks, ① and ② are used. They resemble each other very closely in external appearance and configuration. Carefully examine the illustration for correct installing positions and directions.

● After

cam stopper and gear shifting forks have been fitted, hook cam stopper spring onto the crankcase.

CRANKCASE When reassembling the crankcase pay attention to the following. Coat SUZUKI SUPER GREASE "A" to the lip of oil seals. Remove sealant material on the fitting surfaces of right and left halves of crankcase and thor-oughly remove oil stains. Fit dowel pins on the left half. Apply engine oil to the big end of the crankshaft conrod and all parts of the transmission gears. Apply SUZUKI BOND No.1215 (99000-31110) uniformly to the fitting surface of the left half of the crankcase, and after waiting a few minutes, fit the right half on the left half. A

99000-25010 : SUZUKI SUPER GREASE "A" 99000-31110 : SUZUKI BONDNo.1215

3-41

ENGINE

After the crankcase bolts have been tightened, check if driveshaft and countershaft rotate smoothly.

If a large resistance is felt to rotation, try to free the shafts by tapping the driveshaft or countershaft with a plastic hammer as shown in Fig.

GEAR SHIFTING CAM DRIVEN GEAR When installing the gear shifting pawls into the cam driven gear. The large shoulder A must face to the outside as shown. Next, install cam guide and pawl lifter, Apply a small quantity of THREAD LOCK "1342" to the threaded parts of the securing screws. 99000-32050 : THREAD LOCK “1342"

GEAR SHIFTING SHAFT Install the gear shifting shaft. Match the center teeth of the gear on the shifting shaft with the center teeth on the shifting driven gear as shown. NOTE: After the cam driven gear, cam guide, gear shifting shaft and neutral cam stopper have been fitted, confirm that gear change is normal while turning the countershaft and driveshaft. If gear change is not obtained, it means that assembly of gears or installation of gear shifting fork is incorrect. If this is the case, disassemble and trace the mistake. Fit key in the key slot on the crankshaft, and install the primary drive gear.

3-42

FI SYSTEM A N D FUEL SYSTEM CONTENTS ............ ................................... D-FI SYSTEM INJECTION VOLUME ...... .......................... CONTROLLING THE END OF THE INJECTION ............... WIRE DIAGRAM OF THE D-FI SYSTEM .................. ........................... ECU (CONTROL UNIT OF FI) .................................. SELF-DIAGNOSIS ........... CURRENT FAULT CODE/HISTORY FAULT CODE ................. FI WARNING LIGHT---FLASHING MODE CHECK FI WARNING LIGHT .......................... ......................... FAULT DIAGNOSIS DEVICE ............. TROUBLESHOOTING FOR THE D-FI SYSTEM PRE-DIAGNOSIS INSPECTION ........................ FAULT ANALYSIS FOR THE ELECTRONIC INJECTION SYSTEM . TABLE OF DIAGNOSTIC TROUBLE CODE (DTC) ............ DTC '12': CRANK SHAFT POSITION SENSOR ............... DTC ‘15': ENGINE TEMPERATURE SENSOR ............... DTC ‘23': TIP-OVER SENSOR ......................... DTC ‘24': IGNITION COIL ............................ DTC '32': (D) .................................. DTC '40’: (IDLE SPEED CONTROL VALVE) . . . . . . . . . . . . . . DTC '44’ ( OXYGEN SENSOR) . . . . . . . . . . . . . . . . . . . . . . .

4-1 4-3 4-3 4-3 4-4 4-5 4-6 4-6 4-6 4-6 4-7 4-9 4-9 4-9 4-10 4-11 4-12 4-13 4-14 4-15 4-16 4-18

DTC '13', '14' OR '21': INTAKE AIR PRESSURE, THROTTLE POSITION OR INTAKE AIR TEMPERATURE SENSOR . . . . . . . . .

4-19

........... ECU AND TIP-OVER SENSOR .......................... .................... CRANK SHAFT POSITION SENSOR D ........................................... THROTTLE POSITION SENSOR AND MAQ SENSOR .......... ................................ OXYGEN SENSOR ENGINE TEMPERATURE ............................. ..................................... FUEL SYSTEM

4-20 4-20 4-20 4-21 4-21 4-22 4-22 4-23

ELECTRICAL DIAGRAM FOR THE D-FI SYSTEM

DISMOUNTING THE ELECTRONIC INJECTION UNIT

4

FI SYSTEM A N D FUEL SYSTEM

ELECTRICAL DIAGRAM FOR THE D-FI SYSTEM 3

2

6

5

4 1

13

12

9

10

7

11 8

① ② ③ ④ ⑤ ⑥

ECU TOS(Tip-over sensor) Turn signal relay Fuel gauge Ignition SW Ignition coil

⑦ ⑧ ⑨ ⑩ 11 12 13

ETS(Engine temperature sensor) Starter motor REG/REC Oxygen sensor Fuse box Starter relay Battery

4-1


2

4

1

3

5

6

① ② ③ ④

⑤ CKPS -Crank shaft position sensor ⑥ MAQ sensor

ISCV-Idling speed control valve D Throttle body TS plug

IAPS : Intake air pressure sensor IATS : Intake air temperature sensor TPS : Throttle Position Sensor

4-2


D-FI SYSTEM INJECTION VOLUME The three major signals that determine the injection volume are: Intake air pressure from the Intake air pressure sensor, rotational speed from the crank shaft position sensor and the throttle opening from the throttle position sensor. These signals calculate the basic injection volume. This basic volume, combined with modification signals produced by other sensors and the storage battery voltage, will lead to an optimized injection volume. IAPS Basic fuel injection volume

CKPS

Throttle position sensor IATS Oxygen sensor ETS Battery voltage

Modifications of the injection volume

Final injection volume

D

MODIFICATION OF THE INJECTION VOLUME SIGNAL Oxygen sensor signal Engine temperature signal Intake air temperature sensor signal Start up signal. (produced by the crank shaft sensor) Acceleration/deceleration signal. (produced by the air throttle position sensor)

CONTENT Oxygen sensors will check the oxygen content in the exhaust pipe, modifying the injection volume. When engine temperature rises, the injection volume should be reduced, and vice versa. When intake air temperature rises, the injection volume should be reduced, and vice versa. Make sure fuel injection is done in a timely manner. When the vehicle slows down, the fuel supply should be cut off. When engine speed rises, the injection volume should be increased. When the engine slows down, the fuel supply should be cut off.

CONTROLLING THE END OF THE INJECTION CONTENT

SIGNAL Tip-over sensor signal

When the vehicle has a tilting angle greater than 45° for more than 5 seconds, the ECU will cut off the D and the ignition coil.

Speed limit signal

When engine speed reaches 9000rpm, the ECU will cut off the fuel supply for the injection units to limit engine speed.

Throttle position sensor signal

Deceleration control signal

When engine starts with a throttle opening larger than 3/10, the fuel supply and ignition coil will be cut off. When the rider releases the accelerator abruptly (deceleration), the throttle position sensor will send a deceleration signal to the ECU, cutting off fuel supply to the injection units. When engine speed is down to 2000 rpm, the ECU will restart the fuel supply.

4-3

4-4 CLUTCH-SW

FREE

PUSH

O

MAGNETO

P

ON OFF

M

STARTER-MOTOR

OY

OY R

IGNITION-SW

R O

O

LIGHTS

BBr

L

Gr

START

YG OW

Gr

YW

G

G B B B

Br

Br

Gr

RB

RB

G

NE

OY

YG YB

AT

P

R

THE

LB

R

NT

12V

D-

D+ TS

WR

DIAG

BY

BW

MAQS

MAP

P

TPS

IG OX GP DON ST

RB R

VCC

OW W

KS OXH

O

+B E2

ISCV

BW

E1

YR

YR

ECU

BATTERY

STARTER-RELAY

FUSE-BOX(B) 20A

THA

OL

RW

O

FUSE-BOX(Y) 10A

VTA PM

GB Gg

OG

R

WL BG BW

WG PB BrW R GB Dg

AT

BBr

BBr OW

ISCV

BW E0

D 0 2-SNSR

Gr

GND

W

+B

P

BBr

OW BBr WG W

FI

B

OX

ETS

BBr

B

FUEL-CUT,SNSR

RW R

WL

BrW

W

OXH

OL

B

WR

TS

BW BG

IGNITION-COIL

BY OW

FI SYSTEM WIRING FI SYSTEM A N D FUEL SYSTEM

4-5

4

3

2

SPEEDOMETER ASSY

1

DIAGNOSIS DEVICE

R(825Ω 1/8W)

R(825Ω 1/8W)

R(1.5KΩ 1/8W)

R(2.74KΩ 1/8W)

OXYGEN SENSOR

INTAKE AIR TEMP SENSOR

TEST SW

FUEL CUT SENSOR

GEAR POSITION SW

+ Bs

GND DON VCC

MANIFOLD PRESSSENSOR

ENG TEMP SENSOR

GND VTA VCC

GND PM VCC

THROTTLE POSITION SENSOR

CRANK SHAFT POSITION SENSOR

26

23

13

OX

TS

GP

17

12

4

22

THA

E2

21

THE

24 DON 11

PM

VTA

VCC 9

NE AT

E1 E0

1

20 NT

10 ST

KS

8

+B

3

5

15 DIAG

2 ISCV

14 IG

6 OXH

25

16 D-

18 D+

NEUTRAL LAMP

ISCV SOLENOID

NEUTRAL SW

DIAG LAMP

IGN. COIL

IGNITION SW

M

STG MOTOR

STG RELAY

+Bs

1KΩ

KILL SW

CLUTCH-SW

STG SW

DISCHARGE PUMP

O 2 SENSOR HEATER

ANTI THEFT SIGNAL

( -)

( +)

BATTERY

15A

RECTIFIER

MAGNETO


WIRE DIAGRAM OF THE FI SYSTEM


ECU TERMINAL

1 3 12 11 10 9

8

6

26 25 24 2 3 22 21 20

NO.

CYCLE

5

4

3

2

1

18 1 7 16 15 14

NO.

CYCLE

1

ECU grounding

14

Ignition coil

2

ISCV(Idle Speed Control valve)

15

FI light

3

ECU grounding

16

D

4

Sensor system grounding

17

TS signal

5

Power supply

18

D

6

Heater of the oxygen sensor

20

Neutral signal

8

Power supply of starter check

21

ETS (Engine Temperature Sensor )

9

ECU power supply

22

IATS (Intake Air Temperature Sensor)

10

Starter motor

23

IAPS (Intake Air Pressure Sensor)

11

TOS (Tip-Over Sensor)

24

TPS (Throttle Position Sensor)

12

Gear pistion light

25

Starter switch

13

Oxygen sensor

26

Crankshaft position sensor

4-6

_

+

+


SELF-DIAGNOSIS FUNCTION The ECU is capable of self-diagnosis. Abnormal operations within the D-FI system will trigger the ECU, which will turn on the FI warning light (fault signals) and store DTC in an erasable memory.

CURRENT DTC/HISTORY DTC There are two kinds of DTC under different conditions. ● If the ECU detects an on-going fault, the FI warning light will blink in a fault-specific mode, which can be read and converted into the current DTC. Alternatively, special tools can be used to read the DTC directly. ● If the ECU hasn't detected any on going faults, but a previous fault is stored, the FI warning light will not blink. Special tools can be used to extract the fault history, a s well as read or delete previous DTC.

FI WARNING LIGHT---FLASHING MODE ● DTC can be read from the blinking pattern of the FI warning light. They can also be extracted using a diagnosis device. ● If the ECU hasn't detected any ongoing faults, when the ignition switch is turned 'ON', the FI warning light will light up for several seconds before switching off again. ● If the ECU detects an ongoing fault, when the ignition switch is turned 'ON', the FI warning light will light up for a few seconds, turn off and then blink in a fault-specific manner.

FAULT-SPECIFIC BLINKING METHOD For first number, the warning light goes on for 1 second and for units digit numbers for 0.3second. The blinking interval is 0.3 second while the interval between first and second number is 1 second. The interval between two DTC is 3 seconds. How to read a current DTC: As shown in the figure below: '23' The warning light will blink twice, going on 1 second each time, with an interval of 0.3 second. After these two long blinks, the light will go off for 1 second and then blink faster three times, turning on for 0.3 second each time. 3 seconds later, the warning light will repeat the above mentioned sequence.

First number

Second number

On Next DTC

Interval

Off

CHECK FI WARNING LIGHT If the FI warning light cannot conduct self-inspection when the ignition switch is turned 'ON', the control circuit fuse for the central relay and the warning light should be checked for burning damage or open circuit.

4-7


FAULT DIAGNOSIS DEVICE NTRODUCTION TO FAULT DIAGNOSIS DEVICE

Screen

Esc

Enter

Up Imposed upgrade Power indicator

Next page Previous page Down

Communication indicator USB updating interface

Diagnosis interface

Screen brightness adjustment

Power switch

DC12V power Intake air socket

STEPS TO USE THE FAULT DIAGNOSIS DEVICE ● Make sure the ignition switch and the power switch for the diagnosis device are both turned off.

4-8


● Dismantle the storage battery cover, take out the wiring harness plug for the diagnosis device. Connect the wiring harness plug to the diagnosis device.

● Turn on the ignition switch first and then the diagnosis device. This will lead to the static diagnosis stage. Alternatively, the engine can be switched on and then the diagnosis device turned on, which will lead to the dynamic diagnosis stage. NOTE: When the diagnosis has been completed, follow the same steps in the opposite order to disconnect the diagnosis device.

● A system menu will pop up on starting the diagnosis device. ●Select 'Fault Diagnosis', press 'Enter' and access the diagnosis menu. ●Select 'HJ125T - 16A' and press 'Enter'.

●Click on the 'D' menu and enter the 'Function Selection' menu. ●Select to read the current fault code and take appropriate measures to fix it after confirmation. ●Then select to read the fault history to make sure there are no hidden faults to fix. ●When all the faults have been fixed, select 'Clear Fault Codes' to delete the fault codes. ●Select 'Read Data Stream' to make sure the vehicle can display the fault codes. ●'TPS idling setting' refers to the pre-set value of the air throttle position stored in the ECU. WARNING: No adjustment of idling speed is allowed. * FUNCTIONAL KEY F1 will read current fault code: An ongoing fault is one that the vehicle currently possesses. Once the problem has been solved, it will be erased by the system. Fault information will be stored in the ECU memory under the fault history folder. F2 will read the fault history: F2 will read the current fault code, including the fault code for loose connections, which come and go and may not be recurrent, as well as fault codes left undeleted from the last repair. Note: The current fault code will be written into the memory each time the ignition switch is fired. (a maximum of 16 items can be stored.) F3 will erase the fault codes: Eliminate the fault history. F4 will read the data stream. F5 will set the TPS idling speed. F6 will read the current computer version.

4-9


TROUBLESHOOTING FOR THE D-FI SYSTEM PRE-DIAGNOSIS INSPECTION The following inspections should be carried out before the fault diagnosis. ●Engine oil volume and oil leakage ●Melted fuse ●Fuel volume and leakage ●Working condition of the FI warning light ●Air filter blockage ●Working condition of the speedometer ●Storage battery condition ●Exhaust leakage ●Clearance of air throttle cable ●Connection of plugs and sockets ●Cracking, damaging or loosening of vacuum throat

FAULT ANALYSIS FOR THE ELECTRONIC INJECTION SYSTEM ◇Fault with specific DTC: System faults that have specific fault codes corresponding to it. Features: FI warning light displays a single DTC. Causes: Short or broken circuits in the signal circuit or control circuit of electronic control components; short or broken circuits in the electronic control components; Short or broken circuits in the ECU For example: Faults in the engine temperature sensor and its wiring. Processing steps: Follow the instructions in the fault diagnosis device.

Check the connection of the plugs and sockets.

Check the terminals of the plugs and sockets.

Faults in electronic control components or the ECU

Check the connection of the electric wires.

◇Faults without specific DTC: The actual fault is not the one indicated by the FI warning light or the diagnosis device. Features: FI shows several DTC at the same time. Causes: Short or broken circuits in the bus wiring. For example: Faults in the central relay, relay fuse, sensor power supply or sensor wiring. Processing steps: Check all the related fuses.

Follow the steps mentioned above to solve faults in bus wiring.

Check the bus wiring based on the fault pattern.

◇ The vehicle tests 'normal' using a diagnosis device but will not start or will not work normally after starting. Features: The FI warning light doesn't display any DTC. Causes: Non-electrical faults or inaccurate signals in the electrical controlled components. For example: Fuel spray blockage, blocked air throttle or increased resistance in the signal circuit. Processing steps: Extract data stream of the vehicle from the fault diagnosis device.

Analyze the data stream for anomalies.

Solve problems with the electric controlled components.

Find the fault based on an abnormal data stream.

4-10


TABLE OF DIAGNOSTIC TROUBLE CODE (DTC) DTC

BLINKING OF FI WARNING LIGHT

SENSORS/LOAD

12

Crank shaft position sensor

13

Intake Air Pressure Sensor

14

Throttle Position Sensor

15

Engine temperature Sensor

21

Intake Air Temperature Sensor

23

Tip-Over Sensor

24

Ignition coil Gear position signal

31

D

32

Idle speed control valve

40

Heater of the oxygen sensor

44

4-11


DTC '12': CKPS INSPECTION Sequence 1 1) Switch the ignition switch 'OFF' 2) Remove the seat cushion/helmet box. 3) Check if there is any looseness or poor with the socket connector of the CKPS. 4) If not, measure the resistance of the CKPS.

5) Remove the socket connector of the CKPS, and measure its resistance. Resistance of the crank shaft position sensor: 150-230 KΏ (G-L) 09900-25008 : Pocket tester Dose the resistance fall within the normal range? Yes-Go to sequence 2. No-Replace crank shaft position sensor.

Sequence 2 1) Check if there is any looseness or poor with the ECU socket connector. 2) If not, replace the ECU.

3) Delete the fault code with specific tools after repairing.

4-12


DTC '15': ETS INSPECTION Sequence 1 1) Switch the ignition switch 'OFF' 2) Remove the seat cushion/helmet box. 3) Check if there is any looseness or poor with the socket connector of the ETS. 4) If not, measure the resistance of the ETS.

5) Remove the socket connector of the ETS, and measure its resistance. Electric resistance of the ETS: 5-14kΏ under temperature of 20-40℃(B-B) 09900-25008 : Pocket tester Dose the resistance fall within the normal range? Yes-Go to sequence 2. No-Replace the ETS.



4-13


DTC '23': TOS INSPECTION Sequence 1 1) Switch the ignition switch 'OFF' 2) Remove the front-slanted plate. 3) Check if there is any looseness or poor with the socket connector of the TOS. 4) If not, measure the resistance of the TOS.

5) Remove the socket connector of TOS, and measure its voltage. Input voltage of the TOS: 4.5 - 5.5V(R-Grounding) 6) Check the output voltage of the Tip-Over Sensor Output voltage of theTOS: Upright position: 0.4 - 1.4V Tip-Over: 3.7 - 4.4V (Br/W-B/Br) 09900-25008 : Pocket tester Dose the voltage fall in the normal range? Yes-Sequence 2. No- Replace the TOS. Sequence 2 1) Check if there is any looseness or poor with the ECU socket connector. 2) If not, replace the ECU.


4-14


DTC '24': IGNITION COIL INSPECTION Sequence 1 1) Switch the ignition switch 'OFF' 2) Remove the seat cushion/helmet box. 3) Check if there is any looseness or poor with the socket connector of the IG. coil. 4) If not, measure the resistance of the IG. Coil.

5) Remove the socket connector of the IG. coil, and measure its resistance. IG. coil resistance: 3.4 - 4.6Ώ (Υ/Β-O/W)

09900-25008 : Pocket tester Dose the resistance fall in the normal range? Yes-Sequence 2. No- Replace the IG. coil.



4-15


DTC’32': (D) INSPECTION Sequence 1 1) Switch the ignition switch 'OFF' 2) Remove the seat cushion/helmet box. 3) Check if there is any looseness or poor with the socket connector of the D. 4) If not, measure the resistance of the D.

5) Remove the socket connector of the D, and measure its resistance.

Electric resistance of the D: 1.9Ώ (R/W-W/L) 09900-25008 : Pocket tester

Does the resistance fall in the normal range? Yes-Sequence 2. No- Replace the D



4-16


DTC '40’: IDLE SPEED CONTROL VALVE INSPECTION Sequence 1 1) Switch the ignition switch 'OFF' 2) Remove the seat cushion/helmet box. 3) Check if there is any looseness or poor with the socket connector of the ISCV. 4) If not, measure the resistance of the ISCV.

5) Remove the socket connector of the ISCV, and measure its resistance. Electric resistance of the ISCV: 31 - 39Ώ (Y/R-O/W) 09900-25008 : Pocket tester Does the resistance fall in normal range? Yes- Sequence 2. No- Replace the ISCV.



4-17


DTC ‘44’: (O 2 S) INSPECTION Sequence 1 1) Switch the ignition switch 'OFF' 2) Remove the left lateral strip. 3) Check if there is any looseness or poor with the socket connector of the O 2 S. 4) If not, measure the resistance of the O 2 S.

5) Remove the socket connector of the O 2 S, and measure its resistance. Resistance of the heater: 11.7 - 14.3Ώ (Early stage) 11.7 - 15.6Ώ (After endurance)(B - Gr) 09900-25008 : Pocket tester Dose the resistance fall in normal range? Yes-Sequence 2. No- Replace the oxygen sensor



4-18


DTC ‘13’,'14' OR '21': INTAKE AIR PRESSURE, THROTTLE POSITION OR INTAKE AIR TEMPERATURE SENSOR INSPECTION Sequence 1 1) Switch the ignition switch 'OFF' 2) Remove the seat cushion/helmet box. 3) Check if there is any looseness or poor with the socket connector of the air-throttle housing. 4) If not, measure the resistance of the air-throttle housing.

5) Remove the socket connector of the air-throttle housing, and measure its resistance.

Output voltage of the Intake Air Pressure Sensor: 2.0-3.5V at idle speed (G/B-B/Br) Resistance of the Throttle Position Sensor Fully open 2.9-5.1KΏ (P-B/Br) Completely closed 0.61-0.97KΏ (P-B/Br)

Resistance of the Intake Air Temperature Sensor: About 2.9KΏ ( Dg - B/Br)

Are the output voltages and electric resistances normal? Yes-Sequence 2. No- Replace the air-throttle housing.



4-19


DISMOUNTING THE ELECTRONIC INJECTION UNIT WARNING: Components of the sensors are not shock resistance, so be careful not to drop them during operation. Also, do not pull the wiring.

ECU and TOS DISASSEMBLY ● Turn the ignition switch 'OFF'. ● Dismantle the screws in the front and the itself. ● Pull off the ECU plug and the Tip-over sensor plug. ● Loosen the fastening screw for the Tip-over sensor and dismantle the tiling sensor. ●Take the ECU out of the safety box.

REMOUNTING To mount, reverse the procedure described above.

CRANKSHAFT POSITION SENSOR

2

DISASSEMBLY Dismantle the cover of the electro-magnetic engine. Dismantle the crank shaft position sensor and stator coil.

REMOUNTING Mounting should follow the exact steps in the opposite order of disassembly with special attention paid to the following points. Apply the fastening gel to the stator coil and fastening screws for the crank shaft position sensor. 99000 - 32110: THREAD LOCK SUPER “1322"

4-20

1


D ● Open the pad lock and dismantle the helmet box. ● Put a clean, oil-resistant vessel next to the fuel filter, pull off the fuel pipe and empty the fuel tank.

WARNING: Petroleum is explosive. Handle with care.

● Pull off the D plug and all the fuel pipes. Remove the screws for the D and the pump itself.

REMOUNTING To mont, reverse the procedure described above.

THROTTLE POSITION SENSOR AND MAQ SENSOR WARNING: The MAQ sensor and idling control valves cannot be dismantled separately. Dismantle the air throttle housing as a whole.

DISASSEMBLY ● Dismantle the seat pad and helmet box. ● Disconnect the MAQ sensor, idling control valve and air throttle housing plug. ● Release the installation bolts on the air Intake air pipe and the fastening screws on air filter Intake air pipe. ● Dismantle the accelerator cable and the air throttle housing.

REMOUNTING To mount, reverse the procedure described above.

4-21


OXYGEN SENSOR DISASSEMBLY ● Dismantle the seat pad and the helmet box. ● Dismantle the rear cover and the right lower cover. ● Disconnect the oxygen sensor plug. ● Dismantle the oxygen sensor.

REMOUNTING To mountl, reverse the procedure described above.

ENGINE TEMPERATURE SENSOR DISASSEMBLY ● Dismantle the seat pad and helmet box. ● Dismantle the left and right cover and the side . ● Remove the Throttle Position Sensor as a whole and dismantle the air Intake air pipe. ● Dismantle the upper and lower air deflector of the engine.

● Dismantle the engine temperature.

REMOUNTING Mounting should be conducted following the exact steps in the opposite order of disassembly. Special attention should be paid to the following key points. Don't twist the temperature sensor wiring during mounting. WARNING: Don't pull the engine temperature sensor wires.

4-22


FUEL SYSTEM

4-23


FUEL REMOVAL AND DISASSEMBLY ● Take off the seat and the left & right frame covers. ● Clamp the hose ① and ②，take off the hose, vent fuel tank gasoline.

1

2

● Take off the right and left side cover, remove the mounting bolts, clamp the hose ③ , disconnect the coupler of fuel sensor, then take off the fuel tank.

3

● The fuel tank can be mounted in the reverse order of removal.

THROTTLE BODY ● ● ● ●

Take off the right and left frame covers & the seat & the fuel tank. Take off the fuel pump hose ④. Take off the fuel pump intake hose⑤ 。 Remove the fuel filter⑥ .

5

4

6

● Disconnect the couple of fuel pump⑦. ● Disconnect the couple of ISCV ⑧. ● Disconnect the couple of 3-in-1 sensor ⑨.

7 8

9

● Disconnect the couple of engine temperature sensor.

4-24

● Take off the PVC hose.

● Remove the hose ①. ● Loosen the throttle cable adjuster lock nuts , and take off the throttle cable ② and ③.

1 3

2

● Remove the throttle body from the right side of frame by unscrewing clamp screws.

● Remove the fuel pump by unscrewing clamp screws.

4-25

THROTTLE VALVE CLEANING

ISC

WARNI NG 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. MAQS

● Use a swab moistened with a carburetor cleaner (petroleum

solvent) to clean the ageways, throttle valve, and main bore and then dry the cleaned surfaces with compressed air.

NOTICE Do not use wire to clean ageways. Wire can damage ageways. Never spray a cleaner (petroleum solvent) directly to the throttle valve and and ISC by age. The cleaner, if sprayed, would work its way into the inside of ISC valve and attack the insulation film of the coil there, causing a short circuit and eventual malfunction of ISC valve. In addition, if a short circuit occurs in the coil, an overcurrent would flow through the ISC valve drive circuit causing the ECU to brake down. When the throttle valve is molybdenum-coated, avoid applying the cleaner to the coated surfaces. The cleaner will peel off the coating and this will impair the airtightness of the throttle valve. If the components cannot be cleaned with a spray cleaner it may be necessary to use a dip-type cleaning solution and allow them to soak. Always follow the chemical manufacturer’s instructions for proper use and cleaning of the throttle body components. Do not apply carburetor cleaning chemicals to the rubber and plastic materials.

REMOUNTING ● The throttle body can be mounted in the reverse order of removal.

4-26

By age

CHASSIS CONTENTS FRONT WHEEL

5-1

FRONT ABSORBER

5-3

STEERING STEM

5-10

FRONT BRAKE

5-13

REAR WHEEL AND REAR BRAKE

5-19

REAR SWING ARM

5-25

5

CHASSIS

FRONT WHEEL 18~28N. m

5 0 ~ 8 0 N .m

REMOVAL AND DISASSEMBLY FRONT WHEEL ● ● ●

the motorcycle by center stand. Remove front wheel nut. Draw out the axle shaft and take off the wheel.

NOTE: Do not operate the front brake lever while dismounting the front wheel. ●

Using the appropriate drift, drive out the wheel bearings.

5-1

CHASSIS

● ●

Unlock the washers and remove the four bolts. Separate the disc from the wheel. NOTICE Do not reuse the lock washers.

INSPECTION PLAY

WHEEL BEARING Inspect the play of wheel bearings inner race by hand while fixing it in the wheel hub. Rotate the inner race by hand to inspect whether abnormal noise occurs or rotating smoothly. Replace the bearing if there is something unusual.

AXLE SHAFT Using the special tools, check the axle shaft for runout and replace it if the runout exceeds the limit. TOOL

09900-20606 : Dial gauge(1/100) 09900-20701 : Magnetic stand 09900-21304 : V-block(100mm) Service limit

0.25 mm

THICKNESS OF BRAKE DISC Using the special tools, check the thickness of the brake disc and replace it if the thickness exceeds the limit. (Refer to page 2-10) TOOL

09900-20101 : Vernier caliper (1/50 mm,150 mm) Service limit

4.5 mm

5-2

PLAY

CHASSIS

REASSEMBLY Reassembly and remount the front wheel and front brake in the reverse order of disassembly and removal, and also carry out the following steps.

BRAKE DISC ●

Make sure that the brake disc is clean and free of any greasy matter, after securing bolts, be sure to lock with specified torque. Brake disc bolt : 18~28N•m

NOTE: Always use new lock washers. ●

Bend the washer to the bolts.

WHEEL BEARING ●

Apply grease to the bearings before installing. APPLY SUPER GREASE “A”

●

Install the wheel bearings by using the special tool. 09913-75820 : bearing installer

TOOL

SPEEDOMETER GEAR BOX ●

Before installing the speedometer gear box grease it and align groove on the wheel hub with two drive pawls on speedometer drive gear box. 1

APPLY SUPER GREASE “A”

●

2

When tightening the front axle, check to be sure that the speedometer gear box is in the position shown.

TIRE (Refer to page 2-13)

5-3

CHASSIS

FRONT SHOCK ABSORBER

50~80N.m

1 8 ~28N.m

12~20N.m

25~40N.m 1 5~30N.m

18~28N.m 15~25N . m

5-4

CHASSIS

REMOVAL AND DISASSEMBLY ● ●

Remove the front wheel (Refer to page 5-1). Remove the two bolts and dismount the front caliper.

●

Remove the four bolts and take off the front fender.

●

Remove the two screws and take off the headlight.

● ● ●

Disconnect the couplers and lead wires. Remove the lead wires from the headlight housing. Remove the two bolts and take off the headlight housing.

●

Remove the two bolts and take off the combination meter assembly.

5-5

CHASSIS

●

Disconnect the clutch inner cable from the clutch lever.

● ●

Remove the brake hose clamp bolt. Take off the throttle cable by removing the right handle switch assy.

●

Remove the handlebars clamp bolts after take off the caps.

● ● ●

Loosen the front shock absorber upper clamp bolts. Remove the stem head bolt. Remove the head of steering stem.

NOTE: Slightly loosen the front shock absorber cap bolts to facilitate later disassembly.

● ●

Remove the brackets of headlamp right and left. Remove the cover of steering stem after remove the flashers right and left.

5-6

CHASSIS

●

Loosen the front shock absorber lower clamp bolts.

●

Pull down right and left front shock absorber.

●

Remove the cap bolt and draw out the shock absorber spring.

●

Invert the shock absorber and stroke it several times to remove the oil. ● Hold the shock absorber inverted for a few minutes.

●

Remove damper rod bolt by using the special tools and 8mm hexagon wrench.

11F14-010-01 ： “T”handle 11F14-010-02 : Shock absorber knocked-down tool

5-7

CHASSIS

●

Remove the oil lock piece and damper rod with rebound spring. Separate the inner tube from the outer tube.

●

Remove the stopper ring.

●

Remove the oil seal by using the special tool.

●

09913-50121 ： Oil seal remover NOTICE The oil seal removed should be replaced with a new one.

INSPECTION DAMPER ROD RING ●

Inspect the damper rod ring for wear and damage.

INNER TUBE AND OUTER TUBE ●

Inspect the inner tube and outer tube sliding surface for any scuffing or flaws.

5-8

CHASSIS

SHOCK ABSORBER SPRING ●

Measure the shock absorber spring free length. If it is shorter than the service limit, replace it.

Service limit

338mm

REASSEMBLY Reassembly and remount the front shock absorber in the reverse order of disassembly and removal, and also carry out the following steps:

DAMPER ROD BOLT ●

Apply SUZUKI BOND No.4 and THREAD LOCK CEMENT to the damper rod bolt and tighten the bolt by using the 8mm hexagon wrench and special tools. No.4

99100-31030 ： SUZUKI BOND No.4 99000-32040 ： THREAD LOCK CEMENT

11F14-010-01 ：“T”handle 11F14-010-02 : Shock absorber rempver

D a mper r o d b o lt : 2 0 ~26 N·m

OIL SEAL ●

Install the oil seal to the outer tube by using the special tool as shown. 09940-50112 ： Oil seal installer

SHOCK ABSORBER ●

For the shock absorber oil, be sure to use a front shock absorber oil whose viscosity rating meets specifications below. Absorber oil type ：Special absorber oil Capacity (each leg)

3 8 5±3 m l

5-9

THREAD LOCK CEMENT

SUZUKI BOND NO.4

CHASSIS

●

Hold the front shock absorber vertical and adjust the shock absorber oil level with the special tool.

NOTE: When adjusting oil level, remove the shock absorber spring and compress the inner tube fully. 09943-74111 ： Shock absorber oil level gauge Oil level

120mm

SHOCK ABSORBER SPRING ●

上边 Upside

When installing the front fork spring, the close pitch end should position upside.

下边

REMOUNTING ●

When installing the front fork assembly, align the top ① of inner tube to the upper surface ② of the steering stem head.

2

●

Tighten the upper ④ and lower clamp bolt specified torque.

③ to the

The upper clamp bolt ： 18~28N·m The lower clamp bolt ： 25~35N·m

●

Tighten the stem head bolt ⑤ to the specified torque. The stem head bolt ：

35~55N·m

5-10

1

CHASSIS

STEERING STEM REMOVAL AND DISASSEMBLY ● ● ●

Remove the front wheel ( Refer to page 5-1). Remove the front shock absorber (Refer to page 5-3 ). Remove the steering stem nut and draw outsteering stem.

NOTE: Hold the steering stem by hand to prevent from falling. ●

Remove the upper and lower steel balls.

Upper

14pcs

Lower

14pcs

Number of balls

●

Remove the outer race fitted on the steering stem. This be done with a chisel.

●

Draw out the two inner races fitted to the top and bottom ends of the head pipe.

INSPECTION ●

Inspect and check the remove parts for the following abnormalities. * Handlebars distortion. * Handlebars clamp wear. * Race wear and denudation. * Worn or damaged steel balls. * Distortion of steering stem.

5-11

CHASSIS

REASSEMBLY Reassemble and remount the steering stem in the reverse order of disassembly and removal, and also carry out the following steps:

INNER RACES ●

Press in the upper and lower inner races using the special tool. 09941-34513 ： Steering race installer

OUTER RACE ●

Press in the outer race by using the special tool.

09941-74910 ： Steering bearing installer

STEEL BALL ●

Apply grease to the upper and lower inner races when installing the steel balls. 99000-25010 ： SUZUKI SUPER GREASE “A” Upper

14pcs

Lower

14pcs

Number of balls

STEERING STEM NUT ●

Tighten the steering stem nut to 40-50N· m by using the special tool. 09941-14911 ： Steering nut socket wrench

●

Turn the steering stem right ang left, lock-to-lock, five or six time to “seat”the ball bearings.

5-12

CHASSIS

●

Turn back the stem nut by 1/4-1/2 turn.

NOTE: This adjustment will vary from motorcycle to motorcycle.

●

Tighten the steering stem head bolt, the upper and lower clamp bolts to the special torque (Refer to page 5-12). T he steering stem ： 35~55N·m

WARING After performing the adjustment and installing the steering stem upper head, “rock”the front wheel assembly forward and back-ward to ensure that there is no play and that the procedure was accomplished correctly. Finally check to be sure that the steering stem moves freely from left to right with itsown weight. If play or stiffness is noticeable, readjust the steering stem nut.

HANDLEBARS ●

Set the handlebars to match its punched mark to the mating face of the holder.

●

Secure the each handlebars clamp in such a way that the clearances Ａ ahead of and behind the handlebars should be equalized. Tightening torque ： 20~30N·m

5-13

CHASSIS

FRONT BRAKE

5-14

CHASSIS

BRAKE PAD REPLACEMENT ● ●

Lossen the tow pins of caliper ①. Remove the caliper mounting bolts ② and take off the caliper.

NOTICE 2

Do not operate the brake level while dismounting the caliper. ●

Push the piston and piston holder all the way to the caliper when removing the brake pads.

● ● ●

Remove the bracket. Pull out the pins. Remove the brake pads and replace them.

NOTICE Replace the brake pad with a set, otherwise braking performance will be adversely affected.

● ●

Reassemble the brake pads and the caliper in the reverse orders. Tighten the caliper mounting bolts to the specified torque. Tightening torque ： 18~28N·m

NOTE: Push in the piston and piston holder all the way to the caliper when remounting the caliper.

CALIPER REMOVAL AND DISASSEMBLY ●

● ●

Disconnect the brake hose from the caliper by remove the bolt ① and catch the brake fluid in a suitable receptacle (Refer to page 2-13). Loosen the two pins ② of caliper. Remove the caliper mounting bolts ③ and take off the caliper.

5-15

2

CHASSIS

CAUTION Never re-use the brake fluid left over from the last servcing and stored for long periods. Do not operate the brake lever while dismounting the caliper. ● ● ●

Remove the bracket. Pull out the pins. Remove the brake pads.

●

Place a rag over the piston to prevent popping up. Force out the piston by using air gun.

CAUTION Do not use high pressure air to prevent piston damage.

●

Remove the piston, piston boot and piston seal.

INSPECTION CALIPER CYLINDER ●

Inspect the cylinder bore wall for nick, scratch or other damage.

PISTON ●

Inspect the piston surface for any scratches or damage.

5-16

CHASSIS

RUBBER PARTS ●

Inspect the each rubber part for damage and wear.

BRAKE DISC ●

Measure the micrometer.

disc

thickness

by

using

the

09900-20205 ： Micrometer (0~25 mm)

Service limit

●

3.0 mm

With the disc mounted on the wheel check thedisc for face runout with a dial gauge, as shown. 09900-20606 ： Dial gauge (1/100mm) 09900-20701 ： Magnetic stand

Service limit

0.30 mm

REASSEMBLY Reassemble and remount the caliper in the reverse orders of disassembly and removal, and also carry out the following steps:

WARNING Wash the caliper components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to wash them. Apply brake fluid to the caliper bore and all internal parts before inserting into the bore. ●

Apply SUZUKI SUPER GREASE to the piston holder. 99000-25010 ： SUZUKI SUPER GREASE“A”

5-17

CHASSIS

Tightening torque Hose bolt ① : 20~25N·m Caliper mounting bolt ② : 18~28N·m

2

WARNING Bleed air from the brake fluid circuit after reassembling the caliper (Refer to page 2-13).

MASTER CYLINDER REMOVAL AND DISASSEMBLY ●

Place a cloth underneath the union bolt on the master cylinder to catch spilled drops of brake fluid. Unscrew the union bolt and disconnect the brake hose from the master cylinder t.

NOTICE Immediately and completely wipe off any brake fluid ing any part of the motorcycle. The fluid reacts chemically with paint, plastics, rubber materials, etc. And will damage them severely. ●

Remove two clamp bolts and take off the master cylinder.

● ●

Remove two fitting screws, and remove the cap and diaphragm. Drain brake fluid.

● ●

Remove the dust seal boot. Remove the circlip by using the special tool. 09900-06108 ： Snap ring pliers

5-18

CHASSIS

INSPECTION ●

Inspect the master cylinder bore for any scraches or other damage.

● ●

Inspect the piston surface for scratches or other damage. Inspect the primary cup, secondary cup and dust seal boot for wear or damage.

REASSEMBLY Reassemble and remount the master cylinder in the reverse orders of disassembly and removal, and also carry out the following steps.

NOTICE Wash the master cylinder components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to wash them. Apply brake fluid to the cylinder bore and all internal parts before inserting into the bore. ●

When remounting the master cylinder on the handlebars, first tighten the clamp bolt for upside as shown.

WARNING

Master cylinder

UP

Bleed air from the brake fluid circuit after reassembling master cylinder (See page 2-13). Handlebar Clearance

5-19

CHASSIS

REAR WHEEL AND REAR BRAKE

50~80N.m

8~12N.m

1 8 ~28N.m

REMOVAL ● ● ●

the machine by the center stand. Remove the rear brake adjuster nut ① and disconnect the brake rod ②. Pull off the cotter pin ③ and remove the torque link nut ④ and bolt.

2 1

3 4

5-20

CHASSIS

● ●

Pull off the cotter pin and remove the rear axle nut ⑤. Loosen the chain adjuster lock nut ⑥ and adjuster bolt ⑦, right and left.

5

6

● ●

Draw out the axle shaft and take off the chain from rear sprocket. Take off the rear wheel and separate the brake from the wheel.

DISASSEMBLY REAR WHEEL ● ●

Flatten the washers and remove the four nuts. Separate the rear sprocket and mounting drum from the wheel.

●

Remove the oil seal by using the special tool. 09913-50121 ： Oil seal remover

●

Remove the bearing and retainer from the mounting drum.

5-21

CHASSIS

●

Remove the cushion from the wheel.

●

Remove the right and left side wheel bearings.

NOTE: Removing the left side bearing first makes the job easier.

REAR BRAKE ●

Take off the brake shoes.

●

Remove the cam lever nut and bolt.

●

Pull off the brake cam, washer, O-ring and cam lever.

5-22

CHASSIS

INSPECTION

PLAY

WHEEL BEARING Inspection the wheel bearings for play by hand. Rotate the inner race by hand to inspect whether abnormal noise occurs and it rotates smoothly. Replace the bearing if there are any defects.

PLAY

AXLE SHAFT ●

Using the special tools, check the axle shaft for runout and replace it if the runout exceeds the limit.

09900-20606 : Dial gauge (1/100) 09900-20701 : Magnetic stand 09900-21304 : V-block (100mm) Service limit

0.25mm

SPROCKET ●

Inspect the sprocket teeth for wear. If they are worn as illustrated, replace the sprocket and drive chain.

Normal wear Excessive wear

REAR BRAKE DRUM ●

Measure the brake drum I.D. to determine the extent of wear and, if the limit is exceeded by the wear noted, replace the drum. The value of this limit is indicated inside the drum. Service limit

130.7mm

BRAKE SHOE ●

Check the brake shoes and decide whether it should be replaced or not from the thickness of the brake shoe linings. Service limit

1.5mm

CAUTION Replace the brake shoes as a set, otherwise braking performance will be adversely affected.

5-23

CHASSIS

CUSHION ●

Inspect the cushion for wear and damage.

REASSEMBLY Reassemble and remount the rear wheel and rear brake in the reverse order of disassembly and removal, and also carry out the following steps:

WHEEL BEARING ●

Apply grease to the bearings before installing. 99000-25010 ： SUZUKI SUPER GREASE "A"

●

Install the wheel bearings by using the special tool.

NOTE: First install the wheel bearing for right side. 09913-80112 ： Bearing installer

MOUNTING DRUM ●

Insert the bearing by using the special tool.

09940-53311 ： Bearing installer

●

Apply grease to the mounting drum as shown. 99000-25010 ： SUZUKI SUPER GREASE "A"

5-24

CHASSIS

SPROCKET ●

After tightening the four nuts to specification, bend the lock washers.

Tightening t o r q u e : 18~28N·m

BRAKE CAM ●

Apply grease to the brake cam. 99000-25010 ： SUZUKI SUPER GREASE "A"

WARNING Be careful not to apply too much grease to the brake cam. If grease gets on the lining, brake slippage will result.

BRAKE CAM LEVER ●

Install the brake cam lever and tighten the cam lever nut with specified torque.

Tigh t ening t o r q u e : 6 ~ 8 N·m

TIRE (Refer to page 2-13)

5-25

CHASSIS

REAR SWING ARM

1 0 ~ 1 6 N .m

50~80N . m

REMOVAL AND DISASSEMBLY ● ●

Remove the rear wheel (Refer to page 5-19). Remove the rear shock absorber units and take off the shock absorber units.

5-26

CHASSIS

●

Remove the two screws and take off the chain case.

● ●

Remove the swing arm pivot nut and draw out the shaft. Remove the swing arm.

● ●

Pull off the cotter pin and remove the nut and bolt. Remove the torque link.

● ●

Remove the chain buffer Remove the dust seal covers and draw out the spacers.

●

Draw out the bushings by using the special tools. 09923-73210 : Bearing puller 09923-73200 : Rotor remover slide shaft

5-27

CHASSIS

INSPECTION BUSHING Inspect the bushing for wear and damage.

SWING ARM PIVOT SHAFT Using a dial gauge, check the pivot shaft for runout and replace it if the runout exceeds the limit. 09900-20606 ：Dial gauge (1/100) 09900-20701 : Magnetic stand 09900-21304 : V-block (100mm) Service limit

0.6mm

REASSEMBLY Reassemble and remount the swing arm in the reverse order of disassembly and removal, and also carry out the following steps:

SWING ARM BUSHINGS ●

Force-fit the bushings into the swing arm by using the special tool. 09924-84510 ： Bearing installer set

SPACER AND DUST SEAL COVER ●

Apply grease to the spacer and dust seal cover when installing.

99000-25010 ： SUZUKI SUPER GREASE "A"

5-28

CHASSIS

LEFT & RIGHT SIDE BOX AND BRACKET REMOVE DISASSEMBLY ●

Open the side box, take off the side box bolts, remove the side box.

●

Take off the decorative covers.

●

Disconnect the couplers of turn light.

●

Take off the side box bracket.

REMOUNTING ● The side box can be mounted in the reverse order of removal.

5-29

ELECTRICAL CONTENTS IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 COMBINATION METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6

ELECTRICAL

IGNITION SYSTEM

ECU

Ignition coil CKP sensor

ECU

Ignition switch ERC Battery

IGNITION COIL

MAGNETO

6-1

ELECTRICAL

INSPECTION PICK-UP ● Using

the pocket tester(RX1Ω range), measure the resistance between the lead wires in the following table . 09900-25002 ： Pocket tester Pick-up coil resistance

L-G Approx. 90-300Ω

Charging coil resistance

B-B Approx. 0.5-1.3Ω

NOTE: When mounting the stator on the generator cover, apply a small quantity of THREAD LOCK "1342" to the threaded parts of screws. 99000-32050 ： THREAD LOCK “1342"

IGNITION COIL ● Check the ignition coil with electro tester. ● Test the ignition coil for sparking performance. ● Test connection is as indicated. Make sure that

the three-

needle sparking distance is at least 8 mm. 09900-28106 ： Electro tester STD Spark performance ● Check

8mm

the ignition coil with pocket tester.

09900-25002 ： Pocket tester Ignition coil resistance Primary

O/W -W

Approx.3.5-4.5Ω

Secondary

Plug cap-O/ W

Approx.16-30kΩ

6-2

WIRE COLOR L : Blue G : Green B : Black

ELECTRICAL

SPARK PLUG ● Clean

the plug with a wire brush and pin. Use the pin to remove carbon, taking care not to damage the porcelain.

● Check

the gap with a thickness gauge.

09900-20803 ： Thickness gauge

Spark plug gap

0.7-0.8mm 0.7-0.8mm

6-3

ELECTRICAL

CHARGING SYSTEM CHARGING OUTPUT CHECK Start the engine and keep it running at 5 000r/min. Using the pocket tester, measure the DC voltage between the battery terminal and . If the tester reads under 13.5V or over 16.0V, check the AC generator no-load performance and regulator/rectifier.

NOTE: When making this test, be sure that the battery is full-charged condition.

IG. SWITCH

Regulator Rectifier

STD charging output Battery

14.0V-15.0V

5000r/min

09900-25002 ： Pocket tester

AC GENERATOR NO-LOAD PERFORMANCE Disconnect the three lead wires from the AC generator terminal. Start the engine and keep it running at 5 000r/min. Using the pocket tester, measure the AC voltage between the three lead wires. If the tester reads under 70V, the AC generator is faulty.

STD No-load performance More than 70V (AC) at 5 000r/min 09900-25002 ： Pocket tester

REGULATOR/RECTIFIER ● Replace

the new regulator/rectifier, if it is the question.

6-4

ELECTRICAL

STARTER SYSTEM DESCRIPTION The starter system is shown in the diagram below: namely, the starter motor, relay, engine kill switch, IG switch, starter button and battery. Depressing the starter button (on the right handlebar switch box) energizes the relay, causing the points to close which connects the starter motor to the battery. The motor draws about 80 amperes to start the engine.

STARTER MOTOR REMOVAL AND DISASSEMBLY ● Remove the starter motor . ● Disassemble the starter motor

as follows.

6-5

ELECTRICAL

STARTER MOTOR INSPECTION CARBON BRUSHES When the brushes are worn, the motor will be unable produce sufficient torque, and the engine will be difficult turn over. To prevent this, periodically, inspect the length the brushes, replacing them when they are too short chipping.

to to of or

COMMUTATOR If the commutator surface is dirty, starting per-formance decreases. Polish the commutator with #400 or similar fine emery paper when it is dirty. After polishing it, wipe the commutator with a clean dry cloth.

SEGMENT ①

Check the commutator under cut ¢.

MICA

ARMATURE COIL Using a pocket tester, check the coil for open and ground by placing probe pins on each commutator segment and rotor core (to test for ground) and on any two segments at various places (to test for open), with the brushes lifted off the commutator surface.

If the coil is found to be open-circuited or ground-ed, replace the armature. Continuous use of a defective armature will cause the starter motor to suddenly fail. 09900-25002 ： Pocket tester

STARTER MOTOR REASSEMBLY BRUSH HOLDER AND HOUSING END When fixing brush holder to starter motor case, align the protrusion ① of the starter motor case with the notch ② of the brush holder. When installing housing end, fix the protrusion ③ of the starter motor case to the notch ④ on the housing end.

6-6

2

1

ELECTRICAL

SECURING SCREWS Apply THREAD LOCK "1342" to starter motor securing screws.

99000-32050 ： THREAD LOCK "1342"

STARTER RELAY INSPECTION Disconnect lead wire of the starter motor at starter relay. Turn on the ignition switch, inspect the continuity between the terminals, positive and negative, when pushing the starter button. If the starter relay is in sound condition, continuity is found. 09900-25002 ： Pocket tester

6-7

ELECTRICAL

COMBINATION METER Remove the combination meter (Refer to page 6-6). Disassemble the combination meter.

INSPECTION Using the pocket tester, check the continuity be-tween lead wires in following diagram. If the continuity measured is incorrect, replace the respective part.

速度表 SPEEDOMETER

档位灯燃油表


FI

GPI

FU EL-ME TER

Gr

O PB L BG YL BrR GR WY RB

Y

B

Lg

R(2.74 Ω 1/8 W) R(1.5k Ω 1/8 W) R(82 5Ω 1/8 W) R(82 5Ω 1/8 W)

Gr Lg

Y

B BW

BW

YB

O

Gr

6-8

BW

FUEL

BW

N

NOTE: When making this test, it is not necessary to remove the combination meter.

ELECTRICAL

LIGHTS TURN SIGNAL LIGHT

HEADLIGHT

TAIL/BRAKE LIGHT

SWITCHES Inspect each switch for continuity with the pocket tester referring to the chart. If it is found any abnormality, replace the respective switch as-sembly with new one.


IGNITION SWITCH ① R

O

Br

Gr

OY

ON

○

○

○

○

○

P

○

OFF

○

6-9

ELECTRICAL

LIGHTING SWITCH① Gr

O

○

○

○

○

②

Y/W

○

①

③

ENGINE KILL SWITCH ② O

O/W

○

○

STARTER SWITCH ③ O/W

Y/G

○

○

OFF

FRONT BRAKE LIGHT SWITCH ④ Y

④

O/W

OFF ON

○

○

DIMMER SWITCH ⑤ Y/W

W

Y

○

○

○

5

○

TURN SIGNAL LIGHT SWITCH ⑥ Sb

B

○

6

Lg ○ 7

○

○

HORN SWITCH ⑦ G

B/W

○

○

OFF

6-10

ELECTRICAL

REAR BRAKE LIGHT SWITCH ① O

W/B

○

○

OFF ON

①

GEAR POSITION INDICATOR LIGHT SWITCH G/L

Y/L

Br/R

○ ○

Top

R/B

○

4th

W/Y

○

3rd

○ ○ ○ ○ ○ ○

2nd

○

Low

L

○

N

GRD

WIRE COLOR B ........... Black Br .......... Brown G ........... Green Gr ......... Gray L ........... Blue Lg ......... Light green O ........... Orange R .......... Red P ........... Pink Sb ......... Light blue W .......... White Y .......... Yellow

B/W .......... Black with White tracer Br/R ......... Brown with Red tracer G/L ........... Green with Blue tracer O/W ......... Orange with White tracer R/B .......... Red with Black tracer W/B .......... White with Black tracer W/Y .......... White with Yellow tracer Y/B .......... Yellow with Black tracer Y/G........... Yellow with Green tracer Y/L ........... Yellow with Blue tracer Y/W .......... Yellow with White tracer

6-11

ELECTRICAL

BATTERY SPECIFICATIONS Type designation Capacity Standard electrolyte S.G.

YTX7L-BS 6AH/(10HR) 1.320±0.01 (20℃)

INTIAL CHARGING FILLING ELECTROLYTE Remove aluminium strip ① which seals battery electrolyte filling hole.

Remove special electrolyte cover ②. NOTE: After filing electrolyte, seal battery filing hole with the remove cover②. Do not remove or pierce sealing part ③ of electrolyte bottle.

Insert electrolyte container port into battery electrolyte filling hole, holding bottle fast to prevent dropping.

CAUTION Do not splash the fluid.

Ensure that there are bubbles coming up in every electrolyte container and keep this state for over 20 minutes.

6-12

ELECTRICAL

NOTE: If there are no bubbles coming up the filling hole, pat the bottle bottom for twice or three times. In so doing, there is no need to remove electrolyte container from battery. ● After

ascertaining that electrolyte is fully filled into battery, remove electrolyte container from battery and wait for about 20 minutes; ● Insert cover into filling hole, press it hard to make cover surface flush with battery upper surface;

CAUTION Never use anything except the specified battery. Once install the caps to the battery; do not remove the caps. Insert cover securely

Inspect battery voltage by means of circuit tester. Circuit tester reading should reach 12.5～ 12.6V as illustrated (DC). If battery voltage is below specified value, charge battery with charger (Refer to recharge operation). NOTE: If production date is two years ago, it is advised to effect initial charge of the new battery.

(V) 30 seconds 13

SERVICING

25℃

12

Inspect battery surface visually. If there are fissures round battery or there is electrolyte leakage traces, the new battery should be replaced. If battery connecting terminal is covered with rust or an acidic powdery sludge, remove it with sandpaper.

11 10

0

2

RECHARGE OPERATION Inspect battery voltage by means of circuit tester. If voltage reading is below 12.0V (DC), charge battery with charger.

CAUTION When recharging the battery, remove the battery from the motorcycle. NOTE: Do not remove the cover on battery when charging.

(V) 18 17 16 15 14 13 12

4

time

6

8

10(minute)

charging time stop charging

time 0

10

20

30

60 (minute)

40

50

O

O

CAUTION Be carful not o permit the charging current to exceed 3A at any time.

(V) 14

0 ~ 40 C

13

● After

recharging, wait for over 30 minutes before inspecting battery voltage with circuit tester; ● If battery voltage is below 12.5V, charge battery again; ● If measured voltage is still below 12.5V, use a new battery for replacement; In case motorcycle is not in use for a long time, battery should be ● inspected once a month to prevent battery discharge. 6-13

12 11 10 0（%） 100 75 50 25 battery state after charging

SERVICING INFORMATION CONTENTS TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 WIRE AND CABLE ROUTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

7

SERVICE INFORMATION

TROUBLESHOOTING FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION ENGINE COMPLAINT ENGINE WILL NOT START OR IS HARD TO START

SYMPTOM AND POSSIBLE CAUSE

REMEDY

Compression too low 1. Valve clearance out of adjustment 2. Worn valve guides or poor seating of valves 3. Mistiming valves 4. Excessively worn piston rings 5. Worn-down cylinder bores 6. Too slowly starter motor cranks 7. Poor seating of spark plug

Adjust. Repair or replace. Adjust. Replace. Replace. See electrical section. Retighten.

Plug not sparking 1. Fouled spark plug 2. Wet spark plug 3. Defective ignition coils 4. Defective CKP sensor 5. Defective ECU 6. Open-circuited wiring connections 7. Open or short in high-tension cords

Clean. Clean and dry. Replace. Replace. Replace. Repair or replace. Replace.

No fuel reaching the intake manifold 1. Clogged fuel filter or fuel hose 2. Defective fuel pump 3. Defective fuel pressure regulator 4. Defective fuel injector 5. Defective fuel pump relay 6. Defective ECU 7. Open-circuited wiring connections

Clean or replace. Replace. Replace. Replace. Replace. Replace. Check and repair.

Incorrect fuel/air mixture 1. TP sensor out of adjustment 2. Defective fuel pump 3. Defective fuel pressure regulator 4. Defective TP sensor 5. Defective CKP sensor 6. Defective IAP sensor 7. Defective ECU 8. Defective ECT sensor 9. Defective IAT sensor 10. Clogged ISC valve air age way

Adjust. Replace. Replace. Replace. Replace. Replace. Replace. Replace. Replace. Repair or replace.

7-1

SERVICE INFORMATION

COMPLAINT


REMEDY

ENGINE IDLES POORLY

1. Valve clearance out of adjustment 2. Poor seating of valves 3. Defective valve guides 4. Worn down camshaft 5. Too wide spark plug gaps 6. Defective ignition coils 7. Defective CKP sensor 8. Defective ECU 9. Defective TP sensor 10. Defective fuel pump 11. Imbalanced throttle valve 12. Damaged or cracked vacuum hose 13. Damaged or clogged ISC valve 14. ISC bad learning

ENGINE STALLS OFTEN

Incorrect fuel/air mixture 1. Defective IAP sensor or circuit 2. Clogged fuel filter 3. Defective fuel pump 4. Defective fuel pressure regulator 5. Defective ECT sensor 6. Defective thermostat 7. Defective IAT sensor 8. Damaged or cracked vacuum hose 9. Damaged or clogged ISC valve

Repair or replace. Clean or replace. Replace. Replace. Replace. Replace. Replace. Replace. Replace or repair.

Fuel injector improperly operating 1. Defective fuel injectors 2. No injection signal from ECU 3. Open or short circuited wiring connection 4. Defective battery or low battery voltage

Replace. Repair or replace. Repair or replace. Replace or recharge.

Control circuit or sensor improperly operating 1. Defective ECU 2. Defective fuel pressure regulator 3. Defective TP sensor 4. Defective IAT sensor 5. Defective CKP sensor 6. Defective ECT sensor 7. Defective fuel pump relay 8. Defective ISC valve 9. ISC bad learning

Replace. Replace. Replace. Replace. Replace. Replace. Replace. Replace. Reset learned value.

Engine internal parts improperly operating 1. Fouled spark plug 2. Defective CKP sensor or ECU 3. Clogged fuel hose 4. Out of adjustment valve clearance

Clean. Replace. Clean. Adjust.

7-2

Adjust. Replace or repair. Replace. Replace. Adjust or replace. Replace. Replace. Replace. Replace. Replace. Adjust. Replace. Replace or repair. Reset learned value.

SERVICE INFORMATION

Complaint

Noisy engine

Remedy

Symptom and possible causes

Excessive valve chatter 1. Too large valve clearance 2. Weakened or broken valve springs 3. Worn rocker arm or cam surface 4. Worn and burnt camshaft journal

Adjust. Replace. Replace. Replace.

Noise seems to come from piston 1. Worn down pistons or cylinders 2. Carbon combustion chambers fouled with carbon 3. Worn piston pins or piston pin bore 4. Worn piston rings or ring grooves

Replace. Clean. Replace. Replace.

Noise seems to come from timing chain 1. Stretched chain 2. Worn sprockets 3. Tension adjuster not working

Replace. Replace. Repair or replace.

Noise seems to come from clutch 1. Worn splines of countershaft or hub 2. Worn teeth of clutch plates 3. Distorted clutch plates, driven and drive 4. Worn clutch release bearing

Replace. Replace. Replace. Replace.

Noise seems to come from crankshaft 1. Rattling bearings due to wear 2. Worn and burnt big-end bearings 3. Worn and burnt journal bearings 4. Too large thrust clearance

Replace. Replace. Replace. Replace thrust bearing.

Noise seems to come from balancer 1. Worn and burnt journal bearings

Replace.

Noise seems to come from transmission 1. Worn or rubbing gears 2. Worn splines 3. Worn or rubbing primary gears 4. Worn bearings


Noise seems to come from water pump 1. Too much play on pump shaft bearing 2. Worn or damaged impeller shaft 3. Worn or damaged mechanical seal 4. between pump case and impeller


7-3

SERVICE INFORMATION

Complaint Engine runs poorly in high speed range

Engine overheats

Remedy


Defective engine internal/electrical parts 1. Weakened valve springs 2. Worn camshaft 3. Valve timing out of adjustment 4. Too narrow spark plug gaps 5. Ignition not advanced sufficiently due to poorly working timing advance circuit 6. Defective ignition coils 7. Defective CKP sensor 8. Defective ECU 9. Clogged air cleaner element 10. Clogged fuel hose, resulting in inadequate fuel spply to injector 11. Defective fuel pump 12. Defective TP sensor

Replace. Replace. Adjust. Adjust. Replace ECU. Replace. Replace. Replace. Clean. Clean and prime. Replace. Replace.

Defective air flow system 1. Clogged air cleaner element 2. Defective throttle valve 3. Sucking air from throttle body t 4. Defective ECU 5. Imbalancing throttle valve synchronization

Replace. Adjust or replace. Repair or replace. Replace. Adjust.

Defective control circuit or sensor 1. Low fuel pressure 2. Defective TP sensor 3. Defective IAT sensor 4. Defective CKP sensor 5. Defective GP sensor 6. Defective IAP sensor 7. Defective ECU 8. TP sensor out of adjustment 9. Defective ISC valve

Repair or replace. Replace. Replace. Replace. Replace. Replace. Replace. Replace. Replace.

Defective engine internal parts 1. Heavy carbon deposit on piston crowns 2. Not enough oil in the engine 3. Defective oil pump or clogged oil circuit 4. Sucking air from intake pipes 5. Use incorrect engine oil 6. Defective cooling system

Clean. Add oil. Replace or clean. Retighten or replace. Change. See radiator section.

Lean fuel/air mixture 1. Short-circuited IAP sensor/lead wire 2. Short-circuited IAT sensor/lead wire 3. Sucking air from intake pipe t 4. Defective fuel injectors 5. Defective ECT sensor

Repair or replace. Repair or replace. Repair or replace. Replace. Replace.

Other factors 1. Ignition timing is too advanced due to defective timing advance system (ECT sensor, GP sensor, CKP sensor and ECU) 2. Drive chain is too tight 3. ISC bad learning 7-4

Replace. Adjust. Reset learned value.

SERVICE INFORMATION

Complaint

Engine lacks power

Defective engine internal/electrical parts 1. Loss of valve clearance 2. Weakened valve springs 3. Valve timing out of adjustment 4. Worn piston rings or cylinders 5. Poor seating of valves 6. Fouled spark plug 7. Incorrect spark plug 8. Clogged fuel injectors 9. TP sensor out of adjustment 10. Clogged air cleaner element 11. Imbalancing throttle valve synchronization 12. Sucking air from throttle valve or vacuum hose 13. Too much engine oil 14. Defective fuel pump or ECU 15. Defective CKP sensor and ignition coils Defective control circuit or sensor 1. Low fuel pressure 2. Defective TP sensor 3. Defective IAT sensor 4. Defective CKP sensor 5. Defective GP sensor 6. Defective IAP sensor 7. Defective ECU 8. TP sensor out of adjustment 9. Defective ISC valve 10. Imbalanced throttle valve synchronization

Dirty or heavy exhaust smoke

Remedy


1. Too much engine oil in the engine

Adjust. Replace. Adjust. Replace. Repair. Clean or replace. Adjust or replace. Replace. Adjust. Replace. Adjust. Retighten or replace. Drain out excess oil. Replace. Replace.

Repair or replace. Replace. Replace. Replace. Replace. Replace. Replace. Adjust. Replace. Adjust.

2. Worn piston rings or cylinders 3. Worn valve guides 4. Scored or scuffed cylinder walls 5. Worn valves stems 6. Defective stem seal 7. Worn oil ring side rails

Check with inspection window, drain out excess oil. Replace. Replace. Replace. Replace. Replace. Replace.

Slipping clutch

1. Weakened clutch springs 2. Worn or distorted pressure plates 3. Distorted clutch plates or pressure plates 4. Clutch release screw out of adjustment

Replace. Replace. Replace. Adjust.

Dragging clutch

1. Some clutch spring weakened while others are not 2. Distorted pressure plates or clutch plates 3. Clutch release screw out of adjustment

Replace.

7-5

Replace. Adjust.

SERVICE INFORMATION

Complaint

Remedy


Transmission will not shift

1. Broken gearshift cam 2. Distorted gearshift forks 3. Worn gearshift pawl

Replace. Replace. Replace

Transmission will not shift back.

1. Broken return spring on shift shaft 2. Rubbing or stickily shift shaft 3. Distorted or worn gearshift forks 1. Worn shifting gears on driveshaft or countershaft 2. Distorted or worn gearshift forks 3. Weakened stopper spring on gearshift stopper 4. Worn gearshift cam plate

Replace. Repair or replace. Replace. Replace.

Transmission jumps out of gear

Replace. Replace. Replace.

CHASSIS Complaint

Remedy


Heavy steering

1. Overtightened steering stem nut 2. Broken bearing in steering stem 3. Distorted steering stem 4. Not enough pressure in tires

Adjust. Replace. Replace. Adjust.

Steering oscillation.

1. Loss of balance between right and left front suspensions. 2. Distorted front fork. 3. Distorted front axle or crooked tire.

Replace. Repair or replace. Replace.

Wobbly front wheel.

1.Distorted wheel rim. 2.Warn-down front wheel bearings. 3.Defective or incorrect tire. 4.Loose nut on axle.

Replace. Replace. Replace. Retighten.

Front suspension too soft.

1. Weakened springs. 2. Not enough fork oil.

Replace. Refill.

Front suspension too stiff.

1. For oil too viscous. 2. Too much fork oil.

Replace. Remove excess oil.

Noisy front suspension. 1. Not enough fork oil. 2. Loose nuts on suspension.

Refill. Retighten.

Wobbly rear wheel.

1. Distorted wheel rim. 2. Worn-down rear wheel bearings. 3. Defective or incorrect tire. 4. Loose nut on axle. 5. Worn swing arm bushings. 6. Loosen nuts on the rear shock.

Remedy Replace. Replace. Retighten. Replace. Retighten.

Rear suspension too soft.

1. Weakened springs. 2. Rear suspension adjuster improperly set.

Replace. Adjust.

Rear suspension too stiff.

1. Rear suspension adjuster improperly set. 2. Warn swing arm bushings.

Adjust. Replace.

Noisy rear suspension.

1. Loose nuts on suspension. 2. Worn swing arm bushings.

Retighten. Replace.

7-6

SERVICE INFORMATION

BRAKES Complaint


Remedy

Poor braking.

1. Not enough brake fluid in the reservoir. 2. Air trapped in brae fluid circuit. 3. Pads worn down. 4. Top much play on brake lever or pedal. 5. Linings worn down.

Refill to level mark. Bleed air out. Replace. Adjust. Replace.

Insufficient brake power.

1. Leakage of brake fluid from hydraulic system. 2. Worn pads. 3. Oil adhesion on engaging surface of pads. 4. Worn disc. 5. Air in hydraulic system.

Repair or replace. Replace. Clean disc and park Replace Bleed air

Brake squeaking.

1.Carbon adhesion on pad surface. 2.Tilted pad. 3.Damaged wheel bearing. 4.Loose front-wheel axle or rear-wheel axle. 5.Worn pads. 6.Foreign material in brake fluid. 7.Clogged return port of matter cylinder

Repair surface with sandpaper. Modify pad fitting. Replace. Tighten to specified torque. Replace. Replace brake fluid. Disassemble and clean master cylinder.

Excessive brake lever stoke.

1.Air in hydraulic system. 2.Warn brake lever cam. 3.Insufficient brake fluid. 4.Improper quality of brake fluid.

Bleed air. Replace brake lever. Replenish fluid to specified lever; bleed air. Replace with correct fluid.

1.Insufficlent tightening of connection ts. 2.Cracked hose. 3.Worn piston and/or cup.

Tighten to specified torque. Replace. Replace piston and/or cup.

Leakage of brake fluid.

7-7

SERVICE INFORMATION

ELECTRICAL COMPLAINT


REMEDY

No sparking or poor sparking

1. Defective ignition coils 2. Defective spark plug 3. Defective CKP sensor 4. Defective ECU 5. Defective TO sensor 6. Open-circuited wiring connections

Replace. Replace. Replace. Replace. Replace. Check and repair.

Spark plug soon become fouled with carbon

1. Mixture too rich 2. Idling speed set too high

Inspect FI system. Adjust fast idle or throttle stop screw. Change. Replace. Replace with hot type plug.

3. Incorrect gasoline 4. Dirty air cleaner element 5. Too cold spark plug Spark plug become fouled too soon

Spark plug electrodes overheat or burn

1. Worn piston rings 2. Worn piston or cylinders 3. Excessive clearance of valve stems in valve guides 4. Worn stem oil seal

Replace. Replace. Replace.

1. Too hot spark plug

Replace with cold typeplugs. Tune up. Retighten. Inspect FI system.

2. Overheated the engine 3. Loose spark plug 4. Too lean mixture

Replace.

Generator does not charge

1. Open- or short-circuited lead wires, or loose lead connections 2. Short-circuited, grounded or open generator coil 3. Short-circuited or punctured regulator/rectifier

Repair or replace or retighten. Replace. Replace.

Generator does charge, but charging rate is below the specification

1. Lead wires tend to get shorted or open-circuited or loosely connected at terminals 2. Grounded or open-circuited generator coil 3. Defective regulator/rectifier 4. Defective cell plates in the battery

Repair or retighten.

Generator overcharges

1. Internal short-circuit in the battery 2. Damaged or defective regulator/rectifier 3. Poorly grounded regulator/rectifier

Replace the battery. Replace. Clean and tighten ground connection.

Unstable charging

1. Lead wire insulation frayed due to vibration, resulting in intermittent short-circuiting 2. Internally shorted generator 3. Defective regulator/rectifier

Repair or replace.

1. Run down battery 2. Defective switch s 3. Brushes not seating properly on starter motor commutator 4. Defective starter relay/starter interlock switch 5. Defective main fuse

Repair or replace. Replace. Repair or replace.

Starter button is not effective

7-8

Replace. Replace. Replace the battery.

Replace. Replace.

Replace. Replace.

SERVICE INFORMATION

BATTERY COMPLAINT

REMEDY


“Sulfation”, acidic white powdery substance or spots on surface of cell plates

1.storage battery case with fissure 2.long period of battery storage

Replace storage battery Replace storage battery

Storage battery consumption too fast

1.incorrct charging system

Inspect generator, stabilized rectifier and electric terminals, effect necessary adjustment to ensure specified charging Replace storage battery and rectify charging system Replace storage battery Recharge storage battery Replace storage battery

2.battery plate with no active substance due to overcharging 3.short circuit in storage battery 4.storage battery voltage too low 5.stale storage battery Storage battery sulphation

Storage battery discharge too quick

1.overcharging or undercharging (When storage is not in use, inspect it at least once a month to prevent it from sulphation) 2.storage battery not in use for a long time in cold weather

dirty battery top and flanks

Replace battery In case of serious sulphation, replace storage battery

clean

7-9

SERVICE INFORMATION

SPECIAL TOOLS

09900-06107 snapring pliers

09900-06108 snapring pliers

09900-20101 vernier caliper (1/50mm,150mm)

09900-20203 micrometer (1/100mm,50~75mm)

09900-20508 cylinder bore gauge kit (1/100mm,40~80mm)

09900-20606 dial gauge (1/100mm,10mm)

09900-20701 magnetic gauge bracket

09900-20803 thickness gauge

09900-21304 V-block (set) (100mm)

09900-22401 small bore gauge (10~18mm)

09900-25002 circuit tester

09900-28403 hydrometer

09910-20116 Conrod holder

09910-32812 crankshaft installer

09910-34510 piston pin remover

09913-50121 oil seal remover

09913-80112 bearing installer

09915-64510 cylinder pressure gauge 09915-63310 (adapter)

09916-20630

09916-20620 valve seat cutter (N-122) valve seat cutter (N-126)


09915-74510 oil pressure gauge

09916-21110 valve seat cutter kit

7-10


09915-74531 oil pressure gauge adapter

09916-34542 valve tube reamer arm

09900-20205 micrometer (1/100mm,0~25mm)


09916-20610 valve seat cutter (N-121)

09916-34570 valve tube reamer (5.0mm)

SERVICE INFORMATION

09920-13120 crankcase separator

11F14-019 valve adjustor

09921-20210 bearing remover 09920-53710 clutch sleeve hub holder (12mm)

09922-55131 bearing remover

09923-73210 bearing puller (15 17mm)

09923-74510 bearing remover (20 35mm)

09924-84510 bearing installer set

09924-84521 bearing mounting kit


09930-30180 rotor separator, M28

09930-30102 slide shaft

09940-14921 four claw wrench

09930-44511 rotor holder


09941-34513 steering race installer

09930-40113 rotor and sprocket holder

09930-30190 gear remover

09940-34561 front fork tool

09930-44400 rotor holder

09943-74111 front fork oil level gauge

09941-74910 09940-50112 front fork oil seal installer steering bearing installer

11F14-003 rotor separator

11F14-005 rotor separator,M30

11F14-006 rotor separator, M33

7-11


11F14-012 clutch nut socket wrench


11F14-018 valve spring tool


TIGHTENING TORQUE ENGINE Kg·m

N·m

Cylinder head nut

2.8-3.2

28-32

Cylinder bolt

0.8-1.2

8-12

Cylinder head cover bolt

0.9-1.1

9-11

Generator rotor nut

9.0-11.0

90-110

Clutch nut

3.0-5.0

30-50

Adjusting nut of valve clearance

1.3-1.6

13-16

Mounting bolt of the engine (front)

3.3-3.9

33-39

Mounting bolt of the engine (rear)

3.3-3.9

33-39

Mounting bolt of the engine (top)

3.3-3.9

33-39

Bolts on the starting clutch hub

1.9-2.3

19-23

Primary drive gear nut

4.0-6.0

40-60

Kg·m

N·m

5.0-8.0

50-80

L

1.8-2.8

18-28

R

1.8-2.8

18-28

M

5.0-8.0

50-80

Steering lower bracket bolts

2.5-4.0

25-40

Clamping bolt on the handlebar

1.2-2.0

12-20

Bolt on the exhaust pipe

1.8-2.8

18-28

Bolt/nut on the engine cover

3.3-3.9

33-3.9

Front footrest bolt

1.8-2.8

18-28

Front brake disc bolt

1.8-2.8

18-28

Front brake caliper mounting bolt

2.7-4.3

27-43

Front brake hose union bolt

2.0-2.5

20-25

Nuts on the rear absorbers

2.2-3.5

22-35

Rear brake link bolt

1.0-1.6

10-16

Rear axle nut

5.0-8.0

50-80

Bolt/nut on the rear swing arm

5.0-8.0

50-80

ITEM

CHASSIS ITEM Front axle nut

S teering upper bracket bolts

(top and front)

7-12


TIGHTENING TORQUE CHART For other bolt and nuts who's torque is not listed, refer to this chart: Bolt Diameter (mm)

"7" marked bolt

Conventional or "4" marked bolt kg·m

N·m

kg·m

N·m

4

0.1-0.2

1.0-2.0

0.15-0.3

1.5-3.0

5

0.2-0.4

2.0-4.0

0.3-0.6

3.0-6.0

6

0.4-0.7

4.0-7.0

0.8-1.2

8.0-12.0

8

1.0-1.6

10.0-16.0

1.8-2.8

18.0-28.0

10

2.2-3.5

22.0-35.0

4.0-6.0

40.0-60.0

12

3.5-5.5

35.0-55.0

7.0-10.0

70.0-100.0

14

5.0-8.0

50.0-80.0

11.0-16.0

110.0-160.0

16

8.0-13.0

80.0-130.0

17.0-25.0

170.0-250.0

18

13.0-19.0

130.0-190.0

20.0-28.0

200.0-280.0

A "4" marked bolt

Conventional bolt

"7" marked bolt

SERVICE DATA CYLINDER + VALVE

Unit：mm

ITEM

STANDARD

LIMIT

IN

25.40-25.60

——

EX

22.40-22.60

——

IN

0.04-0.07

——

EX

0.10-0.13

——

Valve guide to valve stem

IN

0.010-0.035

——

clearance

EX

0.055-0.085

——

Valve guide I.D.

IN&EX

5.000-5.010

——

IN

4.975-4.990

——

EX

4.955-4.970

——

Valve diam

Valve clearance (when cold)

Valve stem O.D. Valve stem runout

IN&EX

——

0.05

Valve stem deflection

IN&EX

——

0.35

Valve head thickness

IN&EX

——

0.03

Valve seat width

IN&EX

0.9-1.1

Valve spring free length

——

IN

——

31.24

EX

——

33.58

10-14kg/cm²

Compression pressure

——

Cylinder head distortion 7-13

8kg/cm² 0.05


CAMSHAFT

Unit：mm

STANDARD

ITEM Cam height

LIMIT

IN

33.650-33.690

33.350

EX

33.300-33.340

33.000

21.959-21.980

Camshaft O.D.

——

Camshaft runout

—— 0.10mm

Rocker arm I.D.

12.000-12.018

——

Rocker arm shaft O.D.

11.977-11.995

——

CYLINDER + PISTON + PISTON RING STANDARD

ITEM Cylinder b o re P i ston diam

57.000-57.015 56 .95 5- 56 .97 0 (Mea su re at 8 mm from the sk irt en d) ——

Cyl i nder d istortio Piston ring end gap

Piston ring groove clearance

Piston ring groove width

Piston ring thickness

Unit：mm

LIMIT 57.135 56.835 0.05

1st

——

0.50

2nd

——

0.50

1st

——

0.180

2nd

——

0.180

1st

1.01-1.03

——

2nd

1.01-1.03

——

Oil ring

2.01-2.03

——

1st

0.97-0.99

——

2nd

0.97-0.99

——

Piston pin bore

15.002-15.008

Piston to pin clearance

0.002-0.014

Piston pin O.D.

14.996-15.000

7-14

15.030 —— 14.980


CONROD + CRANKSHAFT ITEM Conrod small end I.D.

Unit：mm

STANDARD

LIMIT

15.006-15.014mm

15.040mm

——

3.0mm

Conrod deflection

0.10-0.45mm

Conrod bag end clearance Conrod big end width

52.9-53.1mm

—— ——

——

0.08mm

15.95-16.00mm

Cranksha ft web to web widt h

1.00mm

Crankshaft runout

CLUTCH

Unit：mm

STANDARD

LIMIT

4

——

Drive plate thickness

2.70-2.90

2.40

Drive plate claw width

——

0.10

Driven plate distortion

——

29.45

11.80-12.00

11.40

ITEM Clutch cable play

Clutch spring free length

TRANSMISSION + DRIVE CHAIN

Unit：mm

STANDARD

ITEM

LIMIT

Primary reduction ratio

3.500(70/20)

——

Final reduction ratio

2.867(43/14)

——

Low

3.000(33/11)

——

2nd

1.875(26/14)

——

3rd

1.368(26/19)

——

4th

1.142(24/21)

——

5th

0.956(22/23)

——

0.10-0.30

0.50

1& 2

4.80-4.90 mm

——

3

5.30-5.40 mm

——

Gear ratio

Shift fork to groove clearance Shift fork thickness

Type Drive chain

Drive chain slack

KMC 428H

——

Links

130

——

20-pitc h length

——

259.0 mm

10-20 mm

7-15

——


FI-SENSORS STD/SPEC

ITEM

150~230 kΩ

CKP sensor resistance

4.5~5.5V

IAP sensor input voltage

2.0~3.5V at idle speed

IAP sensor output voltage

4.5~5.5V

TP sensor input voltage TP sensor resistance

Closed Opened

0.61~0.97 kΩ 2.9~5.1 kΩ 4.5~5.5

ET sensor input voltage

5~14 kΩ (20~40℃)

ET sensor resistance

4.5~5.5V

IAT sensor input voltage

About 2.5 kΩ (20℃）

IAT sensor resistance TO sensor output voltage

NOTE

Nutural Leaning

0.4~1.4V 3.7~4.4V

When leaning 65°

19.1~19.7 kΩ

TO sensor resistance

FUEL PUMP + FIAV SPECIFICATION

ITEM

NOTE

1.9 Ω (20℃)

Fuel pump resistance

31 -39 Ω

FIAV resistance

ELECTRICAL SPECIFICATION

ITEM

NOTE

Ignition timing

Spark plug

Type

NGK CR7E

Gap

0.7mm-0.8mm

Spark performance Ignition coil resistance

Generator coil resistance Generator no-load voltage Regulated voltage

Battery

Over 8mm at 1atm Primary

3.4Ω-4.6Ω

W-O/W

Secondary

About 10.4KΩ-15.6KΩ

Plug cap-O/W

Pick up

130-180Ω

G-Bl

Charging

About:0.7Ω

B-B

More than 70V (AC) at 5000 r/min 14-15V at 5 000 r/min

Type designation

YTX7L-BS

Capacity

6Ah

Standard electrolyte S.G.

1.32±0.01 (20oC)

Fuse

10A, 20A 7-16


SPECIFICATION

ITEM

SPECIFICATION

HI

35W

Neutral indicator light

2W

LO

35W

Turn light

10W

5/21W

Position light

5W

ITEM Headlight

Taillight/brake light

BRAKE + WHEEL

Unit：mm

ITEM

STANDARD

Rear brake pedal free travel

20-30

Rear brake pedal height

62.5

LIMIT

Brake disc thickness

F

Brake disc runout

F

Brake cylinder bore

F

12.700-12.743

Master cylinder piston diam

F

12.657-12.684

Brake caliper cylinder bore

F

27.000

Brake drum I.D.

R

130.7

Brake lining thickness

R

1.5

F

0.25

R

0.25

Wheel axle runout

5.0±2

0.30

F

90/90-18 51P

R

120/80-16 60P

Tire size

SUSPENSION ITEM

4.5

Unit：mm

STANDARD

(Front absorber) stroke

120

Front absorber spring free length

345

Front absorber oil level

120

LIMIT 338

68

Rear absorber stroke Swingarm pivot shaft runout

0.6

7-17


TIRE PRESSURE NORMAL RIDING COLD INFLATION TIRE PRESSURE

DUAL RIDING

SOLO RIDING psi

kpa

kg/cm2

psi

1.75

25

175

1.75

25

2.25

33

225

2.25

33

kpa

kg/cm

FRONT

175

REAR

225

2

FUEL + OIL ITEM

SPECIFICATION

Fuse type

Use gasoline with an octane number of 90-97 (Research Method), preferably nonleaded.

Including reserve

11.5 L

Fuel tank

2.0 L

Reserve

Engine oil type and grade Engine oil capacity

SAE10W/40,API SF orSG

Change

1000 ml

Filter change

1100 ml

Overhaul

1350 ml

Front shock absorber oil capacity (each leg)

385±3 ml

7-18

NOTE

7-19

AREA OF ENGINE LEAD WIRE

HANDLE-SW,L&R FUEL-METER GPI SPEEDOMETER FRONT-TURN LAMP,L&R

FUEL-METER

SPEEDOMETER

STARTER MOTOR LEAD

ENGINE EARTH

CLAMPING

STARTER MOTOR LEAD

BATTERY BRKT ENGINE EARTH

HEAD-LAMP

FRONT-TURN,R

FRONT-BRAKE HOSE

FUEL-METER HANDLE-SW,R

THROTTLE CABLE 2

FRONT-BRAKE HOSE THROTTLE CABLE 2 CUT AFTER CLAMPING

HANDLE-SW,R

HANDLE-SW,R FRONT-BRAKE HOSE CUT AFTER CLAMPING

WIRING HARNESS

HANDLE-SW,L GPI

HANDLE-SW,R

FRONT-TURN LAMP,L&R

HOSE,CANISTER VACUUM

IGNITION COIL

THROTTLE CABLE 2

WIRING HARNESS WELDING CLAMP

O-SNSR

FUSE

WIRING HARNESS REG&REC

WIRING HARNESS

ENGINE EARTH CUT AFTER CLAMPING

STARTER MOTOR LEAD

WELDING CLAMP STOP-LAMP,SW

WIRING HARNESS(ECU)

WIRING HARNESS STOP-LAMP,SW

WIRING HARNESS

STARTER MOTOR RELAY TERMINAL

BATTERY PLUS TERMINAL

WIRING HARNESS O-SNSR THE HAND OF CLAMP MUST BE BACK WARDS

THROTTLE CABLE 2 IGNITION COIL

HANDLE-SW,L CLUTCH CABLE CUT AFTER CLAMPING

LONG WIRE

HORN ASSY, HIGH PICTHED

FRONT-TURN,L

WIRINGHARNESS

SPEEDOMETER CABLE

HORN ASSY, LOW PICTHED

EXCEPT FRAME VIEW

SHORT WIRE

FRAME

MAGNETO

INSIDE

HOSE, PURGE(PVC TO TB)

ISC HOSE

WELDING CLAMP BASE FOR ASSEMBLING

MAGNETO ETS GPS MAQS THE END OF CLAMP MUST BE INSIDE THE FRAME

CLAMP

ECU

REAR-TURN, R

REAR TURN, L

FRAME

ALARM

WIRING HARNESS NO.2 REAR TURN, L BASE FOR ASSEMBLING

HOLE(Φ12)

BOLT

BOOT, WELDING HARNESS REAR-COMB, LAMP

CUT AFTER CLAMP

WELDING HARNESS

OUTSIDE

PVC BOOT(TS)

FRAME

REAR-TURN, L

WELDING CLAMP

REAR-TURN, L

WIRING HARNESS NO.2 CUT AFTER CLAMP (SURPLUS:2-3 TEETH)

REAR-TURN, L

FRAME

WIRING HARNESS ECU

HOSE, BRTHR VALVE&T

HOSE, BRTHR VALVE&T

REAR- TURN, R

TOOL BOX 工具盒

REAR- TURN, R BASE FOR ASSEMBLING

ECU PROTECTOR

WIRING HARNESS

OUTSIDE

GPS

PROTECTOR

PROTECTOR

WIRING HARNESS NO.2 REAR- TURN, R

STARTER-RELAY BRKT

ECU

WELDING HARNESS

HOSE PURGE(PVC TO TB)

VALVE ASSY, PURGE CUT

HOSE, FUEL INJECTOR & 3 WAY

HOSE, FUEL 3 WAY& TANK

CLIP

TURN RELAY

FUEL-CUT, SNSR

STARTER-RELAY

STARTER MOTOR LEAD

PVC BOOT STARTER MOTOR STOP- LAMP, SW BATTERY

BATTERY BRKT

FRAME

FUEL GAUGE MAGNETO

CAN`T PUT MAGNETO BETWEEN HOSE, PURGE(PVC TO TB) AND CLEANER ASSY, AIR ETS WELDING HARNESS

WELDING HARNESS

HORN CLUTCH CABLE

WELDING HARNESS GPS

CLUTCH CABLE HANDLE-SW,L NOT TO MAKE THE SUPERABUNDANCE LEAD WIRE INSIDE OF HEAD LAMP IN ASSEMBLING SPEEDOMETER LEAD

GPS MAGNETO PUT THE OF CLAMP OUTSIDE THE FRAME AND CUT AFTER CLAMPING

GPS

WIRING HARNESS(W) (ETS) GPS

BASE FOR ASSEMBLING

HOSE, CANISTER VACUUM

HOSE, FUEL INJECTOR & 3 WAY

OUTSIDE

CABLE GUIDE

WIRING HARNESS(ETS)

REG & REC

HOSE, CANISTER VACUUM

EXCEPT VALVE ASSY, PURGE CUT

ASSEMBLING MARKER(WHITE TAPE)

INCLUDE VALVE ASSY, PURGE CUT

FRAME

WIRING HARNESS

DATUMPLANE

BREATHER HOSE

O-SNSR

BRIKT

INSIDE

ENGINE EARTH STARTER MOTOR LEAD

STARTER MOTOR RELAY TERMINAL

IGNITION SW

UPPER BRACKET

INSIDE


WIRE AND CABLE ROUNTING

YB

YB

O

Gr

Gr

FRONT-TURN,L

BW

B

BW

BW

B

OG

POSITION-LAMP

BW

Br

W

BW

Y

HEAD-LAMP

Y

BW

B

W Br

BW

BL

CLUTCH-SW

FREE

PUSH

HORN

HANDLE-SW,L

TURNSIGNAL

HORN-L

Gr Gr

B

DIMMER

YG YG

O

Y

Y

R

Lg

Gr

Gr Lg

B

HORN-R

OB O

BW

BW

ALARM

BL

BW

BW Lg

B

BW

Lg

O PB L BG YL BrR GR WY RB

OG PB LB BG YL BrR GR WY RB

OW OW

B

B

G BW

BW Lg

Sb

Lg

YB Lg

FRONT-TURN,R

YB

B

B

Sb

R(2.74Ω 1/8W) R(1.5kΩ 1/8W) R(825Ω 1/8W) R(825Ω 1/8W)

BL BL

N

BW BW

O OG

Y Y

WB OG O

OY

Br Br

Gr Gr

R O

OY R O

1 2 3 4 5

N

IGNITION-COIL

GPS

Y

STARTER-MOTOR

O OG B

MAGNETO

Y

M

NE G

FUEL-GAUGE

燃油传感器

REG&REC

R R

ON

W W

YW YW

OFF

LB L

GPI

RB RB

FI

WY

BY

GR GR

WY

FUEL

OW BrR BrR

WB WB

B B

BW BW

FRONT-BRAKE

YG

O

AT OY

R

THE

THA Gg

12V

OL

NT

BATTERY

STARTER-RELAY

FUSE-BOX(B) 20A

FUSE-BOX(Y) 10A

OG

IG

MAQS

BrW

D+ TS WR

RW

ECU

FIAV

D

KS OXH OW W

STOP-LAMP,SW

BBr L

YB YB

E1 BW

FUEL-METER

P

FUEL-CUT,SNSR

0 2-SNSR

R

P

ON OFF

WR

ETS TURN-RELAY

O

IGNITION-SW

G G

BW BW

KILL

YL YL

Y RB RB

P R

FIAV YR

LIGHTS

YB

VTA PM GB

R

DWL

R

OX BBr

DIAG BG P

BY

TPS

AT

VCC R

YR

DON ST RB OW

E2 BBr

WL

+B O RW

GP

WG PB

GB Dg MAP

BW

W

BBr Gr +B

OW

B OX

LB BW BW

WG

E0 W W GND

BBr

BBr B

BrW OL B

7-20

OXH

START

Sb

HANDLE-SW,R

TS

BW

SPEEDOMETER

B

WB

BW

BW

B

Br BW

Br

BG

HARNESS,WIRING NO.2

REAR-TURN,L

BW

BW WB

LICENSE-LAMP

Br BW

REAR-COMB,LAMP

BW Lg

REAR-TURN,R

Br

BW Lg


WIRING DIAGRAM

YW

JIANG MEN DACHANGJIANG GROUP CO., LTD Customer service department 1st Ed. DEC, 2011 Printed in China

JIANGMEN DACHANGJIANG GROUP CO., LTD. Add:No.5,Jiandabei Road,Jiangmen City,Guangdong Provice P.R.C Tele: 86-750-3288999 Fax:86-750-3288333 Postcode:529000

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