SERVICE DATA. Unit: mm (in) ITEM STD/SPEC. LIMIT Valve diam. 29 IN. (1.14) EX IN. ( ) EX.

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Gregory Mills
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1 4 STROKE VALVE + GUIDE SERVICE DATA Date: November 23, 2000 Valve diam. 29 (1.14) 24 (0.94) Valve clearance (when cold) ( ) ( ) Valve guide to valve stem clearance ( ) ( ) Valve guide I.D & ( ) Valve stem O.D ( ) ( ) Valve stem deflection & Valve stem runout Valve head thickness Valve seat width Valve head radial runout Valve spring free length Valve spring tension & & & & & CAMSHAFT + CYLINDER HEAD ( ) N 0.35 (0.014) 0.05 (0.002) 0.5 (0.02) 0.03 (0.001) 37.0 (1.46) & ( kgf ) lbs at length mm (1.29 in) Cam height ( ) (1.445) ( ) (1.405) Camshaft journal oil clearance & ( ) (0.0059) Camshaft journal holder I.D & ( ) 1/9

2 Camshaft journal O.D & ( ) Camshaft runout 0.10 (0.004) Cam chain pin (at arrow 3 ) 14th pin Cylinder head distortion 0.20 (0.008) CYLINDER + PISTON + PISTON RING Compression pressure kpa kpa Compression pressure ( kgf/cm2 ) ( 10 kgf/cm2 ) psi 142 psi 200 kpa difference ( 2 ) kgf/cm2 28 psi Piston to cylinder clearance ( ) (0.0047) Cylinder bore Nicks or ( ) Scratches Piston diam ( ) (2.8693) Measure at 15 mm (0.6 in) from the skirt end. Cylinder distortion 0.20 (0.008) Piston ring free end gap st R Approx. (0.28) (0.23) 2nd RN Approx (0.40) (0.32) Piston ring end gap st R ( ) (0.020) 2nd RN ( ) (0.020) Piston ring to groove clearance st (0.0071) 2nd (0.0059) Piston ring groove width st ( ) 2nd ( ) Oil ( ) Piston ring thickness st ( ) 2nd ( ) Piston pin bore ( ) (0.6311) Piston pin O.D ( ) (0.6291) 2/9

3 CONROD + CRANKSHAFT Conrod small end I.D ( ) (0.6315) Conrod big end side clearance ( ) (0.012) Conrod big end width ( ) Crank pin width ( ) Conrod big end oil clearance ( ) (0.0031) Crank pin O.D ( ) Crankshaft journal oil clearance ( ) (0.0031) Crankshaft journal O.D ( ) Crankshaft thrust bearing Right side thickness ( ) Left side ( ) Crankshaft thrust clearance ( ) Crankshaft runout 0.05 (0.002) BALANCER Balancer journal oil clearance ( ) ( ) Balancer journal O.D ( ) OIL PUMP Oil pressure (at 60 C, 140 F) kpa ( kgf/cm 2, psi) at r/min. CLUTCH Clutch lever play ( ) Clutch release screw ¼ turn back Drive plate thickness No. 1, and 3 ( ) (0.095) Drive plate claw width No. 1, and 3 ( ) (0.5138) Driven plate distortion 0.10 (0.004) Clutch spring free height (3.062) (2.909) 3/9

4 TRANSMISSION + DRIVE CHAIN Except ratio Primary reduction ratio (73/47) Final reduction ratio (42/17) Gear ratios Low (43/16) 2nd (39/19) 3rd (37/22) 4th (29/20) 5th (30/23) Top (29/24) Shift fork to groove clearance ( ) (0.020) Shift fork groove width ( ) Shift fork thickness ( ) Drive chain Type DID50V4 Links 110 links 20-pitch length (12.57) Drive chain slack (on side-stand) ( ) Gearshift lever height ( ) THERMOSTAT + RADIATOR + FAN + COOLANT Thermostat valve opening temperature Approx. 82 C (180 F) Thermostat valve lift Over 8 mm (0.31 in) at 95 C (203 F) Engine coolant temperature 20 C sensor resistance (68 F) Approx kω 50 C (122 F) Approx kω 80 C (176 F) Approx kω 110 C (230 F) Approx kω 130 C (226 F) Approx kω Radiator cap valve opening kpa pressure ( kgf/cm 2, psi) Cooling fan thermo-switch OFF ON Approx. 105 C (221 F) operating temperature ON OFF Approx. 100 C (212 F) Engine coolant type Use an antifreeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50:50. Engine coolant Reserve Approx. 250 ml tank side (0.3/0.2 US/Imp qt) Engine Approx ml side (2.3/1.9 US/Imp qt) 4/9

5 INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR ITEM STD/SPEC. NOTE Injector resistance Ω at 20 C (68 F) Fuel pump discharge amount Approx. 1.2 L (1.3/1.1 US/Imp qt) /30 sec. Fuel pressure regulator operating set pressure Approx. 300 kpa (3.0 kgf/cm 2, 43 psi) FI SENSORS + SECONDARY THROTTLE VALVE ACTUATOR ITEM STD/SPEC. NOTE CMP sensor resistance kω CMP sensor peak voltage More than 0.7 V CKP sensor resistance Ω CKP sensor peak voltage More than 0.5 V IAP sensor input voltage IAP sensor output voltage Approx V at idle speed TP sensor input voltage TP sensor resistance Closed Approx. 1.1 kω Opened Approx. 4.3 kω TP sensor output voltage Closed Approx. 1.1 V Opened Approx. 4.3 V ECT sensor input voltage ECT sensor resistance kω at 20 C (68 F) IAT sensor input voltage IAT sensor resistance kω at 20 C (68 F) AP sensor input voltage AP sensor output voltage Approx. 3.6 V at 100 kpa (760 mmhg) TO sensor resistance kω TO sensor voltage Approx. 2.5 V GP switch voltage More than 0.6 V (From 1st to Top) Injector voltage Battery voltage Ignition coil primary peak voltage More than 80 V (When cranking) STP sensor input voltage STP sensor resistance Closed Approx. 0.5 kω Opened Approx. 3.9 kω STP sensor output voltage Closed Approx. 0.5 V Opened Approx. 3.7 V STV actuator resistance Approx. 6.5 Ω EXCVA position sensor input voltage EXCVA position sensor resistance Approx. 3.1 kω (At adjustment position) EXCVA position sensor Closed More than 0.2 V output voltage Opened Less than 4.8 V 5/9

6 THROTTLE BODY ITEM Bore size I.D. No. Idle r/min. Fast idle r/min. Throttle cable play STD/SPEC. 38 mm 40F1 (For E-33), 40F0 (For the others) ± 100 r/min r/min. (After warming up) mm ( in) ELECTRICAL ITEM STD/SPEC. NOTE Firing order Spark plug NGK: CR9E Type DENSO: U27ESR-N Gap ( ) Spark performance Over 8 (0.3) at 1 atm. CKP sensor resistance Ω CKP sensor peak voltage More than 0.5 V Ignition coil resistance Terminal Primary Ω Terminal Secondary 8 15 kω Ignition coil primary peak voltage More than 80 V Generator coil resistance Ω Generator no-load voltage (when engine is cold) More than 65 V (AC) at r/min. Regulated voltage V at r/min. Starter relay resistance 3 5 Ω GP switch voltage More than 0.6 V (From 1st to top without neutral) Battery Type designation FTX12-BS Capacity 12 V 36 kc (10 Ah)/10 HR Fuse size HI 15 A Headlight LO 15 A Signal 15 A Ignition 15 A Fuel 10 A Fan 10 A Main 30 A Plug cap Terminal 6/9

7 WATTAGE ITEM STD/SPEC. E-03, -24, -28, -33 For the other countries Headlight HI 60 W 55/55 W LO 55 W Parking or position light 5 W Brake light/taillight 21/5 W 2 Turn signal light 21 W 4 Combination meter light LED Turn signal indicator light LED High beam indicator light LED Neutral indicator light LED FI indicator light/oil pressure indicator light/engine coolant LED temp. indicator light Fuel level indicator light LED BRAKE + WHEEL brake pedal height ( ) Brake disc thickness ( ) (0.177) ( ) (0.177) Brake disc runout 0.30 (0.012) Master cylinder bore ( ) ( ) Master cylinder piston diam ( ) ( ) Brake caliper cylinder bore Leading ( ) Trailing ( ) ( ) Brake caliper piston diam Leading ( ) Trailing ( ) ( ) Brake fluid type DOT 4 7/9

8 Wheel rim runout 2.0 Axial (0.08) Radial 2.0 (0.08) Wheel rim size 17 MT MT 6.00 Wheel axle runout 0.25 (0.010) 0.25 (0.010) TIRE Cold inflation tire pressure 250 kpa (Solo riding) (2.50 kgf/cm 2, 36 psi) 290 kpa (2.90 kgf/cm 2, 42 psi) Cold inflation tire pressure 250 kpa (Dual riding) (2.50 kgf/cm 2, 36 psi) 290 kpa (2.90 kgf/cm 2, 42 psi) Tire size 120/70 ZR17 (58W) 190/50 ZR17 (73W) Tire type BRIDGESTONE: BT011F E BRIDGESTONE: BT010R E Tire tread depth 1.6 (Recommended depth) (0.06) 2.0 (0.08) SUSPENSION fork stroke 120 (4.92) fork spring free length (9.28) (9.09) fork oil level (without spring, 90 outer tube fully compressed) (3.54) fork oil type SUZUKI FORK OIL L01 or an equivalent fork oil fork oil capacity (each leg) 517 ml (17.5/18.2 US/Imp oz) fork spring adjuster 4th groove from top fork damping force Rebound 6 clicks out from stiffest position adjuster Compression 10 clicks out from stiffest position shock absorber spring 177 pre-set length (6.97) shock absorber damping Rebound 7 clicks out from stiffest position force adjuster Compression 8 clicks out from stiffest position 8/9

9 wheel travel 130 (5.1) Swingarm pivot shaft runout 0.3 (0.01) FUEL + OIL ITEM STD/SPEC. NOTE Fuel type Use only unleaded gasoline of at least 90 pump R + M octane ( 2 ). Gasoline containing MTBE (MethyI Tertiary ButyI Ether), less than 10% ethanol, or less than 5% E-03, 28, 33 methanol with appropriate cosolvents and corrosion inhibitor is permissible. Gasoline used should be graded 95 octane or higher. An unleaded gasoline is recommended. The others Fuel tank capacity including 18 L reserve (4.8/4.0 US/lmp gal) Fuel level Approx. 4.0 L indicator light flickering (1.1/0.9 US/lmp gal) Fuel level Approx. 2.0 L indicator light lighting (0.5/0.4 US/lmp gal) Engine oil type SAE 10W/40, API, SF or SG Engine oil capacity 3.0 L Change (3.2/2.6 US/lmp qt) Filter change 3.3 L (3.5/2.9 US/lmp qt) Overhaul 3.6 L (3.8/3.2 US/lmp qt) 9/9

SERVICE DATA. Unit: mm (in) ITEM STANDARD LIMIT Valve diam. IN (1.42) EX ( ) EX.

SERVICE DATA. Unit: mm (in) ITEM STANDARD LIMIT Valve diam. IN (1.42) EX ( ) EX. 4 STROKE VALVE + VALVE GUIDE CAMSHAFT + CYLINDER HEAD SERVICE DATA Valve diam. 36.0 (1.42) 33.0 (1.30) Tappet clearance (when cold) 0.10 0.20 (0.004 0.008) 0.20 0.30 (0.008 0.012) Valve guide to valve