A-PDF Split DEMO : Purchase from to remove the watermark SERVICING INFORMATION

Transcription

1 SEVICIN INFMATI 9-1 A-PDF Split DEM : Purchase from to remove the watermark SEVICIN INFMATI CTENTS TULESHTIN ENINE CAUET SHAFT DIVE CHASSIS AKES ELECTICAL ATTE IIN DIAAM (F E-02, 19 / F E-03, 28, 33 / F E-24) IE HANESS, CALE AND HSE UTIN IE HANESS UTIN CALE UTIN FUEL HSE UTIN CLIN HSE UTIN FT AKE HSE UTIN ATTE PTECT SPEED SENS LEAD IE UTIN SPECIAL TLS TIHTENIN TQUE ENINE SECDA AND FINAL CHASSIS TIHTENIN TQUE CHAT SEVICE DATA

2 9-2 SEVICIN INFMATI TULESHTIN ENINE Complaint Symptom and possible causes emedy Engine will not start or is hard to start. Engine stalls easily. Compression too low 1. orn cylinder. 2. orn piston ring. 3. orn valve guide or improper valve seating. 4. Loose spark plug. 5. roken, cracked, or damaged piston. 6. Slow cranking starter motor. 7. Mistimed valves. 8. Valve clearance out of adjustment. Spark plug not sparking 1. Damaged spark plug. 2. Damaged spark plug cap. 3. Fouled spark plug. 4. et spark plug. 5. Defective ignition coil. 6. pen or short in high-tension cord. 7. Defective pick-up coil or ignitor unit. No fuel reaching the carburetor 1. Clogged hole in the fuel tank cap. 2. Defective fuel pump. 3. Clogged or defective fuel valve. 4. Defective carburetor needle valve. 5. Clogged fuel hose. 6. Clogged fuel filter. 1. Fouled spark plug. 2. Defective signal coil or ignitor unit. 3. Defective fuel pump. 4. Clogged or defective fuel valve. 5. Clogged carburetor jet. 6. Valve clearance out of adjustment. epair or replace. Tighten. See electrical section. Clean or replace. Clean and dry or replace. Clean or replace. Clean or replace. Clean or replace. Clean or replace. Clean or replace. Clean or replace. Clean.

3 SEVICIN INFMATI 9-3 Complaint Symptom and possible causes emedy Engine is noisy. Clutch drags. Transmission will not shift. Transmission will not shift back. Excessive valve chatter 1. Excessive valve clearance. 2. eak or broken valve spring. 3. orn camshaft. 4. orn or burnt camshaft journal. Noise seems to come from the piston 1. orn piston. 2. orn cylinder. 3. Carbon buildup in combustion chamber. 4. orn piston pin or piston pin bore. 5. orn piston ring or ring groove. Noise seems to come from the cam chain 1. Stretched cam chain. 2. orn cam chain sprocket. 3. Improperly working cam chain tensioner. Noise seems to come from the clutch 1. orn countershaft spline. 2. orn clutch hub spline. 3. orn clutch plate teeth. 4. Distorted clutch plate. 5. eak clutch damper. 6. eak clutch spring. Noise seems to come from the crankshaft 1. attling bearing. 2. orn or burnt crank pin bearing. 3. orn or burnt journal bearing. 4. Excessive thrust clearance. Noise seems to come from the transmission 1. orn or rubbing gear. 2. orn countershaft spline. 3. orn driveshaft spline. 4. orn or rubbing primary gear. 5. orn bearing. 1. Clutch out of adjustment. 2. Clutch release screw out of adjustment. 3. Some clutch springs are weak, while others are not. 4. orn or distorted clutch pressure plate. 5. Distorted clutch plate. 1. roken gearshift cam. 2. Distorted gearshift fork. 3. orn gearshift pawl. 1. roken gearshift shaft return spring. 2. ubbing or stuck gearshift shaft. 3. orn or distorted gearshift fork. Clean. eplace cam chain and sprockets. eplace cam chain and sprockets. epair or replace. eplace countershaft. eplace clutch hub. eplace clutch plate. eplace primary driven gear. eplace thrust bearing. eplace countershaft. eplace driveshaft. epair or replace.

4 9-4 SEVICIN INFMATI Complaint Symptom and possible causes emedy Transmission jumps out of gear. Engine idles poorly. Engine runs poorly in high-speed range. Exhaust smoke is dirty or thick. Engine lacks power. 1. orn gear. 2. orn or distorted gearshift fork. 3. eakened gearshift stopper spring. 4. orn gearshift pawl. 1. Valve clearance out of adjustment. 2. Improper valve seating. 3. orn valve guide. 4. orn camshaft. 5. Excessive spark plug gap. 6. Defective ignition coil. 7. Defective generator. 8. Defective ignitor unit. 9. Incorrect float chamber fuel level. 10. Clogged carburetor jet. 1. eak valve spring. 2. orn camshaft. 3. Insufficient spark plug gap. 4. Mistimed valves. 5. Ignition not advanced sufficiently due to poorly working timing advance circuit. 6. Defective ignition coil. 7. Defective generator. 8. Defective ignitor unit. 9. Low float chamber fuel level. 10. Dirty air cleaner element. 11. Clogged fuel hose, resulting in inadequate fuel supply to carburetor. 1. Excessive amount of engine oil. 2. orn cylinder. 3. orn piston ring. 4. orn valve guide. 5. Scored or scuffed cylinder wall. 6. orn valve stem. 7. Defective valve stem oil seal. 8. orn oil ring side rail. 1. Insufficient valve clearance. 2. eak valve spring. 3. Mistimed valves. 4. orn cylinder. 5. orn piston ring. 6. Improper valve seating. 7. Fouled spark plug. 8. Incorrect spark plug. 9. Clogged carburetor jet. 10. Incorrect float chamber fuel level. 11. Dirty air cleaner element. 12. Air leakage from intake pipe. 13. Excessive amount of engine oil. epair or replace. Adjust or replace. Adjust float height. Clean. egap or replace. eplace ignitor unit. Adjust float height. Clean or replace. Clean and prime. Check level and drain. ebore or replace. eplace valve. eplace oil ring. epair or replace. Clean or replace. Clean. Adjust float height. Clean or replace. Tighten or replace. Check level and drain.

5 SEVICIN INFMATI 9-5 Complaint Symptom and possible causes emedy Engine overheats. CAUET 1. Carbon buildup on piston crown. 2. Insufficient amount of engine oil. 3. Defective oil pump. 4. Clogged oil circuit. 5. Float chamber fuel level too low. 6. Air leakage from intake pipe. 7. Incorrect engine oil. Clean. Check level and add. Clean. Adjust float height. Tighten or replace. Change. Complaint Symptom and possible causes emedy Starting difficulty. Idling or low-speed trouble. Medium or highspeed trouble. verflow and fuel level fluctuations. SHAFT DIVE 1. Clogged starter jet. 2. Clogged starter jet passage. 3. Air leaking from carburetor joint or vacuum hose joint. 4. Improperly working starter (enricher) plunger. 1. Clogged or loose pilot jet. 2. Clogged or loose pilot air jet. 3. Air leaking from carburetor joint, vacuum pipe joint, or starter. 4. Clogged pilot outlet port. 5. Clogged bypass port. 6. Starter (enricher) plunger not fully closed. 1. Clogged main jet. 2. Clogged main air jet. 3. Clogged needle jet. 4. Improperly working throttle valve. 5. Clogged fuel filter. 1. orn or damaged needle valve. 2. roken needle valve spring. 3. Improperly working float. 4. Foreign matter on the needle valve. 5. Incorrect float chamber fuel level. Clean. Clean. Tighten or replace defective part. Clean or tighten. Clean or tighten. Tighten or replace defective part. Clean. Clean. Clean. Clean. Clean. Clean or replace. Adjust or replace. Clean or replace with needle valve seat. Adjust float height. Complaint Symptom and possible causes emedy Noisy shaft drive. Noise seems to come from secondary bevel gear and final bevel gear assemblies. 1. il level too low. 2. Drive and driven bevel gears damaged or worn. 3. Excessive backlash. 4. Improper tooth contact. 5. Damage to bearings. Noise seems to come from propeller shaft area. 1. Propeller shaft universal joint damaged. 2. Propeller shaft splines damaged or worn. 3. Insufficient lubricant. 4. Cam dog contacting surface damaged or worn. efill. (Check oil jet/replace oil seal) efill. (eplace oil seal)

6 9-6 SEVICIN INFMATI CHASSIS Complaint Symptom and possible causes emedy Steering is heavy. Handlebar wobbles. Front wheel wobbles. Front suspension too soft. Front suspension too stiff. Front suspension too noisy. ear wheel wobbles. ear suspension too soft. ear suspension too stiff. ear suspension too noisy. 1. vertightened steering stem nut. 2. roken bearing in steering stem. 3. Distorted steering stem. 4. Low tire pressure. 1. Loss of balance between right and left front forks. 2. Distorted front fork. 3. Distorted front axle. 4. Twisted tire. 1. Distorted wheel rim. 2. orn front wheel bearing. 3. Defective or incorrect tire. 4. Loose front axle nut. 5. Incorrect fork oil level. 1. eak spring. 2. Insufficient fork oil. 1. Excessively viscous fork oil. 2. Excessive fork oil. 1. Insufficient fork oil. 2. Loose front suspension fastener. 1. Distorted wheel rim. 2. orn rear wheel bearing. 3. Defective or incorrect tire. 4. orn swingarm bearing. 5. Loose rear axle nut. 6. Loose rear suspension fastener. 1. eak rear shock absorber spring. 2. ear shock absorber leaks oil. 3. Improper suspension setting. 1. Improper suspension setting. 2. ent rear shock absorber shaft. 3. orn swingarm bearing and rear suspension related bearing. 1. Loose rear suspension fastener. 2. orn swingarm bearing and rear suspension related bearing. egulate. Adjust or replace. epair or replace. Tighten. Check level and add. Check level and drain. Check level and add. Tighten. Tighten. Tighten. Tighten.

7 SEVICIN INFMATI 9-7 AKES Complaint Symptom and possible causes emedy rake power insufficient. rake squeaks. rake lever or pedal stroke excessive. rake fluid leaks. rake drags. 1. Leakage of brake fluid. 2. orn brake pad/shoe. 3. il on brake pad surface. 4. orn brake disc. 5. Air in hydraulic system. 1. Carbon adhesion on brake pad/shoe surface. 2. Tilted brake pad. 3. Damaged wheel bearing. 4. orn brake pad/shoe. 5. Foreign material in brake fluid. 6. Clogged return port of master cylinder. 7. Loose front or rear axle nut. 1. Air in hydraulic system. 2. Insufficient brake fluid. 3. Incorrect brake fluid. 1. Loose connection joint. 2. Cracked hose. 3. orn piston seal. 4. orn secondary cup. 1. usty part. 2. Insufficient brake lever or brake pedal pivot lubrication. epair or replace. Clean brake disc and brake pads. leed. Clean surface with sandpaper. eadjust brake pad position or replace. Change brake fluid. Disassemble and clean master cylinder. Tighten. leed. Check level and add. leed any air. Change. Tighten. Clean and lubricate. Lubricate.

8 9-8 SEVICIN INFMATI ELECTICAL Complaint Symptom and possible causes emedy No sparking or poor sparking. Spark plug is wet or quickly becomes fouled with carbon. Spark plug quickly becomes fouled with oil or carbon. Spark plug electrodes overheat or burn. enerator does not charge. over- enerator charges. enerator charges but charging rate is below the specifications. Unstable charging. Starter button does not work. 1. Defective ignition coil. 2. Defective spark plug. 3. Defective pick-up coil. 4. Defective ignitor unit. 1. Excessively rich air/fuel mixture. 2. Excessively high idling speed. 3. Incorrect gasoline. 4. Dirty air cleaner element. 5. Incorrect spark plug (cold type). 1. orn piston ring. 2. orn piston. 3. orn cylinder. 4. Excessive valve-stem-to-valve-guide clearance. 5. orn valve stem oil seal. 1. Incorrect spark plug (hot type). 2. verheated engine. 3. Loose spark plug. 4. Excessively lean air/fuel mixture. 1. pen or short in lead wires, or loose lead connections. 2. Shorted, grounded, or open generator coil. 3. Shorted or punctured regulator/rectifier. 1. Lead wires tend to get shorted or open-circuited or loosely connected at terminal. 2. ounded or open-circuited stator coils or generator. 3. Defective regulator/rectifier. 4. Defective battery cell plates. 1. Internal short-circuit in the battery. 2. Damaged or defective regulator/rectifier. 3. Poorly grounded regulator/rectifier. 1. Lead wire insulation frayed due to vibration, resulting in intermittent shorting. 2. Internally shorted generator. 3. Defective regulator/rectifier. 1. un down battery. 2. Defective switch contact. 3. rushes do not seat properly on the commutator in the starter motor. 4. Defective starter relay. 5. Defective turn signal/side stand relay. 6. iring connections loose or disconnected. Adjust carburetor. Adjust carburetor. Change. Clean or replace. Change to hot type spark plug. Change to cold type spark plug. Tune-up. Tighten. Adjust carburetor. epair, replace, or connect properly. epair or tighten. eplace battery. eplace battery. epair, replace, or connect properly. epair or replace. echarge or replace. epair or replace. Tighten or repair.

9 SEVICIN INFMATI 9-9 ATTE Complaint Symptom and possible causes emedy Sulfation or spots on surfaces of cell plates. attery runs down quickly. attery sulfation. 1. Cracked battery case. 2. attery has been left in a run-down condition for a long time. 1. Incorrect charging method. 2. attery cell plates have lost much of their active material as a result of overcharging. 3. Internally shorted battery. 4. Excessively low battery voltage. 5. attery is too old. 6. Dirty container top and sides. 1. Incorrect charging rate. (hen not in use, the battery should be checked at least once a month and properly charged if necessary, to avoid sulfation.) 2. The battery was left unused in a cold climate for too long. Check generator, regulator/ rectifier circuit connections, and make necessary adjustment to obtain specified charging operation. eplace battery and correct charging system. Charge. Clean. eplace the battery if badly sulfated.

10 SEVICIN INFMATI IIN DIAAM For E-03, -28, -33 HI NU T PUSH L PUSH HI L UN PUSH P LCK INITI FEE PUSH FEE 1 IE CLS.. lack lue rown Dark brown Dark green een ay Light blue Light green range Pink ed hite ellow lack with lue tracer lack with rown tracer lack with een tracer lack with ed tracer lack with hite tracer lack with ellow tracer lue with lack tracer lue with hite tracer een with lue tracer een with ellow tracer range with lack tracer range with lue tracer range with een tracer range with ed tracer range with hite tracer range with ellow tracer ed with lack tracer ed with hite tracer hite with lack tracer ellow with lack tracer ellow with een tracer ellow with hite tracer l r Dbr Dg Lbl P /l /r / / / l/ l/ /l / / /l / / / / / / / / / TU I EA TUN SINAL LIHT (L) M 12 V TU : TUN SINAL INDICAT LIHT HI : HIH EAM INDICAT LIHT NU : NEUTAL INDICAT LIHT T : ENINE CLANT TEMPEATUE INDICAT LIHT I : IL PESSUE INDICAT LIHT SPEED SENS FT TUN SINAL LIHT () HEADLIHT FT TUN SINAL LIHT (L) FAN MT VL800K1 E-03, 28, 33 SPEEDMETE H FAN MT H TUN SINAL DIMME HANDLEA (L) HANDLEA () ENINE STP STATE UTT FT AKE INITI CIL EA FT EA AKE IL PESSUE NEUTAL SIDE-STAND FUSE X CLUTCH LEVE PSITI THTTLE PSITI SENS FUEL LEVEL AUE ENINE CLANT TEMPEATUE INIT 1 HEAD (HI) 10 A 2 HEAD (L) 10 A 3 METE 10 A 4 INITI 15 A 5 TUN SINAL 15 A 6 PE SUCE 10 A ENEAT EULAT/ ECTIFIE STATE MT STATE ELA 1 MAIN: 30 A ATTE EA TUN SINAL LIHT () AKE LIHT/ TAILLIHT / / /l / P l / / /l / / / / l/ / P / / r / l / /l / r / l / /l / /l / / / / l/ l / / Lbl l/ / /r / / / l / /l l/ / / / / /r Dg Dbr r / / r / P /l Lbl Sb / / / /l Lbl Sb / / / / / / / / / /l / / / / / l / / l / /

11 + + SEVICIN INFMATI 9-11 For E-02, -19 IE CLS.. lack lue rown Dark brown Dark green een ay Light blue Light green range Pink ed hite ellow lack with lue tracer lack with rown tracer lack with een tracer lack with ed tracer lack with hite tracer lack with ellow tracer lue with lack tracer lue with hite tracer een with lue tracer een with ellow tracer range with lack tracer range with lue tracer range with een tracer range with ed tracer range with hite tracer range with ellow tracer ed with lack tracer ed with hite tracer hite with lack tracer ellow with lack tracer ellow with een tracer ellow with hite tracer.. S UN PUSH PUSH L PUSH PUSH HI L P LCK INITI FEE PUSH FEE l r Dbr Dg Lbl P /l /r / / / l/ l/ /l / / /l / / / / / / / / / HI T TU I NU EA TUN SINAL LIHT () EA TUN SINAL LIHT (L) 2 3 M 12 V TU : TUN SINAL INDICAT LIHT HI : HIH EAM INDICAT LIHT NU : NEUTAL INDICAT LIHT T : ENINE CLANT TEMPEATUE INDICAT LIHT I : IL PESSUE INDICAT LIHT SPEED SENS FT TUN SINAL LIHT () HEADLIHT FT TUN SINAL LIHT (L) PSITI LIHT FAN MT VL800K1 E-02, 19 SPEEDMETE LIHTIN HANDLEA () ENINE STP STATE UTT FT AKE INITI CIL EA FT EA AKE CAUET HEATE THTTLE PSITI SENS FUEL LEVEL AUE FAN MT H TUN SINAL PASSIN H DIMME HANDLEA (L) CLUTCH LEVE PSITI IL PESSUE NEUTAL SIDE-STAND FUSE X 1 HEAD (HI) 10 A 2 HEAD (L) 10 A 3 METE 10 A 4 INITI 15 A 5 TUN SINAL 15 A 6 PE SUCE 10 A ENINE CLANT TEMPEATUE INIT ENEAT EULAT/ ECTIFIE STATE MT CAUET THEM- STATE ELA 1 MAIN: 30 A ATTE AKE LIHT/ TAILLIHT / / /l / P l / / r / l / /l / / /l / r / l / /l / /l l/ l / / Lbl / / / / /r / / / / / l/ / P l/ / / / l / /l l/ / / / / /r r r / / r / P /l Lbl Sb / / / / /l Lbl Sb / / / / / / / / / l / /l / / / / / / l / / / / l l

12 SEVICIN INFMATI For E-24 HI NU T UN PUSH PUSH L PUSH HI L LCK FEE PUSH FEE 1 IE CLS.. lack lue rown Dark brown Dark green een ay Light blue Light green range Pink ed hite ellow lack with lue tracer lack with rown tracer lack with een tracer lack with ed tracer lack with hite tracer lack with ellow tracer lue with lack tracer lue with hite tracer een with lue tracer een with ellow tracer range with lack tracer range with lue tracer range with een tracer range with ed tracer range with hite tracer range with ellow tracer ed with lack tracer ed with hite tracer hite with lack tracer ellow with lack tracer ellow with een tracer ellow with hite tracer l r Dbr Dg Lbl P /l /r / / / l/ l/ /l / / /l / / / / / / / / / TU I M 12 V EA TUN SINAL LIHT (L) TU : TUN SINAL INDICAT LIHT HI : HIH EAM INDICAT LIHT NU : NEUTAL INDICAT LIHT T : ENINE CLANT TEMPEATUE INDICAT LIHT I : IL PESSUE INDICAT LIHT SPEED SENS FT TUN SINAL LIHT () HEADLIHT FT TUN SINAL LIHT (L) FAN MT VL800K1 E-24 SPEEDMETE HANDLEA () ENINE STP STATE UTT FT AKE INITI CIL EA FT EA AKE FAN MT H TUN SINAL H DIMME HANDLEA (L) INITI CLUTCH LEVE PSITI IL PESSUE NEUTAL SIDE-STAND FUSE X THTTLE PSITI SENS FUEL LEVEL AUE ENINE CLANT TEMPEATUE INIT 1 HEAD (HI) 10 A 2 HEAD (L) 10 A 3 METE 10 A 4 INITI 15 A 5 TUN SINAL 15 A 6 PE SUCE 10 A ENEAT EULAT/ ECTIFIE STATE MT STATE ELA 1 MAIN: 30 A / ATTE EA TUN SINAL LIHT () AKE LIHT/ TAILLIHT / r / / /l / P l / / / l / /l / / /l / r / l / /l / /l / / / / / / / / l/ / P l/ l / / Lbl l/ / /r / / / l / /l l/ / / / / /r r / / P /l Lbl Sb / / / /l Lbl Sb / / / / / / / / / /l / / / / / l / / l / /

13 SEVICIN INFMATI 9-13 IE HANESS, CALE AND HSE UTIN IE HANESS UTIN After clamping, cut the excessive end. 50 mm 200 mm 200 mm Clamp After clamping, cut the excessive end. Handlebar switch (L & ) Speed sensor iring harness Front turn signal light (L & ) Clamp Clamp Clutch cable Starter motor lead wire Engine coolant temp. switch C egulator/ectifier To generator To wiring harness Fuse VIE C Electrical parts holder

14 9-14 SEVICIN INFMATI Fuel level gauge lead wire Fuel pump & carburetor hose iring harness Fuel pump vacuum hose Install between wiring harness and fuel pump vacuum hose. TPS Pass the battery +-lead wire under the starter relay. Clamp To speedometer Carburetor heater lead wire Frame head cover (L & ) To fuel level gauge end iring harness D Thermo-switch A VIE D attery --lead wire iring harness Frame adiator SECT VIE A

15 SEVICIN INFMATI il pressure switch 14 N.m 1.4 kgf. m ( lb-ft ) VIE Starter motor A VIE A enerater lead wire Clamp attery - lead wire Starter motor lead wire Clamp Crankcase () ear position switch lead wire Clamp enerator cover Startor 45 25

16 9-16 SEVICIN INFMATI CALE UTIN Clutch cable Throttle cable (pulling) Throttle cable (returning) rake hose Throttle cable plate 1 2 mm Throttle cable (pulling) eservoir hose iring harness uide High-tension cord Throttle cable clip 1 2 mm Clutch cable Fuel hose Clamp Starter cable eservoir hose Clutch cable Clamp Throttle cable (returning) Clutch cable Clamp Starter cable Clamp between the projections. Clutch cable Starter cable Throttle cable (pulling) Cable guide Throttle cable (pulling) Throttle cable (returning) 200 mm 40 mm Clamp Front Cable guide Cable guide iring Clamp harness Clutch cable Starter cable Throttle cable plate

17 SEVICIN INFMATI 9-17 FUEL HSE UTIN Fuel valve Face the clamp ends down. Fuel hose A Clamp Face the clamp ends down. To fuel valve Clamp VIE A 11.5 mm Fuel hose 10 mm Clamp Spring Clamp To fuel pump

18 9-18 SEVICIN INFMATI CLIN HSE UTIN Pass through the vacuum hose left side of the breather hose. Air vent hose iring harness Clutch cable Clamp from behind. Cylinder joint hose VIE Clamp from right side. VIE A Clamp from left side. ellow marking VIE C Clamp from right side. adiator cap Conduction hose Clamp from left side. adiator inlet hose ellow marking adiator Face the clamp ends downward. Marking Throttle cables Clamp from left side. C Clamp from top. eservoir hose iring harness Fuel hose Vacuum hose Vacuum hose SECT E E eservoir inlet hose E E F D H F adiator verflow hose eservoir Cooling fan Marking LH 17 N. m (1.7 kgf. m, 12.5 lb-ft) A Face the clamp ends backward. VIE D VIE F Marking Clamp from left side. ellow marking adiator outlet hose hite marking Face the clamp ends right. Face the clamp ends left.

19 SEVICIN INFMATI 9-19 FT AKE HSE UTIN Front brake master cylinder asket washer Set the brake hose union parallel with the handlebars, tighten the union bolt to the specified torque. 42 Clamp After touching the brake hose union to the stopper, tighten the union bolt to the specified torque. Pass the brake hose through the hose guides. Clamp the brake hose firmly. Front brake hose Speed sensor lead wire Clamp the brake hose firmly. Speed sensor lead wire guide asket washer rake caliper Insert the projection on the brake hose clamp into the hole of the steering stem lower bracket.

20 9-20 SEVICIN INFMATI ATTE PTECT attery protector 60 mm 90 mm 90 mm 30 mm 65 mm 30 mm attery protector SPEED SENS LEAD IE UTIN 30 mm Speed sensor lead wire clamp Speed sensor guide hook Speed sensor lead wire

21 SEVICIN INFMATI 9-21 SPECIAL TLS Snap ring pliers Snap ring pliers Impact driver set Hexagon socket (12 mm) Hexagon socket (14 mm) Vernier calipers (200 mm) Micrometer (25 50 mm) Micrometer (50 75 mm) Micrometer ( mm) Micrometer (0 25 mm) Cylinder gauge set Dial gauge (1/1000 mm, 1 mm) Dial calipers (10 34 mm) Dial gauge (1/100, mm, 10 mm) Magnetic stand Thickness gauge Tire depth gauge V-block (100 mm) Plastigauge Small bore gauge (18 35 mm) Multi circuit tester set il seal remover earing installer set earing installer earing installer il filter wrench Adaptor Compression gauge il pressure gauge hose il pressure gauge adaptor

22 9-22 SEVICIN INFMATI Meter (For high pressure) Valve lapper set Valve lifter Valve lifter attachment Valve seat cutter set Valve seat cutter (N-128) Valve guide reamer (5.5 mm) Valve guide reamer (10.8 mm) Valve guide remover/installer Valve guide installer attachment Tweezers Vacuum pump gauge Compression gauge adaptor Chain tensioner lock tool Crankcase & Shaft remover Clutch sleeve hub holder earing remover set earing retainer wrench earing remover acklash measuring tool (27 50) Final drive gear bearing holder wrench mm Long socket Final drive gear coupring holder earing installer Spark plug wrench set Torx bit JT40H it holder Sliding shaft otor remover otor holder

23 SEVICIN INFMATI Steering stem nut wrench T handle Attachment A Front fork oil seal installer Spring scale Steering outer race installer earing remover set earing outer race remover earing remover Steering bearing installer Front fork oil level gauge

24 9-24 SEVICIN INFMATI TIHTENIN TQUE ENINE ITEM N.m kgf.m lb-ft ocker arm shaft Cylinder head cover bolt 6 mm mm Cylinder head bolt and nut Initial mm Final mm Initial Final Cam sprocket bolt Cam chain tension adjuster mounting bolt Cam chain tensioner bolt Primary drive gear bolt Clutch spring set bolt Clutch sleeve hub nut Driveshaft bolt Secondary drive gear shaft nut Secondary gear case bolt Initial Final enerator rotor bolt Starter clutch allen bolt Crankcase bolt 6 mm mm Initial Final Conrod cap nut Initial Final il pressure regulator il pump mounting bolt il pressure switch il drain plug

25 SEVICIN INFMATI 9-25 ITEM N.m kgf.m lb-ft il plug 6 mm mm mm mm mm Engine mounting bolt Engine mounting bracket bolt Frame mounting bolt/nut 8 mm mm Exhaust pipe clamp bolt Muffler mounting bolt Speed sensor rotor bolt Spark plug SECDA AND FINAL ITEM N.m kgf.m lb-ft Secondary drive bevel gear bearing retainer bolt Secondary driven bevel gear bolt Secondary driven bevel gear bearing stopper Final gear case mounting nut Final drive bevel gear coupling nut Final drive bevel gear bearing stopper Final gear case oil drain plug Final gear case bolt 8 mm mm Final driven bevel gear bearing retainer screw

26 9-26 SEVICIN INFMATI CHASSIS ITEM N.m kgf.m lb-ft Front axle Front axle pinch bolt rake disc bolt Front fork cap bolt Front fork spring stopper nut Front fork damper rod bolt Front fork lower clamp bolt Steering stem head nut Front master cylinder mounting bolt Front brake caliper mounting bolt rake hose union bolt Air bleeder valve Handlebar set bolt Handlebar holder nut Front footrest bolt Frame down tube mounting bolt (M8) Frame down tube mounting bolt (M10) ear brake pedal bolt ear swingarm pivot bolt (Left) ear swingarm pivot bolt (ight) ear swingarm pivot bolt lock nut ear shock absorber mounting nut (Upper and Lower) ear cushion lever/rod mounting nut ear axle nut ear torque link nut (front) ear torque link nut (rear) ear brake cam lever bolt Driven joint stopper bolt Frame handle grip mounting bolt (M10) Fuel level gauge mounting bolt

27 SEVICIN INFMATI 9-27 TIHTENIN TQUE CHAT For other bolts and nuts listed previously, refer to this chart: olt Diameter Conventional or 4 marked bolt 7 marked bolt A (mm) N.m kgf.m lb-ft N.m kgf.m lb-ft Conventional bolt 4 marked bolt 7 marked bolt

28 9-28 SEVICIN INFMATI SEVICE DATA VALVE + UIDE Unit: mm (in) ITEM STANDAD LIMIT Valve diam. 30 IN. (1.18) EX. 26 (1.02) Valve clearance (when cold) IN. ( ) EX ( ) Valve guide to valve stem IN. clearance ( ) EX ( ) Valve stem deflection 0.35 IN. & EX. (0.014) Valve guide I.D IN. & EX. ( ) Valve stem.d IN. ( ) Valve stem runout Valve head thickness Valve stem end length Valve seat width Valve head radial runout Valve spring free length Valve spring tension EX ( ) IN. & EX. IN. & EX. IN. & EX. IN. & EX ( ) IN. & EX. INNE UTE INNE UTE 0.05 (0.002) 0.5 (0.02) 3.1 (0.12) 0.03 (0.001) 38.3 (1.51) 40.1 (1.58) kgf ( lbs) at length 32.5 mm (1.28 in) kgf ( lbs) at length 36.0 mm (1.42 in)

29 SEVICIN INFMATI 9-29 CAMSHAFT + CLINDE HEAD Cam height Unit: mm (in) ITEM STANDAD LIMIT Front IN ( ) (1.404) EX ( ) (1.442) ear IN ( ) (1.386) EX ( ) (1.428) Camshaft journal oil clearance ( ) (0.0059) Camshaft journal holder I.D. No.1 Left side No.2 ight side ( ) No.1 ight side No.2 Left side ( ) Camshaft journal.d. No.1 Left side No.2 ight side ( ) No.1 ight side No.2 Left side ( ) Camshaft runout ocker arm I.D. ocker arm shaft.d. Cylinder head distortion Cylinder head cover distortion IN. & EX. IN. & EX. CLINDE + PIST + PIST IN ( ) ( ) 0.10 (0.004) 0.05 (0.002) 0.05 (0.002) Unit: mm (in) ITEM STANDAD LIMIT Compression pressure kpa kpa ( kgf/cm2 ) ( 11 kgf/cm psi 156 psi ) Compression pressure difference 200 kpa ( 2 kgf/cm2 28 psi ) Piston to cylinder clearance ( ) (0.0047) Cylinder bore ( ) (3.2711) Piston diam ( ) (3.2630) Measure at 15 mm (0.6 in) from the skirt end. Cylinder distortion 0.05 (0.002)

30 9-30 SEVICIN INFMATI ITEM STANDAD LIMIT Piston ring free end gap st Approx. (0.38) (0.30) Piston ring end gap Piston ring groove clearance 2nd Approx. 1st 2nd 1st 2nd (0.46) (0.37) ( ) (0.028) ( ) (0.028) (0.007) (0.006) Piston ring groove width st ( ) 2nd ( ) il ( ) Piston ring thickness st ( ) 2nd ( ) Piston pin bore ( ) (0.7886) Piston pin.d ( ) (0.7866) CD + CANKSHAFT Unit: mm (in) ITEM STANDAD LIMIT Conrod small end I.D ( ) (0.7890) Conrod big end side clearance ( ) (0.012) Conrod big end width ( ) Crank pin width ( ) Conrod big end oil clearance ( ) (0.0031) Crank pin.d ( ) Crankshaft journal oil clearance ( ) (0.0031) Crankshaft journal.d ( ) Crankshaft thrust bearing thickness ( ) Crankshaft thrust clearance ( ) Crankshaft runout 0.05 (0.002)

31 SEVICIN INFMATI 9-31 IL PUMP ITEM STANDAD LIMIT il pressure (at 60 C,140 F) Above 350 kpa (3.5 kgf/cm 2, 50 psi) elow 650 kpa (6.5 kgf/cm 2, 92 psi) at r/min. CLUTCH Unit: mm (in) ITEM STANDAD LIMIT Clutch cable play ( ) Clutch release screw 1/4 turn back Drive plate thickness No.1 ( ) (0.103) No ( ) (0.123) Drive plate claw width ( ) (0.594) Driven plate distortion 0.10 (0.004) Clutch spring free length (1.94) (1.84) TANSMISSI Unit: mm (in) Except ratio ITEM STANDAD LIMIT Primary reduction ratio (71/42) Secondary reduction ratio (17/15) Final reduction ratio (34/11) ear ratios Low (32/13) 2nd (31/19) 3rd (27/22) 4th (25/25) Top (22/27) Shift fork to groove clearance No.1 ( ) (0.020) Shift fork groove width Shift fork thickness No.2 No.1 No.2 No.1 No ( ) (0.020) ( ) ( ) ( ) ( )

32 9-32 SEVICIN INFMATI SHAFT DIVE Unit: mm (in) ITEM STANDAD LIMIT Secondary bevel gear backlash ( ) Final bevel gear backlash Drive side ( ) Damper spring free length 58.5 (2.30) CAUET ITEM SPECIFICATI E-02, 19, 24 E-03, 28 E-33 Carburetor type MIKUNI DS34 ore size 34 mm I.D. No. 41F1 41F2 41F3 Idle r/min ± 100 r/min. Fuel level Float height 7.0 ± 0.5 mm (2.76 ± 0.02 in) Main jet (M.J.) #132.5 # Main air jet (M.A.J.) φ 1.8 Jet needle (J.N.) 5E22-3 5E23 Needle jet (N.J.) P-0M Throttle valve (Th.V.) #95 Pilot jet (P.J.) #27.5 # Pilot screw (P.S.) PE-SET (3.0 turns back) PE-SET Throttle cable play 2 4 mm (0.08 ± 0.16 in) THEMSTAT + ADIAT + FAN + ENINE CLANT ITEM STANDAD/SPECIFICATI LIMIT Thermostat valve opening temperature Approximately 75 C (167 F) Thermostat valve lift ver 6 mm (0.24 in) at 90 C (194 F) Engine coolant temp. switch Approximately 120 C (248 F) operating temperature Approximately 113 C (235.4 F) adiator cap valve opening kpa pressure ( kgf/cm 2, psi) Cooling fan thermoswitch Approximately 105 C (221 F) operating temperature Approximately 100 C (212 F) Engine coolant type Use an antifreeze/coolant compatible with aluminum radiators, mixed with distilled water only, at the ratio of 50:50 Engine coolant capacity ml (1.6 US qt, 1.3 lmp qt)

33 SEVICIN INFMATI 9-33 ELECTICAL Unit: mm (in) ITEM SPECIFICATI NTE Firing order 1.2 Spark plug NK: DP7EA-9 Type DENS: X22EP-U9 Spark performance Ignition coil resistance ap Primary Secondary ( ) ver 8 (0.3) at 1 atm. 2 6 Ω kω Terminal Terminal Plug cap Terminal Ignition coil primary peak voltage #1+:, -:ound More than 200 V #2+:/, -:ound enerator coil resistance Pickup coil Ω l Charging coil Ω Pickup coil peak voltage More than 1.5 V +: l, -: enerator no-load voltage (hen engine cold) More than 70 V (AC) at r/min. egulated voltage V at r/min. enerator maximum output 375 at r/min. Starter relay resistance 3 7 Ω attery Type designation FTX12-S Capacity 12 V 36 kc (10Ah)/10H Fuse size HI 10 A Headlight L 10 A Signal 15 A Ignition 15 A Meter 10 A Main 30 A Power source 10 A ATTAE ITEM SPECIFICATI E-03, 28, 33 E-24 The others Headlight HI 60 L 55 Position/Parking light 4 rake light/taillight 21/5 Turn signal light 21/5 (Front), 21 (ear) 21 Speedometer light LED ater temp. meter light LED Turn signal indicator light LED High beam indicator light LED Neutral indicator light LED il pressure indicator light LED Unit:

34 9-34 SEVICIN INFMATI SUSPENSI Unit: mm (in) ITEM STANDAD/SPECIFICATI LIMIT Front fork stroke 140 (5.51) Front fork spring free length (21.73) (21.29) Front fork oil level (without spring) 177 (6.96) Front fork oil type SUZUKI FK IL SS-08 or an equivalent fork oil Front fork oil capacity 412 ml (each leg) (24.0 US oz, 25.0 lmp oz) Front fork spring adjuster ear shock absorber spring adjuster 4 ear wheel travel 105 (4.13) Swingarm pivot shaft runout 0.3 (0.01) AKE + HEEL Unit: mm (in) ITEM STANDAD LIMIT ear brake pedal free travel ( ) ear brake pedal height ( ) rake drum I.D ear (7.11) rake disc thickness 5.0 ± Front (0.20 ± 0.01) (0.18) rake disc runout 0.30 (0.012) Master cylinder bore Front ( ) Master cylinder piston diam Front ( ) rake caliper cylinder bore Front ( ) rake caliper piston diam Front ( ) heel rim runout 2.0 Axial (0.08) heel axle runout adial Front 2.0 (0.08) 0.25 (0.010) ear 0.25 (0.010) heel rim size Front J16 MT3.00 or J16M/C MT3.00 ear J15 M/C MT4.00

35 SEVICIN INFMATI 9-35 TIE Unit: mm (in) ITEM STANDAD/SPECIFICATI LIMIT Cold inflation tire pressure 200 kpa (Solo riding) Front (2.00 kgf/cm 2, 29 psi) Cold inflation tire pressure (Dual riding) ear Front 250 kpa (2.50 kgf/cm 2, 36 psi) 200 kpa (2.00 kgf/cm 2, 29 psi) ear 250 kpa (2.50 kgf/cm 2, 36 psi) Tire size Front 130/ H ear 170/80-15 M/C 77H Tire type Front IC S-23F ear IC S-23 Tire tread depth 1.6 Front (0.06) FUEL + IL + CLANT ear 2.0 (0.08) ITEM SPECIFICATI NTE Fuel type Use only unleaded gasoline of at least 87 pump + M octane or 91 octane ( 2 ) or higher rated by the esearch Method. asoline containing MTE (MethyI Tertiary utyi Ether), less than 10% ethanol, or less than 5% E-03, 28, 33 methanol with appropriate cosolvents and corrosion inhibitor is permissible. asoline used should be graded 91 octane or higher. An unleaded gasoline is recommended. ther models Fuel tank including reserve 17.0 L (4.5/3.7 US/lmp gal) reserve 1.5 L (flicker) (0.4/0.3 US/lmp gal) Engine oil type SAE 10/40, API SF or S Engine oil capacity ml Change (3.2/2.6 US/lmp qt) Filter change ml (3.6/3.0 US/lmp qt) verhaul ml (3.9/3.3 US/lmp qt) Final bevel gear oil type SAE 90 hypoid gear oil with L-5 under API classification Final bevel gear oil capacity ml (6.8/ /7.7 US/lmp oz) rake fluid type DT 4 Coolant capacity ml (1.6/1.3 US/lmp qt)