SUZUKI GS750E ES SERVICE MANUALFOREWORD The Suzuki GS750E/ES has been developed as a further refinement of the GS model line. It features highly advanced design concepts including a full floater suspension system. The GS750E/ES provides excellent performance, precise control and handling plus outstanding riding comfort. This service manual has been produced primarily for experienced Suzuki mechanics. Apprentice and do-it yourself mechanics will also find this manual to be an extremely useful repair quide. This manual contains the most up-to-date information at the time of publication. The rights are reserved to update or make corrections to this manual at any time. IMPORTANT All GS mode! SUZUKI motorcycles that were manufactured after January 1, 1978 are subject to Environ- mental Protection Agency emission regulations. These regulations set specific standards for exhaust emission output levels as well as particular servicing requirements. This manual includes specific information required to properly inspect and service the GS75QE/ES in accordance with all EPA regula- tions. It is strongly recommended that the chapter on Emission Control, Periodic Servicing and Carbure- tion be thoroughly reviewed before any type of service work is performed. Further information concerning the EPA emission regulations and U.S. SUZUKI’s emission contro! program can be found in the U.S. SUZUKI EMISSION CONTROL PROGRAM MANUAL/SERVICE BULLETIN. SUZUKI MOTOR CO.,LTD. Administration Department Overseas Service Division Quoting, copying or otherwise using any part of this manual without explicit authorization from Suzuki Motor Co., Ltd. is not permitted as all rights to the publication are reserved under copyright law.VIEW OF SUZUKI GS750ESGROUP INDEX PERIODIC MAINTENANCE AND GENERAL INFORMATION TUNE-UP PROCEDURES __ SERVICING ENGINE FUEL AND LUBRICATION sy Ee EMISSION CONTROL & REGULATIONS i | ja] ~]o| ELECTRICAL SYSTEM CHASSIS SER VICING INFORMATIONGENERAL INFORMATION ; —— CONTENTS e SERIAL NUMBER LOCATIONS «--+-+++++0++-0100000see0+ - ott FUEL AND OIL RECOMMENDATIONS - oe 1) BREAKING-IN PROCEDURES: +2 | e CYLINDER IDENTIFICATION SPECIAL FEATURES -- cee seonenenete 3 | TSCC (TWIN SWIRL COMBUSTION CHAMBER) --:++-0:+:0---te 3 CAMSHAFT DRIVE CHAIN TENSIONER FULL TRANSISTORIZED IGNITION SYSTEM. -- ANTI-DIVE FORK ------ FULL-FLOATING SUSPENSION SYSTEM:--- PRECAUTIONS AND GENERAL INSTRUCTIONS: --- | SPECIAL MATERIALS. Ls SPECIFICATIONS -1-1_ GENERAL INFORMATION SERIAL NUMBER LOCATIONS FRAME NUMBER The frame serial number steering head pipe. ) is stamped on the ENGINE NUMBER The engine serial number @) is located on the right side of the crankcase. FUEL AND OIL RECOMMENDATIONS FUEL Use only unleaded or low-lead type gasoline of at least 85 — 95 pump octane (.2*™M method) or 89 octane or higher rated by the Research method. ENGINE OIL SUZUKI recommends the use of SUZUKI PERFORMANCE 4MOTOR OIL or an oil which is rated SE or SF under the API (American Petroleum Institute) classification system. The viscosity rating should be SAE 10W-40. If an SAE 10W-40 oil is not available, select an alternate according to the chart below. SAE 0 0 2ow 50} 101 50} 10.20} 20W 108 BRAKE FLUID (for front and rear brakes) Specification and ] DOTS, DOT4 classification NOTE: * Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix different types of fluid such as silicone- based and petroleum-based fluid for refill- ing the system, otherwise serious damage will resutt, used or unsealed containers. previous servicing and stored for a long | me |GENERAL INFORMATION. 1-2 FRONT FORK OIL Use fork oil #10, BREAKING-IN PROCEDURES. During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still neces- sary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during it early life. The general rules are as follows: © Keep to these breaking-in engine speed limits Initial 500 miles aero BOOM) | Below 6000 p.m Over 1.000 miles, | Below 10.000 r.p.m 600 ki ‘* Upon reaching an odometer reading of 1.000 miles (1.600 km), you can subject the motor- cycle to full throttle operation. However, do not exceed 10000 r.p.m. at any time. © Do not maintain constant engine speed for an extended time period during any portion of the break-in, Try to vary the throttle position. CYLINDER IDENTIFICATION The four cylinders of this engine are identified as No. 1, No. 2, No. 3 and No. 4 cylinder, as counted from left to right (as viewed by the rider on the seat). No. 1 No.2. No.3 No. 4 J |1-3 GENERAL INFORMATION SPECIAL FEATURES TSCC (TWIN SWIRL COMBUSTION CHAMBER) SUZUKI has introduced a new breed of 4-valves-per-cylinder high-performance 4-stroke engines-the TSCC series. TSC describes the heart of the engine, the Twin Swirl Combustion Chamber. What the TSCC engine series does better than conventional 4-stroke engines, either 2 valve or 4 valve, is to improve on the two major factors which affect engine performance, charge burning efficiency and intake charging efficiency. First, charge burning efficiency. The TSCC* system consists of a subtle, yet unique shape machined into the head. Each of the two intake valves is set into adjoining semi-hemispherical depressions in the head. During the intake stroke these depressions channel the incoming fuel/air mixture to form two separate high-speed swirls. During the compression stroke the squish areas machined in the front and the rear of the cylinder head’s combustion chamber accelerate the speed of the swirls. Thus, when the spark plug ignites the mixture, the flame spreads rapidly and completes the combustion more quickly. To further aid burning efficiency, the spark plug is centrally located, the ideal location. This results in the shortest possible path for the flame to travel. "US. PATENT NO. 3633577GENERAL INFORMATION 1-4 The quick completion of burning results in more energy being developed while the piston is in position to transmit maximum power to the crankshaft. High burning efficiency results in more power, improved throttle response at all rpm's, more complete combustion of the air/fuel mixture (cleaner combustion) and less chance of detonation. Second, charging efficiency. The benefits of increased burning efficiency are further multiplied if intake charging efficiency is also increased. Basically, increasing the charging efficiency results in more fuel and air being drawn into the engine during each intake stroke. Thus, greater energy potential. To achieve this, the four valve head was adopted. Two smaller diameter intake valves can flow more than ‘one large valve, Additionally, two smaller valves run cooler due to increased valve seat area and two valve guides to increase heat transfer. PISTON SQUISH AREA (8) 7 swint CYLINDER BORE PROFILE SQUISH HEIGHT (a (8) wall wall PLUG HOLE 1a) U.S. PATENT NO. 36335771-5 GENERAL INFORMATION But, SUZUKI went one step further. The valves are set in at a much shallower angle than other engines. The result is a smoother intake tract with less valve guide protrusion than in conventional cylinder heads, Therefore, increased flow, and smoother, less turbulant flow which contributes to more power and im- proved throttle response at all engine speeds. There are several other benefits. This design is more efficient and will flow more air/fuel mixture than a conventional 4 valve head. Therefore, even smaller, lighter valves can be used with no decrease in power. Also, the valves can be shorter due to the placement angle. This allows more precise valve control since shorter, lighter valves are more easily controlled--especially at higher rpm's. Yet another benefit of valves set at shallower angles is that the volume of the cylinder head combustion area is decreased. This allows the use of racing type flat-topped pistons since the desired compression ratio can be achieved without resorting to domed pistons. Flat topped pistons offer no restriction to the incom- ing air/fuel mixture and a flat-topped piston exposes the minimum amount of surface area to the hot burning mixture. This means that the flat piston absorbs less heat and therefore has to dissipate less heat ‘through the rings and to the oil than a conventional domed piston. The result is a cooler running engine. Flat-topped pistons can also be made lighter resulting in less vibration and stress. Increased burning efficiency. Increased charging efficiency. The result is more power throughout, from idle to redline. Throttle response is instant and clean. Displacement for displacement, no conventional engine, 2 valve or 4 valve, can compare. This could be enough, but SUZUKI went even further to ensure reliability and ease of maintenance, A direct acting rocker arm is utilized to activate the valves. Each rocker arm, when depressed by the cam. lobe, directly activates two valves at one time. With this system, engine height is reduced and tappets are not necessary. This system allows more room for cooling air flow and allows the use of larger valve springs which increases spring life by reducing stress. Valve adjustment is accomplished without special tools-- quickly and easily. ‘Special sintered steel valve seats are incorporated, manufactured from premium alloys to ensure even more reliability under higher heat loads. The patented TSCC combustion system combined with SUZUK('s high efficiency charging design results in power and throttle response found only in this new generation 4-stroke engine. ‘The SUZUKI TSCC engine series-performance without compromise.GENERAL INFORMATION 1-6 Ht valve pitch () isthe same, spring TSCC valve angle a is smaller than B. diameter @ is larger than © sce ® avai F - A | | sa Conventional 4ualve "U.S. PATENT NO. 36335771-7 GENERAL INFORMATION CAMSHAFT DRIVE CHAIN TENSIONER The chain tensioner used in the Model GS750E/ES is of self-adjusting type in that it adjusts itself to apply ‘a constant tensioning force to the chain by compensating for the stretch of the chain. PUSH ROD AND LOCK SCREW During normal service the cam drive chain will stretch. A spring controlled push rod is used to constantly reposition the cam chain guide firmly against the chain to prevent slack from occurring. A lock screw and nut are utilized to eliminate the constant, high spring pressure exerted on the push rod. The lock screw is only used during either removal or installation of the adjuster push rod to ease the procedures. LOCK SHAFT The cam drive chain tension tries to vary during engine operation. The spring controlled push rod is designed so as to only move in, towards the chain guide preventing slack from occurring if the spring pressure on the push rod were overcome. A steel ball is “jammed” against a angled surface prevent- ing backwards movement of the push rod. The lock shaft is preloaded with a light spring @ which keeps the ball in contact with the push rod and angled surface ® Steel ball Lock shaft Haddlelong ent 5 Bt ‘rol! GENERAL INFORMATION 1-8 TRANSISTORIZED IGNITION SYSTEM WITH ELECTRONIC ADVANCE On the Model GS750E/ES, the timing advance characteristics of the ignition timing have been changed from the previously-employed mechanical timing advance system incorporating a centrifugal advance governor to an electronic timing advance system. The introduction of this new electronic timing advance system minimizes fluctuations in the ignition timing and also has improved the timing advance perform- ance during high-speed operations. Ignitor unit L Signal rotor When the signal rotor is rotated in the system block diagram above, the signal “A” is generated in the pick- up coil. The thus-generated signal will be converted to the signal waveform “B” at the inside of the ignitor unit, Based on this “B” waveform, control is made by means of the advancing control circuit and the clos- ing angle control circuit, As a result, the timing advance takes place, as shown in Fig. "C”. A c Slow-speed revolution —— He>L—Advance angle 6° Medium-speed — revolution — como angle 0° Highspeed revolution |1-13 GENERAL INFORMATION WHAT HAPPENS WHEN THE MOTORCYCLE RECEIVES A JOLT FROM THE ROAD, WHILE THE ANTI-DIVE DEVICE IS ACTIVE? While the anti-dive device is restricting fork oil flow, any road shock could be directly transmitted to the chassis because the front fork would react as if it were equipped with very stiff springs. However, the road shock is reduced by the following mechanism: The relief valve, mounted on a spring, is ‘compressed and opened in direct proportion to the pressure on the front-fork oil, permitting the oil to progressively flow through the clearance between the valve and valve seat. Hence the pressure of the fork il is automatically regulated at a predetermined level. In other words, the clearance at the relief valve represents the difference of fork oil pressure developed by the upward load from the road and the strength of the relief valve’s spring. In order to ensure safety, separate chambers are provided for the fork oil and brake fluid to prevent their mixture, SS SSC Fork oil starts to flow Relief spring is compressed, SSS on Load directed upwardGENERAL INFORMATION 1-14 FULL-FLOATING SUSPENSION SYSTEM Suzuki's exclusive Full Floater rear suspension has been acclaimed the best. Its dominance on motcross and roadrace tracks around the world has proven it. The Full Floater is a remarkable step forward in suspension technology. It is compact and lightweight with the majority of its weight low and near the motoreycle’s center of gravity. Its geometry is such that it is responsive to small bumps and road irregularities, yet it will soak up vicious pot holes and ledges without bottoming out, Shock absorber control is superior for stable handling under all conditions. The Full Floater of the GS750E/ES has also been designed with the single shock absorber. Suzuki Full Floater features remote controlled hydraulic spring pre-load adjustment and remote controll- ed damping force adjustment. This is a description for a simple device. The remote controlled damping force is comprised of a knob driven cable, A rotation of the knob and cable turns the damping adjuster to one of four positions. ber spring via a piston. This allows quick adjustment of spring preload to the rider's requirements. The remote controlled damping force is comprised of a knob driven cable. Rotation of the knob and cable turns the damping adjuster to one of four positions. Stable handling, a smooth ride, light weight, convenience and a natural and comfortable riding position — all with Suzuki's exclusive Full Floater.1-15 GENERAL INFORMATION PRECAUTIONS AND GENERAL INSTRUCTIONS Observe the following items without fail when disassembling and reassembling motorcycles. © Be sure to replace packings, gaskets, circlips, O rings and cotter pins with new ones, CAUTION: Never reuse a circlip after a circlip has been removed from a shaft, it should be discarded and a new clip 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, © Tighten cylinder head and case bolts and nuts beginning with larger diameter and ending with smaller diameter, and from inside to out-side diagonally, to the specified tightening torque. © Use special tools where specified. Use specified genuine parts and recommended oils, © When more than 2 persons perform works together, pay attention to the safety of each other. © After the reassembly, check parts for tightness and operation. © Treat gasoline, which is extremely flammable and highly explosive, with greatest care. Never use gasoline as cleaning solvent. Warning, caution and note are included in this manual occasionally, describing the following contents. WARNING . Personal safety of the rider is involved, and disregard of the information could result in his injury. CAUTION . For the protection of the motorcycle, the instruction or rule must be strictly adhered to, NOTE Advice calculated to facilitate the use of the motorcycle is given under this heading. USE OF SUZUKI GENUINE PARTS. To replace any part of the machine, use a genuine SUZUKI replacement part. Imitation parts or parts supplied from any other source than SUZUKI, if used to replace SUZUKI parts, can reduce the machine's performance and, even worse, could induce costly mechanical trouble.GENERAL INFORMATION 1-16 SPECIAL MATERIALS The materials listed below are needed for maintenance work on the GS75OE/ES, and should be kept on hand for ready use. They supplement such standard materials as cleaning fluids, lubricants, emery cloth and the like, How to use them and where to use them are described in the text of this manual. MATERIAL, PART PAGE | PART PAGE Oil seals 3:60. | Brake pedal shaft Throttle grip ‘© Speedometer cable Gearshift over shaft ‘© wheal bearings 76 ‘Center stand spacer SUZUKI SUPER GREASE “A” | Wheel bearing dust seal el 99000-25030 7.56 — ‘Caliper axle shaft 7.28 &) ‘© Swing arm bearings 756 | SUZUKI SILICONE GREASE 99000-25100 ‘¢Valve stem 336 ‘©Comshatt journal 3.76 ‘Chain tensioner adjuster | a1 shaft ‘Crankshaft journal 363 Crank pin 3.50 ‘Drive shaft 359 SUZUKI MOLY PASTE 99000-25140 |_| ‘Oil pressure switeh 3.70 | ¢Damper rod bolt ao feMating surface of crankcase | 3.67 | eCylinder stud bott (X-mark) and clutch cover, generator. | 3-70 Front ‘¢Mating surface of upper and | 3-64 lower erankcase. SUZUKI BOND NO. 12078 | @Mating surface of cylinder head | 3-81 99104-31140 and cylinder head cover ‘*Cam chain guide bolt 343 ‘*Cam chain guide screw 343 ‘Gearshift shaft stopper THREAD LOCK SUPER 19614" 99104-320201.17 GENERAL INFORMATION MATERIAL aR [race vant ‘(PAGE caine andre eer | a Scam rocker bot 299 Ssururmotorseiirabot | 386 Soi pump ca sen a7 THREAD Lock SUPER "1363" | 210432090 Scabuctroateantcew | 419 Seaburn stenerhattock | 419 Toot va ro +m ‘Front force rosbae—| 723 Sern td bat Soi tere na ne Stminesroctetspscr | 388 uneao Lock cenent | “iersurae 2200032040 Geoertoraworseiingscew | 358 | Ene ol amp ferssew | 988 Scenetor ator ind nese 356_ | oO alr ple srw 260 Seas com oper ot Scamutor trate nop pte | 15 Sserarmetoreiinaboit | 619. stow Soinesat oitescew | $60 |eStrermotrhowingbolt | 686 Scoumertat Berane ow | 367 Snore ollpimpsetcew | 367 Scemmittcampootcen | 302 THREAD LOCK "amc" | Seni pide sw | 382 ooros eso tNodsitorsave wt tai | 76 Generator orb 26s THREAD Lock SUPER "a2ae" 991082090SPECIFICATIONS GENERAL INFORMATION 1-18 DIMENSIONS AND DRY MASS Overall length . Overall width Overall height Wheelbase........ Ground clearance ........ Dry mass (weight) .... 022-022-005 ENGINE Type... Number of cylinders Bore .. Stroke Piston displacement Compression rati Carburetor Air cleaner Starter system Lubrication system . TRANSMISSION Clutch 2... Transmission. Gearshift pattern Primary reduction ..... Final reduction .... Gear ratios, Low ... and... Drive chain 3rd 4th Top . Links oo... - 2.200 mm (86.6 in) 760 mm (29.9 in) 1190 mm (46: - 1495 mm (58.9 in) 140 mm ( 5.5 in) 213 kg (469 Ibs) ......... GS750E 214 kg (471 Ibs) GS750ES «+ Four-stroke, air-cooled, DOHC v4 =. 67.0 mm (2.638 in) - 53,0 mm (2,087 in) = 747 om? (45.6 cu.in) - 96:1 . MIKUNI BS32SS, four Polyurethane foam element Electric . Wet sump - Wet multi-plate type 5:speed constant mesh » L-down, 4-up -++ 1,895 (91/48) = 3.071 (43/14) = 2,500 (35/14) = 1.750 (28/16) +++ 1,368 (26/19) +++ 1.130 (26/23) = 0.956 (22/23) ... DAIDO D.I,D, 50V or TAKASAGO RK50GO = 112 links119 GENERAL INFORMATION CHASSIS. Front suspension ........-. Rear suspension « Telescopic, pneumatic/coil spring oil damped, with ANTI-DIVE - Full-floating suspension system, damper 4-way adjustable, spring 5-way adjustable 37° (right & left) Steering angle Caster ...... . 62°10" Trai . . = 105 mm (4,49 in) Turning radius... + 28m (9.2 ft) Front brake . +++ Dise brake, twin Rear brake . Disc brake Front tire size «+» 100/90-16 54H Rear tire size . 120/90-17 64H Front fork stroke . = ++ 160 mm (5.91 in) Rear wheel travel . . 107 mm (4,21 in) «1.75 kg/cm? (25 psi) (Normal solo riding) 2.00 kg/cm? (28 psi) (Normal solo riding) Front tire pressure . . Rear tire pressure .. ELECTRICAL Ignition type ..-...-.60605 « Transistorized Ignition timing - 13° B.T.D.C. below 1 500 r/min and 35° B.T.D.C. above 2 350 r/min Spark plug . : +++. NGK D8EA or NIPPON DENSO X24ES-U Battery .. = 12V50.4kC (144h)/10HR Generator .. . Three-phase A.C. generator Fuse ..... = 10/10/10/10/154 CAPACITIES Fuel tank including reserve . 19.5 L (5.2 US gal) reserve . 4.0 L (1.1 US gal) Engine oil ..... : 3.2 L (3.4 US qt) Front fork oil (each leg) . .. - 307.6 ml (10.40 US oz) * These specification are subject to change without notice.PERIODIC MAINTENANCE AND eet) eg ; CONTENTS — —_____ e PERIODIC MAINTENANCE SCHEDULE --.--.----- Qe | MAINTENANCE AND TUNE-UP PROCEDURES21 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES PERIODIC MAINTENANCE SCHEDULE IMPORTANT: The periodic maintenance intervals and service requirements have been established in ac- cordance with EPA regulations. Following these instructions will ensure that the motorcycle will not exceed emission standards and it will also ensure the reliability and performance of the motorcycle. NOTE: More frequent servicing may be performed on motorcycles that are used under extreme severe condi- tions, however, it is not necessary for ensuring emission level compliance. The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and to maintain proper emission levels. Mileages are expressed in terms of kilometers, miles and time for your convenience. PERIODIC MAINTENANCE CHART INTERVAL: mil 00 | 4000 | 7600 | 11000 | 16000 THISINTERVAL SHOULD BEIUDGED Tym | 4000 | 6000 | 12000 | 18000 | 24000 MONTHS WHICHEVER COMES FIRST mon?) i Battery, - - 1 1 1 ad Cylinder head nuts and exhaust pipe bois T pot ptt 7 Air cleaner element = c c c c Vale cerance 1 1 1 1 Spark plug - - [ef e |e f Carburetor - - 1 1 1 1 Ful line — - Replace every four years. 1 Engine oil and oil filter - ch ch Ch cr | Gh Clutch 1 1 1 1 1 Drive chain ' ' ! C ' ‘lean ad brat every 1000 kn (60 miles) Brake pr Ls 1 1 i Brake hose - Replace every four years. | Brake uid Chane every two yar Tire - q To 1 1 “Steering stem 1 q 1 i | Front fork = = ! = ' Gheak air presur every 6 months [hos bots and nuts T]r [1 []t | 7 NOTE: T= Tighten, I = Inspect, R = Replace, C = Clean, Ch » ChangePERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2.2 MAINTENANCE AND TUNE-UP PROCEDURES This section describes the service procedures for each section of the Periodic Maintenance require- ments, BATTERY = ————— Inspect Every 6 000 km (4 000 mi) * Remove the right and left frame covers. * Remove the seat. © Check electrolyte for level and specific gravity. Add distilled water, as necessary to keep the surface of the electrolyte above the LOWER level line but not above the UPPER level line, * For checking specific gravity, use a hydrometer to determine the charged condition, | 09900-28403 Hydrometer Standard specific sravity | 1.28 at 20°C An S.G. reading of 1.22 (at 20°C) or under means the battery needs recharging. Remove the battery from the machine and charge it with a battery charger. | CAUTION: | Be careful not to bend, obstruct, or change | the routing of the air vent tube from the | battery. Make certain that the breather pipe is attached to the battery vent fitting and that L the opposite end is always open. CAUTION: Never charge a battery while still in the machine as damage may result to the battery or regulator rectifier. ‘* Check that the breather pipe is tightly secured and undamaged, and is routed as shown, a \2.3 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES AIR CLEANER Clean Every 6 000 km (4 000 mi) © Open the seat and remove the air cleaner case cover complete with element frame by loosening two screws. ¢ Remove the polyurethane foam element from the element frame, WASHING THE ELEMENT Wash the element a follows: «Fill 2 washing pan of a proper size with non flammable cleaning solvent. Immerse the ele- ment in the solvent and wash it clean ‘© Squeeze the solvent off the washed element by pressing it between the palms of both hands: Do not twist and wring the element, or it will tear. @ Immerse the element in a pool of lightweight motor oil, and squeeze the oil off the element to make it slightly wet with the oi. [ caurior | Before and during the cleaning operation, | | carefully examine the element for any tears in ‘the material. A torn element must be replaced with a new one. CAUTIO! If driving under dusty conditions, the air cleaner element must be cleaned more frequently. NEVER OPERATE THE | ENGINE WITHOUT THE ELEMENT IN POSITION. Operating the engine without the air cleaner element will increase engine wear. Always be sure that the air cleaner element is. in excellent operational condition at all times. The life of the engine depends largely on this single component. Reinstall the cleaned element in reverse order of removal and carry out the following steps. Be absorutely sure that the element is securely in posi- tion. © Install the element fame into the air cleaner case groove.VALVE CLEARANCE The valve clearance specification is the same for Inspect Initial 1 000 km (600 mi) and - Every 6 000 km (4.000 mi) both intake and exhaust valves. Valve clearance adjustment must be checked and adjusted 1) at the time of periodic inspection, 2) when the valve mechanism is serviced, and 3) when the camshafts are disturbed by removing them for servicing, lve clearance ES (when cold) 0.09-0.13 mm. (0.004—0,008 in) ‘¢ Remove the fairing covers. ‘* Remove the fairing retaining screws and take off, the fairing ¢ Disconnect the headlight and turn signal lead wires. ‘¢ Remove the ignition coil and coil cap. © Loosen and remove the fairing mounting bolts, and then take off the fairing bracket. ‘* Remove the fuel tank. © Remove the breather pipe from the cylinder head cover cap. ‘¢ Remove the cylinder head cover. NoTt * The cam must be at position @) or @ in © Turn the crankshaft to bring the “T’” mark on the signal generator to timing mark on the Nos. 1 and 4 pick up coil and also bring the notches @® in the both camshaft (EX and IN) of the right ends to the position as shown. In this condition, read the valve clearance at the valves order to check the valve clearance or to ad just valve clearance. Clearance readings should not be taken with the cam in any other position than this @) position, The clearance specification is for COLD state, To turn the crankshaft for clearance check- ing, be sure to use a 19-mm wrench and to rotate in normal running derection. All spark plugs should be removed. PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2.4 © (IN and EX of No. 1 cylinder, EX of No, 2 and IN of No. 3).25 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES ‘© Use thickness gauge between rocker arm and valve. If clearance is off the specification, bring it into the specified range by using the tappet adjusting driver @ 09900-20803 | Thickness gauge (09917-14910 | Tappet adjust driver ‘© Rotate the crankshaft in the clockwise direction 360° and realign the “T 1.4” mark. In this posi tion the notches in the right ends of the cam- shafts should be facing towards each other. The valves © can be checked and adjusted if neces- sary. —_Noteh © position Cam Exhaust Position Camshaft__| Camshaft e © G ® GS © NOTE: The cylinder head cover gasket should be replaced with new one whenever valve adjust- ment is performed. A thin film of SUZUKI Bond No. 1207B on cylinder head cover groove and gasket will ensure an oil tight seal, The O-ring, utilized under the ten special cap bolts that help ensure an oil leakage, should also be replaced with new one at this time.PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2.6 SPARK PLUG __ Clean and Adjust Every 6 000 km (4 000 mi), Replace Every 12.000 km (7 500 mi) The plug gap is adjusted to 0.6 — 0.7 mm (0.024 — 0.028 in). The gap is correctly adjusted using a thickness gauge (special tool). When carbon is, deposited on the spark plug, remove the carbon, with @ spark plug cleaning machine. If electrodes are extremely worn or burnt, replace the plug. Also replace the plug if it has a broken insulator, damaged thread, etc. [09930-13210 | Socket wrench (09930-14530 Universal joint 09914-24510 Thandie | 09900-20803 | Thickness gauge NGK D8EA or NIPPON DENSO X24ES-U listed in the table should be used as the standard plug. However, the heat range of the plug should be selected to meet the requirements of speed, actual load, fuel, etc. If the plugs need to be replaced, it is recommended that ones having a heat range closest to the standard plug in the table be selected. Remove the plugs and inspect the insulators. Proper heat range would be indicated if all insulators were light brown in color. If they are blackened by carbon, they should be replaced by a hot type NGK D7EA or NIPPON DENSO X22ES-U and if backed white, by NGK D9EA or NIPPON DENSO X27ES-U. Plugs with high heat range number are used for high speed running. These plugs are designed to be sufficiently cooled to prevent overheating and are called cold type plugs. NOTE OY To check the spark plugs, keep the engine running on unleaded gasoline, and after test tide if the plugs are either sooty with carbon or burnt white, replace them altogether ep gett CAUTION Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the screw portion of the plug hole and the engine will be damaged. ‘NIPPON | NcK | Denso REMARKS If the standard plug is apt to get D7EA | x226S-U | wet, replace with this plug, Hot type. DaEA |X24ES-U | Standard If the standard plug is apt to D9EA | X27ES-U | overheat, replace with this plug Cold type.27 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES CARBURETOR Inspect Initial 1 000 km (600 mi) and Every 6 000 km (4 000 mi) IDLING ADJUSTMENT NOTE: Make this adjustment when the engine is hot. © Set idle rpm at anywhere between 1 100 and 1200 r/min by turning throttle stop screw THROTTLE CABLE PLAY There should be 0.5 —1.0 mm (0.02 — 0.04 in) play @ on the throttle cable. To adjust the throt- tle cable play: Loosen the lock nut @ and turn the adjuster @ fully in on the lock nut side, © Tug on the throttle cable to check the amount of play. @ Loosen the lock nut and turn the adjuster ® in or out until the specified play is obtained, FUEL LINE Replace every four years ENGINE OIL AND OIL FILTER Change Initial 1000 km (600 mi) and Every 6 000 km (4 000 mi) ENGINE OIL The oil should be changed while the engine is hot. ‘* Keep the motorcycle upright, supported on the center stand. Place an oil pan below the engine and drain the oil by removing drain plug @ and filler cap @PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 28 © Fit drain plug @ securely, and add fresh oil through the filler. The engine will hold about 3.2L (3.4 US at) of oil. Use API classification of SF or SE oil with SAE 10W/40 viscosity. © Start up the engine and allow it to run for several seconds at idling speed. '* Turn off the engine and wait about one minute, then check the oil level through the inspection window ® . If the level is below mark “F”, supply oil to that level. ENGINE OIL FILTER Oil filter replacement at the above intervals should be done together engine oil change. After draining engine oil and securely tightening the engine oil drain plug, perform the following: Remove three nuts @ and remove the cover and drain oil, ‘© Pull out old filter @) , and replace with new one, '® Replace O-ring and filter cover, and secure nuts @® with applying thread lock cement. 99000-32040 Thread lock cement NECESSARY AMOUNT OF ENGINE OIL [_ Oil change NOTE: Be sure to take care of O-ring © to prevent any damage. CLUTCH Inspect Initial 1000 km (600 mi) and Every 6 000 km (4 000 mi) @ Loosen lock nut on the lever side of the clutch cable and screw adjust nut @ fully in on the clutch lever side. |PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES * Loosen the lock nut @) and adjust the clutch play by turning the adjuster @ in or out to acquire the specified play 4 mm (0.16 in) © Tighten the lock nut while holding the adjuster in position. © Temporarily loosen the lock nut @) and tighten the release adjusting screw ® until resistance is, felt, then loosen it 1/4 — 1/2 turn, © Secure the lock nut DRIVE CHAIN Inspect Initial 1000 km (600 mi) and | Every 6 000 km (4.000 mi) |__Slean and Lubricate Every 1.000 km (600 mi) | Visually check the drive chain for the below-listed possible malconditions. (Set up the machine on its center stand, and turn the rear wheel slowly by hand with the transmission shifted to Neutral.) Loose pins Damaged rollers Dry or rusted links * Kinked or binding links Excessive wear Improper chain adjustment * Missing O-rings If any defects are found, the drive chain must be replacedPERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-10 CHECKING — ‘* Remove the axle cap by unscrewing the two screws. | 123 192021 © Loosen axle nut @ after pulling out cotter pin Ree TE Eee A * Loosen chain adjuster support bolt @ ‘ Tense the drive chain fully by tightening the adjusters @ . * Remove the chain case. Count out 21 pins (20 pitch) on the chain and measure the distance between the two. If the distance exceeds follow- ing limit, the chain must be replaced. [ Service Limit [319mm (126 in) ADJUSTING * Loosen the adjuster @ until the chain has 30 — 40mm (1,.2—1.6 in) of sag at the middle between engine and rear sprockets. The mark on both chain adjusters must be at the same position on the scale to ensure that the front and rear wheels are correctly aligned. Place on center stand for accurate adjustment. Standard 30 — 40 mm (1.2 — 1.6 in) | l J ‘© After adjusting the drive chain, tighten the axle nut @ securely, and lock with cotter pin @ Always use a new cotter pin, © Tighten the chain adjuster support bolts and adjuster lock nuts good and hard, Rear axle nut 8.5 —11.5 kgm | tightening torque | (61.5 — 83.0 lb-ft) CLEANING AND LUBRICATING Wash the chain with kerosene. If the chain tends to rust faster, the intervals must be shortened.2-11 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES CAUTION | | ] Do not use trichlene, gasoline or any similar fluids. These fluids have too great a dissolving | | power for this chain and, what is more important, can spoil the “O” rings confining the grease in the bush-to-pin clearance. Remember, high durability comes from the presence of grease in that clearance. Grease “O" ring \ After washing and drying the chain, oil it with @ heavy.weight motor oi [ caution: Do not use any oil sold commercially as “drive chain oil”. Such oil too can spoil the “O" rings. | caution: The standard drive chain is DAIDO D.1.D.50V or TAKASAGO RK50GO. SUZUKI recom: mends that the above-mentioned standard drive chain be used for the replacement. BRAKES Inspect Initial 1000 km (600 mi) and Every 6 000 km (4.000 mi Replace hose Every four years Change fluid Every two years BRAKE FLUID LEVEL a © Support the motoreycle body on the center stand and place the handlebars straight. ‘* Remove the right frame cover. © Check the brake fluid level by observing the upper and lower limit lines on the brake fluid reservoirs, both front and rear. ‘* When the level is below the lower limit line, replenish with brake fluid that meets the follow- ing specification. Specification 7 eae pors,ors |PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-12 CAUTION The brake system of this motorcycle is filled with a glycol-based 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. | WARNING: Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces. Check | the brake hose for cracks and hose joint for | leakage before riding us BRAKE PADS Wearing condition of brake pads can be checked by observing the red limit line @ marked on the each pad. When the wear exceeds the limit line, replace the pads with new ones. (see page 7-25) BRAKE PEDAL HEIGHT © Loosen lock nut (, and turn stopper bolt @ away from the stopper. '* Loosen lock nut @), and rotate push rod @ to locate brake pedal 40 mm (1.6 in) below the top face of the footrest, ‘© Turn the stopper bolt @ in so that the clearance between the stopper bolt and stopper is zero. # Retighten both lock nuts @ and @ . 40mm Brake pedal height | (16 in)2.13 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES: BRAKE LIGHT SWITCHES Adjust both brake light switches, front and rear, so that brake light will come on just before a pressure is felt when the brake lever is squeezed, or the brake pedal is depressed. 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. 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 bleeder valve, and insert the free end of the pipe into a receptacle, Bleeder valve | S(0.6 0.9 kgm | Satening torque | (4.5 6.5 lb-ft) * Bleed the air as following order. Always start with the left side. D Left anti-dive —> ® Left caliper —> @® Right anti-dive —> @ Right caliper ‘* 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 or 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. hPERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-14 It is common for air to become “trapped” in the extra hoses or valves of the anti-dive system. Repeating the sequence of brake bleeding will remove most of this air. If the lever feel is still spongy after several bleeding sequences it may be necessary to remove the anti-dive modulator from the anti-dive assembly. This will allow the modu- lator from the anti-dive assembly. This will allow the modulator to be “tipped” upwards, enabling the trapped air to be purged from the system. | CAUTION Be certain to retorque the modulator mount- ing screws after remounting onto the anti- dive assembly body. Thread lock cement (99000-32040) should be used when rein- stalling the bolts. (Refer to page 7-16) NOTE: Replenish the brake fluid reservoir as neces- sary 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. | caution: | Handle the brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials, ete. © Differences between front and rear are that the master cylinder is actuated by a pedal. CYLINDER HEAD NUTS AND EXHAUST PIPE BOLTS Tighten initial 1 000 km (600 mile) and every | 6 000 km (4 000 mile) _| TIGHTENING TORQUE _ kgm loft Cylinder head nut 35-40 | 255-290 Cylinder head bolt os-12 | 60-85 | Exhaust pipe bolt 10-16 | 70-115 Mutter mounting bolt | 22-35 | 160-255 |2.15 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES TIRES Inspect Initial 1000 km (600 mi) and Every 6 000 km (4.000 mi) TIRE TREAD CONDITION Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recom- mended to replace the tire when the remaining depth of tire tread reaches the following specifica- tions. FRONT REAR | 1.6 mm (0.06 in) 2.0 mm (0.08 in) eee TIRE PRESSURE orl If the tire pressure is too high or too low, steering \ lj ill be adversely affected and tire wear increased. Therefore, maintain the correct tire pressure for ‘good roadability or shorter tire life will result. Cold | inflation tire pressure is as follows. [—_ Normal riding Solo Dual kg/em? psi kg/em? psi kg/em? psi kg/em? | psi [FRONT | 200 | 28 225 | 32 200 | 28 200 | 2 | REAR | 2.50 3 | 280 | 40 225 | 32 280 | 40 | The standard tire fitted on this motorcycle is 100/90-16 54H for front and 120/90-17 64H for rear. The use of a tire other than the standard may cause instability. It is highly recommended to use a SUZUKI Genuine Tire.PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-16, STEERING STEM Inspect Initial 1 000 km (600 mi) and Every 6 000 km (4.000 | Taper roller type bearing are applied on the steer- ing system for better handling. Steering should be adjusted properly for smooth manipulation of handlebars and safe running. Too stiff steering prevents smooth manipulation of handlebars and too loose steering will cause poor stability, Check that there is no play in the front fork as- sembly by supporting the machine so that the front wheel is off the ground, with wheel straight ahead, grasp lower fork tubes near the axle and pull forward. If play is found, perform steering bearing adjustment as described in page 7-31 of this manual. FRONT FORK Inspect Every 12 000 km (7 500 miles) Check air pressure Every 6 months FRONT FORK OIL, © Place a jack under the engine and lift the front Wheel off the floor and remove the front wheel. ¢ Remove the front fender. Remove front fork top caps @ , both right and left. ‘© Unscrew front fork oil drain bolts @ , right and left, and drain oil in the fork tube completely by moving the front fork outer tube up and down, © Loosen the lower clamp bolts and remove the front fork assembly. (See page 7-8) Mount the drain screw and washer onto the ‘ ‘outer tube and pour specified amount of oii the top of the inner tube. 202:17 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES Specified amount | {oooh log) 308 ml (10.4 US oz) Fork oi specification TIGHTENING TORQUE item [kom [tte Handlebar clamp bolt | 15-20 | 110-145 [Handlebar mounting bolt | 25-35 | 180-255 | Upper clamp bolt [is-20 | 10-145 | Fork top cap_ 25-30 180-215 | Steering stem head bolt | 2.0—3.0 145-215 | Steering stem clamp bolt |1.5-25 | 110-180 | FRONT FORK AIR PRESSURE Check the front fork air pressure, when the fork is cold. ‘* Place the motorcycle on the center stand and keep the front wheel off the ground. ‘* Measure the air pressure by placing the pressure gauge on the valve as shown. r 1 | 09940-44120 | ‘Air pressure gauge | | a Standard air pressure | 0.2 kglem (2.84 psi) | © If necessary, use a hand air pump to raise the front air pressure, (See page 7-18) CAUTION: Do not exceed 2.5kg/em* (35 psi) when | note: | Just before charging air confirm that the valve is tight. Inspect the front fork for oil leakage, scoring and scratches on the outer surface of the inner tube —~ and replace the defective parts, if necessary. — Air prossure gauge @ Hand air pumpPERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-18, CHASSIS BOLTS AND NUTS lh. - “| Inspect Initial 1000 km ( 600 mi) and Every 6 000 km (4 000 mi) The bolts and nuts listed hereunder are important safety parts. They must be retightened, as neces- sary, to the specified torque with a torque wrench. Refer to the photograph for position of the follow- ing bolts and nuts. LC [kom | 36-52 | 60-975 ) Front axle holder nut | 1.8 2.6 11.0 @® Disc plate bolt 15- 25 | 11.0-18.0 @ Frorteinermounig 25 49 | 20-780 5) Caliper axle bolt 25-35 (180-255 1 Front fork lower Front fork 18-25 110-180 | Front fork upper [Fron fo 20- 30 | 145-215 @ Duwrnestenon> 5 25 a -400 |® bor | [iq Steprnastom head 29 30 145-215 |@ |Handlebar clamp bolt 14.5 -21.5 @ Brake hose union bolt | 20- 25 | 14.5— 180 | | i0o]| [Master evlinder clamp | pg ~ o Ms oss os | 28 on ® [Brake pedal arm bolt 06-07 | 45- 5.0 ‘Swing arm pivot bolt ig [Swing oo [Sirsa 50-80 | 360-580 @ [Torque tink nut 20- 30 [as —218 [a ew ac rat 50-80 [360-580 | } Modulator planger bolt | 0.3— 0.5 | 20- 35 | {B Modulator valve bolt [Ge [Rear caliper bolt | [Rew eshion verbo y06- 09 | 45- 65 20-30 45-218 0-100 /605-726 | | | |g [Rese cushion rod upper | © leer iner bole 18- 28 | 130-200 a [Reet master evlinder eo lwo” |mounting bole eee cet e a |Rearshock | Lower | 40- 60 |200-435 | |= absorber unit | : fitting Unper [48-72 [345-520 Handlebar holder moun {ting bolts 25- 35 |180-25.52.19 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURESCONTENTS | COMPRESSION CHECK .. ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE::- ENGINE REMOVAL AND REINSTALLATION | ENGINE DISASSEMBLY- ENGINE COMPONENTS INSPECTION AND SERVICING: - | ENGINE REASSEMBLY -341_ SERVICING ENGINE COMPRESSION CHECK COMPRESSION Standard | Limit 9-13 kg/cm? | 7 kg/em? (1280-186. psi) | (99.5 psi | 2 kg/cm? (28.4 psi) | Difference = Low compression can indicate any of the following malconditions: * Excessively worn cylinder wall * Worn-down piston or piston rings * Piston rings stuck in the grooves * Poor sealing of valves * Leaking or otherwise defective cylinder head gasket Overhaul the engine in the following cases: * Compression pressure in any one of cylinders is less than 7 kg/cm? * Difference in compression pressure between the two, highest and lowest, is more than 2 kg/em® * All compression pressures are below 9 kg/cm? (standard) even when they measure more than 7 kg/emn? COMPRESSION TEST PROCEDURE * Before testing the compression of the engine, make sure that the cylinder head nuts and bolts are torqued to the specified torque value. * Warm up the engine before testing. ‘* Remove the fairing cover. © Unscrew the fairing retaining screws and take off the fairing, '* Loosen and remove the fairing bracket mounting bolts, and then take off the fairing bracket. * Remove the seat and frame covers (left and right). Remove fuel tank. Remove all spark plugs. Ground all plug leads. [09930-13210 09930-14530 0991424510 | Socket wrench Universal joint _Thandle ‘* Fit the compression gauge ‘to one of the plug holes, taking care that the connection is absolutely tight. Compression gauge 09915-64510 09915-63210 Compression adapter ‘Twist the throttle grip into full-open position. ‘© Crank the engine a few seconds with the starter, and read the maximum gauge reading as the compression of that cylinder. procedure with the other eylinders. Repeat this32 SERVICING ENGINE ENGINE COMPONENTS REMOVAL WITH ENGINE IN PLACE ove ove ove ee ere” ae ee ee ae oe aBed 29S, 4296 anlip wee pue med BuNytys 129) a yeys Buny1ys 1295) Asse duind [19 4296 Uanlip Aieuilig 496 antup duund [19 saie|d uantip, pue anuip ‘aunssaud young “7 Bun4eag aseajas young Jeno yoni 40,e18U06 eUbIS *yan09 s0yes9U86 [eUBIS soverauaé jeubs adls LHOIY 3NIDNA suon9as snoinaid ayp BulMo}|04 ‘s0y41NqUeO 0} pus dor wos} siUa\UCD |eUO!Re1ado aquiOsap suo!IoeS BuIMo ‘apls Aejas JojOW Gunes ay Wo1y panowas aq Pinoys ‘u1M pea} JOLOW 491815 UE s9n09 JOVeI2UaD © ee uaaeaaaee *** 49]009 110 le vores Joyous saueig pecs : ro oe ce CS + peay sapurjAd, ite cies eee bee * Janoo peay s9pullAd vee sess 8+ yauoisuay ujeys wed Le ooo saU29}9 a1 Le sa1qeo ax}ous pue aproiyL Le verre goyainqueg et aiqeo youn), bees Jeho9 saujeasq peay 1epuI|AD eee ve gay dung eee a ued 110 azo ++ youms aunssaid 10 Lee 7 sa 0 ekemua Jaqyjnuu pue rsneyxg afed 20g ¥31N39 3NIONA we 1896 3p! younjo sase1s wen aa yoanja 1921S ages “+ goneis s01e10u85 2c an 40101 10181U@5 wwe B08 49R09 s01e18Ua 1Z-€°""* Apoq youms soyeo1pu! uon|sod 4eD) 6 ‘jeyo anuup pue yaxoo1ds au6u3 Che maaaooal sano i9x001ds au16Ug ee Heres gana ius 1295 abed aag Adis 1437 3NION3 ‘suonesado s1a43 01 1adse4 ym saGed aouasajay 99g, ‘a1ay paguiosap ase aulBue ain BUNUNOWSIP InoYLIM pandWA: aq VED YOIYM sLIed “|eAOWIas aUIBUE YRIM Buljeop 4 SUL “eulBua ayy BunuNoWsIp Noy panowal aq AEW ey Sieg &33 SERVICING ENGINE ENGINE REMOVAL AND REINSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, wash the engine with a steam cleaner and drain engine oil. The procedure of engine removal is sequential- ly explained in the following steps, and engine installation is effected by reversing the removal procedure. © Place an oil pan under the engine and drain oil by removing oil drain plug, ‘¢ Remove the right and left frame cover. ‘* Remove the seat. cable, © Disconnect the battery @ ani ¢ Remove the battery, © Take off the tool case and battery holder.SERVICING ENGINE 3.4 * Loosen the fuel tank mounting bolts. © Disconnect the fuel gauge lead. ‘* Turn the fuel cock to “ON” or RES" positions. © Disconnect fuel hose and vacuum hose, ‘© Remove the fuel tank, © Take off the fairing cover (right and left) 435 SERVICING ENGINE © Remove the fairing mounting screws. © Take off the harness clamp. ‘* Loosen the fairing bracket mounting bolts, © Take off the fairing bracket,SERVICING ENGINE 36 NOTE: |_ Do not forget the spacer. © Disconnect the gear position lead wire, signal generator lead wire and generator lead wire. © Disconnect the starter lead wire (to starter motor). © Disconnect the © lead wire.3-7 SERVICING ENGINE ‘© Disconnect the breather pipe. © Loosen the carburetor clamp screws. ® Loosen and remove the air cleaner mounting serews. ‘¢ Remove the air cleaner mounting bracket. © Take off the carburetors, © Loosen the lock nuts and take off the throttle cable, ‘* Remove the choke cable.SERVICING ENGINE 38 © Loosen and remove the exhaust pipe clamp. bolts. © Remove the oil cooler joint hoses,3.9 SERVICING ENGINE © Remove the gearshift lever and engine sprocket cover. Flatten the lock washer. ‘* Loosen the engine sprocket nut by applying the rear brake. ‘© Remove the axle cap. ‘* Remove the cotter pin and loosen the axle nut. © Loosen the lock nut and adjuster. ‘® Remove the rear brake,‘© Remove the engine mounting bolts, © Gradually lift up the engine and lower the engine ass'y on the right side making sure that it does not make contact with the rear bracket, SERVICING ENGINE 3:103-11 SERVICING ENGINE ENGINE REINSTALLATION Reinstall the engine in the reverse order of engine removal. * After inserting the engine mounting bolts, tighten engine mounting bracket bolts and engine mounting bolts. Insert all three long bolts from the left side, and insert the rear upper bolt through the spacers (Right side: 50 mm, Left side: 45 mm). _ NoTI The engine mounting nuts are self-lock nuts. Once the nut has been removed, itis no longer of any use, Be ure to use new nuts and tighten them to the specified torque. Tightening torque enath [kom BR [7] 35mm | 0-60 | 360-435 2| tim | 60-72 | 435-620 3 205mm | 6.78.0 48.5 oO [4] 265mm 85-66 | 400-475 © The nut ( takes its position in the place indica- ted. ‘ The engine sprocket should be installed on the drive shaft beforehand as shown in the figure at the same time of the installation of drive chain. If it is difficult to assemble the engine sprocket, remove the rear axle cotter pin, loosen the axle ut, torque link mounting nut, and chain adjuster bolt to push the wheel forward, and give the drive chain some play. When replacing the engine sprocket nut, stepped side should be faced inside. After completing tightening of the engine mounting bolts, adjust free play of the drive chain. (see page 2-10). Tightening torque Engi t rut Rear axle nutCilcooler side | 15-18 11.0-13.0 Crankease side 25-30 180-215 f NOTE: - Be sure to install the washers on both side of hose union. © Securely tighten bolts) connecting exhausts and muffler of No, 2 and 3 to prevent gas leak- age. Tightening [ 0.9—1.4kg-m torque (6.5 — 10.0 Ib-ft) © Install exhaust pipe gasket (), and tighten ex- haust pipe bolts. © Mount mufflers and gearshift lever, and tighten bolts with specified torque, Tightening torque [ree be Muffler mounting | -: Mute mo 22-38 160-255 Exhane pe toe | 70-118 eer : ‘¢ Replace the plug caps on the spark plugs so that their code markings correspond to the cylinder numbers arranged in the order of 1, 2, 3 and 4 from the left, SEAVICING ENGINE 3:123:13 SERVICING ENGINE '* Connect the fuel hose correctly. Install 3.8 L (4.0 US qt} of engine oil SAE 10W/ 40 under API classification SF or SE into the engine, Several minutes after starting and stopping the engine, check that the oil level remains between the marks of oil level window, © After remounting the engine, route wiring harness and cables properly by referring to the sections, wire routing and cable routing, and adjust the following items to the specification. Page * Rear brake pedal. 212 * Brake light switch . 2243 * Clutch cable 28 + Throttle cable. 27 * Drive chain play . 212 * Balancing carburetor ...............412 * Idling adjustment... 27SEAVICING ENGINE 3-14 ENGINE DISASSEMBLY ¢ Loosen the oil hose union bolts, and the remove the oil hose. © Remove cylinder head cover. * This is accomplished by first loosen lock nut @ and tightening screw @ and then removing ‘two mounting bolts (3) of cam chain tensioner. NOTE: Tightening screw @) prevents an inside spring ‘¢ Remove the oil pipe,3-15 SERVICING ENGINE ‘® Remove the signal generator cover. © Turn the crankshaft to align the “T"’ mark on the signal generator with timing mark of No. 1 and No. 4 pick up coil. ‘* Remove the two camshafts, intake and exhaust. NOTE: _ ] * Be sure to loosen camshaft holder bolts evenly by shifting the wrench diagonally. * Hold down each camshaft with vice pliers @ , and remove the bolts securing the camshaft holders, four on each camshaft. Then, remove the pliers and take off the camshaft.SERVICING ENGINE 316 ‘* The cylinder head becomes free for removal when its 6-mm bolt @ and twelve 10-mm nuts are removed, | 09911-74510 ‘Long socket 14 mm ] 09914-24510 T handle L NoTt Be sure to use the special tool (“’T”” wrench) designed to enter the pockets formed in the | head and reach the nuts down below to loosen the 10-mm nuts, and to shift the tool sequentially in the nuts descending order of numbers in order to reduce the pressure |_ equally and eventy. ‘© Mark the piston number on the piston, ‘© Firmly grip the oylinder block at both ends, and lift it straight up. If the block does not come off, lightly tap on the finless portions of the block with a plastic mallet to shake the gasketed joint loose. | note Cylinder removal from crankcase is made easier by the use of the cylinder disassembling tool. This tool can be used on the cylinder head and crankcase, to0. | 09912-34510 | Cylinder disassembling tool3417 SERVICING ENGINE Place a cloth beneath the piston so as not to drop the parts in the crankcase, and remove the circlip with pliers. ‘© Draw out the piston pin with the special tool (.) Place the drawn-out piston pin in the same place as that given the cylinder No. on the head of the piston, 09910-34510 09910-33210 Piston pin puller Attachment ‘© Remove the filter cap by loosening the three nuts. © Take off the filter.SERVICING ENGINE 318 '* Remove the signal generator by using 19-mm off set wrench and the special tool. 09914: ase | T-type hexagon wrench. © Unclamp the signal generator rotor lead wire, ‘* Remove the signal generator assembly by re- moving the screws. Remove the oil pressure switch,3419 SERVICING ENGINE © Remove clutch cover and gasket. © Using special tool, remove the clutch spring mounting bolts in a criss cross manner. Remove the spring, pressure plate, push piece, thrust bearing, drive plate and driven plate. | 09910-20116 | Conrod holder ‘© Flatten clutch sleeve hub nut lock washer, and firmly secure clutch sleeve hub to remove mounting nut with clutch sleeve hub holder @ .. [_ovs2053710 Clutch sleeve hub holder | Remove clutch sleeve hub and retaining washer. © Push the spacer and bearing backward, and then remove the clutch housing with oil pump drive gear.SERVICING ENGINE 320 ‘© Separate the clutch housing and oil pump drive gear, ‘® Remove the spacer, bearing and thrust washer. ‘* Remove the gearshift shaft by removing the cir- clip and washer. Using the special tool, remove oil pump driven gear and its drive pin, Then remove oil pump with O-ring — ee 09900-06107 Snap ring pliers3:21 SERVICING ENGINE ‘© Remove the counter shaft bearing retainer by removing the retaining screws. © After flattening the lock plate, loosen and remove the bolts. ‘© Remove the oil seal retainer plate. ‘* Remove the gear position switch, contact point and spring. ‘© Remove the starter motor cover. ® Remove the starter motor by loosening the ‘mounting bolts.SERVICING ENGINE ¢ Remove generator cover and gasket. ‘© Extract starter motor idle gear shaft D and remove washer and idle gear. © Using rotor holder @, remove rotor securing bolt. © Install rotor remover attachment @ and sliding hammer assembly @ into the boss of rotor and remove rotor with starter clutch assembly while sliding the remover. NOTE: Do not hit the rotor with a hammer. (09930-30102 Rotor remover shaft 09930-30180 Attachment E 3:223.23 SERVICING ENGINE ‘* Remove crankcase securing nut @ . © Remove crankcase securing bolts from upper crankcase. ‘Remove the oil temperature lead wire, © Turn engine up side down and remove oil pan. ‘¢ Remove the O-ring and oil sump filter.SERVICING ENGINE 324 © Remove the oil strainer protector by loosening the mounting bolts. © Take off the O-ring. ‘* Remove the neutral cam stopper. ‘* Make sure that all bolts are removed without fail. Loosen in a criss-cross manner. Hammer lightly the lower crankcase side with a plastic hammer to separate the upper and lower crank- o case halves and then lift the latter. f NOTE: Two allen bolts are used for securing crank- |_ ease at the portion @. | [09914-25811 | “T” type hexagon wrench {09912-34510 | Cylinder disassembling tool |3:25 SERVICING ENGINE © Remove the counter shaft and drive shaft. NOTE: Be careful not to drop two ““C” rings and the like. ‘* Remove the crankshaft. ‘© Pull out the chain guide and two dampers. ‘* Remove the cam stopper spring.SERVICING ENGINE 3.26 * Remove gearshift cam guide and gearshift paw! screws @ ‘¢ Remove the cam driven gear. NOTE: : When removing the cam driven gear, do not loose the gear shifting pawl, pin, and spring. * Hold gear shifting forks by hand and extract the gear shifting fork shafts from the lower crankcase, ¢ Remove the gearshift cam circlip. © Slid the gearshift cam. ‘¢ Remove the washer, spacer, cam stopper retainer, and washer. © Extract gearshift cam from the right side,3.27 SERVICING ENGINE ENGINE COMPORNENTS INSPECTION AND SERVICING CYLINDER HEAD rT © After removing the rocker arm shaft stop bolt, pull the rocker arm shaft by using the 6 mm bolt. © Using valve lifter and its attachment, compress the valve springs. [09916-14510 | Valve liter (09916-14910 | Valve lifter attachment ‘© Take off the two cotter halves (@ from the valve stem, using tweezer, 09916-84510 Tweezer @ Take out the valve spring retainer and spring, ‘© From the other side, pull out the valve,SERVICING ENGINE 3.28 ‘© Remove oil seal by using long-nose pliers. © Take out the lower spring seat. ‘¢ Remove valve guid | 99916-44910 Valve guide remover CYLINDER HEAD DISTORTION © Decarbonize the combustion chambers. © Check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading at several places indicated. If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder head. 09900-20803 Thickness gauge Service Limit | 0.2 mm (0.008 in)3:29 SERVICING ENGINE VALVE FACE WEAR ‘* Visually inspect each valve for wear of its seating face. Replace any valve with an abnormally worn face. ‘¢ The thickness ‘P decreases as the wear of the face advances. Measure the thickness and, if the thickness is found to have been reduced to the limit, replace it. [Service Limit 0.5 mm (0.02 in) VALVE STEM RUNOUT ‘© Support the valve with “V"" blocks, as shown, and check its runout with a dial gauge. The valve must be replaced if the runout exceeds the limit Service Limit VALVE HEAD RADIAL RUNOUT © Place the dial gauge at right angles to the valve head face, and measure the valve head radial runout. If it measures more than limit, replace the valve. [Service Limit l 0.03 mm (0.001 in) VALVE GUIDE-VALVE STEM CLEARANCE Measure the clearance in two directions, “X"" and “Y", perpendicular to each other, by positioning the dial gauge as shown, If the clearance measured exceeds the limit, (see below) then determine whether the valve or the guide should be replaced to reduce the clearance to the standard range: [Service Limit Intake valves : 0.35 mm (0.0138 in) [Exhaust valves | 0.35 mm (0.0138 in) |SERVICING ENGINE VALVE STEM WEAR If the valve stem is worn down to the limit, as measured with a micrometer, where the clearance is found to be in excess of the limit indicated, replace the valve; if the stem is within the limi then replace the guide. After replacing valve or guide, be sure to recheck the clearance, 09900-20205 | Micrometer (0 — 25 mm) 2mm’ Valve | Standard | 5.460 — 6.475 mm (0.2160 ~ 0.2156 in) 5.445 — 5.460 mm (0.2144 ~ 0.2150 in) | Intake valves | Exhaust valves VALVE GUIDE SERVICING ‘* Using valve guide remover ( , drive the valve guide out toward intake or exhaust port side. 09916-44910 Valve guide remover NOTE: a * Discard the removed valve guide sub- assemblies, * Only oversized valve guide is available, © Re-finish the valve guide holes in cylinder head with a 11.2 mm reamer. — 09916-34560 09916-34540 Valve guide hole reamer Reamer handle r | 330331 SERVICING ENGINE © Fit a ring to each valve guide. Be sure to use new rings and valve guides. Reuse of rings and valve guides removed during disassembly is prohibited. Remember that the guide for intake valve differs in shape from that of the exhaust valve in production, however, the replacements of valve guide and oil seal are identical in shape. 11116-49290 Valve guide (09289-05003 Valve guide oil seal * Oil the stem hole, too, of each valve guide and drive the guide into the guide hole with the valve guide remover and attachment. [09916-44910 Valve guide remover aes Valve guide installer attachment CAUTION: Failure to oil the valve guide hole before driv- ing the new guide into place many result in a damaged guide or head. © Install the valve spring guide. © Re-finish the valve guide inner surface with a 5.5 mm reamer. _ es Valve guide reamer ce Reamer handle 09916-34550 09916-34540SERVICING ENGINE 332 © Oil each oil seal, and drive them into position with the valve guide remover. 09916-44910 Valve guide remover [ NOTE: _ Do not use the oil seals removed once: Use new seals, 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 contact. In this operation, use the valve lapper to hold ‘the valve head. © The ringdlike dye impression left on the valve face must be continuous—without any break— and, in addition to this requirement, the width of the dye ring, which is the visualized seat “width”, must be within the following specifica- tion: Valve seat width Seat width Standard ® 0.9 1.1mm ~ |___ (0.035 0.043 in) _| If either requirement is not met, correct the seat by servicing it as follows: VALVE SEAT SERVICING * The valve seats for both intake and exhaust valves are angled to present two bevels, 45° (seat contact surface) and 15° (top). To reface the seat, proceed as follows: Valve seat333 SERVICING ENGINE NOTE: The valve seat contact area must be inspected after each cut. © Insert the pilot © with a slight rotation, and then tighten the bottom screw that gives a snug fit, Install the 45° cutter, attachment and T handle, © Using the 45° cutter, descale and cleanup the seat with one or two turns. © Inspect the seat by the previous seat width measurement procedure. If the seat is pitted or burned, additional seat conditioning with the 48° cutter is required. NOTE: Cut the minimum amount necessary from the | seat to prevent the possibility of the valve stem becoming too close to the rocker arm | for correct valve contact angle. | . —__I If the contact area is too low, use 15° cutter to raise and narrow the contact area. If the contact area is too high, use 45° cutter to lower the contact area. After cutting the 15° angle, it is possible that the valve seat (45°) is too narrow. If so, re-cut the seat to the correct width. ¢ After the desired seat position and width is achieved, use the 45° cutter very lightly to clean up any burrs caused by the previous cutting operations. DO NOT use lapping compound after the final cut is made. The finished valve seat should have a velvety smooth finish and not @ highly polished or shiny finish. This will provide a soft surface for the final seating of valve which will occur during the first few seconds of engine operation. Contact area too high and too wide on face of valve Contact area too low and too narrow on face of valveUsing part list of valve seat servicing own] ex” sd Nan Vane | 4°] pert ater | cutter Na16 head | 18°! 15°x45° cutter [Solid pilot | N-100-10 | ‘| Adapter N5031 | * | Thandle N503 | =| * Clean and assemble the head and valve com- ponents. Fill the intake and exhaust ports with gasoline to check for leaks. If any leaks occur, inspect the valve seat and face for burrs or other ‘things that could prevent the valve from sealing. NOTE: * Always use extreme caution when handling gasoline. * After servicing the valve seats, be sure to adjust the valve clearance after the cylinder head has been reinstalled. (see page 2-4) | caution: * Refacing valve stem end face is permissible where the length D) will not be reduced to tess than 3.6 mm(0.14 in). If this length becomes shorter than 3.6 mm (0.14 in), then the valve must be replaced. * After installing the valve whose stem end has been ground off as above, check that the face @ of valve stem end is above the valve cotter @) . SERVICING ENGINE 3.34 a3.35 SERVICING ENGINE VALVE SPRINGS ‘© The force of the two coil springs keeps the valve seat tight. Weakened springs result in reduced engine power output, and often account for the chattering noise coming from the valve mechanism. © Check the springs for strength by measuring their free lengths and also the force required to compress them. If the limit indicated is exceed- ed by the free length reading or if the measured force does not fall within the range specified, replace with a SUZUKI spring. [ cautio Replace all of the valve springs at a time, if any one of these is found to be beyond the Valve spring free length 37.95mm (1.494 in} [Standard 11.7153 kg aed (25.79 — 33.73 Ibs) tension at length 32.5 mm (1.30 in) 11.7 ~ 15.3 kg (25,79 — 33.73 lbs) gu ~Y32.5 mm (1.30 inSERVICING ENGINE 3:36 REASSEMBLY ‘© Install valve spring lower seats. Be careful not to confuse the lower seats with the spring retainer @ . © Insert the valves, with their stems coated with high quality molybdenum disulfide lubricant (SUZUKI MOLY PASTE) all around and along the full stem length without any break. CAUTION: When inserting each valve, take care not to damage the lip of the stem seal. 99000-25140 SUZUKI Moly Paste Position valve spring in place, making them rest ‘on lower spring seat @ by their closed-pitch end @) . Spring has varied coil pitches: the coil pitch progressively becomes shorter from one end to the other. Large-pitch portions are indicated as @) : small-pitch portions as @ . ‘© Put on the valve retainer and, using the valve lifter, press down the springs, fit the cotter halves to the stem end, and release the lifter to allow the cotter (@ to wedge in between retainer and stem, Be sure that the rounded lip @ of the cotter fits snugly into the groove @ in the stem end. 09916-14510 | Valve lifter. 09916-14910 | Valve lifter attachment 09916-84510 | Tweezer CAUTION: Be sure to restore each spring and valve to their original positions.