Home

2006 Suzuki 50 LTZ Quad Sport Service Manual

1. 3 24 CAM ROCKER ARME WP neeo AL 3 27 FINAL REDUCTION GEAR BOX AND CVT CASE 3 28 CVT CASE COVER JP Wi d NB 3 33 GENE RA 3 33 WWEI S 3 34 MOVABLE AND FIXED DRIVE AND DRIVEN FACE 3 35 iq A pug e uum m 3 43 ENGINE REASSEMBLY N 3 47 3 28 ENGINE FINAL REDUCTION GEAR BOX AND CVT CASE DISASSEMBLY Remove the snap ring D and engine sprocket 2 Remove the drain plug and gasket Drain final reduction gear box oil Remove the final reduction gear box cover 4 NOTE Loosen the final reduction gear box cover bolts little by little and diagonally Remove the dowel pins 5 Remove the washer 7 Remove the drive shaft 8 Remove the counter shaft 9 with the special tool 09920 13120 Crankshaft separator COUNTER SHAFT INSPECTION Inspect the counter shaft wear or damage If itis worn or damaged replace it with a new one ENGINE 3 29 DRIVE SHAFT INSPECTION Inspect the dri
2. 7 52 mm 2 0 in Rear wheel travel EP itm QD 51 mm 2 0 in Caster ae clic eT We tib 10 mm 0 39 in Toe in EP iD 1 5 mm 0 06 in Camber ee f AL 0 Steering angle A A RR 35 right amp left Turning PII 2 0 m 6 6 ft Front brake a V MIB 2 Drum brake Rear Ae Drum brake Front tire 5 2 M ND ER sesso AT16 x 8 7 tubeless Rear tire size AT16 x 8 7 tubeless ELECTRICA Ignition type WB me Assess Electronic ignition CDI Ignition timing 999 79B Ness 14 B T D C at 2 000 r min Spark plug BB d BRA NGK CR6HSA or DENSO U20FSR U caes c Le fe CR E tete 12 V 14 4 kC 4 Ah 10 HR ee er UR UE LL ne eee 10A CAPACITIES oic 2 6 L 0 7 0 6 US Imp gal Eng
3. 25 ml 0 8 0 9 05 oz Ot 30 ml 1 0 1 1 US Imp oz These specifications are subiect to change without notice PERIODIC MAINTENANCE 2 1 PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE 2 2 PERIODIC MAINTENANCE CHART 2 2 MAINTENANCE TUNE UP PROCEDURES 2 3 AIR CLEANER u u u uu w usaq aa usa 2 3 EXHAUST PIPE NUTS AND MUFFLER MOUNTING BOLT 2 5 VALVE CLEARANCE 2 5 uou E cu LL EE 2 7 SPARK ARRESTER asa ssaasassssssssssssusasisasa 6 2 8 FUEL LINE DEI _ 2 8 ENGINE OIL L amp 2 9 FINAL REDUCTION GEAR BOX OIL 2 10 THROTTLE CABLE PLAY 5 2 10 ENGINE IDLE SPEED ME e0 4 I 2 11 DRIVE BELT QM 4 S ai 2 11 DRIVE CHAIN WA 2 14 BRAKES Luis a
4. 1 7 SPECIFICATIONS aliene 1 8 DIMENSIONS AND DRY MASS U Q 1 8 ENGINE DU WaN m Deere 1 8 DRIVE TRAIN 1 8 CHASSIS dii rad 1 9 ELECTRIGETTQB Vu PN 1 9 CAPACINP 1 9 COUNTRY AND AREA CODES The following codes stand for the applicable country ies and area s MODEL CODE COUNTRY or AREA EFFECTIVE FRAME NO LT Z50K6 LM4AZ413 61100001 12 GENERAL INFORMATION WARNING CAUTION NOTE Please read this manual and follow its instructions carefully To emphasize special information the symbol and the words WARNING CAUTION and NOTE have special meanings Pay special attention to the mes sages highlighted by these signal words WARNING Indicates a potential hazard that could result in death or injury Indicates a potential hazard that could result in vehicle damage NOTE Indicates special information to make maintenance easier or instructions clearer Please note however that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing or lack of servicing of the vehicle In addition to the WARNINGS
5. 5 27 REAR BRAKE AND REAR AXLE HOUSING 5 28 CURES TRUCTION W 5 28 REVIVAL 0 rre r 5 29 INSPECTION AND DISASSEMBLY 5 31 REASSEMBLY AND REMOUNTING 5 33 REAR SUSPENSION 1 11111 ener 5 38 5 38 REMOVAL AND DISASSEMBLY 5 39 INSPECTION yku 5 40 REASSEMBLY AND REMOUNTING 5 40 CHASSIS 5 1 52 CHASSIS EXTERIOR PARTS CONSTRUCTION CHASSIS 5 3 FASTENER REMOVAL AND INSTALLATION FASTENER Removal Depress the head of fastener center piece 1 Pull out the fastener Installation Let the center piece stick out toward the head so that the pawls close Insert the fastener into the installation hole NOTE To prevent the pawl from damage insert the fastener all the way into the installation hole Push in the head of center piece until it becomes flush with the fastener outside face 5 4 CHASSIS REMOVAL SEAT Remove the seat FRONT FRAME COVER Remove the fasteners e Remove
6. 2 17 TIRES 2 18 STEERING 4 mes SENm 2 19 SUSPE NS 2 19 CHASSIS NUTS AND BOL ISR u 2 2 20 GENERAL OSBEICATIONSKE 2NA 2 22 COMPRESSION PRESSURE CHECK 2 23 COMPRESSION TEST PROCEDURE 2 23 INITIAL ENGAGEMENT AND CLUTCH LOCK UP INSPECTION 2 24 INITIAL ENGAGEMENT INSPECTION 2 24 CLUTCH LOCK UP INSPECTION 2 25 2 2 PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the vehicle operating at peak performance and economy NOTE More frequent servicing may be required on vehicles that are used under severe conditions PERIODIC MAINTENANCE CHART Initial Every Every Pm aaa C Eee Air Air cleaner element _____ element 1 A9 O 9 i Fuel line LG Replace every 4 years 249 a en k gt _ Inspect each time the vehicle is ridden ge
7. 5 3 REMOVAL 5 4 REMOUNTING 5 6 FRONT AND REAR WHEELS 5 7 CONSTRUCTION u 2 0o ui 5 7 REMOVAL Ua DL IL 5 7 REMOUNTING Msn oie 5 7 5 8 TIRE REPLACEMENT m 5 8 FRONT BRAKE ay v SD 5 10 CONSTRUCTION r BD DA 5 10 REMOVAL aos rro nn 5 11 INSPECTION AND DISASSEMBLY 5 12 REASSEMBLY AND REMOUNTING 5 14 STEERING AND FRONT SUSPENSION 5 16 CONSTRUCTION dp AT uuu 5 16 REMOVAL AND DISASSEMBLY 5 18 INSPECTION 4 9 Ibo 22 5 21 REASSEMBLY AND REMOUNTING 5 23 TOE IN USTMENT 2 s
8. 753 39 TC Ute TINO US ecc a d 3 40 Movable drive and driven face 3 36 38 Release the parking brake lock PERIODIC MAINTENANCE 2 25 ENGINE 3 1 CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE 3 2 ENGINE CENTER EVI NUEVE VE RYREUE 3 2 ENGINE LEFT SIDE oisi usse uisa 3 2 ENGINE RIGHT SIDE uuu as 3 2 ENGINE REMOVAL AND INSTALLATION 3 3 ENGINE REMOVAL 3 3 ENGINE INSTALLATION WD W 3 6 POWER REDUCTION SPACER 3 8 ENGINE DISASSEMBLY s 3 9 ENGINE COMPONENTS INSPECTION AND SERVICING 3 15 CYLINDER HEAD 3 15 ROCKER ARM PUSH ROD G 7 3 20 CAMSHAFT ASSEMBLY 3 21 UPPER CRANKCASE CYLINDER 3 21 PISTON AND PISTON RING
9. 3 22 CONROD AND CRANKSHAFT 3 24 CAM ROCKER ARME WP neeo AL 3 27 FINAL REDUCTION GEAR BOX AND CVT CASE 3 28 CVT CASE COVER JP Wi d NB 3 33 GENE RA 3 33 WWEI S 3 34 MOVABLE AND FIXED DRIVE AND DRIVEN FACE 3 35 iq A pug e uum m 3 43 ENGINE REASSEMBLY N 3 47 3 2 ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and installed without removing the engine from the frame Refer to the page listed in each section for removal and installation instructions ENGINE CENTER Carburetor 3 3 3 7 Muffler 3 3 3 8 Spark plug 3 9 3 56 ENGINE LEFT SIDE PARTS REMOVAL INSTALLATION Recoil starter CVT case cover Starter pinion Starter cup Fixed drive face Clutch housing Clutch shoe movable driven face Drive belt ENGINE RIGHT SIDE Generator cover Generator rotor Generator coil Pick up coll Starter motor ENGINE 3 3 ENGINE REMOVAL AND INSTALLATION ENGINE REMO
10. Install the crankshaft bearing retainer to the upper crank case cylinder Apply engine oil to the cylinder Apply a small quantity of engine oil to the piston ring Install the piston and crankshaft to the upper crankcase cylin der Install the crankshaft and dowel pins to the upper crank case cylinder NOTE Apply engine oil to the bearing balls and conrod big end 7 CRANKCASE Apply SUZUKI BOND 1215 to the lower crankcase matching surface 99000 31110 SUZUKI BOND 1215 or equivalent NOTE Use of SUZUKI BOND is as follows Make surfaces free from moisture oil dust and other foreign materials Spread on surfaces thinly to form an even layer and assemble the crankcases within few minutes Tighten the crankcase bolts to the specified torque V Crankcase bolt 11 1 1 kgf m 8 0 ib ft Install the bushing CD to the upper crankcase cylinder Install the bushing Q to the generator case ENGINE 3 49 3 50 ENGINE CAM ROCKER ARM Assemble the cam rocker arms 1 shaft 2 and washer 3 NOTE Align the hollows of the cam rocker arm Apply engine oil to the cam rocker arm shaft Install the cam rocker arms 5 spring and washer to the upper crankcase cylinder Keep the rocker arms open CAMSHAFT ASSEMBLY Install the camshaft assembly and washer 2 Align the hole of the camshaft D with the matchi
11. Remove the rear brake panel Remove the rear brake cam lever bolt and cam lever Remove the rear brake camshaft 40 brake lining indicator plate 17 spring 42 and O rings 43 Remove the rear axle housing INSPECTION AND DISASSEMBLY BRAKE DRUM Inspect the brake drum and measure the brake drum 1 0 to determine the extent of wear Replace the brake drum if the measurement exceeds the service limit The value of this limit is indicated inside the brake drum 09900 20101 Vernier calipers Brake drum 0 Service Limit 110 7 mm 4 36 in CHASSIS 5 31 5 32 CHASSIS BRAKE SHOE Inspect the brake shoes for wear or damage If any wear or defects are found replace the brake shoes as a Set Replace the brake shoes as a set Otherwise braking performance will be adversely affected REAR AXLE Support the rear axle with the V blocks and measure the rear axle runout with the dial gauge as shown If the runout exceeds the service limit replace the rear axle with a new one 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block set 100 mm Rear axle runout Service Limit 3 mm 0 12 in STOPPER RING Inspect the stopper ring for wear or damage If any wear or defects are found replace it with a new one CAUTION W F n 05 0 HN The removed stopper ring must be replace with a new one REAR SPROCKET Inspect the sprocket teeth for wear I
12. 1 1 kgf m 8 0 Ib ft NOTE Tighten the drain plug 2 together with the new gasket ENGINE 3 33 Install the engine sprocket 8 Install the snap ring 9 The removed snap ring must be replaced with a new one When installing a new snap ring pay attention to the direction of the snap ring Fit it to the side where the thrust is as shown in the illustration CVT CASE COVER BUSHING INSPECTION Inspect the CVT case cover bushing for wear or damage If anything unusual is found replace the bushing or CVT case cover GENERATOR CASE BUSHING INSPECTION Inspect the bushing CD for wear or damage If any defects are found replace it with a new one OIL SEAL INSPECTION Damage to the lip of the oil seal may result in leakage of the fuel air mixture or gear oil Inspect the oil seal and if it is dam aged replace it with a new one 3 34 ENGINE Remove the oil seal D with the special tool 09913 70210 Bearing installer set The removed oil seal must be replaced with a new one Install the oil seal 2 with the special tool 09913 70210 Bearing installer set Apply SUZUKI SUPER GREASE A to the oil seal lip 99000 25010 SUZUKI SUPER GREASE or equivalent STARTER PINION INSPECTION Check that the gear D rotates in the direction when hold ing the gear 2 e Check that the gear D rotates in the direction B when holding the gear 2 If anythi
13. REGULATOR RECTIFIER e Remove the frame center cover C 775 5 e Disconnect the regulator rectifier coupler 0 Remove the regulator rectifier 2 Measure the voltage between the terminals with the multi circuit tester as indicated in the table below f the voltage is not within the specified value replace the regulator rectifier with a new one 09900 25008 Multi circuit tester set Tester knob indication Diode test lt 8 U 9 9 51 4 V and more tester s battery voltage NOTE If the tester reads 1 4 V and below when the tester probes are not connected replace its battery ELECTRICAL SYSTEM 6 11 STARTER SYSTEM Starter relay mpm Fuse 10A WB WB Y G B W W B O OW OG O G O O R I LA LA Starter Parking Engine Remote engine Ignition button brake switch stop switch stop switch switch Starter motor TROUBLESHOOTING Make sure that the fuse Is not blown and the battery is fully charged before diagnosing Starter motor will not run Step 1 1 Turn on the ignition switch with the engine stop switch parking brake switch and remote engine stop Switch in the RUN ON and SET positions and listen for a click from the starter relay when the starter button is pushed Is a click sound heard ves T 68 5 Step 2 NO Goto Step 3 Step 2 1 Check if the starter motor runs when its terminal is connected to the battery terminal Does the star
14. Rear brake cable Z a Wiring harness Throttle cable NU Fuel tank breather hose v i Handlebars ws Fuel tank breather hose Cable guide N Fuel hose Air vent hose Vacuum hose Air breather hose Air vent hose Fuel valve Throttle cable Fuel hose Install the rounded side of fuel hose to the fuel valve 7 18 SERVICING INFORMATION CARBURETOR AND CVT CASE HOSE ROUTING Air vent hose E Rt uS c i LP ur d dara AN hee e ER n a THEE a e W amp L Ms ima Drain hose Clamp SERVICING INFORMATION 7 19 HANDLEBARS AND HANDLEBAR PAD INSTALLATION Handlebar upper holder x n Handlebars Handlebar lower holder Align the center of knurling on handlebars Punched mark with the center of handlbar holders Handlebars Clamp Handlebar pad ftu j 5 Clamp Handlebar pad 7 20 SERVICING INFORMATION HEAT SHIELD INSTALLATION a 13 17 mm 0 51 0 67 in uta Right frame cover Heat shield r qj bee ee SPECIAL TOOLS 09900 20101 09900 20102 Vernier calipers Micrometer 25 50 mm 09900 20607 Dial gauge 09915 64512
15. When connecting the multi circuit tester use the needle pointed probe to the back side of the lead wire coupler and connect the probes of tester to them Use the needle pointed probe to prevent the rubber of the water proof coupler from damage 09900 25009 Needle pointed probe set ELECTRICAL SYSTEM 6 5 LOCATION OF ELECTRICAL COMPONENTS D Battery 5 Ignition coil Starter relay 6 Starter motor 3 Fuse box 7 Generator 4 CDI unit Pick up coil 6 6 ELECTRICAL SYSTEM Ignition switch 4 Starter button 2 Parking brake switch Regulator rectifier 3 Engine stop switch 6 Remote engine stop switch ELECTRICAL SYSTEM 6 7 CHARGING SYSTEM Regulator rectifier Ignition switch W R Battery Generator I TROUBLESHOOTING Battery runs down quickly Step 1 1 Check accessories which use excessive amounts of electricity Are accessories being installed No GotoStep2 Step 2 1 Check the battery for current leaks C gt 6 8 Is the battery current leaks OK Goto Step 3 Short circuit of wiring harness Faulty electrical equipment Step 3 1 Measure the regulated voltage between the battery terminals gt 6 9 Is the regulated voltage OK YES Faulty battery Abnormal driving condition Go to Step 4 Step 4 1 Measure the resistance of the generator coil 0 77 6 9 Is the resistance of generator coil OK VES 600 5 5 NO Faulty generato
16. 6 FUELSYSTEM 4 9 Remove the gasket 7 e Remove the float pin Remove the float 9 Remove the needle valve 40 Remove the main jet 4 and needle jet 42 Remove the pilot jet 43 e Remove the screw 4 Remove the needle valve retainer and needle valve seat 46 e Remove the throttle stop screw 7 4 10 FUEL SYSTEM e Remove the spring 49 washer 49 and O ring 00 e Remove the choke lever Qf Remove the starter plunger Q2 FUELSYSTEM 4 11 CLEANING Some carburetor cleaning chemicals especially dip type soaking solutions are very corrosive and must be handled carefully Always follow the chemical manufacturer s instructions on proper use handling and storage Clean all jets with a spray type carburetor cleaner and dry them with compressed air Clean all circuits of the carburetor thoroughly not just the perceived problem area Clean the circuits in the carburetor body with a spray type cleaner and allow each circuit to soak if necessary to loosen dirt and varnish Blow the body with compressed air Do not use a wire to clean the jets or passageways A wire can damage the jets and passageways f the components cannot be cleaned with spray type cleaner it may be necessary to use a dip type clean ing solution and allow them to soak Always follow the chemical manufacturer s instructions for proper use and cleaning of the carburetor compo
17. 9 980 mm 0 3929 in 09900 20205 Micrometer 0 25 mm 3 24 ENGINE CONROD AND CRANKSHAFT CONROD SMALL END I D Measure the conrod small end inside diameter with a caliper gauge If the conrod small end inside diameter exceeds the service limit replace the conrod Conrod small end Service Limit 10 040 mm 0 3952 in 09900 20605 Dial calipers 10 34 mm CONROD DEFLECTION Wear on the big end of the conrod can be estimated by checking the movement of the small end of the rod This method can also check the extent of wear on the conrod s big end Conrod deflection Service Limit 3 0 mm 0 12 in 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block set 100 mm ENGINE 3 25 CRANKSHAFT BEARING INSPECTION Pla Inspect the outer race play and smooth rotation of the bearing by hand while it is on the crankshaft If any abnormality is found replace the bearing with a new one Play NOTE If there is no abnormal noise the bearing removal is not neces Sary CRANKSHAFT BEARING REMOVAL Remove the cam drive gear 1 together with the right crankshaft bearing The cam drive gear 1 is the cam timing gear Because extreme accuracy is required when press fitting it replacing the crankshaft assem bly is recommended Remove the crankshaft bearing and cam drive gear with the suitable tool as shown in the photograph LJ 3 26 ENGINE CRANKSHAFT BEARIN
18. LEFT SIDE Difference between photograph and actual vehicle may exist depending on the markets SERIAL NUMBER LOCATION The frame serial number or V I N Vehicle Identification Number D is stamped on the left side of the rear frame pipe The engine serial number is located on the right side of the generator case These numbers are required especially for registering the machine and ordering spare parts GENERAL INFORMATION 1 5 FUEL AND OIL RECOMMENDATION FUEL FOR USA AND CANADA Use only unleaded gasoline of at least 87 pump octane R 2 M 2 91 octane or higher rated by the Research Method Gasoline containing MTBE Methyl Tertiary Butyl Ether less than 10 ethanol or less than 5 methanol with appropriate cosolvents and corrosion inhibitor is permissible FUEL FOR OTHER COUNTRIES Gasoline used should be graded 91 octane Research Method or higher Unleaded gasoline is recom mended ENGINE OIL AND FINAL REDUCTION GEAR BOX OIL FOR USA Oil quality is a major contributor to your engine s performance and life Always select good quality engine oil Suzuki recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or equivalent engine oil Use of SF SG or SH SJ with J ASO MA Suzuki recommends the use of SAE 10W 40 engine oil If SAE 10W 40 engine oil is not available select an alternative according to the following chart ENGINE OIL AND FINAL REDUCTION GEAR BOX OIL FOR OTHER COUNTRIES Oil quality
19. Loosen the clutch shoe nut A WARNING Do not remove the clutch shoe nut before attaching the clutch spring compressor Attach the special tool to the clutcn shoe movable driven face assembly and compress the clutch shoe assembly by turning in the special tool handle 2 09922 31420 Clutch spring compressor Remove the clutch shoe nut 3 WARNING Since a high spring force applies to the clutch shoe assembly care must be used so as not to cause the clutch shoe assembly and movable driven face to come off abruptly 3 38 ENGINE Loosen the special tool handle slowly and remove the clutch shoe assembly and spring Do not attempt to disassemble the clutch shoe assem bly Remove the movable driven face spring seat Remove the pins together with rollers e Remove the movable driven face INSPECTION Inspect the movable driven face metal for wear or damage If anything unusual such as scratches in the movable driven face metal replace it with a new one Inspect the rollers and pins for abnormal wear or damage If they are worn or damaged replace them with new ones ENGINE 3 39 BEARING INSPECTION Rotate the bearing inner race by finger to inspect for abnormal play noise and smooth rotation while the bearing is in the fixed driven face Replace the bearing in the following procedure if there is any thing unusual Play Play Remove the needle bearing D
20. lock up two inspection checks must be performed to thoroughly check the operation of the drive train Perform the following Warm up the engine INITIAL ENGAGEMENT INSPECTION Connect multi circuit tester onto the spark plug high ten sion cord Start the engine Slowly open the throttle and note the engine speed r min when the vehicle begins to move forward 09900 25008 Multi circuit tester set Engagement speed 2 400 3 000 r min If the engagement speed does not coincide with the standard range inspect the following items for any abnormalities Clutch shoe 4m 5 773 39 Clutch housing 8 299 73 40 Movable drive and driven face gt 3 36 38 CLUTCH LOCK UP INSPECTION Perform this inspection to determine if the clutch is engaging fully and not slipping Connect a multi circuit tester onto the spark plug high tension code Start the engine Apply the front and rear brakes as firmly as possible Fully open the throttle for a brief period and note the maxi mum engine speed sustained during the test cycle Lock up speed 3 300 4 300 r min Do not apply full power for more than 5 seconds or damage to the clutch or engine may occur If the lock up speed r min does not coincide with the standard range inspect the following items for any abnormalities C WUTC MY
21. services described in this manual Improper repair may result in injury to the mechanic and may render the vehicle unsafe for the rider SUZUKI MOTOR CORPORATION COPYRIGHT SUZUKI MOTOR CORPORATION 2005 99500 4001 1 03E SUPPLEMENTS 8 LT Z50K9 09 HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR 1 The text of this manual is divided into sections 2 The section titles are listed in the GROUP INDEX 3 Holding the manual as shown at the right will allow you to find the first page of the section easily 4 The contents are listed on the first page of each section to help you find the item and page you need a COMPONENT PARTS AND WORK BE DONE Under the name of each system or unit is its exploded view Work instructions and other service information such as the tightening torque lubricating points and locking agent points are provided Example Front and rear wheel Front wheel Wheel set nut front amp rear Nem kgf m Ib ft_ 20 0 SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servic ing The meaning of each symbol is also included in the table SYMBOL DEFINITION SYMBOL DEFINITION Torque control required Data beside it indicates specified torque Apply oil Use engine oil unless other wise specified Apply molybdenum oil solut
22. 2 to the specified torque V Exhaust pipe nut 10 N m 1 0 kgf m 7 0 Ib ft Muffler mounting bolt 23 N m 2 3 kgf m 16 5 Ib ft VALVE CLEARANCE Inspect initially at 1 month and every 6 months there after Excessive valve clearance results in valve noise and insufficient valve clearance results in valve damage and reduced power Check the intake and exhaust valve clearances at the interval indicated above and adjust the valve clearances to specification if necessary e Remove the right frame cover 775 4 e Remove the spark plug gt 2 7 e Remove the cylinder head cover 4 Remove the generator rotor cover 2 NOTE Valve clearance is to be checked when the engine is cold The intake and exhaust valves must be checked and adjusted when the piston is at Top Dead Center TDC of the compres sion stroke 2 6 PERIODIC MAINTENANCE Turn the crankshaft counterclockwise to bring the line on the generator rotor to the index mark of the generator case Press intake and exhaust rocker arm to the inside and mea sure the valve clearance 09900 20806 Thickness gauge Valve clearance when cold IN 0 05 0 10 mm 0 002 0 004 in EX 0 10 0 15 mm 0 004 0 006 in If the clearance is out of specification adjust it to the specified range with a special tool and 2 5 mm hexagon wrench V valve clearance adjuster locknut 7 N m 0 7 kgf m 5 0 Ib ft Tighten th
23. 341 in CAM ROCKER ARM INSPECTION Inspect the cam rocker arms for abnormal wear or damage If they are worn or damaged replace the cam rocker arm with a new one ENGINE 3 1 CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE 3 2 ENGINE CENTER EVI NUEVE VE RYREUE 3 2 ENGINE LEFT SIDE oisi usse uisa 3 2 ENGINE RIGHT SIDE uuu as 3 2 ENGINE REMOVAL AND INSTALLATION 3 3 ENGINE REMOVAL 3 3 ENGINE INSTALLATION WD W 3 6 POWER REDUCTION SPACER 3 8 ENGINE DISASSEMBLY s 3 9 ENGINE COMPONENTS INSPECTION AND SERVICING 3 15 CYLINDER HEAD 3 15 ROCKER ARM PUSH ROD G 7 3 20 CAMSHAFT ASSEMBLY 3 21 UPPER CRANKCASE CYLINDER 3 21 PISTON AND PISTON RING 3 22 CONROD AND CRANKSHAFT
24. Compression gauge set 09913 10750 Adaptor 09900 20202 09900 20205 Micrometer 0 25 mm 09900 20803 09900 20806 Thickness gauge 09900 25009 Needle pointed 09920 13120 Crankshaft separator SERVICING INFORMATION 7 21 09900 20602 Dial gauge 09900 20605 Dial calipers 1 1000 mm 1 mm 1 100 mm 10 34 mm 09900 20805 Tire depth gauge 09913 50121 Oil seal remover 09921 20240 09900 21304 V block set 100 mm 09913 70210 Bearing installer set 09922 31420 Clutch spring Bearing remover set compressor 7 22 SERVICING INFORMATION 09930 40113 Rotor holder 09941 50111 Bearing remover NOTE When order the special tool please confirm whether it is available or not SERVICING INFORMATION 7 23 TIGHTENING TORQUE ENGINE ITEM km _ Cylinder head cover bolt Cylinder head bolt 10 0 Valve clearance adjuster locknut 5 0 Generator rotor nut 25 5 Clutch housing nut 36 0 Clutch shoe nut 6 ___ 43 5 Initial 9 5 Fixed drive face nut Final 36 0 Generator coil bolt 7 0 Pick up coil bolt 3 0 Crankcase bolt Generator case bolt CVT case bolt Generator cover bolt CVT case cover bolt ngine oil drain plug 8 5 inal reduction gear box cover bolt ngine mounting nut 22 5 Muffler mounting bolt 16 5 xhaust pipe nut 7 0 Recoil starter friction plate bolt park plug Carburetor mounting bolt 06 4 5 ntake pipe bolt 06 4 5 FUEL _____ __ kfm b Fuel val
25. Spark plug 11 N m 1 1 kgf m 8 0 Ib ft SPARK ARRESTER Clean every 3 months Extract the spark arrester from the muffler Clean the spark arrester 4 by brush Reinstall the spark arrester 1 FUEL LINE Inspect every 3 months Replace every 4 years Inspect the fuel hose for damage and fuel leakage If any defects are found replace it with a new one When replacing the fuel hose remove the left frame cover 725 4 ENGINE OIL Inspect each time the vehicle is ridden Replace initially 1 month and every 6 months thereaf ter ENGINE OIL LEVEL CHECK Follow the procedure below to inspectthe engine oil level Place the vehicle on level ground e Remove the maintenance lid C 775 6 e Start the engine and run it for a few minutes Stop the engine and wait three minutes Check the engine oil level with the engine oil dipstick CD Check the engine oil level with the dipstick before each time the vehicle is ridden Be sure the engine oil level is always between the L low line and the F full line Install the filler cap 2 securely ENGINE OIL REPLACEMENT The oil should be changed while the engine is warm Place the vehicle on level ground e Remove the maintenance lid C7 5 6 Place an oil pan under the engine oil drain plug 0 and then drain out the engine oil by removing the engine oil drain plug D and engine oil filler cap Tighten the e
26. and also the rotor ENGINE 3 53 3 54 ENGINE Tighten the generator rotor nut to the specified torque with the special tool 09930 40113 Rotor holder V Generator rotor nut 35 N m 3 5 kgf m 25 5 Ib ft Be careful not to damage the generator coil by the special tool STARTER MOTOR Install the starter motor 1 CYLINDER HEAD Apply MOLYBDENUM OIL SOLUTION to both ends of the push rods MOLYBDENUM OIL SOLUTION Install the push rods to the cam rocker arm hollows A Turn the crankshaft counterclockwise and align the line B on the generator rotor with the index mark O of the generator case ENGINE 3 55 Install the gasket and dowel pins 3 The removed gasket must be replaced with a new one Install the cylinder head Position the push rods 4 to the rocker arm adjust bolt hollows D Install the push rods 1 to the rocker arm adjust bolt hollows and cam rocker arm hollows surely Tighten the cylinder head bolts to the specified torque 9 Cylinder head bolt 14 N m 1 4 kgf m 10 0 b ft NOTE Tighten the bolts little by little and diagonally Adjust the valve clearance 0 772 5 to 6 Valve clearance when cold IN 0 05 0 10 mm 0 002 0 004 in EX 0 10 0 15 mm 0 004 0 006 in V valve clearance adjuster lock nut 7 N m 0 7 kgf m 5 0 Ib ft GENERATOR COVER Tighten the generator cover bolts to the spec
27. be put on the level ground Remove the caps 2 NOTE After filling the electrolyte completely use the removed cap 2 as sealing caps of battery filler holes Do not remove or pierce the sealed areas 3 of the electrolyte container Insert the nozzles of the electrolyte container into the bat tery s electrolyte filler holes holding the container firmly so that it does not fall Take precaution not to allow any of the fluid to spill Make sure air bubbles 5 are coming up in each electrolyte container and leave in this position for about more than 20 minutes O Oo O FELD C ES NOTE If air bubbles are coming up from a filler port tap the bottom of the electrolyte container two or three times Never remove the container from the battery After confirming that the electrolyte has entered the battery completely remove the electrolyte containers from the bat tery Waitfor about 20 minutes Insert caps into the filler holes pressing in firmly so that the top of the caps do not protrude above the upper surface of the battery s top cover Never use anything except the specified battery Once the caps have been installed to the battery do not remove the caps Do not tap the caps with a tool such as hammer when installing them CORRECT ELECTRICAL SYSTEM 6 25 INCORRECT For initial charging use the ch
28. circuit nearby when charging the battery Be sure to recharge the battery in a well ventilated and open area Note that the charging system for the MF battery is different from that of a conventional battery Do not replace the MF battery with a conventional battery CONNECTING THE BATTERY When disconnecting terminals trom the battery for disassem bly or servicing be sure to disconnect the battery lead wire first e When connecting the battery lead wires be sure to connect the CO battery lead wire first f the terminal is corroded remove the battery pour warm water over it and clean it with a wire brush After connecting the battery apply a light coat of grease to the battery terminals Install the cover over the battery terminal WIRING PROCEDURE Properly route the wiring harness according to the WIRING HARNESS ROUTING section C 777 14 ELECTRICAL SYSTEM 6 3 INCORRECT 64 ELECTRICAL SYSTEM USING THE MULTI CIRCUIT TESTER Properly use the multi circuit tester and probes Improper use can cause damage to the vehicle and tester If the voltage and current values are not known begin mea Suring in the highest range e When measuring the resistance make sure that no voltage is applied If voltage is applied the tester will be damaged After using the tester be sure to turn the switch to the OFF position 09900 25008 Multi circuit tester set NOTE
29. hand ed carefully in an area well ventilated and away from fire or sparks 42 FUEL SYSTEM FUEL TANK AND FUEL VALVE O Fuel hose 2 Fueltenkcap O ring Fuel tank inletrubber Vacuum hose 5 Fuel valve bol FUELSYSTEM 4 3 REMOVAL Gasoline is highly flammable and explosive Keep heat spark and flame away Remove the frame center cover 7775 5 Turn the fuel valve to ON position Disconnect the fuel hose 1 Disconnect the vacuum hose Remove the fuel tank 3 Remove the fuel valve assembly 4 FUEL FILTER INSPECTION AND CLEANING If the fuel filter is dirty with sediment or rust fuel will not flow smoothly and loss in engine power may result Clean the fuel filter with compressed air also check the fuel filter for cracks WARNING The gaskets and O ring must be replaced with new ones to prevent fuel leakage 4 4 FUEL SYSTEM REMOUNTING Remount the fuel tank and fuel valve in the reverse order of removal Pay attention to the following points Tighten the fuel valve bolts to the specified torque V Fuel valve bolt 4 5 N m 0 45 kgf m 3 3 Ib ft The removed O ring and gaskets must be replaced with new ones NOTE Install the rounded side of fuel hose to the fuel valve Install the fuel tank NOTE Fuel tank breather hose D routing 27 17 FUELSYSTEM 4 5 CARBURETOR Q Carburetortop cap 0 Thro
30. in valve guides Worn stem oil seal SPARK PLUG ELECTRODES OVERHEAT OR BURN Symptom possible causes and remedy Too hot spark plug Overheated the engine Loose spark plug Too lean mixture GENERATOR DOES NOT CHARGE Symptom possible causes and remedy Open or short circuited lead wires or loose lead connections Short circuited grounded or open generator coil Short circuited or punctured regulator rectifier Adjust carburetor Change Replace Replace Replace Replace Replace Replace Replace with cold type plug Tune up etighten Adjust carburetor Repair or replace or retighten Replace Replace GENERATOR DOES CHARGE BUT CHARGING RATE IS BELOW THE SPECIFICATION Symptom possible causes and remedy Lead wires tend to get short or open circuited or loosely connected at terminals Grounded or open circuited generator coil Defective regulator rectifier Defective cell plates in the battery GENERATOR OVERCHARGES Symptom possible causes and remedy Internal short circuit in the battery Damaged or defective regulator rectifier Poorly grounded regulator rectifier Repair or retighten Replace Replace Replace the battery Replace the battery Replace Clean and tighten ground connection UNSTABLE CHARGING Symptom possible causes and remedy Lead wire insulation frayed due to vibration resulting in intermittent short cir
31. initially at 1 month and every 3 months there after Adjust the throttle cable play as follows PERIODIC MAINTENANCE 2 11 e Loosen the lock nut of the throttle cable Turn the adjuster in or out to obtain the correct play D After adjusting the throttle cable play tighten the locknut CD Throttle cable play 3 5 0 12 0 20 A WARNING After the adjustment is completed check that handle bar movement does not raise the engine idle speed and that the throttle lever returns smoothly and auto matically ENGINE IDLE SPEED Inspect initially at 1 month and every 3 months there after Adjust the throttle cable play gt 2 10 Warm up the engine NOTE Make this adjustment when the engine Is hot Start the engine turn the throttle stop screw 1 and set the engine idle speed as follows Engine idle speed 2 000 150 r min DRIVE BELT Inspect every 3 months Replace every 6 months REMOVAL Remove the left frame cover 77 5 4 Remove the left footrest 1 Remove the CVT case cover 2 2 12 PERIODIC MAINTENANCE Remove the fixed drive face nut and starter cup with the Special tool 09930 40113 Rotor holder Remove the fixed drive face 5 Remove the clutch housing with the special tool 09930 40113 Rotor holder Remove the movable driven face 7 with drive belt 8 INSPECTION Ins
32. one e When the vehicle is not used for a long period check the bat tery every 1 month to prevent the battery discharge Battety charged condition SERVICING INFORMATION 7 1 SERVICING INFORMATION CONTENTS TROUBLESHOOTING 7 2 ENGINE 7 2 CARBURETOR aaaea aiaa Aaaaoi 7 6 CHASSIS 7 7 BRAKES 7 9 ELECTRICAL u sassa s EM 7 10 BATTERY IE 7 12 WIRING DIAGRAM am S 7 13 WIRING HARNESS CABLE AND HOSE ROUTING 7 14 WIRING HARNESS ROUTING 7 14 CABLE ROUTING W e 7 16 FUEL HOSE PIPING 45 7 17 CARBURETOR AND CVT CASE HOSE ROUTING 7 18 HANDLEBARS AND HANDLEBAR PAD INSTALLATION 7 19 HEAT SHIELD INSTALLATION 7 20 SPECIAL TOOLS T R 7 21 TIGHTENING TORQUEY K S r S 7 23 ENGINE
33. proce dure Connect multi circuit tester with the peak volt adaptor as follows Pick up coil P robe Brown lead wire Peak volt adaptor Probe Black White lead wire or ground B W 09900 25008 Multi circuit tester set a Br i coupler W R Br Generator Pick up coll Turn the ignition switch to the ON position Press the starter button and allow the engine to turn for a few seconds and then measure the pick up coil peak voltage 6 22 ELECTRICAL SYSTEM Repeat the above procedure a few times and measure the highest pick up coil peak voltage Tester knob indication Voltage Pick up coil peak voltage 1 5 V and more If the peak voltage measured on the CDI unit coupler is lower than the standard value measure the peak voltage on the gen erator coupler as follows Remove the left frame cover 25 4 Disconnect the generator coupler 2 and connect the multi circuit tester with the peak volt adaptor as follows Pick up Probe Brown lead wire Probe Ground Measure the pick up coil peak voltage in the same manner as on the CDI unit coupler Tester knob indication Voltage Pick up coil peak voltage 1 5 V and more If the peak voltage on the generator coupler is within the specifi cation but on the CDI unit coupler is not within specification replace the wiring harness with a new one If both peak voltages are not within specification repla
34. spark plug OK VES 600 5 6 NO Faulty spark plug Step 5 1 Inspect the parking brake switch C7 6 23 Is the parking brake switch OK Go to Step 6 NO Faulty parking brake switch Step 6 1 Inspect the ignition coil 7576 21 Is the ignition coil OK VES 6000987 Poor connection of the ignition coil Faulty ignition coil Step 7 1 Measure the pick up coil peak voltage and resistance _7 6 21 to 22 NOTE The pick up coil peak voltage inspection is applicable only with the multi circuit tester and peak volt adaptor Is the peak voltage and resistance OK Faulty CDI unit Poor connection of generator coupler Open circuit in wiring harness NO Faulty pick up coil 6 20 ELECTRICAL SYSTEM INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE Disconnect the spark plug cap e Connect a new spark plug CD to spark plug cap and ground it to the cylinder head NOTE Make sure that the spark plug cap and spark plug are connected properly and the battery is fully charged Measure ignition coil primary peak voltage with the multi circuit tester in the following procedure Connect the multi circuit tester with the peak voltage adaptor as follows Probe Black White lead wire or ground Probe Black lead wire NOTE Do not disconnect the ignition coil primary wires 09900 25008 Multi circuit tester set When using the multi circuit tester and peek volt adaptor re
35. the rear shock absorber 4 Remove the swingarm pivot nut and shaft Remove the swingarm 5 40 CHASSIS INSPECTION REAR SHOCK ABSORBER Inspect the shock absorber body and bushing for damage and oll leakage If any defects are found replace it with a new one CAUTION Do not attempt to disassemble the rear shock absorber It is unserviceable SWINGARM PIVOT SHAFT Check the pivot shaft for runout with a dial gauge and replace it if the runout exceeds the limit 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block set 100 mm Swingarm pivot shaft rumout Service Limit 0 6 mm 0 02 in SWINGARM Inspectthe swingarm for distortion or damage If any defects are found replace it with a new one BUSHING Inspect the bushing for wear or damage If any defects are found replace it with a new one REASSEMBLY AND REMOUNTING Reassemble and remount the rear suspension in the reverse order of removal and disassembly Pay attention to the following points CHASSIS 5 41 Install the swingarm pivot bushings with the special tool 09941 34513 Steering race installer NOTE When installing the swingarm bushings CD to the swingarm and confirm the distance between the end of the swingarm and bushing edge is 1 5 mm 0 059 in Tighten the swingarm pivot nut to the specified torque V Swingarm pivot nut 102 N m 10 2 kgf m 74 0 Ib ft Tighten the rear shoc
36. to go into the oil ring groove is a spacer 1 After placing the spacer fit the two side rails NOTE Side designations top and bottom are not applied to the spacer and side rails Those can be positioned each either way CAUTION When installing the spacer be careful not to allow its two ends to overlap in the groove Install the 2nd ring and 1st ring B Ist ring has letter O marked the side Be sure to bring the marked side to the top when fitting it to the piston 2nd ring has letter R marked on the side Be sure to bring the marked side to the top when fitting it to the piston INCORRECT Position the gaps of three rings as shown Before inserting the piston into the cylinder check that the gaps are so located O 2nd ring Lower side rai D Upper side rail 1st ring Spacer Apply engine oil to the piston pin surface and conrod small end when inserting Install the piston and piston pin Install the piston pin circlip 3 48 ENGINE NOTE End gap of the circlip should not be aligned with the cutaway in the piston pin bore NOTE When installing the piston the punched mark on the piston head is located to the exhaust side CRANKSHAFT Apply engine oil to the crankshaft bearing CD Apply SUZUKI SUPER GREASE A to the oil seal lip 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the oil seal 2 to the crankshaft
37. with a vernier calipers If brush length is less than the service limit replace the housing end assembly with a new one 09900 20101 Vernier caliprs Brush length Service Limit 2 75 mm 0 108 in COMMUTATOR Inspect the commutator for discoloration abnormal wear or undercut A If abnormal wear is found replace the armature with a new one If the commutator surface is discolored polish it with 400 sand paper and wipe it with a clean dry cloth If there is no undercut scrape outthe insulator with a saw blade 1 Insulator 2 Segment ARMATURE COIL INSPECTION Check for continuity between each seament and between each segment and the armature shaft with the multi circuit tester If there is no continuity between the segments or there is conti nuity between the segments and shaft replace the armature with a new one 09900 25008 Multi circuit tester set Tester knob indication Continuity test 4 BEARING Inspect the bearing for wear or damage Check the smooth rotation of the bearing by finger If any wear or damage is found replace the housing end assem bly OIL SEAL INSPECTION Check the oil seal lip for damage or leakage If any defects are found replace the housing end assembly BUSHING Inspect the bushing for wear or damage If any wear or damage is found replace the starter motor with a new one STARTER MOTOR REASSEMBLY Reassemble the starter motor in the reverse order of disassem b
38. 000 4 012 VALVE VALVE GUIDE Unit mm in Valve diam 14 5 12 5 Valve clearance when cold 0 05 0 10 mas gt 0 004 0 006 Valve guide to valve stem 0 010 0 037 clearance 0 0004 0 0015 MEM 0 025 0 052 MEME Valve stem O D 3 975 3 990 3 960 3 975 0 35 0 014 0 05 0 002 IN amp EX IN amp EX IN amp EX IN amp EX IN amp EX IN amp EX Valve spring tension ad 0 12 0 02 0 03 0 001 22 8 0 90 36 5 41 9 N IN amp EX 3 7 4 3 kgf 8 2 9 5 lbs m m m gt lt atlength 15 0 mm 0 59 in SERVICING INFORMATION 7 27 CAMSHAFT CYLINDER HEAD Unit mm in Cam height 28 43 28 63 28 13 Rocker arm I D 4 015 4 027 Rocker arm shaft O D 3 990 4 005 CYLINDER PISTON PISTON RING Unit mm in Compression pressure 1100 1200 kPa 800 kPa 8 kgf cm 2 11 12 kgf cm 156 171 psi 114 psil iston to cylinder clearance 0 015 0 038 0 120 0 0006 0 0015 0 0047 Cylinder bore 36 005 36 015 Nicks or 1 41754 1 4179 Scratches Piston diam 35 977 35 990 35 885 1 4164 1 4169 1 4128 Measure at 5 mm 0 2 in from the skirt end Cylinder distortion 0 AP 0 15 easy 0 15 0 003 0 008 0 020 UN 0 003 0 008 0 020 Piston ring to groove clearance 0 180 0 0071 be vo 7 28 SERVICING INFORMATION ITEM STAND
39. 150 mm 0 0059 in Piston ring groove width Standard 1st 1 01 1 03 mm 0 0398 0 0405 in 2nd 1 21 1 23 mm 0 0476 0 0484 in Oil 1 51 1 53 mm 0 0594 0 0602 in Piston ring thickness Standard 1st 0 97 0 99 mm 0 0382 0 0390 in 2nd 1 17 1 19 mm 0 0461 0 0469 in 09900 20803 Thickness gauge 09900 20205 Micrometer 0 25 mm ENGINE 3 23 PISTON RING FREE END GAP AND PISTON RING END GAP Measure the piston ring free end gap with a vernier calipers Next fit the piston ring squarely into the cylinder and measure the piston ring end gap with a thickness gauge If any of the measurements exceeds the service limit replace the piston ring with a new one Piston ring free end gap Service Limit 1st 3 7 mm 0 15 in 2nd 3 7 mm 0 15 in 09900 20102 Vernier calipers Piston ring end gap Service Limit 1st 0 50 mm 0 020 in 2nd 0 50 mm 0 020 in 09900 20803 Thickness gauge PISTON PIN AND PIN BORE Measure the piston pin bore inside diameter with a small bore gauge If the measurement is more than the service limit replace the piston Piston pin bore I D Service Limit 10 030 mm 0 3949 in 09900 20602 Dia gauge 1 1000 mm 1 mm 09900 22401 Smail bore gauge 10 18 mm Measure the piston pin outside diameter at three positions with micrometer If any of the measurements is less than the service limit replace the piston pin Piston pin O D Service Limit
40. 2 Hook the rope onto the hook part of the reel Turn the reel counterclockwise three or four times with the rope Lace the end of the rope through the recoil starter case hole Tie a knot at the end o the rope Install the cap 9 to the knob Apply SUZUKI SUPER GREASE A to the sliding part of the ratchet and reel 99000 25010 SUZUKI SUPER GREASE A or equivalent ENGINE 3 45 3 46 ENGINE Apply SUZUKI SUPER GREASE A to the return spring 99000 25010 SUZUKI SUPER GREASE or equivalent Install the return spring Apply SUZUKI SUPER GREASE to the sliding part of the friction spring and ratchet 99000 25010 SUZUKI SUPER GREASE or equivalent Align the friction spring with the projection of the ratchet Apply THREAD LOCK 1342 to the bolt Tighten the bolt to the specified torque 99000 32050 THREAD LOCK 1342 or equivalent V Recoil starter friction plate bolt 5 4 N m 0 54 kgf m 4 0 Ib ft Pull the rope and check that the ratchet is pushed out ENGINE 3 47 ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassembly Pay special attention to the following points NOTE Apply engine oil to each running and sliding surface before reas sembling PISTON RING AND PISTON Install the piston rings in the order of oil ring 2nd ring and 1st ring The first member
41. 30 mi m ITEM Nm kgf m C Se WU Tighten the engine mounting nuts to the specified torque 9 Engine mounting nut 31 N m 3 1 kgf m 22 5 Ib ft The engine mounting nuts are self locking Once the nuts have been removed they are no longer of use ENGINE 3 7 Install the drive chain CD Install the clip The drive chain joint clip should be attached in the way that the slit end will face opposite the direction of travel Apply SUZUKI SUPER GREASE to the O ring 99000 25010 SUZUKI SUPER GREASE A or equivalent The removed O ring must be with a new Tighten the carburetor mounting bolts to the specified torque V Carburetor mounting bolt 6 N m 0 6 kgf m 4 5 Ib ft Install the exhaust pipe gasket 4 The removed gasket must be replaced with a new one 3 8 ENGINE Tighten the exhaust pipe nuts to the specified torque V Exhaust pipe nut 10 N m 1 0 kgf m 7 0 lb ft e Tighten the muffler mounting bolt to the specified torque V Muffler mounting bolt 23 N m 2 3 kgf m 16 5 Ib ft After remounting the engine inspect the lead wires and hoses routing C 57 14 to 18 e Pour the specified engine oil C 772 9 e Pour the specified final reduction gear box oil gt 2 10 Perform the following adjustments Drive chain slack 772 15 Engine idle speed C5 2 11 Throttle cable play
42. 82 links GENERAL INFORMATION 1 9 CHASSIS FIO u Independent swing axle coil spring oll damped Rear eet ae e aus Swingarm coil spring oil damped FIontwneel travel ba D uuu 52 mm 2 0 in Rear WIeelIrdVBl sei au u vd ecu em dpa ar iat 5 mm 2 0 in goce 3 r ii u y LI ETENIM DELE 10 mm 0 39 in TWO gt u gt u 1 5 3 mm 0 06 0 12 in BIA mani cat nanan 0 aN amissis ______ REUTERS 357 Eae 2 0 m 6 6 ft 8965 Drum brake DEKO stesse uua Drum brake EH AT16 x 8 7 tubeless 16 x 8 77x tubeless ELECTRICAL Ignition Wi Electronic ignition CDI P l 20 B T D C at 4 600 r min Sparkeop ligu EET luu a n NGK CR6HSA or DENSO U20FSR U Bane i ey 12 V 14 4 kC 4 Ah 10 HR Main fuse lie MR sm 10 A CAPACITIES Fueltank 2 6L 0 7 0 6 US Imp gal Engine oll oll EE 499 300 ml 0 6 0 5 US Imp qt overhaul 9 Wee 350 ml 0 7 0 6 US Imp qt Final reduction gear box oil oil
43. 84 Ibs Before inflating the tire check the MAXIMUM OPER ATING PRESSURE rating of the tire This is indicated by a x following the tire size shown on the sidewall The number of sx on the tire indicates the maximum operating pressure Maximum operating pressure x 25 kPa 0 25 kgf cm 3 6 psi 35 kPa 0 35 kgf cm 5 1 psi Y 45 kPa 0 45 6 5 psi 5 10 CHASSIS FRONT BRAKE CONSTRUCTION Brake cam lever Spcer ront brake cam lever bolt Q Inner dust seal Front hub nut Front brake shoe CHASSIS 5 11 REMOVAL e Remove the front wheel 75 8 Remove the wheel center cap e Remove the cotter pin and front hub nut D CAUTION The removed cotter pin must be replaced with a new one Remove the front wheel hub 2 Remove the front brake shoe assembly 3 Remove the spring 4 Remove the front brake adiusting nut 5 e Remove the front brake cam lever nut and bolt Remove the brake cam lever 8 and front brake camshaft 9 5 12 CHASSIS e Remove the brake plate 40 Remove the axle spacer 17 INSPECTION AND DISASSEMBLY BRAKE DRUM WHEEL HUB Inspect the brake drum and measure the brake drum 1 0 to determine the extent of wear Replace the brake drum if the measurement exceeds the service limit The value of this limitis indicated inside the brake drum 09900 20101 Vernier calipers Brake drum I D Service L
44. 924 84510 Bearing installer set First install the left bearing then install the spacer 2 and right bearing 3 The sealed cover of the bearing must face outside Saa RS SS mi NNSSSSNSNWNNN BRAN d 1 x SN SSS Clearance e Tighten the rear axle housing bolts to the specified torque V Rear axle housing bolt 50 N m 5 0 kgf m 36 0 Ib ft REAR BRAKE Apply SUZUKI SUPER GREASE A to the rear brake cam shaft and new O rings 99000 25010 SUZUKI SUPER GREASE or equivalent Install the new O rings into the brake camshaft hole CHASSIS 5 35 NOTE Face the groove on the camshaft to the inside Install the brake lining indicator plate D spring and rear brake cam lever 3 Align the punched mark on the cam lever with the slit B the camshaft NOTE Align the groove on the camshaft with the tongue of the indicator plate Indicator plate Rear brake camshaft Tighten the rear brake cam lever nut to the specified torque 9 Rear brake cam lever nut 7 7 N m 0 77 5 5 Ib ft Tighten the rear brake panel nut to the specified torque Q Rear brake panel nut 28 N m 2 8 kgf m 20 0 Ib ft Connect the rear brake cable 536 CHASSIS Apply SUZUKI SUPER GREASE A to the brake camshaft and pin 99000 25010 SUZUKI SUPER GREASE A or equivalent Instal
45. ARD LIMIT Piston ring groove width ist 1 01 1 03 0 0398 0 0405 1 21 1 23 151 1 53 0 0594 0 0602 Piston ring thickness ist 0 97 0 99 0 0382 0 0390 1 17 1 19 Piston pin bore 10 002 10 008 10 030 0 3938 0 3940 0 3949 Piston pin O D 9 995 10 000 9 980 0 3935 0 3937 0 3929 CONROD CRANKSHAFT Unit mm in ITEM STANDARD LIMIT Conrod small end I D 10 006 10 028 10 040 0 3939 0 3948 0 3952 Conrod deflection 3 0 0 12 Conrod big end side clearance 0 15 0 50 1 0 0 006 0 019 0 04 Conrod big end width 11 95 12 00 0 470 0 472 Crank web to web width 33 95 34 05 1 337 1 341 Crankshaft runout 0 08 0 003 CLUTCH Unit mm in Clutch housing 1 110 00 110 15 110 50 4 331 4 337 4 350 Clutch shoe thickness 4 0 3 0 0 16 0 12 Clutch engagement 2 400 3 000 r min DERE Clutch lock up 3 300 4 300 r min SERVICING INFORMATION 7 29 REDUCTION GEAR DRIVE BELT DRIVE CHAIN Unit mm in Except raito TEM LIMIT Reduction ratio Reduction gear rati Final reduction ratio Drive belt width 15 9 14 9 0 63 0 59 Movable driven face spring free length 76 8 13 0 3 02 2 87 Drive chain 0 1 0 415 602 Drive chain slack 25 35 B 1 0 1 4 CARBURETOR TEM Float height 23 4 1 0 mm 0 92 0 04 in in 3N39 ict 3 5mm 0 12 0 20 In 7 30 SERVICING INFORMATION ELECTRICAL Unit mm
46. ASSEMBLY AND REMOUNTING Reassemble and remount the carburetor in the reverse order of removal and disassembly Pay attention to the following points The O rings and gasket must be replaced with new ones AIR SCREW AND THROTTLE STOP SCREW Install the throttle stop screw 7 FUELSYSTEM 4 13 GASKET Install the gasket D The gasket must be replaced with a new one PISTON VALVE AND SPRING Install the piston valve 1 and spring to the throttle cable CARBURETOR Apply SUZUKI SUPER GREASE A to the O ring D 99000 25010 SUZUKI SUPER GREASE or equivalent The O ring must be replaced with a new one Install the piston valve to the carburetor Align the slit of the piston valve with the projec tion B on the carburetor body Install the intake pipe clamp 7 18 Tighten the carburetor mounting bolts to the specified torque V Carburetor mounting bolt 6 N m 0 6 kgf m 4 5 Ib ft 4 14 FUEL SYSTEM After remounting the carburetor perform the following Inspect fuel leakage Engine idle r min adjustment gt 2 11 Throttle cable play adjustment 2 10 CHASSIS CONTENTS EXTERIOR PARTSu S 5 2 CONSTRUCTION uuu u 5 2 FASTENER REMOVAL AND INSTALLATION
47. C 572 10 to 11 POWER REDUCTION SPACER The power reduction spacer has been installed inside of the movable drive WARNING Do not remove the power reduction spacer until the rider develops sufficient skills to operate LT Z50 safety at the maximum speed with the power reduc tion system in place REMOVAL e Remove the left frame cover C 5 4 e Remove the CVT case cover C 73 11 e Remove the starter cup 73 11 e Remove the fixed drive face 0773 11 Remove the movable drive spacer 4 and power reduction spacer REMOUNTING Reinstall the movable drive in the reverse order of removal ENGINE 3 9 ENGINE DISASSEMBLY SPARK PLUG Remove the spark plug with a spark plug wrench CYLINDER HEAD COVER Remove the cylinder head cover D and its gasket GENERATOR COVER Remove the generator cover 1 A Hooked part CYLINDER HEAD Turn the crankshaft counterclockwise to bring the line on the generator rotor to the index mark of the generator case NOTE When removing the cylinder head piston must be at TDC on compression stroke Remove the cylinder head bolts NOTE Loosen the cylinder head bolts little by little and diagonally Remove the cylinder head CD NOTE Rocker arm and valve disassembly 3 15 3 10 ENGINE Remove the push rods Q Remove the gasket 3 and dowel pins STARTER MOTOR Remove the starter motor 1 GENERATOR Re
48. EASE A to the oil seal lip 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the bearing with the special tool 09913 70210 Bearing installer set Install the snap ring securely Install the oil seal with the special tool 09913 70210 Bearing installer set Apply SUZUKI SUPER GREASE A to the oil seal lip 99000 25010 SUZUKI SUPER GREASE A or equivalent BUSHING INSPECTION Inspect the CVT case bushing for wear or damage If anything unusual is found replace the bushing with a new one REASSEMBLY Install the counter shaft D into the CVT case with a plastic mallet ENGINE 3 31 332 ENGINE Apply MOLYBDENUM OIL SOLUTION to the inside of the drive shaft journal MOLYBDENUM OIL SOLUTION Install the washer 2 to the drive shaft Install the drive shaft to the CVT case Install the washer and Install the dowel pins Apply final reduction gear box oi to the gears Apply SUZUKI BOND 1215 to the final reduction gear box cover matching surface 99000 31110 SUZUKI BOND 1215 or equivalent NOTE Make surfaces free from moisture oil dust and other foreign materials Spread on surfaces thinly to from an even layer and assemble the cover within few minutes Tighten the final reduction gear box cover bolts and drain plug D to the specified torque 9 Final reduction gear box cover bolt 11
49. FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI LT Z50 and procedures for its inspec tion service and overhaul of its main components Other information considered as generally known is GENERAL INFORMATION not included Read the GENERAL INFORMATION section to familiarize yourself with the vehicle and its mainte PERIODIC MAINTENANCE nance Use this section as well as other sections to use as a guide for proper inspection and service This manual will helo you know the vehicle better so ENGINE that you can assure your customers of fast and reli able service This manual has been prepared on the basis FUEL SYSTEM of the latest specifications at the time of publi cation If modifications have been made since then differences may exist between the con tent of this manual and the actual vehicle CHASSIS Illustrations in this manual are used to show the basic principles of operation and work ELECTRICAL SYSTEM procedures They may not represent the actual vehicle exactly in detail This manual is written for persons who have enough knowledge skills and tools including special tools for servicing SUZUKI vehicles If you do not have the proper knowledge and tools ask your authorized SUZUKI motorcy cle dealer to help you WARNING Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the SERVICING INFORMATION
50. G INSTALLATION Press fit the bearing with the bearing installer and suitable plate as shown in the illustration Press fit the cam drive gear 1 with the suitable tool Phase angle between the crank pin center and the cam drive gear engraved line 0 30 Right crankshaft bearing Cam drive gear Crankshaft ENGINE 3 27 CONROD BIG END SIDE CLEARANCE INSPECTION Push the big end of the conrod to one side and measure the Side clearance with a thickness gauge If the clearance exceeds the limit replace the crankshaft assem bly with a new one or bring the deflection and the side clearance within the service limit by replacing the worn parts conrod crank pin bearing crank pin etc with the new ones Conrod big end side clearance Service Limit 1 0 mm 0 04 in 09900 20803 Thickness gauge CRANKSHAFT RUNOUT Support the crankshaft with V blocks as shown with the two end journals resting on the blocks Position the dial gauge as shown and rotate the crankshaft Slowly to read the runout Replace the crankshaft if the runout is more than the service limit Crankshaft runout Service Limit 0 08 mm 0 003 in 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block set 100 mm CRANKSHAFT REASSEMBLY When rebuilding the crankshaft the width between the webs should be within the specified range Crank web to web width Standard 33 95 34 05 mm 1 337 1
51. Garces nce d u 2Y 7 23 FUEL eee JK un suu SS u uuu 7 23 CHASSIS 0 4 7 24 TIGHTENING TORQUE CHART 7 25 7 2 SERVICING INFORMATION TROUBLESHOOTING ENGINE ENGINE WILL NOT START OR IS HARD TO START Symptom possible causes and remedy 1 Compression too low Valve clearance out of adjustment Worn valve guides or poor seating of valves Mistimed valves Excessively worn piston rings Worn down cylinder bore Starter motor cranks too slowly Poor seating of spark plug Gas leaks from the joint in cylinder or cylinder head Loose spark plug Broken cracked or damaged piston 2 Plug not sparking Damaged spark plug Damaged spark plug cap Fouled spark plug Wetspark plug Defective CDI unit Defective ignition coil Open circuited wiring connections Defective generator coil 3 No fuel reaching the carburetor Clogged fuel hose Clogged or defective fuel valve Defective carburetor needle valve Clogged fuel filter ENGINE STALLS OFTEN Symptom possible causes and remedy Fouled spark plug e Defective CDI unit Defective ignition coil Clogged fuel hose Clogged carburetor jets Clogged exhaust pipe Damaged cylinder head gasket Valve clearance out of
52. NANCE Fill a container with a non flammable cleaning solvent Immerse the air cleaner element in the cleaning solvent and wash it Squeeze the cleaning solvent out of the washed element by pressing it between the palms of both hands do not twist or wring the element or it will develop tears Immerse the element in motor oil and squeeze the oil out of the element leaving it slightly wet with oil Inspect the air cleaner element for tears A torn ele ment must be replaced Non flammable cleaning solvent Motor oil SAE 30 Reinstall the cleaned air cleaner element in the reverse order of removal e When installing the air cleaner box cap Q gt face the UP mark to the top Be sure to position the element snugly and correctly so that no incoming air will by pass it Remember the rapid wear of piston rings and the cylinder bore is often caused by a defective or poorlv fitted element If driving under dusty conditions clean the air cleaner element more frequently The surest way to accelerate engine wear is to operate the engine without the ele ment or to use a torn element Make sure that the air cleaner is in good condition at aii times The life of the engine depends largely on this component PERIODIC MAINTENANCE 2 5 EXHAUST PIPE NUTS AND MUFFLER MOUNTING BOLT Tighten initially at 1 month and every 3 months there after Tighten the exhaust pipe nuts D and muffler mounting bolt
53. ON SPECIFICATIONS DIMENSIONS AND DRY MASS OV ST mM 270 mm 50 0 in Overall lotio u ua uu 760 mm 29 9 in Overall 765 mm 30 1 in WCCO vita anna 830 mm 32 7 in Ground Clearance uu uu yuy u aei Ra 120 mm 4 7 in 535 mm 21 1 in o LM DEI EDU E LE EIN 575 mm 22 6 in 575 mm 22 6 in Dy NIIS T 76 kg 167 Ibs ENGINE jug eT Four stroke air cooled OHV N mber ak tenes sae iot Lu u 1 BOTE 36 0 mm 1 417 in SOK 2 tia ac doe ms 48 6 mm 1 913 in DISDlacembhib wd 49 cm 3 0 cu in CORTDNESSION Fa 10 IM nu EE I Pa 8 4 1 C ID fe Ou EE S MIKUNI VM13 single PAU Polyurethane foam element Starter SVSTOTTL a Electric and recoil starter Idle 5 n rra cc e OE 2 000 x 150 r min DRIVE TRAIN Reduction s 2 091 1 879 Variable change Reduction gear MAU 4 272 47 11 Final reduction ratio Be 97 3 700 37 10 Drive Chain P VAS D I D 415
54. OUBLESHOOTING cisscsossossstsssesesseensissiucsuessssvensensensensatsauensensensaneaneess 6 11 STARTER MOTOR REMOVALL I I 6 12 STARTER MOTOR DISASSEMBI Y II U 6 13 STARTER MOTOR INSPECTION a 6 14 STARTER MOTOR REASSE MBI Y 6 15 STARTER MOTOR INSTALLATION 6 16 STARTER RELAY INSPECTION 6 16 IGNITION SYSTEM C I U U U U 6 18 TROUBLESHOOTING 6 18 6 20 quie 6 23 BATTERY GQ7 U U J J J 6 24 SPECIFICATIONS U U U U 6 24 INITIAL CHARGING 6 24 SERVICING 6 26 RECHARGING 6 26 62 ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTOR When disconnecting a connector be sure to hold the termi nals and do not pull the lead wires e When connecting a connector be sure to push it in until Click is felt Inspect the connector for corrosion contamination and break age in its cover COUPLER With a lock type coupler be sure to release the lock when dis connecting a
55. USPENSION TOO STIFF Symptom possible causes and remedy e Bent shock absorber shaft Worn suspension arms and related bushing NOISY FRONT SUSPENSION Symptom possible causes and remedy Loose nuts or bolts on suspension Worn suspension arms and related bushings WOBBLY REAR WHEEL Symptom possible causes and remedy Distorted wheel rims Damaged or worn rear axle housing bearings Defective or incorrect tires Defective rear axle Loose nuts or bolts on rear suspension Loose rear wheel hub nuts Loosen rear axle housing mounting bolts Improper rear brake adjustment Rear shock absorber leaks oil Damaged or worn rear swingarm and related bush ings REAR SUSPENSION TOO SOFT Symptom possible causes and remedy Weakened spring of shock absorber Leakage of oil from shock absorber REAR SUSPENSION TOO STIFF Symptom possible causes and remedy e Bent shock absorber shaft Worn swingarm and related bushings NOISY REAR SUSPENSION Symptom possible causes and remedy Loose nuts or bolts on rear suspension Worn swingarm Replace Replace Replace Replace etighten Replace Replace Replace Replace Replace Retighten Tighten Tighten Adjust Replace Replace Replace Replace Replace Replace etighten Replace BRAKES INSUFFICIENT BRAKE POWER Symptom possible causes and remedy Worn brake drum Oil adhesion on frict
56. VAL Before taking the engine out of the frame wash the engine using a steam cleaner Engine removal is sequentially explained in the following steps Drain engine C gt 2 9 e Remove the frame center cover 75 5 MUFFLER Remove the exhaust pipe nuts Remove the muffler mounting bolt Remove the muffler CD FOOTREST Remove the left footrest D CARBURETOR Turn the fuel valve to ON position Remove the fuel hose e Loosen the intake pipe clamp bolt Remove the drain hose from the clamp 3 4 ENGINE Remove the vacuum hose 5 Remove the carburetor assembly DRIVE CHAIN Remove the clip D Remove the drive chain 2 ELECTRICAL PARTS AND HOSES e Disconnect the starter motor lead wire coupler CD e Disconnect the generator lead wire coupler e Remove the ground wire 3 Remove the breather hose 4 Remove the spark plug cap Remove the rear brake cable guide Remove the breather hose 7 ENGINE 3 5 ENGINE MOUNTING BRACKET AND BOLTS e Remove the engine mounting bracket D Remove the engine mounting bolts and nuts Remove the engine from the left side 3 6 ENGINE ENGINE INSTALLATION Install the engine in the reverse order of engine removal Pay attention to the following points Engine mounting bolt 25 mm Engine mounting bolt 40 mm Engine mounting bot
57. adjustment Adjust Repair or replace Adjust Replace Replace See electrical section etighten Repair or replace Tighten Replace Replace Replace Clean or replace Clean and dry Replace Replace Repair or replace Replace Clean or replace Clean or replace Replace Clean or replace Clean Replace Replace Clean Clean Clean Replace Adjust NOISY ENGINE Symptom possible causes and remedy 1 Excessive valve chatter Too large valve clearance Weakened or broken valve springs Worn rocker arm or cam surface 2 Noise seems to come from piston Worn down piston or cylinder Combustion chamber fouled with carbon Worn piston pin or piston pin bore Worn piston rings or ring grooves 3 Noise seems to come from clutch Weak clutch shoe spring 4 Noise seems to come from crankshaft Rattling bearings due to wear Worn and burnt journal bearings Too large thrust clearance 5 Noise seems to come from the movable drive and driven face Worn or slipping drive belt Worn rollers in movable drive face CLUTCH SLIPS Symptom possible causes and remedy Worn or damaged clutch shoe Worn clutch housing ENGINE IDLES POORLY Symptom possible causes and remedy Valve clearance out of adiustment Poor seating of valves Defective valve guides Worn down camshaft Worn cylinder Worn piston rings Stiff piston rin
58. all the washer 1 Install the movable drive face assembly 2 and fixed drive face 3 NOTE Degrease the drive belt contact surfaces Install the starter cup assembly wave washer and fixed drive face nut NOTE The concave side of the washer must face the starter cup 4 Tighten the fixed drive face nut to the specified torque with the special tool 09930 40113 Rotor holder V Fixed drive face nut Initial 13 N m 1 3 kgf m 9 5 Ib ft Final 50 N m 5 0 kgf m 36 0 Ib ft NOTE Turn the fixed drive face until the drive belt is seated in and both the drive and driven faces will move together smoothly without slip CVT CASE COVER Install the dowel pins 1 and gasket 2 The removed gasket must be replaced with a new one Install the starter pinion 3 Install the CVT case cover 4 Tighten the CVT case cover bolts to the specified torque V CVT case cover bolt 11 N m 1 1 8 0 lb ft NOTE Tighten the bolt together with the clamp 5 Tighten the bolt together with the earth terminal after remounting the engine GENERATOR ROTOR Tighten the generator coil bolts and pick up coil bolts 2 Pass the generator lead wire to the generator case groove V Generator coil bolt 10 1 0 kgf m 7 0 Ib ft Pick up coil bolt 4 5 N m 0 45 kgf m 3 0 Ib ft Install the key 3 NOTE Degrease the tapered portion of the crankshaft
59. and CAUTIONS stated you must use good judgement and basic mechanical safety principles If you are unsure about how to perform a particular service operation ask a more experienced mechanic for advice GENERAL PRECAUTIONS Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the vehicle When 2 or more persons work together pay attention to the safety of each other When it is necessary to run the engine indoors make sure that exhaust gas is forced out doors When working with toxic or flammable materials make sure that the area you work in is well ventilated and that you follow all of the materia manufacturer s instructions Never use gasoline as a cleaning solvent To avoid getting burned do not touch the engine engine oil final reduction gear box oil and exhaust system until they have cooled After servicing the fuel or exhaust systems check all lines and fittings related to the system for leaks GENERAL INFORMATION 1 3 If parts replacement is necessary replace the parts with Suzuki Genuine Parts or their equiva lent When removing parts that are to be reused keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation Be sure to use special tools when instructed Make sure that all parts used in reassembly are clean Lubricate them when specified Use the specified lubrica
60. and gasket CAM ROCKER ARM Remove the washer D and camshaft assembly Remove the washer 3 spring and cam rocker arms 5 3 14 ENGINE UPPER CRANKCASE CYLINDER AND LOWER CRANK CASE Remove the crankcase bolts Remove the dowel pins D CRANKSHAFT Remove the crankshaft D together with piston e Remove the crankshaft bearing retainer PISTON Remove the piston pin circlip CD e Remove the piston pin and piston ENGINE 3 15 ENGINE COMPONENTS INSPECTION AND SERVICING CYLINDER HEAD DISASSEMBLY Remove the intake pipe and insulator 2 Pull out the rocker arm shaft e Remove the intake rocker arm 4 and exhaust rocker arm Push the spring retainer by the finger and move it side ways Remove the spring retainer from the groove of the valve stem Remove the valve spring 7 e Pull out the intake valve 8 and exhaust valve 3 16 ENGINE Remove the intake valve stem seal with an acute angle bar The removed valve stem seal must be replaced with a new one ROCKER ARM SHAFT INSPECTION Inspect the rocker arm shaft for abnormal wear or damage If itis worn or damaged replace it with a new one ROCKER ARM INSPECTION Inspect the rocker arm for abnormal wear or damage If they are worn or damaged replace them with new ones CYLINDER HEAD DISTORTION Decarbonize the combustion chamber Check the gasket surface of the
61. arbox Gv ww Replace every 2 years Throttle cable play P 44 l lo o Idle speed re _ o Drive belt P 1 R Drive chain marne vehicle is ridden pues QA semn A AC 141 Suspensions l Z a Generallubrications L L NOTE Inspect and clean adjust replace or lubricate as necessary R Replace T Tighten Clean L Lubricate PERIODIC MAINTENANCE 2 3 MAINTENANCE AND TUNE UP PROCEDURES This section describes the servicing procedures for each item of the periodic maintenance requirements Before performing the servicing procedures mentioned in the periodic maintenance chart remove following parts to ease ser vicing work Seat C 5 4 Front frame cover 75 4 Left frame cover gt 5 4 Right frame cover C 5 5 4 e Frame center cover _7 5 5 e Maintenance lid 75 6 Front grip C5 5 6 AIR CLEANER Clean every 3 months If the air cleaner is clogged with dust intake resistance will be increase resulting in a decrease in engine output and an increase in fuel consumption Clean the air cleaner element in the following manner e Remove the seat C gt 5 4 e Remove the battery holder C 775 5 Remove the air cleaner box cap D e When installing the air cleaner box cap 4 face the UP mark to the top Remove the air cleaner element 2 4 PERIODIC MAINTE
62. arger specially designed for MF battery For charging the battery make sure to use the charger specially designed for MF battery Other wise the battery may be overcharged resulting in shortened service life Do not remove the cap during charging Position the battery with the cap facing upward during charging 6 26 ELECTRICAL SYSTEM SERVICING Visually inspect the surface of the battery container If any signs of cracking or electrolyte leakage from the sides of the battery have occurred replace the battery with a new one If the battery terminals are found to be coated with rust or an acidic white powdery substance clean the battery terminals with sandpaper RECHARGING OPERATION e Using the multi circuit tester check the battery voltage If the voltage reading is 12 0 V DC and less recharge the battery with a battery charger A Charging period Stop charging When recharging the battery remove the battery from the vehicle Do not remove the caps on the battery top while recharging Recharging time 0 5 A for 5 to 10 hours or 5 A for 30 min utes Be careful not to permit the charging current to exceed 5 A at any time After recharging wait for 30 minutes and more and check the battery voltage with a multi circuit tester If the battery voltage is the 12 5 V and less recharge the bat tery again f battery voltage is still 12 5 V and less after recharging replace the battery with a new
63. arter relay resistance 70 900 ELECTRICAL SYSTEM 6 17 6 18 ELECTRICAL SYSTEM IGNITION SYSTEM Br B VID Parking brake CDI unit W R unl O W O Q switch O W Engine stop O G Ignition coil Remote engine Spark W R Br B W stop switch B W plug Ignition switch Pick Generator ue up To g R R TROUBLESHOOTING No spark or poor spark NOTE Check that the engine stop switch parking brake switch and remote engine stop switch are in the RUN ON and SET positions Check that the fuse is not blown and the battery is fully charged before diagnos ing Step 1 1 Check the ignition system couplers for poor connections Is there connection in the ignition system couplers Go to Step 2 NO Poor connection of couplers ELECTRICAL SYSTEM 6 19 Step 2 1 Measure the battery voltage between input lead wires O W and B W at the CDI unit with the ignition switch in the ON position Is the voltage OK VES 3 Faulty ignition switch Faulty remote engine stop switch s Faulty engine stop switch Broken wiring harness or poor connection of related circuit couplers Step 3 1 Measure the ignition coil primary peak voltage 6 20 NOTE This inspection method is applicable only with the multi circuit tester and the peak volt adaptor Is the peak voltage OK YES Go to Step 4 No Goto Step 5 Step 4 1 Inspect the spark plug gt 2 7 Is the
64. ce the generator coil with a new one PICK UP COIL RESISTANCE e Remove the left frame cover 75 4 Disconnect the generator coupler 0 Measure the resistance with the multi circuit tester If the resis tance is not within the standard range replace the generator coll 09900 25008 Multi circuit tester set Tester knob indication Resistance 0 Pick up coil resistance 150 230 O Brown Ground Generator m ELECTRICAL SYSTEM 6 23 SWITCHES Measure each switch for continuity using a multi circuit tester If any abnormality is found replace the respective switch assemblies with new ones 09900 25008 Multi circuit tester set Tester knob indication Continuity test IGNITION SWITCH PARKING BRAKE SWITCH SET WIRE COLOR Orange B W Black with White tracer R Red B Y Black with Yellow tracer O G Orange with Green tracer O W Orange with White tracer W B White with Black tracer Y G Yellow with Green tracer 6 24 ELECTRICAL SYSTEM BATTERY SPECIFICATIONS Type designation YTX5L BS 12 V 14 4 4 Ah 10 HR CD Upper cover breather Terminal 2 Cathode plates 6 Safety valve 3 Stopper 7 Anode plates 4 Filter Separator Fiberglass plate INITIAL CHARGING Filling electrolyte Remove the aluminum tape D sealing the battery electrolyte filler holes A NOTE When filling electrolyte the battery must be removed from the vehicle and must
65. ch Handlebar switch L Clamp Engine ground Clamp Remote engine stop switch case z Generator NJ 9 eet Starter motor SERVICING INFORMATION 7 15 V 225 Generator lead wire gt Starter motor lead wire Handleber switch leadwire 7 16 SERVICING INFORMATION CABLE ROUTING 3 5mm Front brake cable R _ 0 12 0 20 in Rear brake cable Throttle cable Front brake cable L i 0 p arant m Align the clearance less than 1 mm difference between W1 and W2 Sy co Tp m Front brake cable R Front brake cable R Front brake cable L Throttle cable Rear brake cable Wiring harness Front brake cable L Front brake cable R L Front brake cable Wiring harness x Throttle cable LS Bracket Hear brake cable p Align the slit of rottle cable Bolt Front brake cable T bracket with Rear brake cable axle housing Front brake cable R y ES 7 Front brake Bracket Threaded cable L Cable guide portion 3 5mm 0 12 0 20 in x gt E 7 2 3 0 08 0 12 in 75 Rear brake cable Fix the boot to the rear brake cable SERVICING INFORMATION 7 17 FUEL HOSE PIPING Front brake cable L Front brake cable R
66. cial tool 09913 70210 Bearing installer set First install the wheel hub inner bearing then install the spacer and outer bearing The sealed cover of the bearing must face outside Install the wheel hub outer bearing with the special tool 09924 84521 Bearing installer set Clearance Apply 3 grams of grease to the each dust seal lip before installing it Install the dust seals with the special tool 09913 70210 Bearing installer set A 99000 25161 WATER RESISTANCE GREASE or equiv alent CHASSIS 5 15 Apply SUZUKI SUPER GREASE A to the camshaft 99000 25010 SUZUKI SUPER GREASE A or equivalent Align the punched mark of the brake cam lever with the slit of the front brake camshaft Apply SUZUKI SUPER GREASE A to the front brake cam shaft and pin and install the brake shoes 99000 25010 SUZUKI SUPER GREASE A or equivalent A WARNING Be careful not to apply too much grease to the cam and If grease gets on the lining brake siippage will result Install the front wheel hub and spring Tighten front brake cam lever nutto the specified torque Q Front brake cam lever nut 3 3 N m 0 33 kgf m 2 5 Ib ft Tighten the front hub nut 3 to the specified torque V Front hub nut 65 N m 6 5 kgf m 47 0 Ib ft Install the new cotter pin to the nut Install the front wheel gt 5 8 After installi
67. cuiting Internally short circuited generator Defective regulator rectifier START BUTTON IS NOT EFFECTIVE Symptom possible causes and remedy Run down battery Defective switch contacts Brushes not seating properly on starter motor commutator Defective starter relay Defective main fuse SERVICING INFORMATION 7 11 Repair or replace Replace Replace Repair or replace Replace Repair or replace Replace Replace 7 12 SERVICING INFORMATION BATTERY SULFATION ACIDIC WHITE POWDERY SUBSTANCE OR SPOTS ON SURFACE OF CELL PLATES Symptom possible causes and remedy Cracked battery case Battery has been left in a run down condition for a long time BATTERY RUNS DOWN QUICKLY Symptom possible causes and remedy Trouble in charging system Cell plates have lost much of their active material as a result of overcharging Internal short circuit in the battery Too low battery voltage Too old battery BATTERY SULFATION Symptom possible causes and remedy Incorrect charging rate When not in use battery should be checked at least once a month to avoid sulfation The battery was left unused in a cold climate for too long Replace the battery Replace the battery Check the generator regulator rectifier and circuit connections and make necessary adjustments to obtain specified charging operation Replace the battery and correct the chargin
68. 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 service limit replace the cylinder head Cylinder head distortion Service Limit 0 05 mm 0 002 in 09900 20803 Thickness gauge VALVE FACE WEAR Visually inspect each valve for wear or damage of its seating face If anything unusual is found replace the valve with a new one Measure the valve head thickness D If the thickness is less than the service limit replace the valve with a new one Valve head thickness IN amp EX Service Limit 0 5 mm 0 02 in 09900 20102 Vernier calipers VALVE STEM RUNOUT Support the valve on V blocks and measure the valve stem runout If the valve stem runout exceeds the service limit replace the valve Valve stem runout IN amp EX Service Limit 0 05 mm 0 002 in 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block set 100 mm VALVE HEAD RADIAL RUNOUT Place the dial gauge at right angles to the valve head face and measure the valve head radia runout If the valve head radial runout exceeds the service limit replace the valve Valve head radia runout IN amp EX Service Limit 0 03 mm 0 001 in 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block set 100 mm VALVE STEM DEFLECTION Liftthe valv
69. e after Check that all chassis nuts and bolts are tightened to their specified torque Refer to page 2 21 for the loca tions of the following nuts and bolts mem mg ff 26 26 m Front shock absorber bolt upper 0 lower 9 Front hub nut Wheel set nut front and rear 15 78 _ PERIODIC MAINTENANCE 2 21 2 22 PERIODIC MAINTENANCE GENERAL LUBRICATIONS Lubricate every 3 months Proper lubrication is important for smooth operation and long life of each working part of the vehicle Major lubrication points are indicated below Steering shaft holder 2 Brake lever holder 3 Brake cable 4 Throttle cable 5 Drive chain 6 Throttle lever NOTE Before lubricating each part remove any rust and wipe off any grease oil dirt or grime Lubricate exposed parts which are subject to rust with a rust preventative spray especially whenever the vehicle has been operated under wet or rainy conditions PERIODIC MAINTENANCE 2 23 COMPRESSION PRESSURE CHECK The compression pressure reading of a cylinder is a good indicator of Its internal condition The decision to overhaul the cylinder is often based on the results of a compression test Periodic mainte nance records kept at your dealership should include compression readings for each maintenance service Compression pressure Standard 1 100 1 200 kPa 11 12 kgf cm 156 171 psi Limit 800 kPa 8 kgf cm 114 psi Lo
70. e cylinder head cover to the specified torque V Cylinder head cover bolt 11 N m 1 1 kgf m 8 0 Ib ft Install the removed parts PERIODIC MAINTENANCE 2 7 SPARK PLUG Inspect every 6 months Replace every 18 months Disconnect the spark plug cap D and remove the spark plug 2 sued CR6HSA CR7HSA DENSO U20FSR U U22FSR U CARBON DEPOSITS Check carbon deposits on the spark plug f carbon is deposited remove it using a spark plug cleaner machine or carefully use a tool with a pointed end SPARK PLUG GAP Measure the spark plug gap with a thickness gauge Adjust the spark plug gap if necessary Spark plug gap Standard 0 6 0 7 min 0 024 0 028 in 09900 20803 Thickness gauge 0 6 0 7 mm 0 024 0 028 in ELECTRODE S CONDITION Check the condition of the electrode If itis extremely worn or burnt replace the spark plug Replace the spark plug if it has a broken insulator damaged thread etc 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 engine dam age may result 2 8 PERIODIC MAINTENANCE SPARK PLUG INSTALLATION CAUTION To avoid damaging the cylinder head threads first tighten the spark plug by hand and then tighten it to the specified torque using the spark plug wrench Tighten the spark plug to the specified torque V
71. e defects listed below Support the vehicle by a jack and a wooden block turn the rear wheel slowly by hand Loose pins Twisted or seized links Damaged rollers Excessive wear Rusted links Kinked or binding links If any defects are found the drive chain must be replaced The standard drive chain is 041 0 415 SUZUKI recom mends to use this standard drive chain as a replace ment NOTE When replacing the drive chain replace the drive chain and sprockets as a set CHECKING e Loosen the bolts 1 Tense the drive chain fully by turning both chain adjusters 2 Count out 21 pins 20 pitch on the chain and measure the distance between the two points If the distance exceeds the service limit the chain must be replaced Drive chain 20 pitch length Service limit 259 0 mm 10 20 in ADJ USTING Place the vehicle on level ground Loosen or tighten both chain adjusters D equally until the chain has 25 35 mm 1 0 1 4 in of slack at the middle of the chain between the engine and rear sprockets as shown Drive chain slack Standard 25 35 mm 1 0 1 4 in e After adjusting the drive chain tighten the bolts 2 to the specified torque V Rear axle housing bolt 50 N m 5 0 kgf m 36 0 ib ft Recheck the drive chain slack NOTE After drive chain adjustment adjustthe rear brake Rear brake adjustment 0 72 17 CLEANING AND LUBRICATING e Remove the righ
72. e head 10 mm 0 39 in from the valve seatand mea sure the deflection in X and Y directions as shown If the deflection exceeds the service limit measure the valve stem outside diameter Valve stem deflection IN amp EX Service Limit 0 35 mm 0 014 in 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand ENGINE 3 17 3 18 ENGINE VALVE STEM WEAR If the valve stem is worn down to the limit as measured with a micrometer replace the valve If the stem is within the limit replace the cylinder head After replacing the valve be sure to recheck the deflection Valve stem O D Standard IN 3 975 3 990 mm 0 1565 0 1571 in EX 3 960 3 975 mm 0 1559 0 1565 in 09900 20205 Micrometer 0 25 mm VALVE SEAT Install the valve and valve spring after cleaning Pour a small quantity of gasoline into the intake or exhaust port Check that no gasoline leaks through the valve seat If leakage is found replace the cylinder head A WARNING Always use extreme caution when handling gasoline VALVE STEM END CONDITION Inspect the valve stem end face for abnormal wear or damage If abnormal wear or damage is found resurface the valve stem end If the length is less than the service limit the valve must be replaced Valve stem end length IN amp EX Service Limit 3 0 mm 0 12 in 09900 20102 Vernier calipers VALVE SPRING The force of the coil spring keeps the valve sea
73. e stem groove Make sure that the spring retainer fits snugly into the groove on the valve stem end Apply engine oil to the rocker arm shaft Install the rocker arm shaft 3 Install the new O rings to the intake pipe and insulator Tighten the intake pipe bolts to the specified torque V Intake pipe bolt 6 N m 0 6 kgf m 4 5 Ib ft ROCKER ARM PUSH ROD INSPECTION Inspect the rocker arm push rods for abnormal wear damage or gt bend If any abnormal condition is found replace the push rod with a new one ENGINE 3 21 CAMSHAFT ASSEMBLY INSPECTION Check the camshaft for abnormal wear or damage Measure cam height with a micrometer If the cam height is less than the service limit replace the camshaft assembly with a new one Cam height IN amp EX Service Limit 28 13 mm 1 1075 in Do not attempt to disassemble the camshaft assem bly 09900 20202 Micrometer 25 50 mm Install the camshaft assembly as shown in the photograph if disassemble it NOTE Align the shaft punch mark with the cam punch mark Assemble the springs CD diagonally 1 Spring UPPER CRANKCASE CYLINDER BUSHING Inspect the bushing for wear or damage If any defects are found replace it with a new one CYLINDER DISTORTION Check the gasket surface of the cylinder for distortion with a straightedge and thickness gauge taking a clearance reading at
74. f they are worn as illus trated replace the sprocket and drive chain Normal wear B Excessive wear e Unlock the rear sprocket washer 1 Remove the bolts and rear sprocket 2 e Remove the rear sprocket washer 1 CAUTION The removed rear sprocket washer must be replaced with new ones CHASSIS 5 33 DUST SEAL Remove the dust seals with the special tool 09913 50121 Oil seal remover The removed dust seals must be replaced with new ones BEARING Inspect the play of the rear axle housing bearings by finger while they are in the rear axle housing Rotate the inner race by finger to inspect it for abnormal noise and smooth rotation If there is anything unusual replace the bearing with a new one Remove the rear axle housing bearings with the special tool 09921 20240 Bearing remover set The removed bearings should be replaced with new ones Remove the spacer 1 REASSEMBLY AND REMOUNTING Reassemble and remount the rear brake and rear axle housing in the reverse order of removal and disassembly P ay attention to the following points BEARING AND REAR AXLE HOUSING Apply SUZUKI SUPER GREASE A to the rear axle housing bearings and the lip of the dust seals before installing them 99000 25010 SUZUKI SUPER GRESE A or equivalent 534 CHASSIS Install the rear axle housing bearing with the special tool Install the dust seals with the special tool 09
75. fer to the appropriate instruction manual Turn the ignition switch to the ON position Press the starter button and allow the engine to crank for a few seconds and then measure the ignition coll primary peak voltage Repeat the above procedure a few times and measure the highest ignition coil primary peak voltage Tester knob indication Voltage Ignition coil primary peak voltage 150 V and more WARNING While testing do not touch the tester probes and spark plug to prevent receiving an electric shock If the voltage is lower than the standard values inspect the igni tion coil C 76 21 Ignition coil 4 New Spark plug ELECTRICAL SYSTEM 6 21 IGNITION COIL RESISTANCE Disconnect the ignition coil lead wires and spark plug cap and remove the ignition coil Measure the ignition coil resistance in both the primary and sec ondary windings with the multi circuit tester If the resistance is not within the standard range replace the ignition coll 09900 25008 Multi circuit tester set Tester knob indication Resistance Ignition coil resistance Primary 0 1 0 7 Terminal Terminal Secondary 14 20 ko Spark plug cap Terminal PICK UP COIL PEAK VOLTAGE Remove the seat C 775 4 NOTE Make sure all of the couplers are connected properly Disconnect the CDI unit coupler 1 Measure the pick up coil peak voltage in the following
76. front and rear The use of tires other than those specified may cause instability It is highly recommended to use the specified tires PERIODIC MAINTENANCE 2 19 STEERING Inspect initially at 1 month and every 3 months there after Steering system should be adjusted properly for smooth manip ulation of the handlebar and safe running TOE IN Place the vehicle on level ground lt Q Make sure the tire pressure for both tire is the same and setto the proper specification Set the front wheels in the straight position e Place a load of 30 kg 66 Ibs on the seat 1 Measure the distance B of the front wheels with a toe in gauge as shown and calculate the difference between and Standard 1 5 3 0 06 0 12 in f the toe in is out of specification bring it into the specified range 75 28 SUSPENSIONS Inspect every 6 months Support the vehicle with a jack and wooden blocks e Remove the front and rear wheels C 5 5 8 e Inspect the suspension arm Swingarm and bushing for scratches wear or defect If any defects are found replace them with new ones C 575 19 and 5 40 Inspect the front and rear shock absorbers for oil leakage or defects If any defects are found replace them with new ones 0775 19 and 5 40 2 20 PERIODIC MAINTENANCE CHASSIS NUTS AND BOLTS Tighten initially at 1 month and every 3 months ther
77. g sys tem Replace the battery Recharge the battery fully Replace the battery Replace the battery Replace the battery if badly sulfated SERVICING INFORMATION 7 13 WIRING DIAGRAM LINN IGO HOLOINN d3lHVlS AdH3llV8 o N d AV 13H dilHvis YOLVYANAD 831514934 HOLIMS 39 4015 ALOWSAY 135 5 7 ae ME z T 2 a 4 a Ox 200 Y VOL MOD xog asn4J HOLIMS 3 Vaa ONDIaVd 3NION3 15 16064 MOJA D A 28064 SHUM H M 10064 Yeg G M 19981 SHUM M H 2006 YOR G g d 1999 SHUM M O D O 1 g o 19981 YUM YOR G A G 19981 SHUM M Z 4 JG weld L OF 0 40 HOLIMS NOLLINSI 7 14 SERVICING INFORMATION WIRING HARNESS CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Battery plus terminal CDI unit Battery minus terminal Starter relay Clamp Clamp Wiring harness Generator Storter motor Wiring harness Clamp Remote engine stop switch To the rear fender Regulator rectifier Ignition swit
78. gs Excessive spark plug gap Defective CDI unit Defective ignition coil Defective generator coil Incorrect float chamber fuel level Clogged carburetor jet Adjust Replace Replace Replace Clean Replace Replace Replace Replace Replace Replace bearing retainer Replace Replace Replace Replace Adjust Replace or repair Replace Replace Replace Replace Replace Adjust or replace Replace Replace Replace Adjust float height Clean SERVICING INFORMATION 7 3 7 4 SERVICING INFORMATION ENGINE RUNS POORLY IN HIGH SPEED RANGE Symptom possible causes and remedy Weakened valve springs Replace Worn camshaft Replace Valve timing out of adjustment Adjust Too narrow spark plug gap Adjust Ignition not advanced sufficiently due to poorly Replace working timing advance circuit Defective CDI unit Replace Defective ignition coil Replace Defective generator coil Replace Low float chamber fuel level Adjust float height Clogged fuel hose resulting in inadequate fuel Clean and prime supply to the carburetor Clogged fuel valve Clean Clogged air cleaner element Clean or replace Sucking air from carburetor joint Repair or replace ENGINE LACKS POWER Symptom possible causes and remedy Loss of valve clearance Weakened valve springs Valve timing out of adjustment Worn pisto
79. he Research Method Gasoline containing MTBE Methyl Tertiary 03 28 Butyl Ether less than 10 95 ethanol or less than 5 methanol with appropriate cosolvents and corrosion inhibitor is permissible Gasoline used should be graded 91 octane or higher The others An unleaded gasoline is recommended Fuel tank capacity 261 0 7 0 6 US Imp gal Engine oil type SAE 10W 40 SF SG or SH SJ with ASO MA Engine oil capacity 300 ml Change 0 6 0 5 US Imp qt 350 ml 0 7 0 6 US Imp qt Final reduction gear box oil type SAE 10W 40 SF SG or SH SJ with ASO MA Final reduction gear box oil capacity 25 ml 0 8 0 9 US Imp oz 30 ml 1 0 1 1 US Imp oz Overhaul LT Z50K9 09 8 1 LT Z50K9 09 MODEL CONTENTS SPECIFICATIONS iniri u u l eet N un NOTE Asterisk mark indicates the New K9 MODEL specifications The service data is the same as K8B MODEL 8 2 LT Z50K9 09 MODEL SPECIFICATIONS DIMENSIONS AND CURB MASS ba da etu c 1270 mm 50 0 in Overall WIG T ERI CS Ia one 760 mm 29 9 in Overall va UU 765 80 1 in Wheelbase X 2 Rm 830 mm 82 7 in uqa Sua 120 mm 4 7 in Seat kaa ua a SS aa yaaa au Glass 535 mm 21 1 in Front ae di
80. he specified torque V Front suspension arm bolt 50 N m 5 0 kgf m 36 0 Ib ft Tighten the front shock absorber bolts to the specified torque V Front shock absorber lower bolt 29 N m 2 9 kgf m 21 0 Ib ft Front shock absorber upper bolt 29 N m 2 9 kgf m 21 0 Ib ft Tighten the knuckle arm nut to the specified torque and install the new cotter pin V Knuckle arm nut 50 N m 5 0 kgf m 36 0 b ft Tighten the tie rod end nut to the specified torque and install the new cotter pin V Tie rod end nut 29 N m 2 9 kgf m 21 0 Ib ft NOTE Make sure that the steering turns smoothly in both directions Install the front brake 5 16 Install the front grip 375 6 Install the front wheel 7775 8 After installing the front brake and front suspension adjust the following items Front brake lever play gt 2 17 TOE IN adjustment 2 19 CHASSIS 5 27 TOE IN USTMENT Adjust the toe in as follows Place the vehicle on level ground and set the handlebar Straight Make sure all the tires are inflated to the standard pressure 272 18 Place 30 kg 66 lbs weight on the seat Loosen the locknuts D on each tie rod The locknuts 2 have left hand threads Measure the distance and B of the front wheels with a toe in gauge as shown and calculate the difference between and B Toe in Standard 1 5 3 mm 0 06 0 12 in Forward Temp
81. hock absorber It is unserviceable TIE ROD TIE ROD END Inspect the tie rod for distortion and the boot for wear and tie rod end for smooth movement If any defects are found replace it with a new one STEERING SHAFT AND HOLDER Inspect the steering shaft for distortion or bends If any defects are found replace it with a new one Inspect the steering shaft holders for wear or damage If any defects are found replace them with new ones CHASSIS 5 23 REASSEMBLY AND REMOUNTING Reassemble and remount the steering in the reverse order of removal and disassembly Pay attention to the following points Install the steering shaft bushing with the special tool 09924 84521 Bearing installer set STEERING SHAFT Apply grease to the steering shaft lower dust seal D steering shaft holders dust seals O ring 4 and steering shaft before remounting the steering shaft 5 AH 99000 25161 WATER RESISTANCE GREASE or eauiv alent e Install the steering shaft lower dust seal CD steering shaft holders dust seals 3 and O ring to the steering shaft 5 To prevent the entry of dirt the dust seal must face forward when installed on the steering shaft Tighten the steering shaft lower nut to the specified torque and install the new cotter pin 9 Steering shaft lower nut 29 N m 2 9 21 0 Ib ft 5 24 CHASSIS Tighten the steering shaft holder bolts to the specified to
82. ier calipers DRIVE BELT Inspect that the drive belt is free from any greasy substance Inspect the contact surface of the drive belt for cracks or dam age and measure the width of the drive belt with a vernier cali pers If any defects are found or the measurement exceeds the ser vice limit replace the drive belt with a new one If grease or oil is present on the surface of the drive belt degrease the belt thoroughly Drive belt width Service Limit 14 9 mm 0 59 in ENGINE 3 41 REASSEMBLY Install the bearing D to the fixed driven face with a suitable Spacer Install the snap ring Install the needle bearing with a suitable spacer Position the needle bearing with its punch mark out Side e Apply SUZUKI SUPER GREASE to the needle bearing 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the movable driven face onto the fixed driven face 2 3 42 ENGINE Install the pins to the pin hole with the rollers fitted Install the movable driven face spring seat to the movable driven face 5 securely Install the spring 9 and clutch shoe assembly onto the movable driven face Compress the spring with the special tool 09922 31420 Clutch spring compressor Align the flats of the fixed driven face end and clutch shoe plate Tighten the clutch shoe nut temporarily Remove the special tool from the clu
83. ified torque V Generator cover bolt 11 N m 1 1 kgf m 8 0 Ib ft NOTE Tighten the bolt together with the washer and clamp T gt 7 15 3 56 ENGINE B Hooked part CYLINDER HEAD COVER Assemble the cylinder head cover gasket D The removed gasket must be replaced with a new one Tighten the cylinder head cover bolts to the specified torque V Cylinder head cover bolt 11 N m 1 1 kgf m 8 0 Ib ft Tighten the spark plug to the specified torque with a spark plug wrench V Spark plug 11 N m 1 1 kgf m 8 0 Ib ft FUELSYSTEM 4 1 FUEL SYSTEM CONTENTS FUEL TANK AND FUEL VALVE iu 4 2 REMOVAL 4 3 FUEL FILTER INSPECTION AND CLEANING 4 3 REMOUNTING sscsiscssncssnstnsssnseisedunnsssnsssdnndescnsanseecssnnsensusvnssnsessuevinscusssnndens 4 4 CARBURETOR aaa o asi 4 5 SPECIFICATIONS u u uu Nu sa 4 6 LD NO LOCATION WU uu 4 6 E a 4 7 DISASSEMBLY u p 4 8 CLEANING ee 4 11 INSPECTION AND ADJ USTMENIT I 4 11 REASSEMBLY AND REMOUNIINGS 4 12 Gasoline must be
84. ighly recommended to use the speci fied tire Mountthe tire on the rim by hand as shown NOTE Inspect the sealing portion of the rim before installing the tire on the rim CHASSIS 5 9 When installing each tire make sure the arrow on the tire points in the direction of rotation Also make sure the outer side of the wheel rim is facing outward NOTE For inspecting the tires refer to page 2 18 Inspect the valve cores before installing Inflate the tire to seat the tire bead Maximum tire bead seat pressure Front 250 kPa 2 5 kgf cm 36 psi Rear 250 kPa 2 5 kgf cm 36 psi Place the tire under a protective tire cage or similar protective covering device before inflating the tire To minimize the possibility of tire damage when seating the tire bead never exceed the MAXIMUM TIRE BEAD SEAT PRESSURE rating shown on the tire NOTE Check the rim line cast the tire sidewalls It must be equi distant from the wheel rim all the way around If the distance between the rim line and the wheel rim varies this indicates that the bead is not properly seated If this is so deflate the tire com pletely and unseat the tire bead on both sides Then coat the bead with clean water and re seat the tire Adjust the tire pressure to the specified pressure Cold inflation tire pressure Front 20 kPa 0 20 kgf cm 2 9 psi Rear 20 kPa 0 20 kgf cm 2 9 psi Vehicle load capacity 38 kg
85. imit 80 7 mm 3 18 in BRAKE SHOE Inspect the brake shoes for wear or damage they are worn or damaged replace it with new ones Replace the brake shoes as a set otherwise braking performance will be adversely affected FRONT BRAKE DUST SEAL Inspect the front brake dust seal for wear or damage If any defects are found replace it with a new one NOTE Apply adhesive all around of the new dust seal and attach it to the brake plate DUST SEAL Remove the each dust seal with the special tool 09913 50121 Oil seal remover The removed dust seal must be replaced with a new one BEARING Inspect the play of the wheel hub bearings by finger while they are in the wheel hub Rotate the inner race by finger to inspect it for abnormal noise and smooth rotation If there is any thing unusual replace the bearing with a new one Remove the wheel hub inner bearing with the special tool 09941 50111 Bearing remover The removed bearing should be replaced with a new one Remove the spacer 1 Remove the wheel hub outer bearing with the special tool 09941 50111 Bearing remover The removed bearing should be replaced with a new one TOOL CHASSIS 5 13 5 14 CHASSIS REASSEMBLY AND REMOUNTING BEARING Apply SUZUKI SUPER GREASE A to the bearing before installing 99000 25010 SUZUKI SUPER GREASE or equivalent Install the wheel hub inner bearing with the spe
86. in Spark plug one NGK CR6HSA DENSO U20FSR U Ga 0 6 0 7 0 024 0 028 S park performance Over 8 0 3 at1 atm MERKEN Ignition coil resistance Primary 01 070 Terminal Terminal Plug cap Secondary 14 20 Ignition coil primary peak voltage Ground Ground W R Ground Generator coil resistance Charging 0 5 2 00 Pick up 150 2300 when engine is cold Starter relay resistance 214 E d em m y IM uc Ww s ws Starter motor brush length 5 5 2 15 0 22 0 11 12 V 14 4 kC 4 Ah 10 HR SERVICING INFORMATION 7 31 BRAKE WHEEL Unit mm in Front brake lever play 0 5 23 Rear brake lever mm 4 23 mishu drum Front Rear axle runout Rear R ear Toe in with 30 kg 12 5 0 05 0 12 Turning radius 2 0m Nw 6 ft Trail E nd Right amp Left TIRE Unit mm in ITEM STANDARD LIMIT Cold inflation tire pressure a 20 kPa MEM Solo riding 0 20 kgf cm 2 9 psi 0 20 kgf cm 2 9 psi 16 8 7 tubeless AT16x87 s tubeless _ Tire tread depth 4 0 4 0 7 32 SERVICING INFORMATION SUSPENSION Unit mm in ITEM STANDARD LIMIT Front wheel travel 52 2 0 Rear wheel travel 51 2 0 Swingarm pivot shaft runout 0 6 0 02 FUEL OIL NOTE Fuel type Use only unleaded gasoline of atleast 87 pump octane R 2 M 2 or 91 octane or higher rated by t
87. ine oil oil change 300 ml 0 3 0 3 US Imp qt aa n uu Ie OD UU UE 350 ml 0 4 0 3 US Imp qt Transmission oil oil change 25 ml 0 8 0 9 US Imp oz c 30 ml 1 0 1 1 US Imp oz
88. ion mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1 1 Apply SUZUKI SUPER GREASE A or equivalent 99000 25010 Apply SUZUKI MOLY PASTE or equiva lent 99000 25140 Apply WATER RESISTANCE GREASE or equivalent 99000 25161 Apply SUZUKI BOND 1215 or equiva lent 99000 31110 Apply THREAD LOCK 1342 or equiva lent 99000 32050 Measure in voltage range Measure in current range Measure in resistance range Measure in diode test range Measure in continuity test range Use special tool Indication of service data GENERAL INFORMATION 1 1 GENERAL INFORMATION CONTENTS WARNING CAUTIONINOTE u u n ce 1 2 GENERAL PRECAUTIONS i ua aaa ua 1 2 SUZUKI LT Z50K6 06 MODEL eren 1 4 SERIAL NUMBER LOCATION u l u 1 4 FUEL AND OIL 1 5 FUEL FOR USA AND CANADA U nnn 1 5 FUEL FOR OTHER COUNTRIES eene nnn 1 5 ENGINE OIL AND FINAL REDUCTION GEAR BOX OIL FOR USA 2 K 1 5 ENGINE OIL AND FINAL REDUCTION GEAR BOX OIL FOR OTHER COUNTRIES Bhau OI ih 1 5 BREAK IN PROCEDURES ABA 1 6 INFORMATION LABELS 1 7 INFORMATION 5 5 amp
89. ion surface of shoes Worn shoe linings Too much play on brake lever BRAKE SQUEAKING Symptom possible causes and remedy Carbon adhesion on lining surface Loose front wheel hub nut or rear wheel hub nut e Damaged wheel hub bearings Worn linings Wrongly fixed spring EXCESSIVE BRAKE LEVER STROKE Symptom possible causes and remedy Worn brake lever cam BRAKE DRAGS Symptom possible causes and remedy Rusty part Insufficient brake lever lubrication SERVICING INFORMATION 7 9 Replace Clean drum and shoes Replace Adjust Repair surface with sandpaper Tighten to specified torque Replace Replace Set correctly Replace brake cam Clean and lubricate Lubricate 7 10 SERVICING INFORMATION ELECTRICAL NO SPARKING OR POOR SPARKING Symptom possible causes and remedy Defective CDI unit Defective ignition coil Defective spark plug Defective generator coil Loose connection of lead wire Open circuited wiring connections Replace Replace Replace Replace Connect or tighten Check and repair SPARK PLUG SOON BECOMES FOULED WITH CARBON Symptom possible causes and remedy Mixture too rich Incorrect gasoline Dirty air cleaner element Incorrect spark plug SPARK PLUG BECOMES FOULED TOO SOON Symptom possible causes and remedy Worn piston rings Worn piston or cylinder Excessive clearance of valve stems
90. is a major contributor to your engine s performance and life Always select good quality engine oil Use of SF SG or SH SJ with J ASO MA Suzuki recommends the use of SAE 10W 40 engine oil If SAE 10W 40 engine oil is not available select an alternative accord ing to the right chart 30 20 10 0 10 20 30 40 22 4 14 32 50 68 86 104 L 15W 40 15W 50 MULTIGRADE a 10W 40 10W 50 1 6 GENERAL INFORMATION BREAK 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 necessary 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 its early life Refer to the following throttle position recommendations Keep to these break in throttle position Brake in engine speeds Up to 10 hours Less than 1 2 throttle GENERAL INFORMATION 1 7 INFORMATION LABELS D Certification plate A For P 03 19 2 Compliance label A For P 28 3 Manual notice label A For P 03 4 Parking brake label English A For P 03 19 28 For P 28 For P 03 A Attached INFORMATION MARKS A No passenger mark English For P 03 19 28 No passenger mark French For P 28 lt 7 PN Label is attached on the left side of frame 1 8 GENERAL INFORMATI
91. k absorber bolt to the specified torque V Rear shock absorber bolt 29 2 9 21 0 Ib ft Tighten the rear shock absorber nut to the specified torque V Rear shock absorber nut 29 N m 2 9 kgf m 21 0 Ib ft 5 42 CHASSIS e Install the rear axle housing and rear brake 75 35 to 37 After installing the rear suspension adjust the following items Rear brake lever play ca ved esie gt 2 17 Drive chain 1 2 15 ELECTRICALSYSTEM 6 1 ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING U U U UU 6 2 CONNECTOR U 6 2 COUPLER ene 6 2 CLAMP uuu 6 2 FUSE uod m E 6 2 SEMI CONDUCTOR EQUIPPED PART aa 6 3 BATTERY 6 3 CONNECTING THE BATTERY I aasan 6 3 WIRING PROCEDURES IU U I 6 3 USING THE MULTI CIRCUIT TESTER U UU T 6 4 LOCATION OF ELECTRICAL COMPONENTS III aaa 6 5 CHARGING SYSTEM raeo e a ge 6 7 TROUBLESHOOTING _ 4 Z 6 7 INSPECTION Te 46 6 8 STARTER SYSTEM eS ND Dr 6 11 TR
92. l the brake shoes A WARNING Be careful not to apply too much grease to the cam and pin If grease gets on the lining brake slippage will result REAR SPROCKET AND REAR AXLE e The stamped mark on the rear sprocket D should face out Side Tighten the rear sprocket bolt to the specified torque V Rear sprocket bolt 23 N m 2 3 kgf m 16 5 Ib ft Bend the rear sprocket washers 2 Install the new stopper ring and rear sprocket 0 e Install the rear axle Install the spacers left and right Tighten the rear hub nut to the specified torque V Rear hub nut 75 N m 7 5 kgf m 54 0 lb ft Install the new cotter pin NOTE Bend the cotter pin to outside After installing the rear brake and rear axle housing the following items Rear brake lever play gt 2 17 Drive chain slack K mem C 5 2 14 to 16 CHASSIS 5 37 2 5 adjust 538 CHASSIS REAR SUSPENSION CONSTRUCTION e Rear shock absorber 2 case 9 6 ____ Rear shock absorber lower bolt Swingarm pivot nut 102 102 74 0 CHASSIS 5 39 REMOVAL AND DISASSEMBLY e Remove the rear brake and rear axle housing 7575 31 and 5 32 e Remove the chain case f Remove the rear shock absorber lower bolt 2 Remove the rear shock absorber bolt 3 Remove
93. ly Pay attention to the following points e Apply SUZUKI SUPER GREASE to the lip of the oil seal 99000 25010 SUZUKI SUPER GREASE A or equivalent Apply a small quantity of SUZUKI MOLY PASTE to the arma ture shaft 99000 25140 SUZUKI MOLY PASTE or equivalent Apply SUZUKI SUPER GREASE A to the O ring 99000 25010 SUZUKI SUPER GREASE A or equivalent ELECTRICAL SYSTEM 6 15 6 16 ELECTRICAL SYSTEM STARTER MOTOR INSTALLATION Tighten the starter motor lead wire screw and starter motor mounting bolts 2 STARTER RELAY INSPECTION e Remove the seat 75 4 e Remove the starter relay from the frame center cover Disconnect the starter relay coupler 2 First check the insulation between and B terminals with the multi circuit tester Then apply 12 V to terminals as shown and check the continuity between and If there is no continuity replace the starter relay with a new one 09900 25008 Multi circuit tester set Tester knob indication Continuity test 4 Do not apply battery voltage to the starter relay for more than five seconds since the relay coil may over heat and get damaged Measure the relay coil resistance between the terminals with the multi circuit tester If the resistance is not within the standard range replace the starter relay with a new one 09900 25008 Multi circuit tester set Tester knob indication Resistance St
94. medy Clogged fuel pipe Air leaking from joint between intake port and car buretor Air leaking from carburetor joint Improperly working starter plunger IDLING OR LOW SPEED TROUBLE Symptom possible causes and remedy Clogged or loose pilot jet Air leaking from carburetor joint Clogged pilot outlet port Clogged bypass port Starter plunger not fully closed MEDIUM OR HIGH SPEED TROUBLE Symptom possible causes and remedy Clogged main jet Clogged needle jet Improperly working piston valve Clogged fuel filter OVERFLOW AND FUEL LEVEL FLUCTUATIONS Symptom possible causes and remedy Worn or damaged needle valve Improperly working float Foreign matter on the needle valve Incorrect float chamber fuel level Clean Tighten or replace gasket Tighten or replace defective parts Adjust Clean or tighten Tighten or replace defective part Clean Clean Adjust Clean Clean Adjust Clean or replace Replace Adjust or replace Ciean or replace with needle valve seat Adjust float height CHASSIS HEAVY STEERING Symptom possible causes and remedy Distorted steering shaft e Not enough pressure in tires Improper front wheel alignment Insufficiently lubricated Linkage connections tending to seize Tie rod ends tending to seize WOBBLY HANDLEBAR Symptom possible causes and remedy Unequally inflated tires Loo
95. move the generator rotor nut with the specia tool 09930 40113 Rotor holder Be careful not to damage the generator coil by the special tool Remove the generator rotor D with the special tool and removed nut 09920 13120 Crankshaft separator Remove the generator rotor 1 and nut Remove the key 3 e Remove the generator coil and pick up coil ENGINE 3 11 RECOIL STARTER Remove the recoil starter 1 MOVABLE DRIVE Remove the CVT case cover f Remove the dowel pins and gasket Remove the starter pinion Remove the fixed drive face nut with the special tool 09930 40113 Rotor holder Remove the starter cup assembly Remove the fixed drive face 3 12 ENGINE e Remove the movable drive spacer together with the power reduction spacer 8 and movable drive face assembly 9 NOTE Movable drive face disassembly 7 3 36 Remove the washer 0 MOVABLE DRIVEN Remove the clutch housing with the special tool 09930 40113 Rotor holder e Remove the clutch shoe movable driven face assembly together with the drive belt 3 NOTE Clutch shoe movable driven face disassembly 773 37 CVT CASE Remove CVT case NOTE Loosen the CVT case bolts little by little and diagonally ENGINE 3 13 Remove the dowel pins 2 and gasket 3 GENERATOR CASE e Remove the generator case D e Remove the dowel pins 2
96. n rings or cylinder Poor seating of valves Fouled spark plug Incorrect spark plug Clogged carburetor jet Insufficient spark plug gap Air leakage from intake pipe Incorrect float chamber fuel level Clogged air cleaner element Sucking air from carburetor or vacuum hose Too much engine oil ENGINE OVERHEATS Symptom possible causes and remedy Heavy carbon deposit on piston head e Not enough oil in the engine Use of incorrect engine oil Low float chamber fuel level Air leakage from intake pipe Incorrect spark plug Clogged exhaust pipe muffler ing DIRTY OR HEAVY EXHAUST SMOKE Symptom possible causes and remedy Too much engine oil in the engine Worn piston rings or cylinder Worn valve guides Scored or scuffed cylinder wall Worn valves stems Defective stem seal Worn oil ring side rail Ignition timing too advanced due to defective tim SERVICING INFORMATION 7 5 Adjust Replace Adjust Replace Repair Clean or replace Adjustor replace Clean Regap or replace Tighten or replace Adjust float height Replace Retighten or replace Drain out excess oil Clean Add oll Change Adjust float height Tighten or replace Change Clean or replace Replace Drain excess oil Replace Replace Replace Replace Replace Replace 7 6 SERVICING INFORMATION CARBURETOR STARTING DIFFICULTY Symptom possible causes and re
97. nd push in fully to engage the lock when con necting When disconnecting the coupler be sure to hold the coupler itself and do not pull the lead wires Inspect each terminal on the coupler for being loose or bent Inspect each terminal for corrosion and contamination CLAMP Clamp the wiring harness at such positions as indicated in WIRING HARNESS ROUTING 5737 14 Bend the clamp properly so that the wiring harness is clamped securely e n clamping the wiring harness use care not to allow it to hang down Do not use wire or any other substitute for the band type clamp FUSE When a fuse blows always investigate the cause to correct it and then replace the fuse Do not use a fuse of a different capacity Do not use wire or any other substitute for the fuse GI RECT INCORRECT SEMI CONDUCTOR EQUIPPED PART Be careful not to drop the part with a semi conductor built in such as a CDI unit and regulator rectifier When inspecting this part follow inspection instruction strictly Neglecting proper procedure may cause damage to this part BATTERY The MF battery used in this vehicle does not require mainte nance e g electrolyte level inspection distilled water replen ishment e During normal charging no hydrogen gas is produced How ever if the battery is overcharged hydrogen gas may be pro duced Therefore be sure there are no fire or spark sources e g short
98. nents INSPECTION AND USTMENT Check the following items for any damage or clogging Pilot jet Starter passageway Main jet Needle jet Starter plunger Throttle stop screw Float Needle valve seat Piston valve et needle Pilot passageway e f any abnormal condition is found clean the part If damage or clogging is found replace the part with a new one NEEDLE VALVE INSPECTION If foreign matter is caught between the valve seat and the nee dle valve the gasoline will continue flowing and overflow If the needle valve is worn beyond the permissible limit similar trouble will occur Conversely if the needle valve sticks the gasoline will not flow into the float chamber Clean the float chamber and float parts with gasoline 4 12 FUEL SYSTEM If the needle valve is worn as shown in the illustration replace the needle valve assembly with a new one Clean the fuel pas sage of the mixing chamber with compressed air CORRECT INCORRECT FLOAT HEIGHT ADJ USTMENT To check the float height turn the carburetor upside down Mea sure the float height while the float arm is just contacting the needle valve with vernier calipers Float height 23 4 1 0 mm 0 92 0 04 in 09900 20102 Vernier calipers f the float height is out of specification bend the float arm D to bring the float height to the standard range After adjusting check the float height again RE
99. ng mark on the cam drive gear 3 NOTE Piston must be at TDC before installing the cam assembly Apply SUZUKI BOND 1215 to the part shown in the photo graph 99000 31110 SUZUKI BOND 1215 or equivalent NOTE Make surfaces free from moisture oil dust and other foreign materials GENERATOR CASE Install the dowel pins and gasket Apply engine oil to the gears The removed gasket must be replaced with a new one Tighten the generator case bolts to the specified torque V Generator case bolt 11 N m 1 1 kgf m 8 0 Ib ft CVT CASE Install the dowel pins and gasket The removed gasket must be replaced with a new one Tighten the CVT case bolts to the specified torque V CVT case bolt 11 1 1 kgf m 8 0 lb ft MOVABLE DRIVEN FACE Install the drive belt CD to the movable driven face NOTE With the clutch shoe spring compressed by hands install the drive belt D between the movable driven face and fixed driven face Degrease the drive belt contact surface pulley face Position the drive belt so that the arrow points the engine rotating direction ENGINE 3 51 3 52 ENGINE Tighten the clutch housing nut to the specified torque with the special tool 09930 40113 Rotor holder V Clutch housing nut 50 5 0 kgf m 36 0 Ib ft NOTE Degrease the inside of the clutch housing and clutch shoe MOVABLE DRIVE FACE Inst
100. ng the brake check to see that the extension line of the index mark is within the range f the index mark goes beyond the range the brake shoe assembly should be replaced with a new set of shoes PERIODIC MAINTENANCE 2 17 2 18 PERIODIC MAINTENANCE TIRES Inspect every month TIRE TREAD CONDITION Operating the vehicle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation It is highly recommended to replace a tire when the remaining depth of the tire tread reaches the following specification 09900 20805 Tire depth gauge Service Limit Tire tread depth Front 4 0 mm 0 16 in Rear 4 0 mm 0 16 in TIRE PRESSURE If the tire pressure is too high or too low steering will be adversely affected and tire wear will increase Therefore main tain the correct tire pressure for good roadability and a longer tire life Cold inflation tire pressure is as follows Cold inflation tire pressure Front 20 kPa 0 20 2 9 psi Rear 20 kPa 0 20 kgf cm 2 9 psi VEHICLE LOAD CAPACITY LIMIT 38 kg 84 Ibs To minimize the possiblility of tire damage from over inflation we strongly recommended that a man ual type air pump be used rather than a high pressure air compressor as found in service stations When fill ing air into the tires never exceed 70 kPa 0 7 kgf cm 10 psi The standard tire fitted on this vehicle is an 16 8 75 for the
101. ng the front brake adjustthe following item Front brake lever play C gt 2 17 5 16 CHASSIS STEERING AND FRONT SUSPENSION CONSTRUCTION Front shock absorber 2 Front suspension arm Bushing Frontsuspension arm nut inner tered end Outer te od end E CHASSIS 5 17 5 18 CHASSIS REMOVAL AND DISASSEMBLY FRONT SUSPENSION e Remove the front wheel gt 5 8 e Remove the front grip 7 5 6 e Remove the front brake 75 12 to 13 e Remove the front brake cable D Remove the cotter pin and knuckle arm nut 2 The removed cotter pin must be replaced with a new one e Remove the cotter pin and tie rod end nut The removed cotter pin must be replaced with a new one Remove the knuckle arm and bolt 5 e Remove the front shock absorber e Remove the front suspension arm CHASSIS 5 19 Remove the dust seals and spacer Remove the knuckle arm bushings with the special tools 09923 73210 Bearing remover 09930 30104 Sliding shaft STEERING Remove the front frame cover gt 5 4 e Remove the front suspension 75 19 Remove the front and rear brake cables Remove the throttle case cover screws e Remove the throttle cable Disconnect the ignition switch coupler 5 20 CHASSIS Remove the cotter pin and steering shaft lower nut D and O ring Remove the cotter pin
102. ng unusual is found replace the starter pinion with a new one ENGINE 3 35 MOVABLE AND FIXED DRIVE AND DRIVEN FACE a m ITEM Nm kgm 1 6 6 60 435 3 36 ENGINE MOVABLE DRIVE DISASSEMBLY Remove the movable drive face plate D and dampers Q Remove the rollers 3 SPACER INSPECTION Inspect the movable drive spacer 4 and power reduction spacer 2 for any wear or damage If they are worn or damaged replace them with new ones MOVABLE AND F XED DRIVE FACE INSPECTION Inspect the drive face for any abnormal condition such as stepped wear or discoloration caused by burning If any defects are found replace them with new ones ROLLER INSPECTION Inspect each roller and their sliding surface for wear or damage 2 If any defects are found replace the rollers as a set w NOTE The rollers must always be changed as a set ENGINE 3 37 DAMPER INSPECTION Inspect the dampers for wear or damage If any defects are found replace the dampers with new ones REASSEMBLY Position the rollers D on the movable drive face 2 e Mount the dampers 3 on the movable drive face plate Check that the rollers D are in normal position in the movable drive face 2 Position the movable drive face plate on the movable drive face 2 CLUTCH SHOE MOVABLE DRIVEN FACE DISASSEMBLY Hold the clutch shoe assembly with the special tool 09930 40113 Rotor holder
103. ngine oil drain plug D with the new washer to the specified torque and then pour the new oi through the oil filler hole When performing an oil change the engine will hold about 300 m 0 6 0 5 US at of oil Use SF SG or SH SJ with ASO MA 9 Engine oil drain plug 12 N m 1 2 kgf m 8 5 Ib ft Check the engine oil level above Engine oil capacity Oil change 300 ml 0 6 0 5 US Imp qt Overhaul 350 ml 0 7 0 6 US Imp qt PERIODIC MAINTENANCE 2 9 2 10 PERIODIC MAINTENANCE FINAL REDUCTION GEAR BOX OIL Inspect every 6 months Replace every 2 years FINAL REDUCTION GEAR BOX OIL LEVER CHECK Place the vehicle on level ground e Remove the right frame cover 75 4 e Remove the generator cover 1 Remove the oil filler cap 2 Inspect the oil level If the oil level is below the edge of the oil filler hole add oil until it flows from the filler hole FINAL REDUCTION GEAR BOX OIL REPLACEMENT Place the vehicle on level ground e Remove the right frame cover 75 4 e Remove the generator cover Remove the oil filler cap 2 Remove the drain plug and drain the oil into an oil pan e Reinstall the drain plug Pour new oil through the oil filler hole until the oil flows from oil filler hole Reinstall the oil filler cap 2 Final reduction gear box oil capacity Oil change 25 ml 0 8 0 9 US Imp oz Overhaul 30 ml 1 0 1 1 US imp oz THROTTLE CA8LE PLAY Inspect
104. nk inlet rubber is 9 forward CHASSIS 5 7 FRONT AND REAR WHEELS CONSTRUCTION Front wheel Wheelsetnut front amp rear REMOVAL Place the vehicle on level ground Support the vehicle with a jack or wooden block and remove the front and rear wheel set nuts Remove the front and rear wheels 9 ITEM kgfm REMOUNTING Remount the wheels in the reverse order of removal Pay atten tion to the following points Installing each wheel make sure the arrow on the tire points in the direction of rotation Tighten the wheel set nuts to the specified torque Q Front and rear wheel set nut 28 N m 2 8 kgf m 20 0 Ib ft 5 8 CHASSIS TIRES TIRE REPLACEMENT e Remove the front and rear wheels C 575 8 After removing the air valve caps release the tire pressure by depressing the valves Dismount the bead from the rim completely as shown Separate the tire from the rim using a setof tire levers and rim protectors When using the tire levers do not scratch or hit the sealing portion hump of the wheel or it may cause air leakage Apply tire lubricant the tire bead and the flange of the rim Never apply grease oil or gasoline to the tire bead because they will deteriorate the tire The standard tire fitted on this vehicle is AT16 x 8 7 for the front and rear The use of tires other than the standard may cause instability It is h
105. nt bond or sealant When removing the battery disconnect the negative cable first and then the positive cable When reconnecting the battery connect the positive cable first and then the negative cable and replace the terminal cover on the positive terminal When performing service to electrical parts if the service procedures do not require use of battery power disconnect the negative cable from the battery When tightening the cylinder head or case bolts and tighten the larger sizes first Always tighten the bolts and nuts diagonally from the inside toward outside and to the speci fied tightening torque Whenever you remove oil seals gaskets packing O rings locking washers self locking nuts cotter pins circlips and certain other perts as specified be sure to replace them with new ones Also before installing these new parts be sure to remove any left over material from the mating surfaces Never reuse a circlip When installing a new circlip take care not to expand the end gap larger than required to slip the circlip over the shaft After installing a circlip always ensure that it is completely seated in its groove and securely fitted Use a torque wrench to tighten fasteners to the specified torque Wipe off grease and oil if a thread is smeared with thein After reassembling check parts for tightness and proper operation 14 GENERAL INFORMATION SUZUKI LT Z50K6 06 MODEL RIGHT SIDE
106. orarily tighten the four locknuts 3 Check that the distance O and D are equal as shown If the distances are not equal adjust the tie rod to the right or left until the toe in is within specification Check the toe in again by measuring distance amp and B f the toe in is not within specification repeat the adjustment as above until the proper toe in is obtained and distance O and become equal After adjustment has been made tighten the four locknuts to the specified torque V Tie rod locknut 29 N m 2 9 kgf m 21 0 Ib ft 5 28 CHASSIS REAR BRAKE AND REAR AXLE HOUSING CONSTRUCTION Rear brake cam lever bolt C Rearbrakecamleverm Rearaxle Rear sprocketbolt _ R S L ij elelee jeee eej CHASSIS 5 29 REMOVAL Remove the cotter pin D The removed cotter pin must be replaced with a new one Remove the rear hub nut by applying the rear brake Remove the rear wheels Remove the center cap holder 2 rear axle washer 3 and rear wheel hub 4 Remove the spacers left and right Remove the chain case cover Loosen the drive chain C 72 14 Remove the rear sprocket 530 CHASSIS Remove the rear brake drum cover Remove the rear axle Remove the rear brake drum Remove the rear brake shoes 7 Disconnect the rear brake cable 8
107. pect the drive belt for wear and damage If any cracks or defects are found replace it with a new one REMOUNTING Remount the drive belt in the reverse order of removal Pay attention to the following points Insert the drive belt as low as possible between the movable driven face to provide the maximum drive belt clearance before installing Install the movable driven face with drive belt Fit the drive belt to the movable driven face so that the arrows on the drive belt outer surface aim toward normal turning direction The drive belt contact surface of the driven face should be thoroughly cleaned NOTE Degrease the movable drive face assembly Use non flammable cleaning solvent to wipe off oily or greasy matter and make its surfaces completely dry Tighten the clutch housing nut to the specified torque with the special tool 09930 40113 Rotor holder V Clutch housing nut 50 N m 5 0 kgf m 36 0 Ib ft Tighten the fixed drive face nut to the specified torque with the Special tool 09930 40113 Rotor holder V Fixed drive face nut Initial 13 1 3 kgf m 9 5 Ib ft Final 50 N m 5 0 kgf m 36 0 Ib ft PERIODIC MAINTENANCE 2 13 2 14 PERIODIC MAINTENANCE Turn the fixed drive face until the drive belt is properly seated and both the drive and driven face rotate together smoothly and without slipping DRIVE CHAIN Visually check the drive chain for the possibl
108. r coil Disconnected lead wires 6 8 ELECTRICAL SYSTEM Step 5 1 Measure the generator no load performance 76 10 Is the generator no load performance OK Step 6 Fauly generator Step 6 1 Inspect the regulator rectifier C 56 10 Is the regulator rectifier OK Go to Step 7 NO Faulty regulator rectifier Step 7 1 Inspect wiring harness Is the wiring harness OK ves Short circuit of wiring harness NO Poor contact of couplers Battery overcharges Faulty regulator rectifier Faulty battery Poor contact of regulator rectifier lead wire coupler INSPECTION BATTERY CURRENT LEAKAGE e Remove the seat C 775 4 Turn the ignition switch to the OFF position Disconnect the battery lead wire D Measure the current between battery terminal and the bat tery lead wire with the multi circuit tester If the reading exceeds the specified value leakage Is evident 09900 25008 Multi circuit tester set Tester knob indication Current 20 mA Battery current leak Under 1 mA n case of a large current leak turn the tester to high range first to avoid tester damage Do not turn the ignition switch to the ON position when measuring current REGULATED VOLTAGE e Remove the seat C 7 5 4 Start the engine and keep it running at 2 800 r min Measure the DC voltage between the and battery termi nals with the m
109. rque and install the new cotter pins Q Steering shaft holder bolt 23 N m 2 3 kgf m 16 5 Ib ft TIE ROD e Tighten the tie rod end nuts to the specified torque V Tie rod end nut 29 N m 2 9 kgf m 21 0 Ib ft NOTE After installing the tie rod end nuts install the new cotter pins into the tie rod ends e When installing the tie rod end make sure the punched mark L on the tie rod ends come inside NOTE The locknuts D have left hand threads HANDLEBAR Set the white mark on the handlebar lower holder to the for ward Align the punched mark on the handlebars with matching sur face of the handlebar holders CHASSIS 5 25 Install the handlebar upper holders as shown First tighten the bolts D to the specified torque and then 25 tighten bolts to the specified torque V Handlebar clamp bolt 26 N m 2 6 kgf m 19 0 Ib ft Make sure the cable harness are routing properly HANDLEBAR SWITCH Align the handlebar switch lug with the handlebar hole 2 THROTTLE LEVER CASE Align the throttle lever case lug D with the handlebar hole FRONT SUSPENSION e Install the Knuckle arm bushing with the special tool 09924 84510 Bearing installer set Apply grease to the knuckle arm bushings dust seals and Spacer Install the spacer and the dust seals AH 99000 25161 WATER RESISTANCE GREASE or equiv alent 5 26 CHASSIS Tighten the front suspension arm bolts to t
110. s and tie rod end nuts 2 The removed cotter pins must be replaced with new ones The removed O ring must be replaced with a new one Remove the tie rods Remove the handlebar clamp bolts Remove the cotter pins The removed cotter pins must be replaced with new ones Remove the steering shaft holder and steering shaft CHASSIS 5 21 Remove the steering shaft bushing The removed steering shaft bushing must be replaced with a new one Remove the dust seals 3 and steering shaft lower dust seal Separate the tie rod ends locknuts 2 and tie rods 8 The locknuts 6 have left hand threads INSPECTION Inspect the removed parts for the following abnormalities Handlebar distortion Handlebar clamp wear DUST SEALS AND O RING Inspect the dust seals and O ring for wear or damage If any defects are found replace them with new ones KNUCKLE ARM BUSHING Insert the spacer into the bushing and inspect for abnormal noise and smooth rotation while rotating the spacer If any defects are found replace it with a new one 5 22 CHASSIS SUSPENSION ARM Inspect the suspension arm and suspension arm bushing for wear or damage If any defects are found replace it with a new one FRONT SHOCK ABSORBER Inspect the shock absorber body and bushing for damage and oll leakage If any defects are found replace it with a new one Do not attempt to disassemble the front s
111. se front wheel hub nuts Damaged or worn front wheel hub bearings Worn or loose tie rod ends Defective or incorrect front tires Damaged or worn suspension arms and related bushings Distorted front wheels Loose chassis nuts and bolts STEERING PULLS TO ONE SIDE Symptom possible causes and remedy Unequally inflated tires Improper front wheel alignment Worn front wheel hub bearings Distorted frame Defective shock absorber SHOCKS FELT IN THE STEERING Symptom possible causes and remedy High tire pressure Worn steering linkage connection Loose suspension system bolts TIRES RAPIDLY OR UNEVENLY WEAR Symptom possible causes and remedy Worn or loose front wheel hub bearings Improper front wheel alignment STEERING TOO NOISY Symptom possible causes and remedy Loose nuts and bolts Damaged or worn front wheel hub bearings e Insufficiently lubricated SERVICING INFORMATION 7 7 Replace Adjust Adjust Lubricate Repair or replace Replace Regulate Tighten Replace Replace or tighten Replace Replace Replace Tighten Regulate Adjust Replace Repair or replace Replace Regulate Replace Tighten Replace Adjust Tighten Replace Lubricate 7 8 SERVICING INFORMATION FRONT SUSPENSION TOO SOFT Symptom possible causes and remedy Weakened spring of shock absorber Shock absorber leaks oil FRONT S
112. several places as indicated If the largest reading at any position of the straightedge exceeds the service limit replace the upper crankcase cylinder Cylinder distortion Service Limit 0 05 mm 0 002 in 09900 20803 Thickness gauge 3 22 ENGINE CYLINDER BORE Inspect the cylinder wall for any scratches nicks or other dam age If anything unusual is found replace the upper crankcase cylin der Measure the cylinder bore diameter at six places Cylinder bore Standard 36 005 36 015 mm 1 4175 1 4179 in PISTON AND PISTON RING PISTON DIAMETER Measure the piston outside diameter at 5 mm 0 2 in height from the skirt with a micrometer If the measurement is less than the service limit replace the pis 5 ton Piston diameter Service Limit 35 885 mm 1 4128 in 09900 20202 Micrometer 25 50 mm PISTON TO CYLINDER CLEARANCE INSPECTION Subtract the piston diameter from the cylinder bore diameter 7733 21 If the piston to cylinder clearance exceeds the service limit replace the upper crankcase cylinder or the piston or both Piston to cylinder clearance Service Limit 0 120 mm 0 0047 in PISTON RING TO GROOVE CLEARANCE Measure the side clearances of the 1st and 2nd piston rings with the thickness gauge If any of the clearances exceeds the limit replace both the pis ton and piston rings Piston ring to groove clearance Service Limit 1st 0 180 mm 0 0071 in 2nd 0
113. sti te t ees 575 mm 22 6 in mimis dec CP 575 mm 22 6 in MASS u m arcad eC touc ee A e i es a Sce canes 78 kg 171 1 5 ENGINE j ee TH TEE E 4 stroke air cooled Number of cylinders Satna 1 o Sua E 36 0 mm 1 417 in SITOKG E ae roma AE 48 6 mm 1 913 in Displacement um TO DD DL 49 cm 3 0 cu in Corrected compression ratio 8 4 1 ne Berit eid am dm k Den MIKUNI VM13 single ide Polyurethane foam element Starter u u caval veneer de oret ete use Medeae NES Electric and recoil Ide spe CO as TET 2 000 150 r min DRIVE TRAIN 4 Pio Da D Dry shoe automatic centrifugal type Gearshit e D E Automatic Primary reduction ratio Automatic drive 2 091 1 879 Variable change Secondary reduction ratio 4 272 47 11 Final reduction Talon ide o x 3 700 37 10 Drive eee D 0 1 0 415 82 links CHASSIS Front suspension e eene eee OE D Independent swing axle coil spring oil damped Rear SUSPENSION Swingarm type coil spring oil damped Front wheel
114. t rear tire 0 775 8 e Remove the chain case cover 75 30 Clean the drive chain with kerosine If the drive chain tends to rust quickly the intervals must be shortened PERIODIC MAINTENANCE 2 15 192021 2 16 PERIODIC MAINTENANCE After cleaning and drying the chain oil it with a heavy weight engine oll CAUTION _ Direction of travel The drive chain joint clip should be attached in the ue e J O Or XX way that the slit end will face opposite to the direction of travel BRAKES Inspect initially at 1 month and every 3 months there after FRONT BRAKE LEVER PLAY Adjust the right and left cable end length to become equal by adjusting nuts D Turn the adjusters 2 so that the brake lever play B is within specification after loosening the locknut Front brake lever play B 4 6 mm 0 16 0 24 in NOTE The difference between W1 and W2 should be 1 mm or less REAR BRAKE LEVER PLAY Adjust the threaded portion length O of brake cable to 3 5 mm 0 12 0 20 by adjusting nut D Turn the adjuster so that the free travel O is within specifi cation after loosening the locknut Rear brake lever play D 4 6 mm 0 16 0 24 in FRONT AND REAR BRAKE SHOE WEAR This vehicle is equipped with brake wear limit indicators for the front and rear brake Check brake lining wear as follows Make sure the brake lever play is properly adjusted While fully applyi
115. t tight Weak ened spring results in reduced engine power output and often account for the chattering noise coming from the valve mecha nism Check the valve springs for proper strength by measuring their free length and also by the force required to compress them f the spring length is less than the service limit or if the force required to compress the spring does not fall within the range specified replace the valve spring Valve spring free length IN amp EX Service Limit 22 8 mm 0 90 in Valve spring tension IN amp EX 36 5 41 9 N 3 7 4 3 kgf 8 2 9 5 Ibs at length 15 0 mm 0 59 in 09900 20102 Vernier calipers REASSEMBLY Reassemble the cylinder head in the reverse order of disassem bly Pay attention to the following points Apply MOLYBDENUM OIL SOLUTION to the new stem seal Press fit the stem seal onto the intake valve guide The removed valve stem seal must be replaced with a new one MOLYBDENUM OIL SOLUTION Insert the valves with their stems coated with MOLYBDE NUM OIL SOLUTION all around and along the full stem length without any break When inserting intake valve take care not to damage the lip of the stem seal MOLYBDENUM OIL SOLUTION ENGINE 3 19 3 20 ENGINE e Assemble the valve spring D and spring retainer Push the spring retainer by the finger with the valve prevented from falling Incline the spring retainer 2 and set it into the valv
116. tch shoe assembly Tighten the clutch shoe nut to the specified torque with the special tool 09930 40113 Rotor holder V Clutch shoe nut 60 N m 6 0 kgf m 43 5 Ib ft ENGINE 3 43 RECOIL STARTER D Startercupspacer 2 Starter cup Spiral spring m ITEM 16 54 054 40 3 44 ENGINE DISASSEMBLY Remove the bolt D and friction plate Remove the ratchet 3 and return spring Remove the cap 5 from the knob Untie a knot atthe rope Hook the rope to the groove of the reel 7 Turn the rope on the reel 2 properly e Remove the reel 7 WARNING Wear hand and eye protection when removing the reel since the spiral spring may quickly unwind and cause an injury Remove the spiral spring from the recoil starter case 9 REASSEMBLY Reassemble the recoil starter in the reverse order of disassem bly Pay attention to the following points e When installing the spiral spring hook the spiral spring end with the recoil starter case WARNING Wear hand and eye protection when installing the reel since the spiral spring may quickly unwind and cause an injury Apply SUZUKI SUPER GREASE A to the spiral spring 99000 25010 SUZUKI SUPER GREASE A or equivalent Turn the rope on the reel properly After installing the spiral spring engage the part of the reel with the spiral spring end
117. ter motor run Faulty starter relay Loose or disconnected starter motor lead wire Loose or disconnected between starter relay and battery terminal YES NO Faulty starter motor 6 12 ELECTRICAL SYSTEM Step 3 1 Measure the starter relay voltage at the starter relay connectors between Y G and B W when the Starter button is pushed Is a voltage OK VES Goto Step4 Faulty engine stop switch Faulty starter button Faulty parking brake switch NO Faulty remote engine stop switch Faulty ignition switch Poor contact of connector Open circuit in wiring harness Step 4 1 Check the starter relay gt 6 16 to 17 Is the starter relay OK Poor contact of the starter relay NO Faulty starter relay Engine does not turn though the starter motor runs Faulty starter pinion 73 34 STARTER MOTOR REMOVAL Disconnect the battery lead wire e Remove the right frame cover gt 5 4 Remove the starter motor 1 Disconnect the starter motor lead wire 2 ELECTRICAL SYSTEM 6 13 STARTER MOTOR DISASSEMBLY Disassemble the starter motor as shown in the illustration Starter motor lead wire 6 14 ELECTRICAL SYSTEM STARTER MOTOR INSPECTION CARBON BRUSH Inspect the brushes for abnormal wear cracks or smoothness in the brush holder If any defects are found replace the housing end assembly with a new one Measure the brush length
118. the ignition switch ring nut D Remove the front frame cover 2 NOTE indicates hook location LEFT FRAME COVER Remove the screws 1 and fasteners Remove the bolts Remove the left frame cover 3 RIGHT FRAME COVER Remove the screws D and fasteners Remove the bolts 2 Remove the right frame cover 3 FRAME CENTER COVER e Remove the seat C 775 4 e Remove the front frame cover 75 4 Remove the left frame cover 75 4 e Remove the right frame cover C 55 4 Disconnect the battery cable first and then battery cable Remove the battery 1 Remove the fuse box Q from the battery holder 3 Remove the battery holder Remove the starter relay 4 from the frame center cover 5 Disconnect couplers Remove the bolts Remove the fuel tank cap Remove the frame center cover 5 NOTE Remount the fuel tank cap 6 after removing the frame center cover 5 CHASSIS 5 5 5 6 CHASSIS MAINTENANCE LID Remove the fastener Remove the maintenance lid D FRONT GRIP Remove the front grip REMOUNTING Remount the exterior parts in the reverse order of removal Pay attention to the following points FUEL TANK INLET RUBBER Align the fuel tank inlet rubber hollow with the fuel tank lug r r p Forward Make sure that F mark on the fuel ta
119. tie stop screw _ _ amp Nrventhose _ fspngse ______ JofFoat S etnede W Nedevavesez S Pistmvave _ Drain hose Pilot et 4 6 FUEL SYSTEM SPECIFICATIONS Carburetor type Bore size rimin Float height 23 4 1 0 mm 0 92 0 04 in Main jet MJ jetneedle J N Needle jet NJ J Pilot et PJ Air screw 5 3 5 mm 012 0 20 in 1 0 NO LOCATION The carburetor has 1 0 Number stamped on its body according to its specifications FUELSYSTEM 4 7 REMOVAL e Remove the left frame cover 5 4 e Remove the right frame cover 75 4 e Remove the fuel hose 4 Remove the air vent hose 2 Remove the vacuum hose 3 Loosen the drain plug 4 Drain the fuel from the carburetor Remove the drain hose from the clamp Remove the carburetor top with throttle cable and pis ton valve 7 Loosen the clamp bolt 8 Remove the carburetor mounting bolts nuts Remove the carburetor assembly 40 4 8 FUELSYSTEM DISASSEMBLY The removed O rings and gasket must be replaced with new ones Remove the spring D and piston valve from the throttle cable Remove the spring seat Remove the jet needle from the piston valve 2 Remove the drain hose 5 Remove the float chamber
120. ulti circuit tester If the voltage is not within the standard range inspect the generator and regulator rectifier C gt 6 9 and 6 10 NOTE When making this test be sure that the battery is in fully charged condition 09900 25008 Multi circuit tester set Tester knob indication Voltage Regulated voltage Charging output 13 5 15 2 V at 2 800 r min GENERATOR COIL RESISTANCE e Remove the left frame cover C gt 5 4 e Disconnect the generator coupler 0 Measure the resistance between the W R wire and ground with the multi circuit tester If the resistance is not within the standard range replace the generator coil with a new one 09900 25008 Multi circuit tester set Tester knob indication Resistance Generator coil resistance 0 5 2 0 O W R Ground NOTE When making above test itis not necessary to remove the gen erator ELECTRICAL SYSTEM 6 9 6 10 ELECTRICAL SYSTEM GENERATOR NO LOAD PERFORMANCE e Remove the left frame cover 5 4 e Disconnect regulator rectifier coupler 0 Start the engine and keep it running at 2 800 r min Measure the voltage between W R wire and ground with the multi circuit tester If the tester reads under the specified value replace the genera tor coil with a new one 09900 25008 Multi circuit tester set Tester knob indication Voltage Generator no load performance 20 V and more at 2 800 r min When engine is cold
121. ve bolt 0 45 7 24 SERVICING INFORMATION CHASSIS km 50 Tie rod locknut 2 2 6 3 1 2 2 7 2 2 50 50 360 29 210 29 210 29 210 23 165 026 _ 029 _ PR S8 975 _ Handlebar clamp bolt Front shock absorber bolt lower Front hub nut Wheel set nut front and rear 29 3 28 Front brake cable equalizerbot 63 055 as Frontbrake 33 033 25 Swngampwtnt 1 39 m 740 Rearshockabsoberbot 2 2 210 _ Rearshockabsobermt 29 25 210 _ Rerhbmt 8 35 540 _ Rear brake cam evert n on 58 _ Rear brake panen o 200 _ Rear axle housing bot 750 80 360 _ Rerspokebo 23 23 165 o a 26 190 _ 0 77 50 50 29 29 9 3 6 29 29 65 8 5 3 02 9 9 75 8 50 3 26 5 0 5 0 2 9 2 9 2 9 2 3 2 6 2 9 29 6 5 2 8 2 9 29 p 2 8 5 0 2 3 6 SERVICING INFORMATION 7 25 TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page refer to this chart Bolt Diameter Conventional or 4 marked bolt 7 marked bolt Nm kgfm Ibft Nm kgfm ibft e m qm 128 mm 0 Conventional bolt 4 marked bolt 17 marked bolt 7 26 SERVICING INFORMATION SERVICE DATA EX 0 0010 0 0020 Valve guide I D 4
122. ve shaft for wear or damage If itis worn or damaged replace it with a new one BEARING INSPECTION Rotate the bearing inner race by finger to inspect for abnormal play noise and smooth rotation while the bearings are in the those cases Replace the bearing in the following procedure if there is any thing unusual Play Play Remove the oil seal D with the special tool 09913 50121 Oil seal remover The removed oil seal must be replaced with a new one Remove the oil seal Z with the special tool 09913 50121 Oil seal remover The removed oil seai must be replaced with a new one Remove the bearings with the special tool 09913 70210 Bearing installer set 09921 20240 Bearing remover set The removed bearings should be replaced with new ones 3 30 ENGINE Remove the snap ring The removed snap ring must be replaced with a new one Remove the bearing with the special tool 09913 70210 Bearing installer set The removed bearing should be replaced with a new one BEARING INSTALLATION Install the bearings with the special tool 09913 70210 Bearing installer set CAUTION Press fit the bearing D 1 1 5 mm 0 04 0 06 in from the end surface Apply SUZUKI SUPER GREASE A to the bearing CD 99000 25010 SUZUKI SUPER GREASE or equivalent Install the oil seal 2 with the special tool 09913 70210 Bearing installer set Apply SUZUKI SUPER GR
123. w compression pressure can indicate any of the following conditions Excessively worn cylinder wall Worn piston or piston rings Piston rings stuck in grooves Poor valve seating Ruptured or otherwise defective cylinder head gasket NOTE When the compression pressure goes below specification check the engine for conditions listed above COMPRESSION TEST PROCEDURE NOTE Before testing the engine for compression pressure make sure that the cylinder head bolts are tightened to the specified torque and the valves are properly adjusted Have the engine warmed up before testing Make sure that the battery is fully charged Remove the related paris and test the compression pressure in the following manner e Remove the spark plug 7 2 7 Install the compression gauge and adaptor in the spark plug hole Make sure that the connection is tight Keep the throttle lever in the fully open position Press the starter button and crank the engine for a few sec onds Record the maximum gauge reading as the cylinder compression 09915 64512 Compression gauge set 09913 10750 Adaptor 2 24 PERIODIC MAINTENANCE INITIAL ENGAGEMENT AND CLUTCH LOCK UP INSPECTION The LT Z50 is equipped with a centrifugal type automatic clutch To insure proper performance and longevity of the clutch assemblies it is essential that the clutches engage smoothly and gradually Before checking the initial engagement and clutch
124. with the special tool 09921 20240 Bearing remover set The removed bearing should be replaced with a new one Remove the snap ring Q The removed snap ring must be replaced with a new one Remove the bearing 3 with the special tool 09913 70210 Bearing installer set The removed bearing should be replaced with a new one CLUTCH SHOE INSPECTION Inspect the boss and centrifugal weight fulcrum sections for looseness damage and operation Inspect the clutch shoe for damage and fouling with oil on the surface If any abnormality is found replace the clutch shoe assembly with a new one 3 40 ENGINE Measure the thickness of clutch shoe at the center position If the thickness Is less than the service limit replace the clutch shoe assembly with a new one Clutch shoe thickness Service Limit 3 0 mm 0 12 in 09900 20102 Vernier calipers CLUTCH HOUSING INSPECTION Inspect the clutch housing for any abnormal surface damage Measure the inside diameter of the clutch housing If the measurement exceeds the service limit replace the clutch housing with a new one Clutch housing I D Service Limit 110 5 mm 4 35 in MOVABLE DRIVEN FACE SPRING INSPECTION Measure the movable driven face spring free length with a ver nier calipers If the length is less than the service limit replace the spring with a new one Movable driven face spring free iength Service Limit 73 0 mm 2 87 in 09900 20102 Vern

2006 Suzuki 50 LTZ Quad Sport Service Manual

Contents

Download Pdf Manuals

Related Search

Related Contents