PERIODIC MAINTENANCE 2
Contents
1. OPTION TAPPET SHIM SET 12800 41810 MEASURED TAPPET CLEARANCE mm 000 004 005 009 010 014 018 019 035 ee ZEL 280 ass 260 zes 270 275 zas 20 ato ars azo a25 sas aas 3 046 050 285 260 205 270 27s 280 205 2 ars 320 azs a30 a40 sas aso CEN ze 265 270 275 26 310 ave a25 amo 056 060 ees 2m ers 2s 200 a25 am ass _ 200 20s zo zos 300 ars sas aas aw 066 070 275 200 26 z 205 315 325 330 335 350 350 071 075 28 285 290 295 300 305 310 315 325 330 335 340 345 3 50 350 076 080 2 290 295 300 305 320 325 230 335 340 34 350 350 CEC a am az 335 091 095 320 25 335 340 345 350 350 MOW TO USE THIS CHART 3 096 100 305 315 325 330 300 345 350 3 1 Measure tappet clear2. Rear suspension Chassis bolts and nuts NOTE and clean adjust replace or lubricate as necessary R Replace T Tighten 2 4 PERIODIC MAINTENANCE LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle Major lubrication points are indicated below ciutch lever holder 1 AGH Side standpivot Footrest pivot and spring hook Brake iever holder and throttle cables AH Brake pedal pivot and footrest pivot NOTE Before lubricating each part clean off any rusty spots and wipe off any grease oil dirt or grime Lubricate exposed parts which are subject to rust with a rust preventative spray whenever the motorcycle has been operated under wet or rainy conditions MAINTENANCE AND TUNE UP CEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements AIR CLEANER Inspect every 6 000 km 4 000 miles 6 months and replace every 18 000 km 11 000 miles 18 months Remove the seat 76 7 e Lift and support the feul tank 74 65 Remove the air cleaner box cap 1 Remove the air cleaner element 2 Carefully use air hose to blow the dust from the cleaner ele ment CAUTION Always use air pressure on the throttle body
3. 2 8 Radiator 5 5 Seat 6 7 PERIODIC MAINTENANCE 2 11 SUFFIX NO 235 pu 240 245 SHIM SELECTION TABLE INTAKE SHIM NO 12892 41 00 TAPPET SHIM SET 12800 41810 MEASURED CLEARANCE PRESENT SHIM SIZE 000 004 0082009 010 020 021 025 240 245 0 81 025 2 255 200 265 270 275 20 285 200 295 305 s15 320 325 330 335 036 040 255 260 265 270 275 285 2 295 345 330 335 aso 265 275 200 290 205 046 050 270 200 285 200 295 310 315 325 335 3 350 EEN 275 200 200 295 aos avs a35 086 060 205 290 295 a10 320 325 330 335 061 006 280 285 290 295 325 330 335
4. aso aso 060 070 265 290 30 305 5 330 335 sas 350 350 ame la 076 080 295 305 320 325 330 335 350 081 085 305 avo ats 325 335 350 0 HOWTO VEE TIS CHAM 086 090 20 3 a aso 1 Measure tappet clearance ENGINE 15 COLD 091 095 315 320 a25 345 350 350 Measure present shim size Match clearance in vertical column with present shim size in horizontal 101 108 asa at EXAMPLE 108 110 _ aw clearanceis 0 23 mm KEKI a30 335 Present shim size 270 mm 116 120 335 345 aso Shim sizeto be used 2 80 mm 121 125 340 aas 1 126 120 131 135 sso 196 140 E 5 21001939 21 2 SHIM SELECTION TABLE EXHAUST TAPPET SHIM NO 12892 41 00
5. ITEM N m kgf m Ib ft Steering stem head nut 90 9 0 65 0 2 Steering stem lock nut 80 8 0 58 0 3 Front fork upper clamp bolt 23 2 3 16 5 Front fork lower clamp bolt 23 2 3 16 5 5 Front fork cap bolt 23 23 165 6 Front axle 100 10 0 72 5 7 Front axle pinch bolt 23 2 3 16 5 8 Handlebar clamp bolt 23 2 3 16 5 9 Front brake master cylinder mounting bolt 10 1 0 7 0 10 Front brake caliper mounting bolt 26 2 6 19 0 17 Front brake caliper housing bolt 23 2 3 16 5 2 Brake hose union bolt 23 23 16 5 Clutch master cylinder mounting bolt 10 1 0 7 0 Clutch hose union bolt 23 2 3 16 5 45 Air bleeder valve Clutch 5 4 0 54 4 0 46 Air bleeder valve Front 7 5 0 75 5 5 47 Air bleeder valve Rear 6 0 6 44 8 Brake disc bolt Front 23 2 3 16 5 49 Brake disc bolt Rear 35 3 5 25 5 4 Rear brake caliper sliding pin 27 0 7 20 0 00 Rear brake caliper mounting bolt 23 2 3 16 5 02 Rear brake master cylinder mounting bolt 10 1 0 7 0 03 Rear brake master cylinder rod lock nut 18 1 8 13 0 09 Front footrest bracket mounting bolt 23 2 3 16 5 5 Front footrest bolt 39 3 9 28 0 06 Swingarm pivot nut 100 10 0 70 0 Swingarm pivot shaft lock nut 90 9 0 65 0 Swingarm pivot shaft 15 1 5 11 0 Rear shock absorber mounting nut 50 5 0 36 0 Upper amp Lower 0 Cushion lever mounting nut 78 7 8 56 5 Cushion lever rod mounting nut 78 7 8 56 5 Rear axle nut For E 03 28 33 100 10 0 72 5 For the others 120 12 0 87 0 33 Seat
6. fully without releasing it Loosen the bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle this will remove the tension of the brake lever causing it to touch the handle bar grip Then close the valve pump and squeeze the lever and open the valve Repeat this process until the fluid flowing into the receptacle no longer contains air bubbles NOTE Replenish the brake fluid in the reservoir as necessary while bleeding the brake system Make sure that there is always some fluid visible in the reservoir Close the bleeder valve and disconnect the pipe Fill the res ervoir with brake fluid to the UPPER line CAUTION Handle brake fluid with care the fluid reacts chemi cally with paint plastics rubber materials and so on The only difference between bleeding the front and rear brakes is that the rear master cylinder is actuated by a pedal e Inspect every 6 000 km 4 000 miles 6 months TIRE TREAD CONDITION Operating the motorcycle 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 tire tread reaches the following specification 09900 20805 Tire depth gauge Tire tread depth Service Limit FRONT 1 6 mm 0 06 in REAR 2 0 mm 0 08 in TIRE PRESSURE If the tire pressure is too high or too low st
7. or stored for a long peri ods Check the clutch hose and hose joints for cracks and oil leakage BLEEDING AIR FROM THE CLUTCH FLUID CIRCUIT The clutch fluid circuit may be purged of air in the following man ner Keep the motorcycle upright and place the handlebars straight Fill up the master cylinder reservoir to the upper end of the inspection window Replace the reservoir cap to prevent entry of dirt Attach a pipe to the bleeder valve and insert the free end of the pipe into a receptacle Squeeze and release the clutch lever several times in rapid succession and squeeze the lever fully without releasing it Loosen the bleeder valve by turning it a quarter of a turn so that the fluid runs into the receptacle this will remove the ten sion of the clutch lever causing it to touch the handlebar grip Then close the valve pump and squeeze the lever and open the valve Repeat this process until the fluid flowing into the receptacle no longer contains air bubbles Close the bleeder valve and disconnect the pipe Fill the res ervoir with brake fluid to the upper end of the inspection win dow Air bleeder valve 5 4 0 54 kgf m 4 0 Ib ft us 9 PERIODIC MAINTENANCE 2 19 COOLING SYSTEM Inspect every 6 000 km 4 000 miles 6 months Replace engine coolant every 2 years ENGINE COOLANT LEVEL CHECK Keep the motorcycle upright Check t
8. rail bolt 55 5 5 40 0 0 Rear sprocket nut 60 6 0 43 5 35 Steering damper bolt and nut 23 2 3 16 5 2 30 PERIODIC MAINTENANCE a amp PERIODIC MAINTENANCE 2 31 COMPRESSION PRESSURE CHECK The compression 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 SPECIFICATION Automatic de comp actuated Standard Limit Difference 1 000 1 400 kPa 800 kPa 200 kPa 10 14 kgf cm 142 199 psi 8 kgf cm 114 psi 2 kgf cm 28 psi Low compression pressure can indicate any of the following conditions Worn down piston or piston rings Piston rings stuck in grooves Poor seating of valves Ruptured or otherwise defective cylinder head gasket Overhaul the engine in the following cases Compression pressure in one of the cylinders is less than 800 kPa 8 kgf cm 114 psi Difference in compression pressure between two cylinders is more than 200 kPa 2 kgf cm 28 psi All compression pressure are below 1 000 kPa 10 kgf cm 142 psi even when they measure more than 800 kPa 8 kgf cm 114 psi COMPRESSION TEST PROCEDURE NOTE Before testing the engine for compression pressure make sure that the cylinder head bolts are tighten
9. straight e Check the brake fluid level by observing the lower limit lines on the front and rear brake fluid reservoirs When the level is below the lower limit line replenish with brake fluid that meets the following specification Specification and Classification DOT 4 PERIODIC MAINTENANCE 2 23 2 4 PERIODIC MAINTENANCE A WARNING The brake system of this motorcycle is filled with a glycol based brake fluid Do not use or mix different types of fluid such as silicone based or petro leum based Do not use any brake fluid taken from old used or unsealed containers Never re use brake fluid left over from the last servicing or stored for a long period Brake fluid if it leaks will interfere with safe running and immediately discolor painted surfaces Check the brake hoses and hose joints for cracks and oil leakage before riding BRAKE PADS The extent of brake pad wear can be checked by observing the grooved limit the pad When the wear exceeds the grooved limit replace the pads with new ones 0776 66 and 77 CAUTION Replace the brake pad as a set otherwise braking per formance will be adversely affected BRAKE PEDAL HEIGHT Loosen the lock nut and rotate the push rod 2 to locate brake pedal 55 65 mm 2 17 2 56 below the top face of the footrest Retighten the lock nut to secure the push rod 2 in the pro
10. that handle bar movement does not raise the engine idle speed and that the throttle grip returns smoothly and auto matically THROTTLE VALVE SYNCHRONIZATION Inspect initially at 1 000 km 600 miles 1 month For E 33 only and every 12 000 km 7 500 miles 12 months thereafter 4 88 EVAPORATIVE EMISSION CONTROL SYS TEM FOR E 33 ONLY Inspect every 12 000 km 7 500 miles 12 months Replace vapor hose every 4 years 279 5 PAIR AIR SUPPLY SYSTEM Inspect every 12 000 km 7 500 miles 12 months 79 6 PERIODIC MAINTENANCE 2 17 2 18 PERIODIC MAINTENANCE CLUTCH CLUTCH HOSE AND CLUTCH FLUID Inspect every 6 000 km 4 000 miles 6 months Replace hose every 4 years Replace fluid every 2 years CLUTCH FLUID LEVEL Keep the motorcycle upright and place the handlebars straight Check the clutch fluid level by observing the lower limit line on the clutch fluid reservoir e If the level is found to be lower than the lower mark replenish with BRAKE FLUID that meets the following specification Specification and Classification DOT 4 A WARNING The clutch system of this motorcycle is filled with a glycol based brake fluid Do not use or mix different types of fluid such as silicone based or petroleum based Do not use any brake fluid taken from old used or unsealed containers Never re use brake fluid left over from the last servicing
11. the rear cylinder at TDC of compression stroke The clearance specification is for COLD state To turn the crankshaft for clearance checking be sure to use a 17 mm wrench and rotate in the normal running direction All spark plugs should be removed Remove the generator cover plug 1 and timing inspection plug Turn the crankshaft to set the 1 Front cylinder at TDC of compression stroke Align the F line on the generator rotor to the index mark of valve timing inspection hole and also bring the camshafts to the position as shown above To inspect the No 1 Front cylinder tappet clearance use thickness gauge between the tappet and the cam If the clear ance is out of specification adjust it into the specified range 09900 20803 Thickness gauge PERIODIC MAINTENANCE 2 9 2 10 PERIODIC MAINTENANCE Turn the crankshaft 270 degrees 3 4 turns to set the No 2 Rear cylinder at TDC of compression stroke Align the R line on the generator rotor to the index mark of valve timing inspection hole and also bring the camshafts to the position as shown in page 2 9 Inspect the 2 Rear cylinder tappet clearance as the same manner of No 1 Front cylinder and adjust the clear ance if necessary 09900 20803 Thickness gauge TAPPET CLEARANCE ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim Remo
12. Imp qt Filter change 2 9 L 3 1 2 6 US Imp qt Overhaul engine 3 3 L 3 5 2 9 US Imp qt CAUTION 1 ONLY USE GENUINE SUZUKI MOTORCYCLE OIL FILTER Other manufacturer s oil filters may differ in thread specifications thread diameter and pitch fil tering performance and durability which may lead to engine damage or oil leaks Also do not use a genuine Suzuki automobile oil filter on this motorcycle PERIODIC MAINTENANCE 2 15 After contacting the o ring tighten 2 turns 246 PERIODIC MAINTENANCE ENGINE IDLE SPEED Inspect initially at 1 000 km 600 miles 1 month and every 6 000 km 4 000 miles 6 months thereafter NOTE Make this adjustment when the engine is hot Start up the engine and set its idle speed to the specified range by turning the throttle stop screw Engine idle speed 1 200 100 r min THROTTLE CABLE PLAY Inspect initially at 1 000 km 600 miles 1 month and every 6 000 km 4 000 miles 6 months thereafter Adjust the throttle cable play with the following three steps MINOR ADJUSTMENT First step Loosen the lock nut 1 of the throttle returning cable and turn in the adjuster 3 fully into the threads Second step Loosen the lock nut 4 of the throttle pulling cable Turn the adjuster 6 in or out until the throttle cable play A should be 2 0 4 0 mm 0 08 0 16 in at the throttle grip Tighten
13. NT FORK Inspect every 12 000 km 7 500 miles 12 months Inspect the front forks for oil leakage scoring or scratches on the outer surface of the inner tubes Replace any defective parts if necessary 0 7 6 20 REAR SUSPENSION Inspect every 12 000 km 7 500 miles 12 months Inspect the damper for oil leakage and the spring unit for dam age Check that there is no play in the swingarm assembly Replace any defective parts if necessary 76 51 EXHAUST PIPE BOLT Tighten initially at 1 000 km 600 miles 1 month and every 12 000 km 7 500 miles 12 months thereafter Tighten the exhaust pipe bolts and muffler mounting bolts to the specified torque Muffler mounting bolt and exhaust pipe bolt 23 N m 2 3 kgf m 16 5 Ib ft Muffler mounting nut F 25 N m 2 5 kgf m 18 0 lb ft 29 99000 32050 THREAD LOCK 1342 EXHAUST GAS SEALER PERMATEX 1372 PERIODIC MAINTENANCE 2 29 CHASSIS BOLT AND NUT Tighten initially at 1 000 km 600 miles 1 month and every 6 000 km 4 000 miles 6 months thereafter Check that all chassis bolts and nuts are tightened to their specified torque Refer to page 2 30 for the loca tions of the following nuts and bolts on the motorcycle
14. PERIODIC MAINTENANCE 2 1 PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE PERIODIC MAINTENANCE CHART LUBRICATION POINTS MAINTENANCE AND TUNE UP PROCEDURES AIR CLEANER v SPARK PLUG TAPPET CLEARANCE FUEL HOSE ENGINE OIL AND OIL FILTER ENGINE IDLE SPEED THROTTLE CABLE PLAY THROTTLE VALVE SYNCHRONIZATION EVAPORATIVE EMISSION CONTROL SYSTEM FOR E 33 ONLY 2 17 PAIR AIR SUPPLY SYSTEM CLUTCH COOLING SYSTEM DRIVE CHAIN BRAKE TIRE STEERING FRONT FORK REAR SUSPENSION EXHAUST PIPE BOLT CHASSIS BOLT AND NUT COMPRESSION PRESSURE CHECK COMPRESSION TEST PROCEDURE OIL PRESSURE CHECK OIL PRESSURE TEST PROCEDURE 22 PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy Mileages are expressed in terms of kilome ters miles and time for your convenience INPORTANT The periodic maintenance intervals and service requirements have been established in accordance with EPA regulations Following these instructions will ensure that the motorcycle will not exceed emission standards and it will also ensure that reliabillity and performance of the motorcycle NOTE More frequent servicing may be performe
15. amshaft position sensor 1 and breather hose 2 Remove the rubber heat shield 3 e Remove the spark plug cap Remove the spark plug with a spark plug wrench HEAT RANGE Check to see the heat range of the plug Standard Cold type NGK CR8EK or CR10EK DENSO U24ETR U27ETR or U31ETR CARBON DEPOSIT Check to see if there are carbon deposits on the plugs If car bon is deposited remove it with a spark plug cleaner machine or carefully using a tool with a pointed end SPARK PLUG GAP Measure the plug gap with a thickness gauge If out of specifi cation adjust it to the following gap 09900 20803 Thickness gauge Spark plug gap Standard 0 6 0 7 mm 0 024 0 028 in ELECTRODES CONDITION Check to see the worn or burnt condition of the electrodes If it is extremely worn or burnt replace the plug And also replace the plug if it has a broken insulator damaged thread CAUTION 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 Confirm the thread size and reach when replacing the PERIODIC MAINTENANCE 2 7 2 8 PERIODIC MAINTENANCE SPARK PLUG AND PLUG CAP INSTALLATION Install the spark plugs to the cylinder heads by finger tight and then tighten them to the specified torque Spark plug 11 N m 1 1 kgf m 8 0 Ib ft CAUTION When installing a spa
16. ance ENGINE IS COLD Measure present shim size 708 110 2 325 330 335 345 Match clearance in vertical column with present shim size in horizontal coum ZEL EZE 325 390 sas kao 121 125 330 336 340 345 350 350 Present shim size 2 90 mm 126 190 ass Shim size tobe used 3 05 mm ESE 141 145 350 en 5 15 81 2 21001039 2 14 PERIODIC MAINTENANCE FUEL HOSE Inspect every 6 000 km 4 000 miles 6 months Replace every 4 years Inspect the fuel feed hose for damage and fuel leakage If any defects are found the fuel hoses must be replaced ENGINE OIL AND OIL FILTER ENGINE OIL Replace initially at 1 000 km 600 miles 1 month and every 6 000 km 4 000 miles 6 months thereafter OIL FILTER Replace initially at 1 000 km 600 miles 1 month and every 18 000 km 11 000 miles 18 months thereafter should be changed while the engine is warm Oil filter replacement at the above intervals should be done together with the engine oil change ENGINE OIL REPLACEMENT Keep the motorcycle upright e Place oil pan below the engine and d
17. d on motorcycles that are used under severe conditions PERIODIC MAINTENANCE CHART Interval km 1 000 6 000 12 000 18 000 24 000 miles 600 4000 7 500 11 000 15 000 Item months 1 6 12 18 24 Air cleaner element Exhaust pipe bolts and muffler bolts T Tappet clearance Spark plugs R l R Fuel hose Replace every 4 years Engine oil R R R R R Engine oil filter R R Idle speed Throttle cable play l Throttle valve synchronization E 33 only Evaporative emission control system z E 33 only Replace vapor hose every 4 years PAIR air supply system 1 Engine coolant Replace every 2 years Radiator hose 1 Clutch hose Replace every 4 years Clutch fluid Replace every 2 years Drive chain 1 Clean and lublicate every 1 000 km 600 miles Brakes 1 Replace every 4 years Brake fluid Replace every 2 years Tires 1 Steering 6 t Interval km PERIODIC MAINTENANCE 2 3 1000 6000 12 000 18 000 24 000 miles 600 4000 7 500 11 000 15 000 months 1 8 12 18 24 Front fork
18. ed to the specified torque values and valves are properly adjusted Have the engine warmed up by idling before testing Be sure that the battery used is in fully charged condition Remove the parts concerned and test the compression pressure in the following manner Lift and support the fuel tank 0 74 65 Remove the radiator mounting bolts and move the radiator forward Remove all the spark plugs 72 6 Fit the compression gauge one of the plug holes while tak ing care of the tight connection Keep the throttle grip full open position While cranking the engine a few seconds with the starter and record the maximum gauge reading as the compression of that cylinder Repeat this procedure with an other cylinder 09915 64512 Compression gauge 09913 10750 Compression gauge adaptor 2 32 PERIODIC MAINTENANCE OIL PRESSURE CHECK Check periodically the oil pressure in the engine to judge roughly the condition of the moving parts OIL PRESSURE SPECIFICATION Above 350 kPa 3 5 kgf cm 50 psi Below 650 kPa 6 5 kgf cm 92 psi at 3 000 r min Oil temp at 60 C 140 F If the oil pressure is lower or higher than the specification the following causes may be considered LOW OIL PRESSURE Clogged oil filter Oil leakage from the oil passage way Damaged O ring Defective oil pump Combination of the above items HIGH OIL PRESSURE Used of high visco
19. eering will be adversely affected and tire wear increased Therefore maintain the correct tire pressure for good roadability or shorter tire life will result Cold inflation tire pressure is as follows COLD INFLATION SOLO RIDING DUAL RIDING TIRE PRESSURE kPa kgf cm psi kPa kgf cm psi FRONT 250 2 50 36 250 2 50 36 REAR 2 50 2 90 42 CAUTION The standard tire fitted on this motorcycle is 120 70 ZR17M C 58W for front and 180 55 ZR17M C 73W for rear The use of tires other than those specified may cause instability It is highly recommended to use a SUZUKI Genuine Tire MICHELIN FRONT PILOT SPORT REAR PILOT SPORT STEERING Inspect initially at 1 000 km 600 miles 1 month and every 12 000 km 7 500 miles 12 months thereafter Steering should be adjusted properly for smooth turning of han dlebars and safe running Overtight steering prevents smooth turning of the handlebars and too loose steering will cause poor stability Check that there is no play in the steering stem while grasping the lower fork tubes by supporting the machine so that the front wheel is off the ground with the wheel straight ahead and pull forward If play is found perform steering bearing adjustment as described in page 6 36 of this manual PERIODIC MAINTENANCE 2 27 2 28 PERIODIC MAINTENANCE FRO
20. ening the axle nut 2 Tighten both chain adjuster lock nuts 3 securely 9 Rear axle nut 100 10 0 kgf m 72 5 Ib ft For E 03 28 33 120 N m 12 0 kgf m 87 0 Ib ft For the others CLEANING AND LUBRICATING Wash the chain with kerosene If the chain tends to rust quickly the intervals must be shortened CAUTION Do not use trichlene gasoline or any similar fluids These fluids have too great a dissolving power for this chain and what is more important they can damage the O rings or seals confining the grease in the bush to pin clearance Remember high durability comes from the presence of grease in that clearance After washing and drying the chain oil it with a heavy weight motor oil CAUTION Do not use any oil sold commercially as drive chain oil Such oil can damage the O rings or seals The standard drive chain is RK530SMOZ1 SUZUKI recommends that this standard drive chain should be used for the replacement Inspect initially at 1 000 km 600 miles 1 month every 6 000 km 4 000 miles 6 months thereafter BRAKE HOSE AND BRAKE FLUID Inspect every 6 000 km 4 000 miles 6 months Replace hoses every 4 years Replace fluid every 2 years BRAKE FLUID LEVEL CHECK Keep the motorcycle upright and place the handlebars
21. for the possible defects listed below Support the motorcycle by a jack and a wooden block turn the rear wheel slowly by hand with the transmission shifted to Neutral Loose pins Excessive wear Damaged rollers Improper chain adjustment Dry or rusted links Missing O ring seals Kinked or binding links If any defects are found the drive chain must be replaced NOTE When replacing the drive chain replace the drive chain and sprockets as a set CHECKING Remove the axle cotter pin For E 03 28 and 33 models Loosen the axle nut 1 Loosen the chain adjuster lock nuts Tense the drive chain fully by turning both chain adjusters 3 2 22 PERIODIC MAINTENANCE e Count out 21 pins 20 pitches 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 319 4 mm 12 6 in ADJUSTING Loosen or tighten both chain adjusters 1 until the chain has 20 30 mm 0 8 1 2 in of slack in the middle between engine and rear sprockets The ends of left and right spacers must be at the same position the scales A to ensure that the front and rear wheels are correctly aligned Place the motorcycle on its side stand for accurate adjust ment After adjusting the drive chain tighten the axle nut 2 to the specified torque Recheck the drive chain slack after tight
22. he engine coolant level by observing the full and lower lines on the engine coolant reserve tank Full line Lower line If the level is below the lower line add engine coolant to the full line from the engine coolant reserve tank filler NOTE To remove the filler cap lift and support the fuel tank 2774 65 ENGINE COOLANT CHANGE Remove the front cowling body 776 5 and 6 Remove the radiator 1 Drain engine coolant by removing the drain bolt A A WARNING Do not open the radiator cap when the engine is hot as you may be injured by escaping hot liquid or vapor Engine coolant may be harmful if swallowed or if it comes in contact with skin or eyes If engine coolant gets into the eyes or in contact with the skin flush thoroughly with plenty of water If swallowed induce vomiting and call physician immediately Flush the radiator with fresh water if necessary Tighten the water drain bolt to the specified torque 9 water drain bolt A 5 5 0 55 kgf m 4 0 Ib ft Pour the specified engine coolant up to the radiator inlet Bleed the air from the engine coolant circuit as following pro cedure NOTE For engine coolant information refer to page 5 3 2 20 PERIODIC MAINTENANCE AIR BLEEDING FROM THE ENGINE COOLANT CIRCUIT Remove the front cowling body 7776 5 and 6 Bleed air from the air bleeder bolt Tighten the air bleeder bolt 7
23. per position Brake pedal height 55 65 mm 2 17 2 56 in Rear brake master cylinder rod lock nut 18 N m 1 8 kgf m 13 0 Ib ft BRAKE LIGHT SWITCH Adjust the rear brake light switch so that the brake light will come on just before pressure is felt when the brake pedal is depressed PERIODIC MAINTENANCE 2 25 206 PERIODIC MAINTENANCE AIR BLEEDING FROM THE BRAKE FLUID CIRCUIT Air trapped in the fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylin der and thus interferes with the full braking performance of the brake caliper The presence of air is indicated by sponginess of the brake lever and also by lack of braking force Considering the danger to which such trapped air exposes the machine and rider it is essential that after remounting the brake and restor ing the brake system to the normal condition the brake fluid cir cuit be purged of air in the following manner up the master cylinder reservoir to the UPPER line Place the reservoir cap to prevent entry of dirt Attach a pipe to the air bleeder valve and insert the free end of the pipe into a receptacle 9 Front air bleeder valve 7 5 0 75 kgf m 5 5 Ib ft Rear air bleeder valve 6 N m 0 6 kgf m 4 4 lb ft Front brake Bleed the air from the air bleeder valve Squeeze and release the brake lever several times in rapid succession and squeeze the lever
24. rain oil by removing the drain plug and filler cap 2 Tighten the drain plug to the specified torque and pour fresh oil through the oil filler The engine will hold about 2 7 L 2 9 2 4 US Imp qt of oil Use an API classification of SF or SG oil with SAE 10W 40 viscosity Oil drain plug 23 N m 2 3 kgf m 16 5 1 8 ud us ud e Start up the engine and allow it to run for several minutes at idling speed Turn off the engine and wait about three minutes then check the oil level through the inspection window If the level is below mark L add oil to level If the level is above mark F drain oil to level OIL FILTER REPLACEMENT Remove the under cowling 76 5 Drain engine oil in the same manner of engine oil replacement procedure Remove the oil filter 1 by using the oil filter wrench Special tool Apply engine oil lightly to the O ring of the new filter before installation e Install the new filter turning it by hand until you feel that the fil ter O ring contacts the mounting surface Then tighten it 2 turns using the oil filter wrench 9 09915 40610 Oil filter wrench NOTE To properly tighten the filter use the special tool Never tighten the filter by hand Pour fresh engine oil and check the oil level in the same man ner of engine oil replacement procedure Engine oil capacity Oil change 2 7 L 2 9 2 4 US
25. rk plug carefully turn the spark plug wrench by finger into the threads of the cylinder head to prevent damage the aluminum threads NOTE When installing the spark plug caps front and rear face the tri angle mark on the water proof cover to the each cylinder exhaust side Insert the spark plaug cap securely to the dead end TAPPET CLEARANCE Inspect every 24 000 km 15 000 miles 24 months Remove the seat 776 7 Lift and support the fuel tank 4 65 Remove the radiator 2775 5 Remove the spark plugs 22 6 Remove the cylinder head covers The tappet clearance specification is different for intake and exhaust valves Tappet clearance must be checked and adjusted 1 at the time of periodic inspection 2 when the valve mechanism is serviced and 3 when the camshafts are disturbed by removing them for servicing Tappet clearance when cold 0 10 0 20 mm 0 004 0 008 EX 0 20 0 30 mm 0 008 0 012 in Water proof cover Ss Head cove cover correct incorrect us wo The tappet clearance should taken when each cylinder is at Top Dead Center TDC of compression stroke The cams amp EX on the front cylinder at position show the front cylinder at TDC of compression stroke The cams amp EX on the rear cylinder at position show
26. side of the air cleaner element If air pressure is used on the other side dirt will be forced into the pores of the air cleaner element thus restricting air flow through the air cleaner element PERIODIC MAINTENANCE 2 5 2 6 PERIODIC MAINTENANCE e Reinstall the cleaned or new air cleaner element in the reverse order of removal CAUTION If driving under dusty condition clean the air cleaner element more frequently The surest way to accelerate engine wear is to use the engine without the element or to use a ruptured element Make sure that the air cleaner is in good condition at all times Life of the engine depends largely on this component NOTE When cleaning the air cleaner element drain water from the air cleaner by removing the drain plug SPARK PLUG Inspect every 6 000 km 4 000 miles 6 months and replace every 12 000 km 7 500 miles 12 months No 1 FRONT SPARK PLUG REMOVAL Remove the radiator mounting bolt Move the radiator forward Remove the spark plug NOTE Be careful not to damage the radiator fins A WARNING The hot radiator and the hot engine can burn you Wait until the radiator and the engine are cool enough to touch Remove the spark plug with a spark plug wrench 9 2 REAR SPARK PLUG REMOVAL Remove the seat C7 6 7 Lift and support the fuel tank C7 4 65 Disconnect the c
27. sity engine oil Clogged oil passage way Combination of the above items OIL PRESSURE TEST PROCEDURE Start the engine and check if the oil pressure indicator light is turned on If it keeps on lighting check the oil pressure indicator light circuit If it is in good condition check the oil pressure in the following manner Remove the under cowling 0 77 6 5 Remove the main oil gallery plug 1 Install the oil pressure gauge with attachment in the position shown in the photo Warm up the engine as follows Summer 10 min at 2 000 r min Winter 20 min at 2 000 r min After warming up increase the engine speed to 000 r min with the engine tachometer and read the oil pressure gauge 09915 72410 Oil pressure gauge attachment 09915 74521 Oil pressure gauge hose 09915 74532 Oil pressure gauge attachment 09915 77331 Meter for high pressure Oil gallery plug 8 18 N m 1 8 kgf m 13 0 Ib ft
28. the lock nut while holding the adjuster Third step While holding the throttle grip at the fully closed position slowly turn out the adjuster 3 of the throttle returning cable 2 to feel resistance Tighten the lock nut 1 while holding the adjuster Throttle cable play A 2 0 4 0 mm 0 08 0 16 in A WARNING After the adjustment is completed check that handle bar movement does not raise the engine idle speed and that the throttle grip returns smoothly and auto matically NOTE Major adjustment can be made by the throttle body side adjuster Co MAJOR ADJUSTMENT Lift and support the fuel tank 24 65 Remove the air cleaner box 0 7 4 75 Loosen the lock nut 7 of the throttle returning cable e Turn the returning cable adjuster 2 to obtain proper cable play Loosen the lock nut of the throttle pulling cable e Turn the pulling cable adjuster in or out until the throttle cable play should be 2 0 4 0 mm 0 08 0 16 in at the throttle grip e Tighten the lock nut 3 securely while holding the adjuster 4 Throttle cable play A 2 0 4 0 mm 0 08 0 16 While holding the throttle grip at the fully closed position slowly turn the returning cable adjuster 2 to obtain a slack of 1 0 mm 0 04 in Tighten the lock nut 1 securely A WARNING After the adjustment is completed check
29. to the specified torque Air bleeder bolt 10 N m 1 0 kgf m 7 3 Ib ft e Add engine coolant up to the radiator inlet Support the motorcycle upright e Lightly tap the thermostat case 2 and slowly swing the motor cycle right and left to bleed the air trapped in the case 2 Add engine coolant up to the radiator inlet Start up the engine and bleed air from the radiator inlet com pletely Add engine coolant up to the radiator inlet Repeat the above procedure until bleed no air from the radia tor inlet e Close the radiator cap 3 securely e After warming up and cooling down the engine several times add the engine coolant up to the full level of the reserve tank CAUTION Repeat the above procedure several times and make sure that the radiator is filled with engine coolant upto Reverse tank side 250 ml 0 3 0 2 US Imp qt Engine side 1 950 ml 2 1 1 7 US Imp qt the reserve tank full level Engine coolant capacity 2 21 RADIATOR HOSES Check to see the radiator hoses for crack damage or engine coolant leakage If any defects are found replace the radiator hoses with new ones DRIVE CHAIN Inspect initially at 1 000 km 600 miles 1 month and every 6 000 km 4 000 miles 6 months thereafter Clean and lubricate every 1 000 km 600 miles Visually check the drive chain
30. ve the intake or exhaust camshafts 0773 18 Remove the tappet and shim by fingers or magnetic hand Check the figures printed on the shim These figures indicate the thickness of the shim as illustrated Select a replacement shim that will provide a clearance within the specified range For the purpose of this adjustment a total of 25 sizes of tappet shim are available ranging from 2 30 to 3 50 mm in steps of 0 05 mm Fit the selected shim to the valve stem end with numbers toward tappet Be sure to check shim size with micrometer to ensure its size Refer to the tappet shim selection table Pages 2 12 and 13 for details NOTE Be sure to apply engine oil to tappet shim top and bottom faces When seating the tappet shim be sure to face figure printed surface to the tappet CAUTION Reinstall the camshafts as the specified manner 733 106 ud ud After replacing the tappet shim and camshafts rotate the engine so that the tappet is depressed fully This will squeeze out oil trapped between the shim and the tappet that could cause an incorrect measurement then check the clearance again to confirm that it is within the specified range e After finishing the tappet clearance adjustment reinstall the following items When installing the cylinder head cover do not forget the gas ket A Page Cylinder head cover 3 112 Spark plug and plug
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