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OWNER`S SERVICE MANUAL

Contents

1. 15 8 CALIPER CLEANING iis E nsn E SP 15 8 FRONT CALIPER REASSEMBLY 15 9 REAR CALIPER REASSEMBLY 15 9 MASTER CYLINDER 15 10 MASTER CYLINDER REMOVAL AND DISASSEMBLY 15 10 REAR MASTER CYLINDER REMOVAL AND DISASSEMBLY 15 11 MASTER CYLINDER INSPECTION 15 12 MASTER CYLINDER CLEANING 15 12 FRONT MASTER CYLINDER REASSEMBLY 15 12 REAR MASTER CYLINDER REASSEMBLY 15 13 BRAKE PEDAL occcisecccccorccetecsreciecescesincustesuseduieednedsesdugedivesndesesduessadecaadeausedas 15 14 BRAKE PEDAL REMOVAL AND REASSEMBLY 15 14 15 2 FRONT AND REAR BRAKES CONSTRUCTION FRONT AND REAR BRAKES V 10 1 0 kgf m 7 3 Ib ft 9 53 am X 16 5 Ib ft 7 7 IN X m sien V 18 oa 13 01b ft 2 7 5 V 23 n 23 dues Ib ft 5 5 Ib ft BRAKE FLUID BRAKE FLUID AIR BLEEDING A WARNING Brake fluid can be hazardous to humans and pets Brake fluid is harmful or fatal if swal
2. 14 6 REAR WHEEL BEARING REASSEMBLY 14 6 REAR WHEEL INSTALLATION 14 6 DISC PLATE REPLACEMENT 14 7 REAR SPROCKET REPLACEMENT 14 7 14 2 FRONT AND REAR WHEELS CONSTRUCTION FRONT AND REAR WHEELS 4 65 Lip 55 S 47 0 Ib ft S Q 8 5 o kgf m 6 0 Ib ft V 8 5 0 85 kgf m 6 0 Ib ft 4 0 4 kgf m 3 0 Ib ft 8 5 0 85 kgf m 6 0 Ib ft FRONT WHEEL REMOVAL Place the motorcycle on a block to lift front wheel off the ground Remove the cotter pin Loosen the axle nut D Remove the axle Remove the front wheel and collars INSPECTION AXLE SHAFT Support the axle shaft with V blocks and measure the axle shaft runout Service Limit 0 25 mm 0 010 in WHEEL RIM Measure the wheel rim runout with a dial gauge Service Limit 2 0 mm 0 08 axial and radial WHEEL BEARING Turn the inner race by finger and inspect it for smooth move ment Inspect the clearance between the outer race and wheel hub Inspect for bearing damage FRONT AND REAR WHEELS 14 3 14 4 FRONT AND REAR WHEELS FRONT WHEEL BEARING REMOVAL Fit the bearing remover into the wh
3. E Punched mark Clearance REAR SUSPENSION REAR SUSPENSION CONTENTS CONSTRUCTION Usu an 17 2 REAR SUSPENSION rara od Spes s Eds aw ERR 17 2 REAR SHOCK ABSORBER raises axes bas 17 3 REAR SHOCK ABSORBER REMOVAL 17 3 SPRING REMOVAL ua EROR XU UE ades 17 4 REAR SHOCK ABSORBER INSPECTION 17 4 SPRING INS FALEA TION aq drame a Eug SES 17 5 REAR SHOCK ABSORBER INSTALLATION 17 5 OIL REPLACEMENT PROCEDURE 17 6 REAR SHOCK ABSORBER DISASSEMBLY AND INSPECTION 17 9 REAR SHOCK ABSORBER REASSEMBDLY 17 10 REAR SHOCK ABSORBER DISPOSAL 17 10 SWINGARBM 17 11 SWINGARM REMOVAL eese urna aaa nana atn nna a a 17 11 SWINGARM INSPECTION 2 tn nura nana natam nn naa 17 12 BEARING REPLACEMENT ierra arra tear aka nean aum un gx kx nella nana wn 17 12 SWINGARM REASSEMBLY 17 13 REAR SUSPENSION LIN
4. RM85 PA RE E RM85L 87 mm 3 4 RM85 85 mm 3 3 RM85L 45 1 9 m 6 2 ft RM85 2 0 m 6 6 ft RM85L Disc brake hydraulically operated Disc brake hydraulically operated 70 100 17 40M RM85 70 100 19 42M RM85L 90 100 14 49M RM85 90 100 16 52M RM85L Electronic Ignition CDI 15 at 11 000 r min NGK BR10ES 5 0 L 1 3 1 1 US Imp gal 650 ml 1 4 1 1 US Imp qt 570 ml 1 2 1 0 US Imp qt 351 ml 11 86 12 36 US Imp oz SERVICING INFORMATION 18 19 SETTING DATA DATE RACE COURSE TEMP HUMIDITY WHETHER COURSE COUDITION MAIN JET JET NEEDLE SLOW JET PILOT SCREW FLOAT LEVEL SPARK PLUG OIL LEVEL ADJ POSITION RE BOUND ADJ POSITION SPRING SPRING SPRING SET LENGTH SUG ADJ POSITION LOW ADJ POSITION HIGH RE BOUND ADJ POSITION FINAL REDUCTION RATIO MAKER SIZE PRESSURE MAKER SIZE PRESSURE DATE LOCATION CARBURETOR CHASSIS Y LL 2 LL 2 2 D 3 lt ui TIRE REAR FRONT TIRE COMMENT COPIES MEMO A WARNING Failure to follow these safety precautions may increase your risk of injury Wear a helmet eye protection and bright protective clot
5. 9 9293 9504 JeujeaJq esou Joveipey esou JeujeeJq SOY apis y 9293 Je oJ eui apis esou 10jeipeJ eui yey euns 9504 JOJOINGED UO SIUM 4 Joyaunqueg V 18 12 SERVICING INFORMATION The front brake hose must be passed in front of the number M plate When loosening or tighten the adaptor hold the front brake hose with a wrench to prevent the brake hose from twisting Front brake master cylinder Washer Front brake hose guide Front brake hose Hose clamp Front fork cover a brake hose Front brake hose Clamp the upper different portion 7 inbrake hose diameter Front brake hose LL Front fork cover Front brake caliper SERVICING INFORMATION 18 13 Clamp iu C Stopper No contact Guide Brake hose Rear caliper Rear master cylinder Bracket 18 14 SERVICING INFORMATION 06 Jo ejBue ue 19 1e e eui V JepuiAo exeJq 1104 Aub eseeJ6 Ajdde
6. Fuel tank cap Fuel valve Carburetor starter knob Gearshift lever 69 69 Rear brake fluid reservoir Rear suspension compression damping adjuster Kick starter lever Front suspension compression damping adjuster Front suspension rebound damping adjuster Rear brake pedal Rear suspension rebound damping adjuster FUEL AND OIL RECOMMENDATION This motorcycle is of the two stroke design which requires a premixture of gasoline and oil Gasoline Use only unleaded gasoline of at least 90 pump octane R 2 M 2 Canada Use only unleaded gasoline of at least 95 octane Research method For other countries Engine oil MOTUL 800 2T or equivalent Two Cycle Racing Lubricant Mixing ratio 30 1 Fuel tank capacity 5 0 L 1 3 1 1 US Imp gal CAUTION A mixture containing too little oil will cause piston sei zure Too much oil will cause excessive carbon forma tion resulting in preignition fouled spark plug and loss of engine power Mix fuel and the engine oil at the ratio of 30 1 NOTE Mix gasoline and the engine oil thoroughly when the tempera ture is below 0 C 32 F Vegetable based oils can separate easier than mineral oils Use premixture oil as soon as possible after mixing or lubrica tion performance of the engine oil can decrease Do not mix vegetable based oil and mineral oil Insert the en
7. emouu eui jesu e1ojeg SERVICING INFORMATION 18 15 18 16 SERVICING INFORMATION Throttle cable NC Cross the throttle cable and clutch cable above the number plate mounting boss A Clutch cable SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length Overall width Overall height Wheelbase Ground Seat lieight Dry mass ENGINE Displacement Corrected compression ratio SERVICING INFORMATION Carburetor Air cleaner 1 805 mm 71 1 in RM85 1 895 mm 74 6 in RM85L 735 mm 28 9 in 1 100 mm 43 3 in RM85 1 165 mm 45 9 in RM85L 1 240 mm 48 8 in RM85 1 280 mm 50 4 in RM85L 325 mm 12 8 in RM85 355 mm 14 0 in RM85L 850 mm 33 5 in RM85 875 mm 34 4 in RM85L 65 kg 143 Ibs RM85 69 kg 152 Ibs RM85L Two stroke liquid cooled Crankcase reed valve 1 48 1 890 46 8 1 843 84 7 cm 5 2 cu in 9 5 1 EX VALVE OPEN 10 9 1 EX VALVE CLOSE KEIHIN PE28 Single Polyurethane foam element Starter system Lubrication system Primary kick Fuel oil premixture of
8. SUZUKI RM85 L OWNER S SERVICE MANUAL This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator The manual contains important safety information and instructions which should be read carefully before operating the motorcycle FOREWORD This manual is presented as a means whereby you can maintain your RM85 in top working condition at all times Your riding skill and the maintenance steps outlined in this manual will assure you of top performance from your machine under any type of competition We sincerely wish you and your Suzuki motorcycle a successful partnership for many years of happy riding All information illustrations photographs and speci fications contained in the manual are based on the latest product information available at the time of publication Due to improvements or other changes there may be some discrepancies in this manual Suzuki reserves the right to make production changes at any time without notice and without incurring any obligation to make the same or similar changes to vehicles previous built or sold Suzuki Motor Corporation believes in conservation and protection of Earth s natural resources To that end we encourage every vehicle owner to recycle trade in or properly dispose of as appropriate used motor oil engine coolant and other fluid and
9. Hold the front fork vertically and adjust fork oil level with the special tool NOTE When adjusting the fork oil level compress the outer tube fully without the fork spring 09943 74111 Front fork oil level gauge 99000 99001 SS5 SUZUKI FORK OIL SS 05 or an equivalent fork oil SPRING STANDARD OIL OIL LEVEL LEVEL ADJUSTABLE RANGE STANDARD SPRING 124 mm 114 147 mm 2 8 N m 0 28 kgf mm 4 88 in 4 49 5 79 in SOFTER SPRING OPTIONAL SPRING 120 mm 110 144 mm 2 6 N m 0 26 kgf mm 51171 03B30 4 72 in 4 33 5 67 in STIFFER SPRING OPTIONAL SPRING 130 mm 117 148 mm 3 0 N m 0 30 kgf mm 51171 03B60 5 12 in 4 60 5 83 in NOTE Be sure to adjust the fork oil level within the above mentioned range the front fork performance will deteri orate The oil level should be increased or decreased by 3 mm 0 12 in at a time Make sure that the oil level is the same as both fork legs Pull up the inner rod with the special tool 09940 52841 Inner rod holder Install the fork spring a Adjust the height of the inner rod threads by turning the lock nut D 14 mm Set the rebound damping adjuster 1 5 mm 0 06 in as shown before assembling the front fork cap Slowly turn the fork cap bolt to seat at the lock nut 3 by hand tightening CAUTION Be sure to adjust the rebound damping force adjuster to the softest position before in
10. Adjust the height of the inner rod threads by turning the lock nut D 14 mm Set the rebound damping adjuster 1 5 mm 0 06 in as shown before assembling the front fork cap Slowly turn the fork cap bolt to seat at the lock nut 3 by hand tightening CAUTION Be sure to adjust the rebound damping force adjuster to the softest position before installing the fork cap bolt Hold the fork cap bolt and tighten the lock nut to the specified torque V Inner rod lock nut 20 2 0 kgf m 14 5 Ib ft Apply fork oil to the fork cap s O ring Temporarily tighten the fork cap bolt to the outer tube TOOL FRONT FORK AND STEERING 16 11 REINSTALLATION Reinstall the front forks Set the aligning line D on the outer tube to the upper surface of the steering stem head Check that the air valve is positioned at the front e Tighten the fork lower clamp bolts to the specified torque V Fork lower clamp bolt 23 N m 2 3 kgf m 16 5 Ib ft Tighten the fork cap bolt 2 to the specified torque V Fork bolt 35 N m 3 5 kgf m 25 5 Ib ft Tighten the fork upper clamp bolts 3 to the specified torque V Fork upper clamp bolt 23 N m 2 3 kgf m 16 5 Ib ft Install the front wheel 14 4 Install the brake caliper 15 8 nstall the fork covers brake hose guide and brake hose cover 16 12 FRONT FORK AND STEERING STEERING REMO
11. Brake noise Brake pads worn Brake disc worn Dirty brake pads and disc Optional stiffer and softer springs are available Replace Replace Clean MEMO MACHINE TUNING 4 1 MACHINE TUNING CONTENTS CARBURETOR TUNING 556 4 2 PRINCIPLES OF CARBURETOR TUNING 4 2 CARBURETOR TUNING IN PRACTICE 4 5 FHONT FORK TONING bia tix cr Fasc ui Ue ux nA 4 8 FRONT FORK iater ndi 4 8 FRONT FORK SPRING REPLACEMENT AND OIL LEVEL ADJUSTMENT 4 9 REAR SUSPENSION TUNING 4 13 REAR SUSPENSION 4 13 SUSPENSION BALANCE ccissssonccssaenncievsesnecisascterciedannscstivednerassenderciaassscsaiees 4 16 BALANCE TEST 4 16 TIPS 4 16 4 2 MACHINE TUNING CARBURETOR TUNING The carburetion of your motorcycle was carefully selected after extensive testing You will find that the carburetion will function smoothly under many varied operating conditions For best results we rec ommend that the adjustments and carburetion jet ting be left as is from the factory Some riders may operate their motorcycle under extreme operating conditions such as very high altitudes or extreme
12. Front fork oil type SUZUKI FORK OIL SS 05 or equivalent fork oil Front fork oil capacity each leg 351 ml 11 86 12 36 US Imp oz Rear shock absorber oil type SUZUKI REAR SUSPENSION OIL SS 25 or an equivalent rear suspension oil Rear shock absorber oil capacity 195 ml 6 6 6 9 US Imp oz SPECIAL TOOLS 09900 00401 Hexagon wrench set 09900 06107 Snap ring pliers 09900 06108 Snap ring pliers SERVICING INFORMATION 09900 09003 Impact driver set 18 7 09900 20101 Vernier calipers 150 mm 09900 20202 Micrometer 25 50 mm 09900 20205 Micrometer 09900 20508 Cylinder gauge set 09900 20602 Dial gauge 09900 20605 Dial gauge 09900 20803 Thickness gauge 09900 25008 Multi circuit tester 09910 20116 Conrod holder 09910 32812 Crankshaft installer 09910 60611 Universal clamp wrench gt 09913 50121 Oil seal remover 09913 70210 Bearing installer set 09916 44910 Valve guide driver 09916 53340 Valve guide installer 09917 50410 Bearing remover 09920 13120 Crankcase separating tool 09920 20310 Spring hook 09920 53740 Clutch sleeve hub holder 09921 20220 Bearing remover set 09923 73210 Bearing puller 18 8 SERVICING INFORMATION 09930 30141 09930 30211 09930 30102 Flywheel rotor Flywheel rotor 09940 14930 09924 84521 Rotor remover slide remover Attach remover Attach
13. 99000 31140 SUZUKI BOND 1207B DRIVE CHAIN AND SPROCKETS DRIVE CHAIN SLACK Place the motorcycle on the side stand Inspect the drive chain slack at the middle point between the two sprockets Drive chain slack 40 50 mm 1 6 2 0 in PERIODIC MAINTENANCE 2 13 2 14 PERIODIC MAINTENANCE DRIVE CHAIN ADJUSTMENT Loosen the axle nut D Loosen the lock nut 2 Adjust the drive chain slack to the specification by turning the adjusters 3 Check that both right and left alignment marks are at the same position Tighten the axle nut and lock nut 2 V Axle nut 72 N m 7 2 kgf m 52 0 Ib ft NOTE Pull the upper drive chain tight and lock it by placing a bar between the drive chain and rear sprocket while tightening the axle nut This will help prevent the chain adjusters from coming to have play 20TH PITCH LENGTH Pull the drive chain tight and measure the 20th pitch length Service Limit 259 mm 10 2 in DRIVE CHAIN LUBRICATION Remove the chain clip and master link from the drive chain and remove the drive chain NOTE Be careful not to bend the chain clip Inspect for wear and damage of the drive chain and replace it if necessary Clean the drive chain with non flammable cleaning solvent Do not use gasoline to clean the drive chain Dry the drive chain Apply Suzuki Chain Lube or an equivalent to the link plates and rollers Rea
14. CYLINDER Remove the cylinder 2576 3 Remove carbon deposits from the exhaust port Check for scratches and wear on the cylinder sleeve PISTON Remove the piston 7 6 4 Remove carbon deposits from the top surface of the piston Check for scratches cracks and wear around the piston bosses Remove minor scuffs with 1 000 1 200 sand paper Check piston ring wear Remove carbon deposits from the piston ring groove EXHAUST VALVE Remove the exhaust valve L7 6 4 Remove carbon deposits from the exhaust valve and exhaust valve guide Check for wear and damage Inspect the breather hose for clogging with tar If clogging is found clean up it NOTE Using several brands of engine oil may cause tar to drip from the breather hoses EXHAUST SILENCER SILENCER INSPECTION AND REPLACEMENT Remove the seat and the right frame cover Loosen the silencer mounting bolts and remove the silencer Remove three bolts and extract the black frontal pipe from the aluminum case Inspect the glass wool for clogging with carbon deposit or tar Replace the glass wool 7 with a new one if necessary SILENCER REASSEMBLY Install the glass wool D and the black frontal pipe to the alu minum case Tighten three bolts NOTE To seal between the black frontal pipe flange and the aluminum case apply SUZUKI BOND 1207 to the contact area of the flange
15. Clutch sleeve hub nut Primary drive gear nut Spark plug Transmission oil drain plug Transmission oil level screw Water pump drain plug Handlebars clamp bolt Front fork upper clamp bolt right and left Front fork lower clamp bolt right and left Steering stem head nut Front fork center bolt Fork cylinder inner rod lock nut Front fork cap bolt Master cylinder mounting bolt front Master cylinder mounting bolt rear Rear master cylinder rod lock nut Brake hose adaptor front Brake hose union bolt front and rear Brake caliper mounting bolt front Brake caliper mounting bolt rear Brake bleeder valve front and rear Disc mounting screw front and rear Disc mounting nut front Front axle nut Engine mounting nut front Engine mounting nut middle Rear axle nut Rear sprocket nut Drive chain tensioner roller bolt Spoke nipple Rear swingarm pivot nut engine mounting Rear shock absorber mounting nut upper and lower Rear cushion lever center nut Rear cushion lever front nut Rear cushion rod nut 2 22 PERIODIC MAINTENANCE For other bolts and nuts not listed in the table refer to this chart Bolt Diameter Conventional or 4 marked bolt 7 marked or crown headed bolt mm N m kgf m lb ft N m kgf m lb ft 2 0 0 2 1 5 2 0 0 2 1 5 3 0 0 3 2 0 5
16. If it has scratches or is bent replace it with a new one Measure the free length of front fork spring Service Limit Standard spring 444 mm 17 48 in Inspect the teflon coating metals slide bushing and guide bushing for wear or damage If they are worn or damaged replace them with new ones Inspect the metal particles on the teflon coating metals If they are not clean clean them with a nylon brush and fork oil REASSEMBLY NOTE Clean all fork parts before reassembling Replace the O rings oil seal and dust seal with the new ones Apply specified front fork oil when installing the O rings slide bushing guide bushing damper unit and other sliding parts Apply front fork oil to the oil seal lip and the dust seal Cover the inner tube with a vinyl film Install the dust seal D stopper ring 2 and oil seal 3 onto the inner tube CAUTION Scratches on the oil seal lip can cause oil leaks When installing the seal place a vinyl film over the bushing attachment groove and edges of the inner tube to avoid damage to the seal lip NOTE The side of the oil seal that has a mark should face the dust seal e Remove the vinyl film and then install the seal retainer 4 guide bushing and slide bushing Clean the parts and keep them free from dust NOTE Inspect the bushings for burrs If there is a burr remove it with a knife taking care not to peel off the teflon co
17. Reassemble the clutch cover and water pump cover 7 5 Connect the radiator hose Pour engine coolant and transmission oil 2 7 and 8 ELECTRICAL SYSTEM 13 1 ELECTRICAL SYSTEM CONTENTS CONSTRUCTION 13 2 ELECTRICAL SYSTEM 13 2 ELECTRICAL CIRCUIT dene 13 2 IGNITION SYSTEM 13 3 IGNITION COIL INSPECTION 13 4 CDI UNIT INSPECTION 13 4 STATOR COIL INSPECTION 13 5 MAGNETO ROTOR AND STATOR REMOVAL AND HEASSEMBEY 13 5 13 2 ELECTRICAL SYSTEM CONSTRUCTION ELECTRICAL SYSTEM V 35 3 5 kgf m 25 5 Ib ft ELECTRICAL CIRCUIT Engine stop switch B Y B R Ignition coil Magneto R W CDI Unit B W Spark plug Color code B W Black with White tracer B Y Black with Yellow tracer B R Black with Red tracer W BI White with Blue tracer R W Red with White tracer ELECTRICAL SYSTEM 13 3 IGNITION SYSTEM IGNITION SYSTEM PEAK VOLTAGE INSPECTION Remove the seat fuel tank C 7 5 2 Remove the spark plug cap and spark plug Connect a new spark plug to the spark plug cap and grou
18. a gas that is colorless and odorless easily n n th or severe injury T 4 cause death or severe Injury Do not smoke when servicing the machine Only run the engine outdoors where there Do not service the machine in an area is fresh air where there are open flames or sparks A WARNING A WARNING Hot engine and muffler can burn you Brake fluids and engine coolant can be hazardous to humans and pets Brake fluid and engine coolant are harmful or fatal if swallowed and harmful if it comes in con tact with your skin or eyes Wait until the engine and muffler cools before servicing Keep brake fluid and engine coolant away from children Call your doctor immedi ately if swallowed and induce vomiting Flush eyes or skin with water if either brake fluid or engine coolant gets in eyes or comes in contact with skin WARNING Servicing the machine with engine running can be hazardous You can be caught in the moving parts such as the drive chain sprockets etc Be sure to stop the engine when servicing the machine WARNING Servicing the machine without proper clothes and protective gear can be hazard ous You can be injured if you do not wear proper clothes and protective gear Be sure to wear proper clothes and shoes for servicing and wear protective glasses mask or gloves as necessary PRECAUTIONS FOR SERVICING Replace gaskets ci
19. of Needle Clip NEEDLE NUMBER 24NAAH O D Changing the needle itself controls air fuel mixture ratio particulary on lower mid throttle opening The smaller the O D the richer the air fuel mixture becomes Air fuel mixture Lean Needle Number O D 24NAAK 24NCDK 2 415 mm 2 405 mm 2 395 mm 2 385 mm 2 375 mm 24NAAJ 24NCDJ 24NAAH 24NCDH 24NAAG 24NCDG 24NAAF 24NCDF MAIN JET The main jet like the pilot jet meters fuel flow MACHINE TUNING 4 5 CARBURETOR TUNING IN PRACTICE In the previous section basic principles of carburetor tuning have been discussed Described in this section are the bases for carburetor tuning required when coping with variations in air oxygen concentration VARIATION IN AIR OXYGEN CONCENTRATION AND CARBURETOR CONDITIONS As the air affected by the temperature altitude and humidity gets expanded or compressed air oxygen concentration varies accordingly Each of these three factors affects the air in different ways and the follow ing graphs show their effects respectively in terms of the oxygen concentration 76 100 100 90 90 80 80 OXYGEN CONCENTRATION 96 10 0 10 20 30 40 C 500 1000 1500 2000 2500 m 20 40 60 80 100 10 30 50 70 90 1600 3200 5000 6500 8200 ft ATOMOSPHERIC TEMPERATURE ALTITUDE HUMIDITY In the above graphs oxygen concentration is graduated on the vertical axis while the temperature
20. onto the inner rod X FORK OIL Place the front fork vertically without spring Compress it fully Pour specified front fork oil up to the top level of the outer tube Move the inner rod slowly with the special tool more than ten times until no more bubbles come out from the oil 09940 52841 Inner rod holder NOTE Refill front fork oil up to the top of the outer tube to find bubbles while bleeding air Refill specified front fork oil up to the top level of the outer tube again Move the outer tube up and down several strokes until no more bubbles come out from the oil Keep the front fork vertically and wait 5 6 minutes NOTE Always keep oil level over the cartridge top end or air may enter the cartridge during this procedure Take extream attention to pump out air completely Hold the front fork vertically and adjust fork oil level with the special tool NOTE When adjusting the fork oil level compress the outer tube fully without the fork spring 09943 74111 Front fork oil level gauge Fork oil level Standard 124 mm 4 88 in 99000 99001 SS5 SUZUKI FORK OIL SS 05 or an equivalent fork oil Standard fork oil capacity each leg 351 ml 11 86 12 36 US Imp oz FRONT FORK AND STEERING 16 9 TOOL 16 10 FRONT FORK AND STEERING Pull up the inner rod with the special tool 09940 52841 Inner rod holder Install the fork spring
21. 0 0 5 3 5 6 0 0 6 4 5 10 0 1 0 7 0 13 0 1 3 9 5 23 0 2 3 16 5 29 0 2 9 21 0 50 0 5 0 36 0 45 0 4 5 32 5 85 0 8 5 61 5 65 0 6 5 47 0 135 0 13 5 97 5 105 0 10 5 76 0 210 0 21 0 152 0 160 0 16 0 115 5 240 0 24 0 173 5 TROUBLESHOOTING 3 1 TROUBLESHOOTING CONTENTS TROUBLESHOOTING 3 2 ENGINE able e bio 3 2 CHASSIS uiae indu 3 5 3 2 TROUBLESHOOTING TROUBLESHOOTING ENGINE Complaint Possible Cause Remedy Engine does not start or hard to start Fuel deterioration No fuel flow to the carburetor Fuel valve clogged Fuel hose clogged Fuel tank cap breather hose clogged Carburetor float valve malfunction Carburetor overflow pipe clogged Carburetor air vent pipe colgged Too rich air fuel mixture in combustion chamber Incorrect ignition timing No spark at spark plug Low compression Piston ring worn or stuck Cylinder worn Air leak from cylinder gasket Air leak from crankshaft oil seal Replace Clean Clean or replace Clean Replace Clean Clean Scavange Adjust 13 1 Replace Replace or rebore Replace Replace Engine stalls Fuel deterioration Fouled spark plug Fuel hose clogged Air cleaner clogged Carburetor jets clogged Low compression Piston ring worn or stuck Cylinder worn Air leak from cylinder gasket Air leak from cranksha
22. 30 1 TRANSMISSION Clutch Gearshift pattern Primary reduction ratio Gear ratios Mae Wet multi plate type 6 speed constant mesh 1 down 5 up 3 444 62 18 2 545 28 11 1 933 29 15 1 571 22 14 1 333 20 15 1 166 21 18 1 045 23 22 3 357 47 14 3 615 47 13 D I D 42805 118 links RM85 0 1 0 42805 122 links RM85L 18 17 18 18 SERVICING INFORMATION CHASSIS Front suspension Rear Suspension Front fork Rear wheel travel EE Steering angle meet ne eee Torning radi Frontbrake iE Ae AAE Rear Fronttire SIZ6 Rear tite ELECTRICAL Ignition timing eeens rererere Spark plug ite tees CAPACITIES Fuel tank tc Transmission Oil Engine oll Telescopic pneumatic coil spring oil damped Link type oil damped 275 mm 10 8 in 277 mm 10 9 in 28 90
23. Align the clutch release rack teeth with the pinion gear Align the water pump empeller to the crankshaft end Install the clutch cover Tighten the bolts diagonally Reassemble the rear brake pedal 15 14 Install the clutch release arm 1 Install the kick starter lever e Pour transmission oil C 72 7 e Pour engine coolant C 72 8 Inspect the clutch cable play 2 9 CLUTCH SLEEVE HUB REMOVAL Remove the pressure plate and clutch plates 7 3 e Flatten the lock washer D Hold the clutch sleeve hub with the special tool and loosen the nut 09920 53740 Clutch sleeve hub holder Remove the clutch sleeve hub 0 CLUTCH 7 5 7 6 CLUTCH Remove the washer 1 primary driven gear ass y 2 Remove the needle bearing 3 and washer 4 Remove the snap ring 5 and kick idle gear 6 CLUTCH SLEEVE HUB INSPECTION Inspect the clutch sleeve hub and primary driven gear ass y for wear and cracks Inspect the kick idle gear and needle bearing for damage and wear gt 19 CLUTCH SLEEVE REASSEMBLY D Install the washer and needle bearing Apply transmission oil to the needle bearing Install the kick idle gear 3 and snap ring 4 CLUTCH 7 7 Install the primary driven gear ass y and washer Install the clutch sleeve hub lock washer and clutch sleeve hub nut Tighten the clu
24. Apply THREAD LOCK SUPER 1322 to the primary driven gear nut and tighten it to the specified torque with the special tool 99000 32110 THREAD LOCK SUPER 1322 09910 20116 Conrod holder V Primary driven gear nut 70 N m 7 0 kgf m 50 5 Ib ft NOTE The primary driven gear nut has left hand thread Reassemble the gearshift linkage 7 9 4 Reassemble the kick idle gear and kick starter shaft 7 8 4 Reassemble the exhaust valve governor C 7 6 13 Reassemble the stator and magnet rotor 7 13 6 Reassemble the clutch and clutch cover 7 7 6 Reassemble the kick starter lever Reassemble the piston and cylinder 7 6 9 and 10 Remount the engine C 7 5 5 Pour transmission oil and coolant C 7 2 7 and 8 TRANSMISSION AND CRANKSHAFT 10 11 Thrust washer MEMO FUEL SYSTEM 11 1 FUEL SYSTEM CONTENTS CONSTRUCTION 11 2 FUEL SYSTEM rg epe rave axe 11 2 CARBURETORS 1 oni iibi enis ker 11 3 REMOVAL AND DISASSEMBLY 11 3 INSPECTION aiiis 11 5 HEASSEMBLY 11 5 FREED VALVE T 11 5 HEMOVAE 11 5 INSPECTION RAMIS UNS 11 5 REASSEMBLY 11 6 11 2 FUEL SYSTEM CON
25. BALANCE Balancing the front to rear suspension properly is the most critical adjustment for suspension performance If the front forks are adjusted harder than the rear suspension such as changing to heavier front fork oil stiffer compression and rebound setting air pressure build up in the forks and so on the front forks will collapse less on bumps This transfers more of the motorcycle and rider weight rearward possibly causing the rear suspension to bottom where as it felt fine before the front fork adjustment was made BALANCE TEST Stand next to the motorcycle on level ground Place one foot on the foot rest closest to you Sharply push down The front and rear suspensions should both collapse equally BALANCING TIPS Check for air pressure build up in front forks Heat and altitude will increase air pressure in the front forks Always stay within sag measurement limits 85 95 mm 3 3 3 7 in when using spring pre set to stiffen or soften rear suspension If this is not possible the next stiffer or softer accessory spring is needed The rear shock compression damping can be used to fine tune suspension balance and is easy to access ENGINE REMOVAL AND INSTALLATION 5 1 ENGINE REMOVAL AND INSTALLATION CONTENTS ENGINE REMOVAL AND INSTALLATION 5 2 RU E USE Y E 5 2 INSTALLATION 5 5 5 2 ENGINE
26. Brake Replace brake hose and fluid every year Front fork oil Change after 1st initial break in Front fork Check front fork inner tube frequently for abnormality Check the air pressure Rear suspension system pivoting portion Check rear suspension system frequently and apply the grease to the pivoting portion as necessary Tire Spoke nipple Inspect every 20 min up to initial 2 hours then check before each ride Steering Bolts and nuts Retighten every 1 hour NOTE R Replace C Clean T Tighten Inspect and clean adjust lubricate or replace if necessary L Lubricate 2 4 PERIODIC MAINTENANCE SPARK PLUG Inspect the spark plug condition electrode color carbon deposits spark plug gap and washer damage after removing the spark plug NOTE Remove the dirt around the spark plug before removing the spark plug to prevent dirt from entering the combustion cham ber Inspect the porcelain tip color Porcelain tip color Cause Hottype spark plug Advanced ignition timing Lean air fuel mixture Deteriorated fuel Cold type spark plug Retarded ignition timing Rich air fuel mixture Rich oil gasoline mixture White overheated Black fouled Check the spark plug gap with a thickness gauge Spark plug gap 0 7 0 8 mm 0 028 0 031 in Standard Spark plug NGK BR10ES CAUTION Changing the spark plug hea
27. Ib ft NOTE Pump the brake pedal several times to seat the brake pads after reassembling BRAKE DISC BRAKE DISC INSPECTION Measure the front and rear brake disc thickness Service Limit 2 5 mm 0 10 in Measure the front and rear brake disc runout Service Limit 0 30 mm 0 01 in BRAKE DISC REPLACEMENT 14 7 15 6 FRONT AND REAR BRAKES BRAKE CALIPER The use of any brake fluid except DOT 4 brake fluid from a sealed container can damage the brake system and lead to an accident Use only DOT 4 brake fluid from a sealed container Never use or mix different types of brake fluid A WARNING Brake fluid can be hazardous to humans and pets Brake fluid is harmful or fatal if swallowed and harm ful if it comes in contact with your skin or eyes Keep brake fluid away from children Call your doctor immediately if brake fluid is swallowed and induce vomiting Flush eyes or skin with water if brake fluid gets in eyes or comes in contact with skin CAUTION Spilled brake fluid can damage painted surfaces and plastic parts Be careful not to spill any fluid when servicing the cal iper Wipe spilled fluid up immediately FRONT CALIPER REMOVAL AND DISASSEMBLY e Drain brake fluid L7 15 4 Place a drain pan under the caliper and remove the union bolt Remove the caliper mounting bolts 2 Remove the brake pads and spring 3 from the caliper R
28. PROCEDURE Bottoms Jump Large bump Adjust the compression damping to a harder H setting See note below Adjust the sag to a smaller measurement closer to 85 mm Replace the spring with an optional stiffer one Medium to large bumps Small to medium bumps Decelerating or braking Adjust the rebound damping to a harder H set ting See note below Adjust the sag to a larger measurement closer to 95 mm Replace the spring with an optional softer one Hits bumps too harshly Jump Large bump Series of medium bumps Adjust the compression damping to a softer S setting See note below Adjust the sag to a larger measurement closer to 95 mm Replace the spring with an optional softer one Feels harsh and tends to sink Series of medium bumps Series of small bumps Adjust the rebound damping to a softer S set ting See note below Feels too soft and unstable Series of medium bumps Series of small bumps Adjust the rebound damping to a harder H set ting Provides poor traction NOTE Accelerating Series of small bumps Adjust the compression and rebound damping to a softer setting one at a time alternatively until the optimum settings are obtained Replace the spring with an optional softer one When adjusting the damping setting attempt turning the adjuster 1 4 to 1 2 turn at a time for each adjust ment 4 16 MACHINE TUNING SUSPENSION
29. REMOVAL AND INSTALLATION ENGINE REMOVAL AND INSTALLATION REMOVAL Remove the frame covers amp right and seat 2 Remove the clamps 3 Turn the fuel valve lever to the OFF position and disconnect the fuel hose Remove the radiator cover 4 Remove the fuel tank mounting bolts 5 left and right Remove the fuel tank by unhooking the band from the hooked part Drain transmission oil 72 7 e Drain engine coolant 2712 3 Remove the exhaust pipe fitting springs with the special tool 09920 20310 Spring hook ENGINE REMOVAL AND INSTALLATION 5 3 Remove the muffler mounting bolts Remove the exhaust pipe and muffler Remove the exhaust pipe and gasket e Disconnect the radiator hose 4 Disconnect the radiator hose 2 Remove the spark plug cap 3 and spark plug 4 Disconnect the magneto lead wire coupler 5 Remove the lead wire hose clamp 54 ENGINE REMOVAL AND INSTALLATION Loosen the carburetor clamp screws and remove the carbure tor Remove the magneto cover Remove the drive chain Remove the clutch release arm and disconnect the clutch cable Remove the engine mounting bolts ENGINE REMOVAL AND INSTALLATION 5 5 Loosen the swingarm pivot nut b Extract three quarters of the swingarm pivot shaft so as to keep the swingarm in position NOTE The swingarm will come
30. RS ENGINE BOTTOM SIDE Dismount the engine C 7 5 2 NOTE The following parts must be removed before disassembling the engine bottom side crankcase Remove the engine sprocket cover and engine sprocket Remove the gearshift lever C 79 3 Remove the cylinder head cylinder and piston C 7 6 3 Remove the intake pipe and reed valve 77 11 5 e Remove the magneto rotor and stator C 5 13 6 Remove the kick starter lever Remove the clutch cover and clutch 7 5 Remove the kick starter idle gear and kick starter shaft 8 3 Remove the gearshift linkage 2 gt 9 3 Remove the exhaust valve governor 7 6 11 PRIMARY DRIVE GEAR REMOVAL Hold the conrod with the special tool and loosen the primary drive gear nut Remove the primary drive gear nut 09910 20116 Conrod holder NOTE The primary drive gear nut has left hand thread CRANKCASE SEPARATION Remove the crankcase bolts Separate the crankcase with the special tool 09920 13120 Crankcase separating tool NOTE Set the crankcase separating tool to the clutch side of the crankcase Separate the crankcase gradually while hitting the crankcase boss and countershaft softly with a plastic hammer TRANSMISSION AND CRANKSHAFT 10 3 TOOL One 74 To 3 10 4 TRANSMISSION AND CRANKSHAFT TRANSMISSION REMOVAL Remove the gearshift fork shafts and forks 2 Remove
31. Remove carbon deposits from the piston Inspect the piston for wear scratches and damage Measure the piston outer diameter 16 mm 0 63 in from the skirt end Piston outer diameter Service Limit 47 880 mm 1 8850 in 09900 20202 Micrometer 25 50 mm Measure the piston pin bore and piston pin diameter Service Limit 14 030 mm 0 5524 in 13 980 mm 0 5504 in Piston pin bore Piston pin O D 09900 20605 Dial gauge 09900 20205 Micrometer 0 25 mm Remove carbon deposits from piston ring and piston ring groove Fit the piston ring into the ring groove and measure the clear ance with a thickness gauge Piston ring to groove clearance Standard 0 020 0 060 mm 0 0008 0 0024 in 09900 20803 Thickness gauge 15 mm 0 59 in 16 mm 0 63 in CYLINDER PISTON AND EXHAUST VALVE 6 7 Fit the piston ring into the cylinder and measure the piston ring end gap with a thickness gauge Piston ring end gap Service Limit 0 80 mm 0 031 in Measure the piston ring free end gap Piston ring free end gap Service Limit 3 2 mm 0 13 in EXHAUST VALVE INSPECTION Remove carbon deposits from the exhaust valve and valve guide Inspect the exhaust valve and valve guide for wear and scratches Inspect the exhaust valve shaft and arm for damage Inspect the exhaust valve breather hoses for
32. altitude and humidity are on the horizontal axis respectively Oxygen concentration is set 10096 under the conditions of 20 68 F 0 m 0 ft and 50 humidity The standard carburetor setting is chosen to obtain the best engine performance under these conditions The graph at the left shows that the oxygen concentration changes about 10 in the 0 to 40 C temperature difference the one in the center shows about 20 change in the 0 to 2 000 m altitude difference and the one at the right shows about 5 change in the 0 to 100 humidity difference As for humidity its normal range is from 20 to 95 Therefore the possible effect of humidity on the oxygen concentration is so little that it can be disregarded Consequently we can say that the oxygen concentration varies by as much as 2096 depending on the temperature and altitude under normal riding conditions On the other hand different from the air the fuel gasoline hardly changes in volume even when such environmental conditions change Therefore increase in oxygen concentration will make the air fuel mixture richer and decrease will make it lean As the carburetor mixes gasoline and air which are metered by each jet in varying proportions to suit throttle opening the air fuel mixture is affected if the air concentration itself varies as described above Then proper engine power output can not be attained and should the mixture become too lean a piston seizure may result To compensate
33. clogging with tar If clogging is found clean up it NOTE Using several brands of engine oil may cause tar to drip from the breather hoses 6 8 CYLINDER PISTON AND EXHAUST VALVE CONROD INSPECTION Measure the conrod small end bore Conrod small end bore Service Limit 18 040 mm 0 7102 in 09900 20605 Dial gauge Fit the piston pin and bearing into the conrod small end and check the play PISTON RING AND PISTON REASSEMBLY Apply engine oil to the piston ring and piston ring groove Install the piston ring into the piston ring groove so the piston ring end comes to the piston ring locating pin Apply engine oil to the piston pin and bearing Install the bearing to the conrod small end Face the depression on the piston top to the exhaust port side and install the piston D Install the piston pin 2 and piston pin circlips 3 End gap of the circlip should not be aligned with the cutaway in the piston pin bore NOTE Replace the piston pin circlip with a new one Place cloth on the crankcase to prevent piston pin circlip from dropping into the crankcase chamber EXHAUST VALVE REASSEMBLY Apply engine oil to the exhaust valves Assemble the exhaust valves and the exhaust valve retainer Install the exhaust valves into the cylinder Tighten the exhaust valve retainer bolts CYLINDER PISTON AND EXHAUST VALVE 6 9 Install the spacers D springs 2 v
34. for such change in the air concentration it is required to carry out carburetor tuning beforehand This requirement applies to all models of motorcycles and ATVs if they are used in areas where temperature and altitude range widely The next section describes the procedure of the above tuning in detail 4 6 MACHINE TUNING JUDGING AIR FUEL MIXTURE For proper carburetor tuning it is necessary to know how to judge the air fuel mixture made in the carburetor whether too rich too lean or properly mixed Given below are the symptoms observed when the engine is not supplied with the proper air fuel mixture ratio from the carburetor Check each item as reference for judging the air fuel mix ture condition When air fuel mixture is too rich 1 The engine noise is dull and intermittent 2 The engine condition becomes worse when the starter is applied 3 The engine condition becomes worse as it is warmed up 4 The engine condition improves when the air cleaner is removed 5 The spark plug is fouled with carbon wet and oily 6 The exhaust gas produces heavy smoke When air fuel mixture is too lean 1 The engine overheats 2 The engine condition improves when the starter is applied 3 Acceleration is poor 4 The spark plug is burned white 5 The speed of the engine fluctuates and lack of power is noticed 6 Detonation and pinging are experienced TUNING PROCEDURE The following indicates the correct tuning procedu
35. ground Remove the air bleed screw 3 and equalize the air pressure in the front forks to atmospheric pressure Re fit the air bleed screw FRONT FORK SPRING REPLACEMENT AND OIL LEVEL ADJUSTMENT Remove the front forks left and right C 7 16 3 Thoroughly clean the fork before disassembly CAUTION Scratches or other damage on the inner tube or on the oil seal lip will cause oil leak Avoid scratching or damaging the inner tube or the oil seal Use a mild detergent or car wash soap and sponge out dirt with plenty of water Drain fork oil C 5 16 4 Place the front fork vertically without spring Compress it fully Pour specified front fork oil up to the top level of the outer tube Move the inner rod slowly with the special tool more than ten times until no more bubbles come out from the oil 09940 52841 Inner rod holder NOTE Refill front fork oil up to the top of the outer tube to find bubbles while bleeding air MACHINE TUNING 4 9 TOOL 4 10 MACHINE TUNING Refill specified front fork oil up to the top level of the outer tube again Move the outer tube up and down several strokes until no more bubbles come out from the oil Keep the front fork vertically and wait 5 6 minutes NOTE Always keep oil level over the cartridge top end or air may enter the cartridge during this procedure Take extream attention to pump out air completely
36. hose Damage Exhaust pipe Damage Piston and Cylinder Combustion chamber carbon deposit Piston head carbon deposit Piston and cylinder wear Front fork Smooth operation Front fork air pressure PERIODIC MAINTENANCE 2 3 PERIODIC MAINTENANCE CHART It is very important to inspect and maintain the machine regularly Follow the guideline in the chart The life of parts varies depending on the riding conditions Perform more often than shown in the chart if you use the motorcycle under severe conditions Interval Every race Every 3 races Every 9 races Service Item Every 2 hours Every 6 hours Every 18 hours Remarks Spark plug R Air cleaner C Replace air cleaner element as necessary Transmission oil R Change after 1st initial break in Cooling system Replace radiator hose and engine coolant every year Flushing for overhaul or storage Clutch Replace clutch plates as necessary Throttle cable and clutch cable Carburetor Fuel hose Replace every 4 years Piston Piston ring Cylinder head cylinder Exhaust valve Muffler Drive chain Adjust slack every 30 minutes Engine sprocket Rear sprocket Check and retighten sprocket bolts at initial and subsequent 10 minutes of riding and each race thereafter Drive chain buffer Drive chain guide Kick starter lever
37. of throttle spool Keep free from dirt Rear brake pedal Pre race Grease the brake pedal pivot Swingarm Every 3 races More often according to conditions Clean and pack the bearings Keep seals fresh Grease the seals Rearsuspension linkage pivot points Every 3 races More often according to conditions Clean and pack the bearings Keep seals fresh Grease the seals Steering stem bearings Every 5 races More often according to conditions Clean and pack the bearings Keep seals fresh Starter shaft Pre race Lightly oil the starter shaft Drive chain Pre race and between every race Keep chain thoroughly lubed at all times Always check wear and align ment The following materials are necessary A Lightweight oil such as WD 40 or penetrating oil B Suzuki chain lube or an equivalent C Water proof wheel bearing grease Follow the schedule closely The disassembly necessary to lubricate many components is in itself valuable preventative maintenance It allows you to inspect for wear fatigue adjustment and fastener tightness and it allows you to clean out the grit which otherwise cannot be gotten out A WARNING Lubricating switches can damage the switches Do not apply grease and oil to the switches TIGHTENING TORQUE PERIODIC MAINTENANCE 2 21 Cylinder head nut Magneto rotor nut Cylinder nut Crankcase bolt
38. off when the swingarm pivot shaft is completely removed Remove the engine from the frame INSTALLATION Fit the swingarm in its position and hold it with the swingarm pivot shaft Mount the engine on the frame Tighten the engine mounting nuts V Tightening torque NOTE Replace the self locking nuts with new ones Reassemble the removed parts in the reverse order of removal NOTE Route the cables and lead wires correctly gt 18 15 and 16 Reassemble the drive chain clip so the slit end faces opposit the direction of rotation Direction of travel gt ODO 5 6 ENGINE REMOVAL AND INSTALLATION Fit the projection of the carburetor to the depression on intake pipe Apply a small quantity of engine oil to the exhaust pipe O ring Install the exhaust gasket and exhaust pipe After mounting the engine inspect the following items Transmission oil level C 72 7 Engine coolant level 7572 8 Throttle cable play 2 10 Clutch lever play 7 2 9 e Drive chain slack 7 2 13 CYLINDER PISTON AND EXHAUST VALVE 6 1 CYLINDER PISTON AND EXHAUST VALVE CONTENTS CONSTRUCTION fua 6 2 CYLINDER PISTON AND EXHAUST VALVE 6 2 ENGINE 6 3 CYLINDER HEAD REMOVAL 6 3 CYLINDER R
39. the gearshift cam 3 Remove the driveshaft ass y 4 and countershaft ass y 5 CRANKSHAFT REMOVAL Remove the crankshaft with the special tool 09920 13120 Crankcase separating tool TRANSMISSION INSPECTION Inspect the gear teeth dogs and gearshift grooves for abnor mal wear and damage Inspect the bushings and splines for abnormal wear and dis coloration Inspect the gearshift cam groove for abnormal wear and dam age Inspect the gearshift forks and shafts for wear and damage Measure the gearshift fork thickness with a vernier calipers Gearshift fork thickness Standard 3 80 3 90 mm 0 150 0 154 in 4 30 4 40 mm 0 169 0 173 in Measure the gearshift fork groove width with a vernier cali pers Gearshift fork groove width Standard 3 95 4 05 mm 0 156 0 159 in 4 45 4 55 mm 0 175 0 179 in No 1 No 2 amp No 3 Measure the gearshift fork to groove clearance with a thick ness gauge Gearshift fork Groove clearance Service Limit 0 45 mm 0 018 in TRANSMISSION AND CRANKSHAFT 10 5 10 6 TRANSMISSION AND CRANKSHAFT CRANKSHAFT INSPECTION Measure the crankshaft runout with V blocks and dial gauge Crankshaft runout Service Limit 0 05 mm 0 002 in 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block NOTE Place the crankshaft
40. the kick starter shaft Turn the kick starter lever counterclockwise until the kick starter 4 come off the kick starter guide Remove the following parts from the kick starter shaft Spacer 6 Kick return spring 7 Washer 2 2 Q Kick starter 9 9 2 Spring ene 0 Kick starter shaft 40 o D Remove the kick starter guide and kick starter stopper 8 4 KICK STARTER INSPECTION Inspect the oil seal for oil leakage and oil seal lip damage me za Inspect the return spring 2 for damage Inspect the kick shaft 3 and drive gear for contact surface wear Inspect the kick drive gear teeth for damage Inspect the kick drive gear ratchet part for wear and damage Inspect the kick starter stopper 4 REASSEMBLY Install the kick starter stopper and kick starter guide Apply THREAD LOCK SUPER 1322 to the bolt Tighten the bolt 99000 32110 THREAD LOCK SUPER 1322 Install the return spring D into the kick shaft s hole Install them to the crankcase Install the kick shaft assembly to the crankcase Hook the return spring to the crankcase s hole Install the kick starter to the kick shaft NOTE Be sure to align the punch marks on the kick starter and kick starter shaft when installing the kick starter Reassemble the kick idle gear Reassemble the primary driven gear ass y and clutch 7 6 Reassem
41. tools Remove the key 09930 30211 Flywheel rotor remover Attachment 09930 30141 Flywheel rotor remover Attachment 4 13 6 ELECTRICAL SYSTEM MAGNETO ROTOR AND STATOR REASSEMBLY Install the key onto the crankshaft Install the magneto rotor Hold the conrod with the special tool Apply THREAD LOCK SUPER 1322 to the nut and tighten the nut to the specified torque 09910 20116 Conrod holder 99000 32110 THREAD LOCK SUPER 1322 V Magneto rotor nut 35 N m 3 5 kgf m 25 5 Ib ft Align the line on the stator with triangle mark on the crank case Install the magneto cover e Reassemble the piston and cylinder C 7 6 8 and 10 FRONT AND REAR WHEELS 14 1 FRONT AND REAR WHEELS CONTENTS CONSTRUCTION 265 14 2 FRONT AND REAR WHEELS Rp us 14 2 FRONT WHEEL 14 3 14 3 INSPECTION 14 3 FRONT WHEEL BEARING REMOVAL 14 4 FRONT WHEEL BEARING REASSEMBLY 14 4 FRONT WHEEL INSTALLATION 14 4 REAR WHEEL t 14 5 REMOVAL testis iE Didi iag 14 5 INSPECTION 14 5 REAR WHEEL BEARING REMOVAL
42. 4 and spring 5 REAR MASTER CYLINDER REMOVAL AND DISASSEMBLY e Drain brake fluid L7 15 4 Remove the rear brake pedal C 7 15 14 Place a rag under the hose to catch spilled brake fluid Remove the union bolt Remove the master cylinder mounting bolts 2 Remove the clamp and disconnect the hose reservoir Remove the dust seal boot 3 Remove the snap rings with snap ring pliers Remove the push rod 5 Remove the piston cup set and spring Remove the connector 6 15 12 FRONT AND REAR BRAKES MASTER CYLINDER INSPECTION Inspect the cylinder bore and piston for scuffing Inspect the piston rod and spring for damage If any abnormal condition is noted replace the master cylinder Inspect the dust boot if any damages are found replace it with a new one MASTER CYLINDER CLEANING Flush the master cylinder ports with pressurized air Wash the master cylinder bore and piston with fresh brake fluid NOTE Do not use gasoline or other cleaning solvents to wash the mas ter cylinder parts Brake fluid DOT 4 FRONT MASTER CYLINDER REASSEMBLY Apply brake fluid to the piston cup set Install the spring piston cup set and washer Install the snap ring with snap ring pliers Install the dust boot e Reassemble the brake lever Tighten the master cylinder mounting bolts to the specified torque When remounting the master cylinder on the handlebars set the brake lever a
43. AFT CONTENTS CONSTRUCTION siccatesasiesassarseravesedestevonsdecasugunptuauasnsdvewiusasssansoehiaasavavuteuanien 10 2 TRANSMISSION AND CRANKSHAFT 10 2 ENGINE BOTTOM SIDE Suctiavertivdstandaniavenciatcesesueats sazniawsasaveugades 10 3 PRIMARY DRIVE GEAR REMOVAL 10 3 CRANKCASE SEPARATION 10 3 TRANSMISSION REMOVAL 10 4 CRANKSHAFT REMOVAL catur yu aue udxEa Kar 10 4 TRANSMISSION INSPECTION 10 4 CRANKSHAFT INSPECTION 1 eee c serre neat an nnn ra nata a natam nna au 10 6 OIL SEAL INSPECTION REMOVAL AND INSTALLATION 10 6 BEARING INSPECTION REMOVAL AND INSTALLATION 10 7 CRANKSHAFT INSTALLATION 10 8 TRANSMISSION 5 10 9 CRANKCASE REASSEMBLY 10 10 PRIMARY DRIVEN GEAR 10 11 10 2 TRANSMISSION AND CRANKSHAFT CONSTRUCTION TRANSMISSION AND CRANKSHAFT V 70N N 7 0 kgf m 50 5 Ib ft Py 6 3 NI 5
44. ANDARD LIMIT Radiator cap valve opening pressure 110 kPa 1 1 kgf cm 16 psi SERVICING INFORMATION 18 3 TRANSMISSION Unit mm in Except ratio ITEM STANDARD Primary reduction ratio 3 444 62 18 Final reduction ratio 3 357 47 14 3 615 47 13 Gear ratios Low 2 545 28 11 2nd 1 933 29 15 3rd 1 571 22 14 4th 1 333 20 15 5th 1 166 21 18 Top 1 045 23 22 Shift fork to groove clearance 0 05 0 25 amp 0 002 0 010 Shift fork groove width 3 95 4 05 0 156 0 159 4 45 4 55 0 175 0 179 Shift fork thickness 3 80 3 90 0 150 0 154 4 30 4 40 0 169 0 173 DRIVE CHAIN Unit mm in STANDARD Drive chain Type 0 1 0 4280 118 122 Links 20 pitch length Drive chain slack CARBURETOR ITEM SPECIFICATION Carburetor type KEIHIN PE28 Bore size 28 mm 1 0 No 03B3 Float height 19 0 0 5 mm 0 75 0 02 in Main jet JJ 11128 Jet needle N 24NAAH 3rd Slow jet JJ 50 Air screw A S 2 turns out Throttle cable play 2 4 mm 0 08 0 16 in at the throttle grip 18 4 SERVICING INFORMATION ELECTRICAL Unit mm in ITEM SPECIFICATION NOTE Spark plug Type NGK BR10ES Gap 0 028 0 081 Spark performance Over 8 0 3 at 1 atm Ignition coil resistance Primary 02 100 W B
45. EARSHIFTING Remove the gearshift cam stopper Remove the spring 2 INSPECTION Inspect the gearshift shaft for bends and damage Inspect the return spring 2 for damage Inspect the pawls 3 springs and pins for damage Inspect the gearshift cam stopper REASSEMBLY Reassemble the washer 1 and gearshift cam stopper 2 and the spring 3 GEARSHIFTING 9 5 Align the pin groove with the pin B when installing the stopper plate 1 Tighten the gear shift cam bolt V Gearshift cam bolt 23 N m 2 3 kgf m 16 5 Ib ft Install the springs pins and to the shifter Wider side of pawl should be positioned outside With the pawls held in pushed position install the pawl lifter 9 6 GEARSHIFTING Reassemble the gearshift cam shifter and pawl lifter Apply THREAD LOCK SUPER 1322 to the screws Tighten the screws 99000 32110 THREAD LOCK SUPER 1322 5 4 Reassemble the gearshift return spring D to the gearshift shaft properly Align the center teeth on the gearshift shaft with the center teeth on the gearshift cam shifter Install the gearshift lever e Reassemble the clutch and clutch cover 7 7 6 Install the kick starter lever and clutch release arm e Pour transmission oil C 72 7 e Pour engine coolant 7772 8 TRANSMISSION AND CRANKSHAFT 10 1 TRANSMISSION AND CRANKSH
46. EMOVAL paa 6 3 PISTON HEMOVAL 6 4 EXHAUST VALVE REMOVAL 6 4 CYLINDER HEAD INSPECTION 6 5 CYLINDER INSPECTION ariete tn itin etin oaa tr 6 5 PISTON AND PISTON RING INSPECTION 6 6 EXHAUST VALVE INSPECTION esee erre eene aan nnne nana ann 6 7 CONROD INSPECTION 6 8 PISTON RING AND PISTON REASSEMDBLY 6 8 EXHAUST VALVE REASSEMBLY 6 8 CYLINDER HEASSEMBLY sicscssssseececsasessvsvsstarsecinisanadenordvesseanasenzertessatin 6 10 EXHAUST VALVE GOVERNOR REMOVAL AND DISASSEMBLY 6 12 EXHAUST VALVE GOVERNOR INSPECTION 6 13 EXHAUST VALVE GOVERNOR REASSEMBLY AND INSTALLATION 6 14 6 2 CYLINDER PISTON AND EXHAUST VALVE CONSTRUCTION CYLINDER PISTON AND EXHAUST VALVE 28 2 8 kgf m 20 5 Ib ft V 28 2 8 kgf m 21 0 Ib ft Z y 2 Se a 18 0 Ib ft CO b 2 CYLINDER PISTON AND EXHAUST VALVE 6 3 ENGINE TOP END CYLINDER HEAD REMOVAL Remove the frame covers and seat C 775 2 Remove the radiator c
47. EMOVAL Remove the cylinder head and cylinder C 7 6 3 Remove the breather hoses e Remove the exhaust valve cover Remove the exhaust valve shaft stop retainer 2 Loosen the bolt 3 Draw out the shaft Remove the spacers 4 springs and valve shaft arm Remove the exhaust valve assembly 7 CYLINDER HEAD INSPECTION Remove carbon deposits from the cylinder head Inspect the cylinder head for cracks around the spark plug hole Inspect for cylinder head distortion Cylinder head distortion Service Limit 0 05 mm 0 002 in CYLINDER INSPECTION Remove carbon deposits from the exhaust port Inspect the cylinder for cracks and replace the cylinder if nec essary Inspect the cylinder bore for wear nicks and scratches NOTE Chrome plated cylinder bore can not be modified such as boring and honing CYLINDER PISTON AND EXHAUST VALVE 6 5 6 6 CYLINDER PISTON AND EXHAUST VALVE Inspect for cylinder distortion Cylinder distortion Service Limit 0 05 mm 0 002 in Measure the cylinder bore for wear with a cylinder gauge 15 mm 0 59 in from the top surface NOTE The cylinder bore must be measured perpendicular to the crank shaft axis direction Cylinder bore Standard 48 000 48 015 mm 1 8898 1 8904 in 09900 20508 Cylinder gauge set 40 80 mm PISTON AND PISTON RING INSPECTION Remove the piston ring from the piston ring groove
48. ENERAL INSTRUCTIONS 1 5 HELMET GOGGLES GLOVES 1 6 GENERAL INSTRUCTIONS Pull the starter knob out Close the throttle Kick the kick starter lever to start the engine If the engine fails to fire up kick again If third or fourth attempt fails then push back starter knob to original position and open the throttle wider by turning the throttle grip fully Then kick the kick starter lever again As this motorcycle has a primary kick start system the engine can be started with the transmission in any gear position only if the clutch is disengaged by squeezing the clutch lever Upon starting the engine run it for 30 to 60 seconds to sta blize its speed Push the starter knob back to original position STARTING WARM ENGINE Shift the transmission into neutral Open the throttle partially 1 8 1 4 NOTE Operation of the starter knob is not necessary to start the warm engine Kick the kick starter lever STARTING OFF Pull in the clutch lever fully and push the gearshift lever down to change the gear from neutral to low position Release the clutch lever gently while twisting the throttle grip slowly WARNING Twisting the throttle grip fully in standing start can jump the machine and it can throw you off the seat Twist the throttle grip gradually when starting off Pick up speed just a little on low Twist
49. I Ground Secondary 12 20 Plug cap Ground Magneto coil resistance 100 160 Q B R R W 140 2300 R W B W 240 3800 B R B W Ignition coil primary peak voltage 200 V and more BRAKE WHEEL ITEM STANDARD Unit mm in Brake lever play Brake disc thickness Brake disc runout Master cylinder bore Front 11 000 11 043 0 4331 0 4348 Rear 12 700 12 743 0 5000 0 5017 Master cylinder piston diam Front 10 957 10 984 0 4314 0 4324 Rear 12 657 12 684 0 4983 0 4994 Brake caliper cylinder bore Front 30 230 30 306 1 1902 1 1931 Rear 27 000 27 076 1 0630 1 0660 Brake caliper piston diam Front 30 150 30 200 1 1870 1 1890 Rear 26 920 26 970 1 0600 1 0618 Wheel rim runout Axial Radial Wheel axle runout Front Rear Tire size Front 70 100 17 40M 70 100 19 42M 90 100 14 49M Rear 90 100 16 52M SUSPENSION ITEM SERVICING INFORMATION 18 5 STANDARD Unit mm in Front fork stroke 275 10 8 Front fork spring free length Front fork spring rate each leg 2 8 N mm 0 28 kgf mm Front fork oil level 124 4 88 Front fork damping force adjuster Rebound 1 and 1 2 turns out Compres 7 clicks out Front fork air pressur
50. KAGE 17 13 REAR SUSPENSION LINKAGE REMOVAL 17 13 REAR SUSPENSION LINKAGE INSPECTION 17 14 CUSHION LEVER AND CUSHION ROD BEARING REPLACEMENT 17 14 REAR SUSPENSION LINKAGE REASSEMBLY 17 16 17 1 17 2 REAR SUSPENSION CONSTRUCTION REAR SUSPENSION 7 N m 6 0 kgf m 43 5 Ib ft 0 kgf m M 7 80 iy lt E V 58 5 8 kgf m 42 0 lb ft 7 6 0 kgf m 43 5 lb ft REARSUSPENSION 17 3 REAR SHOCK ABSORBER REAR SHOCK ABSORBER REMOVAL Place a block under chassis tubes Remove the frame covers and seat C 775 2 e Loosen the air cleaner clamp screw Remove the frame side tube 4 Loosen the bolts and screw 2 Remove the air cleaner box Loosen the rear shock absorber upper mounting bolt and nut Loosen the rear shock absorber lower mounting bolt and nut 4 Remove the rear shock absorber 17 4 REAR SUSPENSION SPRING REMOVAL Remove the rear shock absorber unit from the frame gt 17 3 Loosen the lock nut and turn the adjuster with the spe cial tool Turn the lock nut and adjuster fully to the end of the thread 09910 60611 Universal clamp wrench Remove the spring seat 3 spring retainers 4 and the sp
51. ROUP INDEX GENERAL INSTRUCTIONS PERIODIC MAINTENANCE TROUBLESHOOTING MACHINE TUNING ENGINE REMOVAL AND INSTALLATION CYLINDER PISTON AND EXHAUST VALVE 6 CLUTCH KICK STARTER 8 GEARSHIFTING TRANSMISSION AND CRANKSHAFT FUEL SYSTEM COOLING SYSTEM ELECTRICAL SYSTEM FRONT AND REAR WHEELS FRONT AND REAR BRAKES FRONT FORK AND STEERING REAR SUSPENSION SERVICING INFORMATION GENERAL INSTRUCTIONS 1 1 GENERAL INSTRUCTIONS CONTENTS LOCATION 1 2 FUEL AND OIL RECOMMENDATION 1 3 INTRUCTING YOUNG 1 4 THIS IS IMPORTANT ADVICE TO A PARENT 1 4 STARTING ENGINE Risk 1 5 STARTING 1 7 25005 ORAE aaa Crush ixi ea I a 1 7 STOPPING ENGINE 1 8 BREAK IN RUNNING IN 1 8 1 2 GENERAL INSTRUCTIONS LOCATION OF PARTS A SY Clutch lever Engine stop switch Front brake fluid reservoir Throttle grip Front brake lever
52. SION DAMPING FORCE ADJUSTMENT Fully turn the damping force adjuster clockwise It is at stiffest position and turn it out to standard setting NOTE Do not force the adjuster screw past the stopped position or the adjuster may be damaged Standard setting 3 4 turns out from stiffest position REBOUND DAMPING FORCE ADJUSTMENT Fully turn the damping force adjuster clockwise It is at stiffest position and turn it out to standard setting NOTE Do not force the adjuster screw past the stopped position or the adjuster may be damaged Standard setting 2 turns out from stiffest position SPRING PRE LOAD ADJUSTMENT Remove the seat frame covers and frame side tube Remove the cleaner box Loosen the lock nut D Turn the adjuster 2 clockwise or counterclockwise to change the spring pre load Tighten the lock nut 4 Standard spring set length 3 1 mm 0 12 in compressed from spring free length RM85 Standard spring set length 4 8 mm 0 19 in compressed from spring free length RM85L Spring set length adjustable range 2 12 mm 0 08 0 47 in compressed from spring free length NOTE Turning the adjuster 0 without loosening the lock nut D can damage the rear cushion unit To remount the rear frame assembly reverse the sequence as described MACHINE TUNING 4 13 4 14 MACHINE TUNING REAR SUSPENSION TUNING PROCEDURE Adjust the rear suspension according to the rider s weight and prefe
53. STRUCTION FUEL SYSTEM FUELSYSTEM 11 3 CARBURETOR REMOVAL AND DISASSEMBLY Remove the seat and fuel tank 7 5 2 Turn the fuel valve lever to OFF Disconnect the fuel hose Loosen the carburetor clamp screws and remove the carbure tor Remove the carburetor top cap and throttle valve Compress the spring 2 with collar 3 and disconnect the throttle cable from the throttle valve Remove the spring 4 and jet needle 5 from the throttle valve Throttle valve spring Throttle valve collar Spring Jet needle Throttle valve 11 4 FUEL SYSTEM Remove the air vent hoses D overflow hoses 2 fuel hose Loosen the screws and remove the carburetor float chamber Remove the float pin and floats 7 Remove the jet holder 8 Remove the needle valve ass y 0 Remove the main jet 40 and slow jet 10 Remove the starter knob 2 Remove the pilot screw 43 and throttle stop screw 4 gt a es 2 5 E NS FUELSYSTEM 11 5 INSPECTION Inspect the following parts for damage Jet needle Throttle valve Float Inspect the following jets for clogging Main jet Slow jet Starter jet Inspect the needle valve for wear Good Worn Measure the float height with a vernier calipers To measure the float height tilt the carburetor until the float tip j
54. Starter knob 13 Float chamber 7 Throttle stop screw 14 Jet holder MACHINE TUNING 4 3 As shown below each tuning parts is located between the air fuel passage and has its own air fuel mixture adjustable range in terms of the throttle valve opening The chart indicates that the carburetor can supply correct air fuel mixture to the engine in any range because of the overlapping adjustable range of the each part TUNING PARTS THROTTLE VALVE OPENING NEEDLE CLIP POSITION Br eE 1 8 1 4 1 2 3 4 THROTTLE OPENING MAIN SYSTEM INTERMEDIATE SYSTEM PILOT SYSTEM When performing carburetor turning first find out in AIR SCREW what throttle opening range an improper air fuel mixture is supplied by checking the color of exhaust smoke spark plug throttle response power etc Second replace or adjust the part s related to the throttle opening range by referring to the following instructions The sizes referred to in Lean the illustrations are those of standard setting Rich SLOW JET AIR SCREW The pilot air screw is located in the inlet air passage and meters the air for the pilot system As it has a right hand thread tightening it makes the passage narrower allowing less amount of intake air to flow and resulting in richer air fuel mixture Air flow adjustment is effective within a range of 1 2 2 and 1 4 turns out The pilot jet meter
55. Steering nut socket Bearing installer shaft ment ment wrench 09940 30250 09940 52861 09941 53630 Front fork assem 09940 52841 Front fork oil seal 09941 34513 Rear shock Inner rod holder installer set Bearing installer set absorber wrench 09943 74111 Front fork oil level gauge SERVICING INFORMATION 18 9 WIRE CABLE AND HOSE ROUTING a N peaj yams dois pes un dO N SE X N peau Buueeis eui passed 5 euiBu3 peal youms dois X awed eui ueewjeq eAiseupe Ajddy b V 47 67 4 M youms dois 6 apis UMOG pue au 9924 pue uoiusno uolysnd Ajddy 18 10 SERVICING INFORMATION Radiator hose must be passed on right side of frame E Muffler Radiator Cylinder breather hose x Exhaust breather hose RN Face the clamp screw to 7 up side 18 11 SERVICING INFORMATION apis y 9994 epis eui esou 1
56. T FORK AND STEERING 16 3 16 4 FRONT FORK AND STEERING Compress the front fork spring 3 and loosen the lock nut D 2 Remove the fork 2 Remove the fork spring 3 Remove the lock nut 4 and the spring guide nvert the front fork and stroke the inner rod several times to let out fork oil Under the inverted condition of front fork drain oil to hold it for a few time Remove the damper rod bolt with the special tool 09940 30250 Front fork assembling tool Remove the damper CAUTION Do not disassemble the damper rod assembly Disas sembling the damper rod assembly can lead to trou ble FRONT FORK AND STEERING 16 5 Remove the dust seal 1 and the stopper ring 2 Pull out the inner tube from the outer tube Remove the slide bushing 3 from the inner tube Remove the following parts from the inner tube Slide bushing 3 Seal retainer 4 Oil seal Stopper ring Dust seal 7 INSPECTION Inspect the cylinder bolt for damage If it is damaged replace it with a new one Replace the O ring with a new one 16 6 FRONT FORK AND STEERING Inspect the inner tube for scratches it has scratches replace it with a new one Inspect the outer tube for dent If it is dented all the way to the inner side replace it with a new one Inspect the damper rod assembly for scratches or bending
57. TE The radiator cylinder and cylinder head are made of aluminum alloy Using non recommended engine coolant may corrode alu minum alloy and may clog the coolant passageways A WARNING Engine coolant is harmful if swallowed or if it comes in contact with your skin or eyes Keep engine coolant away from children and pets Call your doctor immediately if engine coolant is swal lowed and induce vomiting Flush eyes or skin with water if engine coolant gets in eyes or comes in con tact with skin COOLING SYSTEM INSPECTION Inspect the following items before practice and races Engine coolant leakage Radiator hose cracks and deterioration Radiator mounting condition Radiator breather hose condition Radiator fin condition CLUTCH CABLE Adjust the clutch cable play as follows MAJOR ADJUSTMENT Loosen lock nut 1 Turn adjuster 2 the clutch lever has 10 15 mm 0 4 0 6 in play at the clutch lever end before pressure is felt Tighten lock nut D Clutch lever play 10 15 mm 0 4 0 6 in 2 10 PERIODIC MAINTENANCE MINOR ADJUSTMENT Loosen lock nut 3 ae m Turn adjuster 4 so the clutch lever has 10 15 mm 0 4 0 6 8 in play clutch lever end before pressure is felt Tighten lock nut 3 Clutch lever play 10 15 mm 0 4 0 6 in THROTTLE CABLE Inadequate throttle cable play can cause engine speed to rise suddenly wh
58. VAL Remove the front wheel 14 3 Remove the brake caliper 15 6 Remove the front number plate Remove the handlebar holder bolts 1 and handlebars Remove the brake hose guide Remove the front fender Loosen the steering stem head nut and upper clamp bolts Remove the steering stem head Remove the front fork Remove the steering nut with the special tools 09940 14930 Steering nut socket wrench Remove the steering stem D INSPECTION Inspect the bearing races for wear Inspect the needle bearings for wear Inspect the steering stem for distortion BEARING REPLACEMENT NOTE Replace the outer race and bearing as a set Remove the upper and lower outer races with the special tools 09941 54911 Steering race remover 09941 74911 Steering bearing installer Remove the lower bearing Install the lower bearing to the steering stem using a suitable size spacer CAUTION Press fit the bearing by pressing the inner race 4 Do not press the cage 8 of the bearing Install the upper and lower outer races with the special tools 09941 34513 Steering outer race and swingarm bearing installer FRONT FORK AND STEERING 16 13 16 14 FRONT FORK AND STEERING REASSEMBLY Apply grease to the bearings and dust seals Install the steering stem uppe
59. ace Clean or replace Replace Replace Adjust or replace Tighten Repair or replace Excessive coolant level decrease Radiator hose cracked or damaged Loose radiator hose connection Radiator cracked or damaged Water pump cover mating surface damage Water pump cover crack Water pump cover gasket damage Water seal wear or damage Radiator cap seal damage Incorrect radiator cap valve pressure Cylinder or cylinder head cracked Cylinder or cylinder head O rings damage Replace Repair Repair or replace Replace Replace Replace Replace Replace Replace Replace Replace Clutch does not disengage Clutch lever play maladjustment Clutch spring damage Clutch plates distortion Adjust Replace Replace Clutch slipping Clutch cable play maladjustment Weakened clutch spring Clutch pressure plate wear Clutch plates distortion Clutch plates worn Adjust Replace Replace Replace Replace Transmission does not shift Gearshift cam damage Gearshift fork distortion Gearshift pawl wear Replace Replace Replace Transmission gears jump out Gearshift fork groove wear or damage Gearshift fork distortion or wear Gearshift cam stopper damage Replace Replace Replace Gearshift lever does not return Weakened gearshift return spring Gearshift lever sticking Replace Repair or replace CHASSIS Complaint Possible Cause TROUBLESHOOTING 3 5 Remedy Heavy handl
60. alve shaft arm 4 and shaft Tighten the bolt 3 Tighten the stopper bolt 5 Install the gasket and cover 6 10 CYLINDER PISTON AND EXHAUST VALVE CYLINDER REASSEMBLY Install the new gasket Install the dowel pins 1 Apply engine oil to the cylinder bore Hold the piston and piston ring and insert the piston into the cylinder CAUTION If the piston pin end is not at the proper position you can not insert the piston into the cylinder properly and the piston ring will be damaged Locate the piston ring end to the locating pin and insert the piston into the cylinder Tighten the cylinder nuts to the specified torque according to the specified tightening order as shown V Cylinder nut 25 N m 2 5 kgf m 18 0 Ib ft Tighten the nut 2 CAUTION Set the 4 provided with machine to the lever before tightening the bolt Tightening the bolt with out setting the pin can damage the valve shaft arm spring Install the exhaust rod cover and gasket Correct Incorrect Install the new O rings onto the cylinder Install the cylinder head Tighten the cylinder head nuts to the specified torque accord ing to the specified tightening order as shown V Cylinder head nut 28 2 8 kgf m 20 5 Ib ft e Reassemble the exhaust pipe 5 6 Reassemble the spark plug and spark plug cap Connect the radiato
61. ating If the bush ings have a large crack or excessive play after installing them replace them with the new ones Apply front fork oil to the guide slide bushing Insert the inner tube into the outer tube nstall the seal with the special tool until the stopper ring groove of the outer tube can be seen 09940 52861 Front fork oil seal installer set FRONT FORK AND STEERING 16 7 16 8 FRONT FORK AND STEERING Attach the stopper ring 7 securely to the stopper ring groove of the outer tube Attach the dust seal 8 NOTE After attaching the dust seal make sure that there are no cracks around the circumference of the seal Cracks could allow water mud and the like to enter and cause an oil leak CAUTION Use of grease as a substitute fork oil when installing the oil seal can result in an oil leak Applying grease to the dust seal and oil seal can cause dirt to accumulate and damage the dust seal lip and oil seal lip Use only a thin coat of fork oil on the oil seal Install the damper rod into the front fork Apply THREAD LOCK SUPER 1322 to the front fork center bolt 99000 32110 THREAD LOCK SUPER 1322 Apply fork oil to the O rings Tighten the front fork center bolt to the special torque with the special tool V Front fork center bolt 55 N m 5 5 kgf m 40 0 Ib ft 09940 30250 Front fork assembling tool Install the spring guide D lock nut
62. atusdeusseeduieres 18 17 SETTING gemere 18 19 18 2 SERVICING INFORMATION SERVICE DATA CYLINDER PISTON PISTON RING ITEM STANDARD Unit mm in LIMIT Piston to cylinder clearance 0 040 0 050 0 0016 0 0020 0 120 0 0047 Cylinder bore 48 000 48 015 1 8898 1 8904 Measure 15 0 59 from the top surface Nicks or scratches Piston diam 47 955 47 970 1 8880 1 8886 Measure 16 0 63 from the skirt end 47 880 1 8850 Cylinder distortion 0 05 0 002 Cylinder head distortion 0 05 0 002 Piston ring free end gap Approx 4 0 0 16 3 2 0 13 Piston ring to groove clearance 0 020 0 060 0 0008 0 0024 Piston ring end gap 0 20 0 40 0 008 0 0016 Piston pin bore 14 002 14 008 0 5513 0 5515 Piston pin O D 18 995 14 000 0 5510 0 5512 Reed valve clearance CONROD CRANKSHAFT ITEM STANDARD Unit mm in Conrod small I D 18 003 18 011 0 7088 0 7091 Crank web to web width 44 9 45 1 1 767 1 775 Crankshaft runout CLUTCH Unit mm in ITEM STANDARD LIMIT Clutch lever play 10 15 0 4 0 6 Drive plate thickness 2 7 2 9 2 4 0 106 0 114 0 094 Driven plate distortion 0 10 0 004 Clutch spring free length 41 5 39 4 1 55 RADIATOR ITEM ST
63. ble the kick starter lever as shown amp CORRECT B INCORRECT Reassemble the clutch release arm e Reassemble the rear brake pedal 7715 14 e Pour transmission oil C 72 7 e Pour engine coolant C 72 8 Inspect the clutch lever play Inspect for transmission oil leaks Inspect the kick starter for smooth movement KICK STARTER 8 5 MEMO GEARSHIFTING 9 1 GEARSHIFTING CONTENTS CONSTRUCTION 9 2 GEARSHIFT LINKAGE 9 2 GEARSHIFT LINKAGE 9 3 9 3 INSPECTION NU UE 9 4 HEASSEMBLY Rea Jn ER E NEL 9 4 9 2 GEARSHIFTING CONSTRUCTION GEARSHIFT LINKAGE V 19 1 9 kgf m 13 5 Ib ft SPAM 16 5 Ib ft GEARSHIFTING 9 3 GEARSHIFT LINKAGE REMOVAL e Drain transmission oil C 72 7 Drain engine coolant C 7 12 3 Remove the kick starter lever and clutch assembly 7 5 Remove the gearshift lever Remove the gearshift shaft Remove the two screws Remove the pawl lifter 3 Remove the gearshift cam shifter NOTE Be careful that the pins and springs do not fly off Remove the gearshift pawls 5 pins 6 and springs C2 Loosen the gearshift cam bolt and remove the stopper plate 9 9 4 G
64. ce the collars together with the dust seal if you find excessive wear on the spacer NOTE Apply grease on the collars and dust seal before reassembling FRONT AND REAR WHEELS 14 5 14 6 FRONT AND REAR WHEELS REAR WHEEL BEARING REMOVAL Remove the dust seals and snap ring from the wheel hub Fit the bearing remover into the wheel bearing 09921 20220 Bearing remover set Remove the bearings and spacer REAR WHEEL BEARING REASSEMBLY Apply grease to the bearings Reassemble the spacer and bearings with the special tool 09941 34513 Bearing installer set NOTE After reassembling the bearings inspect the bearings for smooth movement Install the snap ring D at the left side sprocket side Install the dust seals and apply grease to its lips NOTE The sealed cover of the bearing must face outside Reassemble the left side sprocket side bearing first and then reassemble the right side bearing REAR WHEEL INSTALLATION Reassemble the rear wheel and axle shaft Adjust the drive chain slack 7 2 13 e the axle nut to the specified torque V Rear axle nut 72 N m 7 2 kgf m 52 0 Ib ft FRONT AND REAR WHEELS 14 7 DISC PLATE REPLACEMENT Remove the front and rear wheels 14 3 and 5 Replace the disc Apply THREAD LOCK SUPER 1322 to the screws 44223 99000 32110 THREAD LOCK SUPER 1322 e Tig
65. cold and hot temperatures In these circumstances the jetting of the carburetor or other adjustments may need to be altered slightly Riders who are not familiar with the operation and jetting procedures of the KEIHIN carburetor should have their local authorized Suzuki dealer perform these alterations Mechanically experienced riders can alter the carburetor settings based on the fol lowing information and specifications Carburetor Specifications 28 mm 128 24NAAH 3rd Bore Main jet Jet needle Slow jet 50 2 turns out 19 mm 0 75 in Air screw Float height Setting parts included parts main jet 125 130 135 PRINCIPLES OF CARBURETOR TUNING CARBURETOR COMPONENTS AND FUNCTIONS The carburetor consists of a number of parts as shown below The asterisk marked parts are pre cisely machined which meter the intake air oxy gen and fuel so that the air fuel mixture ratio is controlled accurately They can be divided by three operation related groups pilot slow system inter mediate system and main system and they achieve their functions in each corresponding throttle open ing range It is necessary to have a full understand ing of them for proper carburetor tuning 1 2 E Ss 5 2 1 8 screw 2 Spring 9 Mainjet 3 Clip 10 Slow jet 4 Jet needle 11 Needle valve 5 Throttle valve 12 Float 6
66. d of the breather hose into the steering stem head after refueling GENERAL INSTRUCTIONS 1 3 Gasoline L 5 0 10 0 15 0 20 0 Gasoline gal 1 0 2 0 3 0 4 0 14 GENERAL INSTRUCTIONS INTRUCTING YOUNG RIDER THIS IS IMPORTANT ADVICE TO A PARENT Children are important the sight of a new motorcycle excites their imagination and the expectation is often so great as to make them forget the importance of safty precautions Please go through this manual with aboy or a girl page by page and help him or her to understand not only the mechanism but also the rules of courtesy and safety precaution The RM85 requires the parent s cooperation to actually enjoy the safety available Here are six rules in two groups Please impress upon the mind of the young rider before leaving the machine to his or her dis posal OPERATING SKILL Rule 1 Know the mechanism Memorize the name of each control The name suggests its function Know the route of drive from engine to wheels Learn the order in checking written items for INSPECTION BEFORE RIDING It is highly recommended that the parent shows examples by demonstrating NOTE Check to be sure that young rider has perfectly learned Let your child demonstrate for you Rule 2 Rehearse before riding out for the first time Let the young rider mount the machine and do try rehease Watch the way he or she operates the controls per
67. diator hoses Remove the radiator by removing its mounting bolts COOLING SYSTEM INSPECTION Inspect the following items Radiator coolant leakage Radiator hose cracks and deterioration Radiator mounting condition Radiator breather hose condition Radiator fin condition RADIATOR INSTALLATION Reverse the sequence of removal COOLING SYSTEM HOSE ROUTING 7 18 10 and 11 COOLING SYSTEM 12 5 WATER PUMP WATER PUMP REMOVAL AND INSPECTION e Drain engine coolant and transmission oil 2712 3 and 2 7 Remove the water pump cover 1 Remove the clutch cover 7 7 3 Remove the snap rings 2 with snap ring pliers Remove the impeller Inspect the impeller for damage Inspect the bearing for smooth inner race movement Remove the snap ring and bearing with the special tool 09916 44910 Valve guide driver Inspect the oil seal for damage Remove the oil seal with the special tool eS P 7 09913 50121 Oil seal remover 12 6 COOLING SYSTEM WATER PUMP REASSEMBLY Apply THREAD LOCK SUPER 1322 to the outer surface of the oil seal Install the oil seal with a proper tool 99000 32110 THREAD LOCK SUPER 1322 Apply grease to the machanical seal lip Insert the water pump shaft Install the bearing with the special tool 09916 44910 Valve guide driver 09916 53340 Valve guide installer Install the snap ring
68. e 0 kPa 0 kgf cm 0 psi Rear shock absorber gas pressure 1 000 kPa 10 kgf cm 142 psi Rear shock absorber spring pre set length RM85 3 1 mm 0 12 in compressed from spring free length RM85L 4 8 mm 0 19 in compressed from spring free length Rear shock absorber damping Rebound 2 turns out force adjuster Compres sion 3 4 turns out Rear shock absorber spring rate 85 46 N mm 4 6 kgf mm RM85L 48 N mm 4 8 kgf mm Rear wheel travel 277 10 9 Swingarm pivot shaft runout TIRE PRESSURE Front amp Rear 70 110 kPa 0 7 1 1 kgf cm 10 16 psi 18 6 SERVICING INFORMATION FUEL OIL COOLANT ITEM SPECIFICATION Fuel type Unleaded gasoline minumum 95 octane RON Fuel tank capacity 5 0L 1 3 1 1 US Imp gal Engine oil type MOTUL 800 2T or equivalent Two Cycle Racing Lubricant Air cleaner element oil type MOTUL AIR FILTER OIL or equivalent filter oil Engine coolant type Use an anti freeze amp Summer engine coolant compatible with aluminum radiator mixed with distilled water only at the ratio of 50 50 Engine coolant tank capacity 570 ml 1 20 1 00 US Imp qt Transmission oil type SAE 10W 40 API SF SG or SH SJ with JASO Transmission oil capacity Change 550 ml 1 16 0 97 US Imp Overhaul 650 ml 1 37 1 14 US Imp qt Brake fluid type DOT 4
69. e is rich replace it with 48 slow jet If air fuel mixture is lean replace it with 452 slow jet 2 Adjustment of main system With the throttle opened 3 4 to full make main sys tem adjustment monitoring the air fuel mixture con dition after completion of pilot system settings f selection of the main jet is between the col umns take the larger number main jet first to pre vent the piston seizure Make sure to adjust the main system before adjusting the intermediate system Ex Main jet 128 If air fuel mixture is rich replace it with 125 main jet If air fuel mixture is lean replace it with 130 main jet 8 Adjustment of intermediate system Monitor the air fuel mixture condition and adjust the intermediate system by selecting the proper needle size Changing standard needle within one size larger or smaller will cover almost any race condi tion 4 Fine adjustment of slow system After a proper standard setting has been obtained by the procedure through fine tune the carbu retor according to the actual race conditions MACHINE TUNING 4 7 1 Adjust the air fuel mixture by tuning the air screw within 1 2 2 turns out 1 2 turn out 1 1 2 turns out 2 turns out 2 If the mixture can not be adjusted by the air screw within 1 2 2 and 1 4 turns out range readjust the pilot system 3 Fine adjustment of intermediate system Fine tune the intermediate system by c
70. e malfunction Piston ring stuck Adjust or replace Adjust Adjust Replace Replace Clean or replace Replace Replace Clean adjust or replace Replace Exhaust valve does not work Carbon deposits on exhaust valve Exhaust valve damage Governer damage Exhaust valve shaft damage Valve spring damage Clean Replace Replace Replace Replace Spark plug does not ignite Ignition coil malfunction Spark plug malfunction Generator malfunction CDI unit malfunction Wide spark plug gap Engine stop switch malfunction Replace Replace Replace Replace Adjust Repair or replace Carbon deposits on spark plug porcelain Too rich air fuel mixture Too rich oil gasoline mixture Improper spark plug heat range Adjust Adjust Replace Spark plug electrode damage Improper spark plug heat range Overheating Incorrect ignition timing Loose spark plug Too lean air fuel mixture Replace 3 4 Adjust Tighten Adjust 3 4 TROUBLESHOOTING Complaint Possible Cause Remedy Overheating Low engine coolant level Engine coolant leak Too lean air fuel mixture Incorrect ignition timing Water pump malfunction Cylinder head carbon deposits Cylinder head O ring damage Exhaust pipe carbon deposits Improper spark plug heat range Fuel deterioration Clutch slipping Radiator cap loose Radiator fins damaged Replenish Repair Adjust Adjust Adjust or replace Clean Repl
71. eassemble the following parts into the swingarm D Spacer 2 Dust seal Washer Apply grease to the dust seals bearings and spacers Install the swingarm to the frame Tighten the swingarm pivot nut to the specified torque V Swingarm pivot nut 58 N m 5 8 kgf m 42 0 Ib ft Tighten the rear cushion rod 5 nut to the specified torque V Rear cushion rod nut 80 N m 8 0 kgf m 58 0 Ib ft Reassemble the chain guide e Reassemble the rear brake caliper 15 8 e Reassemble the rear wheel 14 6 e Adjust the drive chain slack 2 13 Frame Engine Frame Swingarm REAR SUSPENSION LINKAGE REAR SUSPENSION LINKAGE REMOVAL Loosen the cushion lever bolt nut Loosen the cushion rod upper bolt nut Loosen the shock absorber lower bolt and nut Remove the cushion lever assy 17 14 REAR SUSPENSION Remove the cushion rod D from the cushion lever 2 REAR SUSPENSION LINKAGE INSPECTION Inspect the cushion lever and cushion rod for damage Inspect the dust seals and spacers for damage Inspect the bearings for damage Insert the spacers into the bearings and inspect them for smooth movement CUSHION LEVER AND CUSHION ROD BEARING REPLACEMENT Remove the spacers and dust seals Remove the circlips Remove the bearings with the special tool 09921 20220 Bearing remover set Apply grease to the bearings nstall t
72. eat 25 2 Remove the CDI unit from the frame Measure voltage between the lead wires with the multi circuit tester as shown in the illustration 09900 25008 Multi circuit tester Tester knob indication Diode 4 Positive probe pin Diode terminal NOTE is open circuit voltage 1 511 V 3 D 2 4 c 0 165 0 765 E 0 000 0 300 0 165 0 765 0 589 1 189 0 589 1 189 0 165 0 765 1 211 1 511 1 244 1 544 1 214 1 511 1 211 1 511 D 0 000 0 300 0 165 0 765 5 6 0 290 0 890 0 657 1 257 ELECTRICAL SYSTEM 13 5 STATOR COIL INSPECTION Remove the seat and fuel tank 7 5 2 Disconnect the magneto lead wire coupler Measure the stator coils electrical resistance Black Red Black White 240 380 Red White Black White 140 2300 Black Red Red White 100 160 Q 09900 25008 Multi circuit tester Tester knob indication Resistance O MAGNETO ROTOR AND STATOR REMOVAL AND REASSEMBLY Remove the screws magneto cover Remove the bolts and stator Disconnect the lead wires Remove the cylinder and piston 6 3 and 4 Hold the conrod with the special tool and loosen the nut 09910 20116 Conrod holder Remove the magneto rotor with the special
73. eel bearing 09921 20220 Bearing remover set Remove the bearings and spacer FRONT WHEEL BEARING REASSEMBLY Apply grease to the bearings Reassemble the spacer and bearings with the special tool 09941 34513 Bearing installer set NOTE The sealed cover of the bearing must face outside Reassemble the left side disc side bearing first and then reassemble the right side bearing After reassembling the bearings inspect the bearings for smooth movement FRONT WHEEL INSTALLATION Install the front wheel axle collars and front axle Tighten the axle nut to the specified torque V Axle nut 44 4 4 kgf m 32 0 Ib ft Replace the cotterpin with a new one REAR WHEEL REMOVAL Place the motorcycle on a block to lift the rear wheel off the ground Remove the axle nut D Hold the rear wheel and remove the rear axle shaft Remove the rear wheel INSPECTION AXLE SHAFT Support the axle shaft with V blocks and measure the axle shaft runout Service Limit 0 25 mm 0 010 in WHEEL RIM Measure the wheel rim runout with a dial gauge Service Limit 2 0 mm 0 08 in axial and radial WHEEL BEARING Turn the inner race by finger and inspect it for smooth move ment Inspect the clearance between the outer race and wheel hub Inspect for bearing damage WHEEL SPACER Inspect the rear wheel collars and the dust seals for wear and cracks Repla
74. emove the caliper bracket 4 from the caliper Wrap the caliper with a rag to prevent brake fluid scatter and piston pop out FRONT AND REAR BRAKES 15 7 Apply low pressure air into the caliper through the hole to remove the piston ES 8 WARNING Fingers can get caught between piston and caliper body when removing the piston Do not place your fingers on the piston when remov ing the piston Remove the piston seal and dust seal REAR CALIPER REMOVAL AND DISASSEMBLY e Drain brake fluid C 7 15 4 Place a rag under the brake hose union bolt to catch spilled brake fluid Remove the caliper mounting bolts and disconnect the brake hose 2 15 8 FRONT AND REAR BRAKES Remove the brake pads and spring 3 from the caliper Remove the caliper bracket 4 Wrap the caliper with a rag to prevent brake fluid scatter and piston pop out Apply low pressure air into the caliper through the hole to remove the piston WARNING Fingers can get caught between piston and caliper body when removing the piston Do not place your fingers on the piston when remov ing the piston Remove the piston seal 5 and dust seal CALIPER INSPECTION Inspect the caliper cylinder wall and piston surface for scratch corrosion or other damages If any abnormal condi tion is noted replace the caliper Inspect the rubber parts If any damages are found replace
75. emove them Remove the clutch springs Remove the pressure plate Remove the rack 3 and bearing 4 from the pressure plate Remove the drive plates and driven plates CLUTCH PLATE INSPECTION Measure the drive plate thickness Drive plate thickness Service Limit 2 4 mm 0 094 in Inspect the drive plates for wear distortion and discoloration Measure the driven plate distortion Driven plate distortion Service Limit 0 10 mm 0 004 in Inspect the driven plates for wear and discoloration CLUTCH 7 3 74 CLUTCH CLUTCH SPRING INSPECTION Measure the clutch spring free length Clutch spring free length Service Limit 39 4 mm 1 55 in NOTE Replace five clutch springs together even if only one spring is exceed the service limit CLUTCH RACK AND PINION INSPECTION Inspect the clutch release rack and pinion for wear and dam age Inspect the clutch release arm for smooth movement and oil leakage around the oil seal CLUTCH PLATE REASSEMBLY Apply transmission oil to the drive plates D and driven plates and install them to the clutch sleeve hub Install the rack 3 and bearing 4 NOTE The roller side of the bearing must face to the rack side Install the pressure plate Install the clutch springs and bolts Tighten the bolts diagonally Replace the gasket with a new one Install the dowel pins
76. en you turn the handlebars This can lead to loss of rider control 2 4mm 0 08 0 16 in Adjust the throttle cable play so that engine speed does not rise due to handlebar movement Adjust the throttle cable play as follows Loosen lock nut 1 Turn adjuster 2 so the throttle grip has 2 4 mm 0 08 0 16 in play in circumference Tighten lock nut 1 Throttle cable play 2 4 mm 0 08 0 16 in Remove the throttle housing cover Apply oil to the throttle cable Apply grease to the throttle cable spool FUEL HOSE Inspect the fuel hose for damage and fuel leakage If any defects are found the fuel hose must be replaced with a new one Replace the fuel hose every four years PERIODIC MAINTENANCE 2 11 FUEL VALVE Drain the fuel Disconnect the fuel hose and remove the fuel valve 2 A WARNING Gasoline is highly flammable and explosive Keep heat sparks and flames away from gasoline Clean the fuel filter with compressed air CAUTION The O ring 3 must be replaced with a new one to pre vent fuel leakage NOTE e If the fuel filter is dirty with sediment fuel will not flow smoothly 2 12 PERIODIC MAINTENANCE CYLINDER HEAD CYLINDER AND PISTON CYLINDER HEAD Remove the cylinder head L7 6 3 Remove carbon deposits from the combustion chamber sur face Inspect for pinholes cracks and other damage
77. enstasadsccdivsasandasietenteduasnduveleniarsunasgedudten 2 18 STEERING 2 19 2 20 TIGHTENING TORQUE 2 21 2 2 PERIODIC MAINTENANCE PERIODIC MAINTENANCE INSPECTION BEFORE PRACTICE WHAT TO CHECK CHECK FOR Spark plug Heat range fouled electrode tightness Loose high tension cord Air cleaner element Lubrication Transmission oil Oil level Engine coolant Engine coolant level Cooling system Radiator hose damage Engine coolant leak Clutch Play Smooth operation Throttle Play Smooth operation Brake fluid Fluid level Brakes Brake lever position brake pedal height Brake lever pedal play Operation Drive chain Slack lubrication chain joint clip condition Drive chain guide buffer Wear damage Suspension Smooth operation Front fork air pressure Wheels Spoke tension Rim lock tightness Tires Tire pressure Steering Smoothness play Exhaust pipe Firm fixation Bolts and nuts INSPECTION BEFORE RACE WHAT TO CHECK Tightening torque CHECK FOR All items of inspection before practice above plus Air cleaner Cleanliness Clutch Clutch disc plates wear and distortion Brake pads Wear Sprockets Wear Fuel tank Leakage Fuel filter clogging Fuel
78. es that your mental and physical skills are fully part of the experience You should not attempt to oper ate a motor vehicle especially one with two wheels if you are tired or under the influence of alcohol or other drugs Alcohol illegal drugs and even some prescription and over the counter drugs and cause drowsiness loss of coordina tion loss of balance and loss of good judge ment If you are tired or under the influence of alcohol or other drugs PLEASE DO NOT RIDE your motorcycle Conclusion The actions of other riders are unpredictable Your motorcycle s condition can change These factors can best be dealt with by giving every ride your full attention Circumstances beyond your control could lead to an accident You need to prepare for the unex pected by wearing a helmet and other protective gear and practicing safe riding techniques to minimize the damage to you and your machine May all of your rides on your new Suzuki be winning rides SERIAL NUMBER LOCATION frame number is stamped on the steering head The engine serial number 2 is stamped on the right side of the crankcase assembly Write down the serial numbers here for your future reference Frame No Engine No WARNINGS FOR SERVICING Never run the engine indoors or in a Fuel can catch on fire if you do not handle garage Exhaust gas contains carbon mon it properly Gasoline vapors can catch fire oxide
79. essure Pour the fresh specified rear suspension oil as shown while moving the rod NOTE Be sure to extend the rod after filling the oil Tilt the shock absorber unit as shown and pour the fresh rear suspension oil fully into the reservoir tank 99000 99001 S25 SUZUKI REAR SUSPENSION OIL SS 25 Oil capacity Approx 195 ml 6 6 6 9 US Imp oz Cover the compression adjuster hole by the root of your thumb Tilt and shake the rear shock absorber unit to fill the reservoir tank with the oil Add the oil and repeat the above procedure until the reservoir tank is filled with the oil completely 17 8 REAR SUSPENSION Reinstall the compression adjuster assembly 1 with the spe cial tool NOTE Replace the O rings on the compression adjuster assembly with new ones V Compression adjuster assembly 18 N m 1 8 kgf m 13 0 Ib ft 09941 53650 Rear shock absorber socket wrench Fill the rear shock absorber unit with nitrogen gas to 1 000 kPa 10 142 psi Tighten the gas valve cap e Reinstall the spring and mount the shock absorber 7 17 5 WARNING Use of flammable gas for pressuring the rear shock absorber unit can be hazardous Flammable gas such as gas welding oxygen can create a fire hazard Use nitrogen gas If is nitrogen gas is not available compressed air free from water can be substituted WARNING Applying too much pressure to the rear shock ab
80. for a few minutes and stop it Wait 5 minutes Place the motorcycle on level ground and hold the motorcycle vertically Remove the oil level screw Check that oil comes out of the hole If oil does not come out of the hole open oil filler and add the specified oil Tighten the filler cap and oil level screw firmly and inspect again as above procedure Tighten the filler cap and oil level screw firmly Q Oil level screw 5 5 N m 0 55 kgf m 4 0 Ib ft TRANSMISSION OIL CHANGE Warm up the engine Place the motorcycle on the level ground and hold the motor cycle vertically Remove filler cap and drain plug 2 Drain oil thoroughly Tighten the drain plug firmly V Cil drain plug 23 N m 2 3 kgf m 16 5 Ib ft Pour specified amount of motor oil change 550 ml 1 2 1 0 US Imp qt Transmission oil type SAE 10W 40 API SF SG or SH SJ with JASO MA Tighten the filler cap Run the engine for a few minutes and stop it Wait a few min utes e Inspect the oil level C 772 7 PERIODIC MAINTENANCE 2 7 2 8 PERIODIC MAINTENANCE ENGINE COOLANT ENGINE COOLANT LEVEL CHECK A WARNING You can be injured by scalding fluid or steam if you open the radiator cap when the engine is hot Do not open the radiator cap when the engine is hot Wait until engine cools Remove the radiator Check that the engine coolant level is at the bottom of the inlet hole If no
81. ft oil seal Incorrect ignition timing Carburetor fuel level maladjustment Replace Clean or replace Clean or replace Clean or replace Clean Replace Replace or rebore Replace Replace Adjust Adjust Insufficient power Carburetor fuel level maladjustment Fuel deterioration Brake dragging Exhaust pipe cracked or clogged with carbon Exhaust valve maladjustment Exhaust valve carbon deposits Air cleaner element clogged Carburetor jets clogged Incorrect fuel level in carburetor Incorrect spark plug gap Cylinder or piston ring worn Reed valve malfunction Incorrect ignition timing Adjust Replace Adjust Replace or clean Adjust Clean Clean or replace Clean or replace Adjust Adjust or replace Replace Replace Adjust Complaint Possible Cause TROUBLESHOOTING 3 3 Remedy Engine runs poorly in low speed range Wide spark plug gap Carburetor air screw maladjustment Incorrect carburetor fuel level Improper jet needle size Incorrect ignition timing CDI unit malfunction Ignition coil damage Magneto malfunction Magneto short circuit Adjust or replace Adjust Adjust Replace Adjust Replace Replace Replace Replace Engine runs poorly in high speed range Narrow spark plug gap Incorrect carburetor fuel level Retarded ignition timing CDI unit malfunction Ignition coil damage Air cleaner element clogged Magneto short circuit Exhaust pipe cracked Exhaust valv
82. h an optional stiffer one Feels too hard near end of travel Jump Decrease fork oil capacity Feels too soft near end of travel and bottoms harshly Jump Large bump Adjust the compression damping to a stiffer set ting Increase fork oil capacity Feels too hard in the beginning of stroke Jump Large bump Series of medium bumps Series of small bumps Adjust the compression damping to a softer set ting Replace the spring with on optional softer one Feels too soft and unstable Series of medium bumps Series of small bumps Adjust the compression and rebound damping to a stiffer setting Bounces Jump Large bump Adjust the rebound damping to a stiffer setting Bounces NOTE Series of small bumps Adjust the rebound damping to a softer setting When adjusting the front fork oil level make sure that the oil level is within the specified range Also the oil level should be increased or decreased by not more than 3 mm Approx 2 6 ml at a time When adjusting the damping setting attempt turning the adjuster 1 to 2 click or 1 4 turn at a time for each adjustment REAR SUSPENSION TUNING REAR SUSPENSION The rear suspension compression and rebound damping force and spring pre load are adjustable for rider s preference rider s weight and course condition NOTE Break in the rear suspension when riding with a new rear cush ion unit COMPRES
83. hanging the clip position 1 2 Lean 3 4 A STD 5 Rich 4 8 MACHINE TUNING FRONT FORK TUNING FRONT FORK The front fork compression and rebound damping force and oil quantity are adjustable for rider s preference rider s weight and course condition NOTE Break in new front forks before attempting adjustment Be sure to adjust both right and left front forks equally COMPRESSION DAMPING FORCE ADJUSTMENT Turn the adjuster screw D clockwise until it stops It is the stiffest position NOTE To set the adjuster you must gently turn the adjuster screw clockwise until it stops then back it out the recommended num ber of turns Do not force the adjuster screw past the stopped position or you may damage the adjuster Turn the adjuster screw out to the standard position Standard setting 7 clicks out from the stiffest position REBOUND DAMPING FORCE ADJUSTMENT e Turn the adjuster screw 2 clockwise until it stops It is the stiffest position NOTE To set the adjuster you must gently turn the adjuster screw clockwise until it stops then back it out the recommended num ber of turns Do not force the adjuster screw past the stopped position or you may damage the adjuster Turn the adjuster screw out to the standard position Standard setting 1 and 1 2 turns out from the stiffest position AIR PRESSURE ADJUSTMENT Place a block under the chassis tube to lift the front wheel off the
84. he bearings with the special tool and pipes 24 mm 0 9 in in diameter and 4 mm 0 2 in in length 09941 34513 Bearing installer set NOTE Position the bearings by refering to the illustration of page 17 16 Install the circlips Install the dust seals Apply grease to the spacers and dust seals NOTE Position the dust seal so that the outside letter faces outside REAR SUSPENSION 17 15 17 16 REAR SUSPENSION REAR SUSPENSION LINKAGE REASSEMBLY Reassemble the rear suspension linkage Tighten the nuts to the specified torque V Tightening torque 4 60 N m 6 0 kgf m 43 5 Ib ft B 60 N m 6 0 kgf m 43 5 Ib ft 80 N m 8 0 kgf m 58 0 Ib ft D 60 N m 6 0 kgf m 43 5 Ib ft 80 N m 8 0 kgf m 58 0 Ib ft Right CAUTION Improperly reassembled rear suspension linkage bolts can interfere with suspension move ment and damage the rear suspension linkage Make sure that the rear shock absorber rebound damping adjuster on the bottom bracket of the rear shock absorber is located to the right side Insert the rear suspension linkage bolts from the left side SERVICING INFORMATION 18 1 SERVICING INFORMATION CONTENTS SERVICE DATA ect 18 2 SPECIAL TOOLS 18 7 WIRE CABLE AND HOSE ROUTING 18 9 SPECIFICATIONS ee
85. he wheel bearing for rattles Replace the bearings if necessary 7 14 3 and 5 Inspect the wheel rim runout 14 3 and 5 SPOKE NIPPLE AND RIM LOCK Inspect the spokes for tension by squeezing the spoke nip ples Retighten the spoke nipples with a spoke nipple wrench so as all spokes have same tension V Spoke nipple 4 N m 0 4 kgf m 2 9 Ib ft CAUTION Improperly tightening the spoke nipples can damage the wheel Tighten the spoke nipples less than 1 2 turn at a time Inspect the spoke tension and then retighten the spoke nipple Inspect the rim lock D for tightness TIRE PRESSURE Inspect front and rear tire pressure Tire pressure cold 70 110 kPa 0 7 1 1 10 16 psi PERIODIC MAINTENANCE 2 19 STEERING Inspect the steering by moving the front forward and back ward and right and left If the steering has play or binds inspect steering stem head nut tightness and steering bear ings 7 16 13 2 20 PERIODIC MAINTENANCE LUBRICATION Apply grease or oil to the moving parts to increase durability and prevent wear ITEM LUBRICANT FREQUENCY COMMENTS Inner cable ends lever A Pre race and between every race Run oil through cables until it exits the lower end Lube the cable ends where they pivot Throttle grip throttle housing cable Pre race Lightly oil the inside
86. hing Don t ride after consuming alcohol or other drugs This owner s service manual contains important safety information Please read it carefully 7 SUZUKI MOTOR CORPORATION 300 TAKATSUKA HAMAMATSU JAPAN Printed in Taiwan
87. hten the screws and nuts 0 front only to the specified torque 9 Brake disc screw 8 5 N m 0 85 kgf m 6 0 Ib ft Front brake disc nut 8 5 N m 0 85 kgf m 6 0 Ib ft NOTE When installing the front disc first tighten the screws to the specified torque and then tighten the nuts D to the specified torque REAR SPROCKET REPLACEMENT Remove the rear wheel 14 5 Replace the rear sprocket Tighten the nuts to the specified torque V Rear sprocket nut 40 4 0 kgf m 29 0 Ib ft MEMO FRONT AND REAR BRAKES 15 1 FRONT AND BRAKES CONTENTS CONSTRUCTIONS t 15 2 FRONT AND REAR BRAKES 15 2 BRAKE EE 15 3 BRAKE FLUID AIR BLEEDING 15 3 BRAKE FLUID REPLACEMENT a vcisenissisccssenertexseseansstonecensniesenseesandeves 15 4 BRAKE PAD REPLACEMENT 15 4 BRAKE DISC 15 5 BRAKE DISC INSPECTION taxa kid 15 5 BRAKE DISC REPLACEMENT 15 5 BRAKE CALIPER TE a DER 15 6 FRONT CALIPER REMOVAL AND DISASSEMBLY 15 6 REAR CALIPER REMOVAL AND DISASSEMBLY 15 7 CALIPER INSPECTION 552
88. ickly Be sure to retighten the bolts and nuts during the break in run ning in period WHEN ENGINE PARTS ARE REPLACED Follow the same produce when any of the following parts are replaced Piston Crankshaft Piston ring Crankshaft bearing Cylinder PERIODIC MAINTENANCE 2 1 PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE io scetecascssesnonduvatavensssssasutiecntrvasunsesunteessitesndenesaness 2 2 SPARK PLUG gm 2 4 AIR CLEANER 2 5 TRANSMISSION OIL 2 6 ENGINE COOL ANT 2 8 CLUTCH CABLE 2 9 THROTTLE CABLE iiie spei alid iain e t aired 2 10 FUEL AOE 2 10 FUEL VALVE qua nb 2 11 CYLINDER HEAD CYLINDER AND PISTON 2 12 EXHAUST VALVE 2 12 EXHAUST SILENCER 2 13 DRIVE CHAIN AND SPROCKETS 2 13 DRIVE CHAIN GUIDE BUFFER TENSIONER ROLLER 2 15 m 2 16 FRONT FOHBMK insedit Fk Bd dev aka x a Eae 2 17 REAR SUSPENSION Rr inia au npn rk pti E uu ako E idosa iinne 2 18 WHEELS AND TIRES vwisivisscasestesedatinsal
89. ing Steering stem nut overtightened Steering head bearings damaged or rusted Steering stem distortion Adjust Replace Replace Front wheel wobbling Loose spoke nipples Wheel distortion Front wheel bearing damage Incorrect axle tightening torque Adjust Replace Replace Retighten Rear wheel wobbling Loose spoke nipples Wheel distortion Rear wheel bearing damage Swingarm pivot bearing damage Incorrect axle tightening torque Incorrect swingarm tightening torque Adjust Replace Replace Replace Retighten Retighten Soft front suspension Weakened spring Low oil level Low fork oil viscosity Damping force maladjustment Damping valve malfunction Stardard spring too soft Replace Replenish Replace Adjust Replace Use optional spring Hard front suspension High fork oil level High fork oil viscosity Damping force maladjustment Inner tube distortion Adjust Replace Adjust Replace Soft rear suspension Weakened spring Damping force maladjustment Low gas pressure Standard spring too soft Replace Adjust Adjust Use optional spring Hard rear suspension Damping force maladjustment Damper rod distortion Rear suspension pivoting portion out of grease Standard spring too stiff Adjust Replace Lubricate Use optional spring Poor braking Brake pads worn Improper air bleeding Dirty pads and disc Brake fluid leak Replace Bleed air Clean Repair
90. ir from the brake system 15 3 and 4 FRONT AND REAR BRAKES 15 9 15 10 FRONT AND REAR BRAKES MASTER CYLINDER Brake fluid can be hazardous to humans and pets Brake fluid is harmful or fatal if swallowed and harm ful if it comes in contact with your skin or eyes Keep brake fluid away from children Call your doctor immediately if brake fluid is swallowed and induce vomiting Flush eyes or skin with water if brake fluid gets in eyes or comes in contact with skin A WARNING The use of any fluid except DOT 4 brake fluid from a sealed container can damage the brake system and lead to an accident Use only DOT 4 brake fluid from a sealed container Never use or mix different types of brake fluid CAUTION Spilled brake fluid can damage painted surfaces and plastic parts Be careful not to spill any fluid when filling the brake fluid reservoir Wipe spilled fluid up immediately FRONT MASTER CYLINDER REMOVAL AND DISASSEMBLY Drain brake fluid gt 15 4 Loosen the brake hose adaptor and disconnect the brake hose Remove the master cylinder holder bolts NOTE Hold the brake hose with a wrench to prevent the brake from twisting when loosening the adaptor FRONT AND REAR BRAKES 15 11 Remove the bolt and brake lever 2 Remove the dust boot 1 Remove the snap ring 2 with snap ring pliers Remove the washer 3 piston cup set
91. it with a new one CALIPER CLEANING Flush the caliper ports with pressurized air Wash the caliper piston and cylinder with fresh brake fluid NOTE Do not use gasoline or other cleaning solvents to wash the cali per parts Brake fluid DOT 4 FRONT CALIPER REASSEMBLY Apply brake fluid to the piston seal and dust seal 2 then install them to the caliper Install the piston into the caliper Apply silicone grease to the caliper axles AGH 99000 25100 SUZUKI SILICONE GREASE Install the boots and caliper bracket e Install the spring and brake pads 15 4 Tighten the caliper mounting bolts to the specified torque V Caliper mounting bolt 23 2 3 kgf m 16 5 Ib ft Tighten the brake hose union bolt to the specified torque V Brake hose union bolt 23 N m 2 3 kgf m 16 5 Ib ft Refill brake fluid and bleed air from the brake system 15 4 REAR CALIPER REASSEMBLY Apply brake fluid to the piston seal and dust seal then install them to the caliper Install the piston into the caliper Apply silicone grease to the caliper axles AGH 99000 25100 SUZUKI SILICONE GREASE Install the boots and caliper bracket e Install the spring and pads 15 5 Tighten the caliper mounting bolts and the brake hose union bolt V Caliper mounting bolt 23 2 3 kgf m 16 5 Ib ft Brake hose union bolt 23 N m 2 3 kgf m 16 5 Ib ft Refill brake fluid and bleed a
92. iver to release nitrogen gas Do not use your finger to push the valve and direct the valve away from your face and body SWINGARM SWINGARM REMOVAL Remove the rear wheel 14 5 Remove the chain guide D Remove the rear brake hose guide 2 Remove the rear brake caliper 3 Remove the drive chain Remove the rear cushion rod bolt and nut Remove the swingarm pivot nut 5 Remove the swingarm by removing the pivot shaft Remove the following parts from the swingarm Spacer 6 Dust seal 7 Washer REAR SUSPENSION 17 11 E an s N E 19 17 12 REAR SUSPENSION SWINGARM INSPECTION Measure the pivot shaft runout with a dial gauge and V blocks Swingarm pivot shaft runout Service Limit 0 3 mm 0 01 in Inspect the swingarm for cracks and damage Inspect the bearings spacers and oil seals for damage Insert the spacers into the bearings and inspect them for play and smooth movement BEARING REPLACEMENT Remove the bearing and coller with the special tool 09930 30102 Sliding hummer 09923 73210 Bearing puller Press fit the bearing and coller 2 into the swingarm 3 with the special tool and a suitable tool 09924 84521 Bearing installer set Apply grease to the bearings lips of dust seal and spacers REAR SUSPENSION 17 13 SWINGARM REASSEMBLY R
93. ll the element in the air cleaner box CAUTION Improper element installation allows dust and dirt to enter the combustion chamber It can result in piston and cylinder wear Be sure to check the element seals properly after installing the elements Install the air cleaner cap NOTE Running the engine without the air cleaner cap can vary the car buretion Do not run the engine without the air cleaner cap NOTE Follow the instructions below to keep the air cleaner element dry when cleaning the motorcycle Cover the element with vinyl bag Install the seat Do not spray high pressure water to the air cleaner box TRANSMISSION OIL Transmission oil and exhaust pipes can be hot enough to burn you Wait until the oil drain plug and exhaust pipes are cool enough to touch with bare hands before draining oil A WARNING New and used oil and solvent can be hazardous Chil dren and pets may be harmed by swallowing new or used oil or solvent Repeated prolonged contact with used engine oil may cause skin cancer Brief contact with used oil or solvent may irritate skin Keep new and used oil and solvent away from chil dren and pets Wear a long sleeve shirt and waterproof gloves Wash with soap if oil or solvent contacts your skin NOTE Recycle or properly dispose of used oil and solvent TRANSMISSION OIL LEVEL INSPECTION AND REPLENISHMENT Run the engine
94. lowed and harm ful if it comes in contact with your skin or eyes Keep brake fluid away from children Call your doctor immediately if brake fluid is swallowed and induce vomiting Flush eyes or skin with water if brake fluid gets in eyes or comes in contact with skin A WARNING The use of any fluid except DOT 4 brake fluid from a sealed container can damage the brake system and lead to an accident Use only DOT 4 brake fluid from sealed container Never use or mix different types of brake fluid CAUTION Spilled brake fluid can damage painted surfaces and plastic parts Be careful not to spill any brake fluid when servicing brake fluid Wipe spilled fluid up immediately Remove the reservoir cap Connect a transparent tube to the bleeder valve and set the other end into a receptacle Pour brake fluid up to the UPPER line Pump the brake lever pedal until air bubbles stop coming out from the reservoir Hold the brake lever pedal in the squeezed position Open the bleeder valve and tighten the bleeder valve Release the brake lever pedal Repeat this sequence until air bubbles stop coming out from the bleeder valve NOTE Do not release the brake lever pedal while the bleeder valve is opened Replenish brake fluid to the UPPER line when the brake fluid level drops below LOWER line FRONT AND REAR BRAKES 153 15 4 FRONT AND REAR BRAKES Tighten the air bleeder
95. n Pan 4 Oilcan 5 Beaker Specified Shock Oil SS25 D Rags Nitrogen tank 9 Filler Hose and Nozzle Regulator Assembly Owner s Service Manual Not Shown in the illustration OIL REPLACEMENT PROCEDURE Remove the rear shock absorber unit from the frame Clean and dry it 17 3 Remove the spring from the rear shock absorber unit 17 4 Inspect the rear shock absorber unit for oil leak Turn the rebound damping force adjuster screw counterclock wise until it stops so that the rear suspension oil can be poured easily Remove the valve cap Press the valve with a screwdriver to bleed out nitrogen gas A WARNING Releasing high pressure gas from the rear shock absorber unit can be hazardous Never perform any servicing until the nitrogen gas pressure has been released from the rear shock absorber unit When releasing the gas pressure place a rag over the gas valve and use the tip of a screw driver etc to press the valve Do not use your finger to depress the gas valve and direct the valve away from your face and body REARSUSPENSION 17 7 Remove the compression adjuster assembly 1 with the spe cial tool from the rear shock absorber 09941 53650 Rear shock absorber socket wrench Place a drain pan under the rear shock absorber unit Move the rod and drain the oil completely Push the valve core again to equalize the bladder to atmo spheric pr
96. n nnn nnn 12 5 WATER PUMP REMOVAL AND INSPECTION 12 5 WATER PUMP REASSEMBLY 12 6 12 2 COOLING SYSTEM CONSTRUCTION COOLING SYSTEM m 2 5 0 25 kgf m 1 8 Ib ft ENGINE COOLANT ENGINE COOLANT REPLACEMENT WARNING You can be injured by scalding fluid or steam if you open the radiator cap when the engine is hot Do not open the radiator cap when the engine is hot Wait until engine cools Place the motorcycle on a block Remove the radiator cap Drain engine coolant by removing the drain plug and dis connecting the radiator hose 2 Tighten the drain plug D and connect the radiator hose 2 Pour engine coolant mic Engine coolant capacity 570 ml 1 2 1 0 US Imp qt Tighten the radiator cap firmly Run the engine a few minutes and inspect the coolant level RADIATOR RADIATOR CAP INSPECTION Inspect the radiator cap for function with a radiator cap pres sure gauge Radiator cap valve release pressure 95 125 kPa 0 95 1 25 kgf cm 13 5 17 8 psi NOTE Apply water to radiator cap seal before fitting the radiator cap to the pressure gauge COOLING SYSTEM 12 3 12 4 COOLING SYSTEM RADIATOR REMOVAL Remove the seat and fuel tank 7 5 2 e Drain engine coolant C 7 12 3 Disconnect all the ra
97. nd it to the cylinder head NOTE Make sure that the spark plug cap and spark plug are connected properly Measure ignition coil primary peak voltage using the multi circuit tester in the following procedure Connect the multi circuit tester with the peak voltage adaptor as follows Ignition coil White Blue terminal Ground probe probe NOTE Do not disconnect the ignition coil primary wire 09900 25008 Multi circuit tester set CAUTION Before using the multi circuit tester and peak volt adaptor be sure to refer to the appropriate instruction manual Shift the transmission into neutral and pull the clutch lever Depress the kick starter lever force fully Repeat the above procedure a few times and measure the highest ignition coil primary peak voltage Tester knob indication Voltage White Blue Ground 200 V and more A WARNING While testing do not touch the tester probes and spark plug to prevent receiving an electric shock f the voltage is lower than the specified values inspect the ignition coil 13 4 13 4 ELECTRICAL SYSTEM IGNITION COIL INSPECTION e Remove the seat and fuel tank C 775 2 Measure the ignition coil electrical resistance 09900 25008 Multi circuit tester Tester knob indication Resistance W Primary White Blue Ground 0 2 1 00 Secondary Plug cap Ground 12 20 CDI UNIT INSPECTION e Remove the s
98. o 16 13 BEARING REPLACEMENT icscisisistwusscsietseesinnaedessisisdesnsscuaiecesuisesedsiueese 16 13 HEASSEMBBEY 16 14 16 2 FRONT FORK AND STEERING CONSTRUCTION FRONT FORK AND STEERING V 26 2 6 kgf m 19 0 Ib ft V 65 6 5 kgf m 47 0 Ib ft 23 2 3 kgf m 16 5 Ib ft 2 0 kgf m 14 5 Ib ft 42 35 8 5 kgf m 25 5 Ib ft F 55 5 5 kgf m 40 0 Ib ft FRONT FORK REMOVAL Place a block under the chassis tubes COVer Remove the brake caliper 15 6 Remove the front wheel 7 14 3 Loosen the fork upper clamp bolts disassembly Hold the fork body and loosen the fork lower clamp bolts 3 Remove the front forks DISASSEMBLY NOTE Set rebound damping adjuster to the softest settings before dis assembling Record the setting before turning the adjuster Thoroughly clean the fork before disassembly Remove the fork covers brake hose guide and brake hose Loosen the front fork cap bolt 1 2 turns to facilitate later CAUTION Scratches or other damage on the inner tube or on the oil seal lip will cause oil leak Avoid scratching or damaging the inner tube or the oil seal Use a mild detergent or car wash soap and sponge out dirt with plenty of water FRON
99. onto the V blocks so that it becomes hori zontally Measure the runout from the tips of the crankshaft Measure the crankshaft web to web width with a vernier cali pers Width between webs Standard 44 9 45 1 mm 1 767 1 775 in OIL SEAL INSPECTION REMOVAL AND INSTALLATION Inspect each oil seal lip for wear and damage Remove the oil seal with the special tool 09913 50121 Oil seal remover Install each new oil seal with the special tools Apply grease to each oil seal lip 09913 70210 Bearing installer set NOTE Be sure to check the direction of the crankshaft bearing oil seals before fitting them BEARING INSPECTION REMOVAL AND INSTALLATION Inspect the bearings for play discoloration wear and seizure Move the inner race by finger and inspect for smooth move ment TRANSMISSION AND CRANKSHAFT 10 7 OUT Left Right OUT SIDE SIDE CT 10 8 TRANSMISSION AND CRANKSHAFT Remove the bearing retainers 7 2 Remove the bearings with the special tool 09913 70210 Bearing installer set Remove the bearing 3 with the special tool 09921 20220 Bearing remover set CRANKSHAFT INSTALLATION Install the crankshaft into the left crankcase half with the spe cial tool 09910 32812 Crankshaft installer TRANSMISSION REASSEMBLY TRANSMISSION AND CRANKSHAFT 10 9 Left lt EM seni
100. overs and fuel tank 7 5 2 Remove the muffler 775 2 Drain engine coolant 12 3 Loosen the clamp and disconnect the radiator hose Remove the spark plug cap 2 and spark plug Remove the cylinder head 4 NOTE Loosen the cylinder head nuts diagonally to prevent cylinder head distortion CYLINDER REMOVAL Remove the cylinder head 7 above Remove the exhaust pipe 7 5 2 Remove the cylinder head O rings and 2 Remove the exhaust valve rod cover 3 and gasket Remove the bolt 4 and disconnect the exhaust valve rod CAUTION Set the pin 4 provided with machine to the lever before loosening the bolt 4 Loosening the bolt with out setting the pin can damage the valve shaft arm spring 6 4 CYLINDER PISTON AND EXHAUST VALVE Loosen the four cylinder nuts D Remove the cylinder 2 NOTE Loosen the cylinder nuts diagonally Remove the gasket 3 and dowel pins 4 PISTON REMOVAL 3 Remove the cylinder head and cylinder C 776 3 27 gt Remove the piston pin circlip poc 2 Joss Place cloth on the crankcase to prevent the piston pin circlip 6 Aa from dropping into the crankcase chamber ON 4 a B Remove the piston pin 2 S i Remove the piston ES gt T e Remove the conrod small end bearing 9 Remove the piston ring EXHAUST VALVE R
101. oves strong boots that fit over the ankle long pants and a long sleeve shirt or jackets Experienced riders often wear a kidney belt and chest or back protector for additional comfort and protection Inspect your machine before riding Before each use perform an inspection per PERIODIC MAINTENANCE section starting on page 2 2 No Passengers Suzuki RMs are designed for the rider only Weight limit 55 kg 120 Ibs Ride with teammates Share the fun of motocross riding A riding part ner can also be great help if one of you gets stranded or injured Of course your friends will need their own motorcycles because motocross models are not designed for passengers If none of your friends rides motocross ask your Suzuki dealer how to go about joining a club If your friends do ride you can all join a club or start one of your own Before you begin riding you should find a good place to practice the skills you need to ride safely Find a flat open area with enough space to maneuver Check with your Suzuki dealer or call police department if you do not know where you can ride Review the controls on your motorcycle before riding Know your limits Always ride within the boundaries of your own skills Knowing these limits and staying within them will help you avoid accidents Ride only in events appropriate for your experience Safely competing on a motorcycle requir
102. r bearing and steering stem nut Tighten the steering stem nut with the special tool 09940 14930 Steering nut socket wrench V Steering stem nut 45 N m 4 5 kgf m 32 5 Ib ft Move the steering stem right and left several times to seat the bearings Turn back the steering stem nut by 1 4 to 1 2 turn Install the front forks temporarity to the steering stem Install the steering stem head and tighten the steering stem nut temporarily Tighten the steering stem head nut to the specified torque V Steering stem head nut 65 N m 6 5 kgf m 47 0 Ib ft e Reassemble the front wheel and the brake caliper 14 3 15 8 Reassemble the handlebars Align the punched mark on the handlebars with the mating surface of front side of the left handlebar holder Set the punched mark FWD mark on the handlebar holders as shown in the illustration Tighten the handlebar holder bolts to the specified torque NOTE First tighten the handlebar holder bolts V Handlebar holder bolt 26 N m 2 6 kgf m 19 0 Ib ft Reinstall the brake hose guide Rock the front fork forward and backward to ensure that the steering has no play Inspect the steering for smooth movement so that handle bars can move right and left under its own weight Reinstall the front number plate and the front fender NOTE When installing the front number plate fit the holes to the steering stem s projections 8
103. r hose and tighten the hose clamp e Pour engine coolant 22 12 3 Inspect engine coolant leak CYLINDER PISTON AND EXHAUST VALVE 6 11 6 12 CYLINDER PISTON AND EXHAUST VALVE EXHAUST VALVE GOVERNOR REMOVAL AND DISASSEMBLY e Drain transmission oil C 72 7 Drain engine coolant 2712 3 Remove the exhaust pipe 7 5 2 Remove the rear brake pedal 15 14 Remove the clutch cover 77 3 Remove the exhaust valve bolt 76 4 Remove the exhaust valve governor 4 Remove the exhaust valve actuator 2 Remove the pin 3 by pushing the retainer 4 down CYLINDER PISTON AND EXHAUST VALVE 6 13 Remove the spring 5 retainer 6 and bearing 7 Remove the washers 6 spacer bearing 40 and stator 40 AS S LOK Remove the balls 2 EXHAUST VALVE GOVERNOR INSPECTION Inspect the bearing for wear Replace the bearing if there is anything unusual 6 14 CYLINDER PISTON AND EXHAUST VALVE Inspect the balls and their grooves of governor and actuator for wear or damage If they are worn or damaged replace them with the new ones EXHAUST VALVE GOVERNOR REASSEMBLY AND INSTALLATION Installation is in the reverse order of removal and disassembly Pay attention to the following points Apply transmission oil to the exhaust valve gevernor Install the exhaust valve actuator D Install the exhaust valve governor with the g
104. r limit FRONT BRAKE LEVER ADJUSTMENT Adjust the brake lever play as follows Loosen lock nut 1 Turn in or out adjuster to obtain the specified play Brake lever play 5 20 mm 0 20 0 79 in Tighten the lock nut 1 CAUTION Brake lever play less than 5 mm 0 20 in can cause brake dragging Do not adjust the brake lever play less than 5 mm 0 20 in BRAKE PEDAL HEIGHT ADJUSTMENT Adjust the rear brake pedal height as follows Loosen lock nut 1 Adjust the brake pedal height by turning the adjuster 2 to locate the pedal 0 10 mm 0 0 4 in below the top face of the footrest Tighten lock nut D V Rear master cylinder rod lock nut 18 N m 1 8 kgf m 13 0 Ib ft 0 0 4 in LE FRONT FORK Move the front fork up and down several times and inspect for smooth movement Inspect for damage and oil leaks Place a stand under the chassis tube to lift the front wheel off the ground Remove the air bleed screw and equalize the air pressure in the front forks to atmospheric pressure 74 8 Refit the air bleed screw Inspect the bolts and nuts for tightness 2 18 PERIODIC MAINTENANCE REAR SUSPENSION Move the rear suspension up and down several times and inspect for smooth movement Inspect for damage and oil leaks Inspect the bolts and nuts for tightness WHEELS AND TIRES WHEEL RIM Inspect t
105. rclips O rings and cotter pins with new ones Take care not to expand the end gap larger than required to slip the circlip over the shaft when installing a circlip Use special tools where specified Use genuine SUZUKI parts and recommended oil When two or more persons work together pay attention to the safety of each other After reassembly inspect parts for tightness and operation REPLACEMENT PARTS Use only genuine SUZUKI replacement parts or their equivalent Genuine SUZUKI parts are high quality parts which are designed and built specially for SUZUKI vehicles NOTE Use of replacement parts which are not equivalent in quality to genuine SUZUKI parts can lead to per formance problems and damage SYMBOL MARKS AND MATERIALS SYMBOL MARK MATERIALS Apply SUZUKI SUPER GREASE 99000 25010 Apply SUZUKI SILICONE GREASE 99000 25100 Apply THREAD LOCK SUPER 1303 99000 32030 Apply THREAD LOCK SUPER 1322 99000 32110 Apply SUZUKI BOND 1207B 99000 31140 Use or apply DOT 4 Brake fluid SYMBOL MARK MATERIALS Use SUZUKI FORK OIL SS 05 99000 99001 SS5 Use SUZUKI REAR SUSPENSION OIL SS 25 99000 99001 S25 Use engine coolant SUZUKI COOLANT 99000 99032 11X Apply engine oil or transmission oil Tighten a nut or bolt to the specified torque T 9 Replace a part with a new one when reassembling MEMO G
106. re for this motorcycle Understand the procedure by first riding the motorcycle where it will be used and adjust the engine to the best condition after judging the air fuel mixture Carburetor standard setting Main jet 128 Jet needle 24NAAH 3rd Slow jet 50 Air screw 2 turns out INCLUDED PARTS AND OPTIONAL PARTS Main jet Air fuel mixture P NO Lean Slow jet Air fuel mixture 09491 23027 09491 23028 09491 24030 09491 24031 09491 25019 09491 25020 09491 26017 09491 26018 09491 27016 09491 27017 09491 28019 09491 28020 09491 29014 P NO Lean 09492 45032 09492 48013 09492 50023 09492 52011 09492 55017 09492 58001 P NO Jet Needle Air fuel mixture SIZE Lean 24NCDK 24NAAK 24NCDJ 24NAAJ 24NCDH 24NAAH 24NCDG 24NAAG 24NCDF 24NAAF NOTE SHADED STANDARD INCLUDED PARTS NONE OPTIONAL PARTS 13383 03B90 13383 03B40 13383 03B80 13383 03B30 13383 03B70 13383 03B20 13383 03B60 13383 03B10 13383 03B50 13383 03B00 D Adjustment of slow system 1 air screw as specified 2 See if the selected slow jet is correct or not by judging the air fuel mixture If air fuel mixture is rich replace it with smaller one If air fuel mix ture is lean replace it with larger one Ex Pilot jet 50 If air fuel mixtur
107. rence by referring to the table below Spring replacement 7 17 4 Spring Spring rate Part No Marking paint Soft Option 44 N mm 4 4 kgf mm RM85 46 N mm 4 6 kgf mm RM85L 6221 1 03B80 GREEN 2 line 6221 1 03B90 GREEN 46 N mm 4 6 kgf mm RM85 6221 1 03B90 GREEN Standard 6221 1 03BA0 BLACK 6221 1 03BA0 BLACK 6221 1 03BB0 RED 48 N mm 4 8 kgf mm RM85 Hard Option _ 50 N mm 5 0 kgf mm RM85L 48 N mm 4 8 kgf mm RM85L Measure the distance L1 from the seat bolt to the chain adjuster lock nut with the motorcycle on the stand and the rear wheel lifted off the ground Measure the distance L2 from the seat bolt to the chain adjuster lock nut with the motorcycle off the stand and riding the motorcycle normally in full riding gear Find the sag by subtracting L2 from L1 Standard sag range is 85 95 mm 3 3 3 7 in When the sag measured is Less than 85 mm 3 3 in More than 95 mm 3 7 in Adjustment procedure Increase spring pre set length by turning the spring adjuster nut Reduce spring pre set length by turning the spring adjuster nut REAR SUSPENSION After the sag measurement has been set between 85 mm 3 3 in to 95 mm 3 7 in test ride the motorcycle and adjust the sus pension for the rider and track conditions referring to the guide below SYMPTOM SECTION MACHINE TUNING 4 15 ADJUSTMENT
108. reservoirs If the brake fluid level is lower than LOWER LWR mark replenish the reservoir with the specified brake fluid to the UPPER level Inspect brake pad wear and brake fluid leakage if the brake fluid level decreases Brake fluid DOT 4 A WARNING Brake fluid can be hazardous to humans and pets Brake fluid is harmful or fatal if swallowed and harm ful if it comes in contact with your skin or eyes Keep brake fluid away from children Call your doctor immediately if brake fluid is swallowed and induce vomiting Flush eyes or skin with water if brake fluid gets in eyes or comes in contact with skin A WARNING The use of any fluid except DOT 4 brake fluid from a sealed container can damage the brake system and lead to an accident Use only DOT 4 brake fluid from a sealed container Never use or mix different types of brake fluid CAUTION Spilled brake fluid can damage painted surfaces and plastic parts Be careful not to spill any fluid when filling the brake fluid reservoir Wipe spilled fluid up immediately BRAKE PAD Inspect the brake pads for wear If the brake pads are worn replace them with new ones 15 4 Wear limit PERIODIC MAINTENANCE 2 17 NOTE Pump the brake lever pedal several times to restore the brake pads after replacing the brake pads Replace both right and left pads together when replacing the brake pads Wea
109. ring 5 from the rear shock absorber REAR SHOCK ABSORBER INSPECTION Inspect the rear shock absorber for oil leakage Inspect the damper rod for scratch damage and smooth movement Inspect the bump rubber for deterioration and damage Inspect the damper rod hidden by the bump rubber by moving the bump rubber Inspect the upper bushing for damage SPRING INSTALLATION nstall the lock nut adjuster spring spring seat and spring retainers NOTE Install the spring as small diameter side is seated to the adjuster Adjust the spring set length and tighten the lock nut Standard spring set length 3 1 mm 0 12 in compressed from spring free length RM85 4 8 mm 0 18 in compressed from spring free length RM85L Spring set length adjustable range 2 12 mm 0 08 0 47 in compressed from spring free length V Rear shock absorber lock nut 45 N m 4 5 kgf m 29 0 Ib ft REAR SHOCK ABSORBER INSTALLATION Remount the rear shock absorber to the frame and the cush ion lever Tighten the upper and lower mounting bolts and nuts to the specified torque V Rear shock absorber mounting nuts 60 N m 6 0 kgf m 43 5 Ib ft Install the air cleaner k REAR SUSPENSION 17 5 17 6 REAR SUSPENSION OIL REPLACEMENT PROCEDURE TOOLS AND EQUIPMENT Following tools and equipment are required to perform oil replacement Screwdriver or small punch Vise 3 Drai
110. roove amp engaged with the actuator arm 8 Install the actuator lever and exhaust valve rod cover 6 10 e Install the brake pedal 7 15 14 e Pour transmission oil C 72 7 Pour engine coolant C 72 8 CLUTCH 7 1 CLUTCH CONTENTS CONSTRUCTION 7 2 CLUTUHM URP ev EROR AS 7 2 E PET S 7 3 CLUTCH PLATE REMOVAL 15 irritat tranne hni de 7 3 CLUTCH PLATE INSPECTION ii 7 3 CLUTCH SPRING INSPECTION 7 4 CLUTCH RACK AND PINION INSPECTION 7 4 CLUTCH PLATE 7 4 CLUTCH SLEEVE HUB REMOVAL 7 5 CLUTCH SLEEVE HUB INSPECTION 7 6 CLUTCH SLEEVE HUB REASSEMBLY 7 6 7 2 CLUTCH CONSTRUCTION CLUTCH V 70N m 7 0 kgf m 50 5 Ib ft CLUTCH CLUTCH PLATE REMOVAL e Drain transmission oil 72 7 Drain the engine coolant 12 3 Remove the rear brake pedal 15 14 Remove the clutch release arm 1 Remove the kick starter lever 2 Remove the clutch cover Loosen the bolts diagonally and r
111. s the fuel supplied to the pilot sys JET NEEDLE tem Each jet size is indicated by a number Larger When the throttle opening is 1 4 to 3 4 the air fuel number means a larger bore diameter and fitting a mixture ratio varies depending on the fuel volume larger numbered pilot jet enriches the air fuel mix Which the vacuum at the needle jet draws through ture the needle jet to needle clearance 44 MACHINE TUNING NEEDLE CLIP POSITION Lean Rich Needle clip The jet needle is linked to the throttle valve by means of the needle clip Its lower part is tapered and it has five grooves cut in the upper part where the needle clip fits To adjust the air fuel mixture with the jet needle change position of the needle clip which is set in the 3rd groove The lower groove the clip is moved to the higher the jet needle rises and the larger the clearance with the needle jet becomes resulting in a richer air fuel mixture ratio The needle clip position can be changed by half to fine tune the setting To change the needle clip position by half change jet needle from 24NAAH type to 24 type This change will move the needle position by half to the leaner side Air fuel mixture Needle type and clip position 24NCDH 1st 24 18 24NCDH 2nd 24NAAH 2nd 24NCDH 3rd 24NAAH 3rd 24NCDH 4th 24NAAH 4th 24NCDH 5th 24NAAH 5th Lean Rich JET NEEDLE O D
112. sorber unit may rupture the rear shock absorber unit Be sure to fill the rear shock absorber unit to the spec ified pressure CAUTION Riding the motorcycle with abnormal gas pressure can damage the rear shock absorber unit Low gas pressure can result in oil leakage Abnormal gas pres sure cannot provide normal rear shock absorber unit performance Be sure to fill the rear shock absorber unit to the spec ified pressure REAR SHOCK ABSORBER DISASSEMBLY AND INSPECTION Remove the rear shock absorber unit from the frame Clean and dry it 7717 3 Remove the spring from the rear shock absorber 7 17 4 Turn the rebound damping force adjuster to the softest posi tion Press the valve with a screwdriver to bleed out nitrogen gas 17 6 Remove the compression adjuster assembly Drain the oil 17 7 Vise the rear shock absorber unit in inverted position Evenly hammer the stopper 1 with the screwdriver or equiva lent and remove it from the rear shock absorber body Depress the seal case 2 with the screwdriver until the circlip 3 is fully exposed Remove the circlip 3 NOTE Avoid scratching the inner surface of the shock absorber body to avoid oil leaks Extract the damper rod assembly from the shock absorber bogy Inspect the oil seal and O rings Inspect the damper for bends and scratches Inspect the inner surface of the body Inspect
113. ssemble the drive chain NOTE Reassemble the drive chain clip so the slit end faces opposite the direction of rotation Adjust the drive chain slack 7 above 123 19 20 21 Mie Xe Xo 55 sYo Xe eX Direction of travel 2659 2 PERIODIC MAINTENANCE 2 15 SPROCKET INSPECTION Inspect the engine sprocket and rear sprocket for wear and cracks Replace the sprockets if necessary NOTE When replacing a worn sprocket it is likely that the drive chain will need to be replaced as well Normal wear Excessive wear DRIVE CHAIN GUIDE BUFFER TENSIONER ROLLER DRIVE CHAIN GUIDE Inspect the drive chain guide D for bends and damage NOTE The drive chain can hit a bent guide causing noise and drive chain wear Inspect the chain guide defense 2 for wear DRIVE CHAIN GUIDE BUFFER Inspect the drive chain guide buffer for wear and cracks NOTE The drive chain can touch the swingarm directly if the chain guide buffer is worn out This will cause drive chain and swing arm damage DRIVE CHAIN TENSIONER ROLLER Inspect the drive chain tensioner rollers 4 for wear Inspect the tensioner roller bolts for tightness V Drive chain tensioner roller bolts 41 N m 4 1 kgf m 29 5 Ib ft 2 16 PERIODIC MAINTENANCE BRAKES BRAKE FLUID LEVEL Inspect the brake fluid level in both front and rear
114. stalling the fork cap bolt Hold the fork cap bolt and tighten the lock nut to the specified torque V Inner rod lock nut 20 2 0 kgf m 14 5 Ib ft Apply fork oil to the fork cap s O ring Tighten the fork cap bolt to the specified torque V Fork bolt 35 N m 3 5 kgf m 25 5 Ib ft e Remount the front forks to the steering stem 5 16 10 OPTIONAL SPRING The number of end coils shows the fork spring rate SOFTER SPRING STANDARD SPRING MACHINE TUNING 4 11 STIFFER SPRING 2 6 N m 0 26 kgf mm 2 8 N m 0 28 kgf mm 3 0 N m 0 30 kgf mm 1 turn 4 12 MACHINE TUNING FRONT FORK TUNING PROCEDURE Test ride the motorcycle and find out how the front suspension reacts on various types of surface According to the symptom noticed adjust the front fork to the best setting for rider and race track conditions To adjust attempt changing fork oil capacity and compression rebound damping following the instructions below SYMPTOM SECTION ADJUSTMENT PROCEDURE Feels too hard overall Jump Large bumps Series of medium bumps Adjust both the compression and rebound damping to a softer setting Decrease fork oil capacity Replace the spring with an optional softer one Feels too soft overall and bottoms Jump Large bump When braking Adjust the compression damping to a stiffer set ting Increase fork oil capacity Replace the spring wit
115. t replenish the radiator with specified engine cool ant Tighten the radiator cap securely CAUTION Improperly tightening the radiator cap will prevent the cooling system from reaching the specified operating pressure and will cause coolant overflow Tighten the radiator cap until it locks firmly NOTE This motorcycle does not have an overflow tank at the end of breather hose Therefore engine coolant level may decrease while riding Check the engine coolant level every time before riding When replenishing engine coolant be sure to use engine cool ant mixed with distilled water at the ratio of 50 50 Adding only water will dilute engine coolant and it may decrease ing performance f the motorcycle is to be exposed to temperatures below 31 C 24 F the percentage of antifreeze should be increased to 55 or 60 according to figure 1 Antifreeze density Freezing point 5096 31 C 24 F 5596 40 C 40 F 6096 55 C 67 F F 0 32 Freezing point 20 40 60 80 100 Density Fig 1 Engine coolant density boiling point PERIODIC MAINTENANCE 2 9 ENGINE COOLANT REPLENISHMENT Drain engine coolant 7 12 3 e Pour engine coolant C 7 12 3 Use an anti freeze and Summer engine coolant which is com patible with aluminum radiator mixed with distilled water at the ratio of 50 50 NO
116. t an angle of 30 degrees to horizon and tighten the upper clamp bolt first as shown to the specified torque V Master cylinder clamp bolt 10 N m 1 0 kgf m 7 3 Ib ft Master cylinder Handlebars Upper clamp bolt UP mark Clearance Master cylinder SN FRONT AND REAR BRAKES 15 13 e Tighten the brake hose adaptor 0 to the specified torque V Brake hose adaptor 18 N m 1 8 kgf m 13 0 Ib ft NOTE Hold the brake hose with a wrench to prevent the brake hose from twisting when tightening the adaptor Refill brake fluid and bleed air from the brake system 15 3 REAR MASTER CYLINDER REASSEMBLY Apply brake fluid to the piston cup and O ring Install the spring piston cup set and push rod Install the connector and O ring nstall the snap rings with snap ring pliers Install the boot Connect the reservoir hose to the connector and clamp it Apply THREAD LOCK SUPER 1322 to the master cylinder mounting bolts 99000 32110 THREAD LOCK SUPER 1322 Tighten the master cylinder mounting bolts to the specified torque V Master cylinder mounting bolt 10 N m 1 0 kgf m 7 3 Ib ft e Reassemble the rear brake pedal 15 14 Tighten the brake hose union bolt to the specified torque V Brake hose union bolt 23 N m 2 3 kgf m 16 5 Ib ft CAUTION Improper brake hose routing can damage the brake hose Set the brake hose so it
117. t range improperly can damage the engine Select the spark plug heat range only after adjusting the ignition timing carburetor setting and oil gasoline mixture Tighten the spark plug with specified tightening torque after tightening the spark plug temporarily with fingers V Spark plug 28 N m 2 8 kgf m 20 5 Ib ft 0 7 0 8 mm NE 0 028 0 031 in EE oa Vp m MXN y y PERIODIC MAINTENANCE 2 5 AIR CLEANER AIR CLEANER ELEMENT REMOVAL Remove the seat Remove the air cleaner cap D Remove the wing nut 2 Remove the element from the element holder WASHING Fill a washing pan large enough to hold the element with a FN non flammable cleaning solvent Immerse the element in P the solvent and wash it Es MOTUL AIR FILTER CLEAN or equivalent cleaning solvent q e Squeeze the element by grasping it to remove excess sol 4 vent Do not twist or wring the element or it will develop 8 cracks 4 Dry the element in a plastic bag pour in some foam filter oil and work the oil into the element B MOTUL AIR FILTER OIL or equivalent filter oil Squeeze the element to remove excess oil INSTALLATION Apply grease to the element base where it contacts the air cleaner box Fit the element onto the element holder 2 6 PERIODIC MAINTENANCE Insta
118. tch sleeve hub nut with the special tool to the specified torque 09920 53740 Clutch sleeve hub holder V Clutch sleeve hub nut 70 N m 7 0 kgf m 51 0 Ib ft Bend the lock washer to secure the nut D 7 8 CLUTCH e Reassemble the clutch plates and pressure plate C 777 4 Install the dowel pins Replace the gasket with a new one Install the clutch cover and bolts Tighten the clutch cover bolts diagonally C 777 5 Connect the radiator hose Install the clutch release arm and kick starter lever Reassemble the rear brake pedal 15 14 e Pour transmission oil C 772 7 Pour engine coolant C 772 8 KICK STARTER 8 1 KICK STARTER CONTENTS CONSTRUCTION 8 2 KICKSTARTER 2 Saa ON EE ERR Days 8 2 KICK STARTER 8 3 REMOVAL 8 3 INSPECTION 8 4 HEASSEMBLY rto por Ene NEL 8 4 CONSTRUCTION KICK STARTER 8 2 KICK STARTER 4 KICK STARTER 8 3 KICK STARTER REMOVAL e Drain transmission oil C 72 7 Drain engine coolant Remove the kick starter lever Remove the clutch assembly 7 5 Remove the snap ring 1 Remove the kick idle gear 2 Remove the kick starter drive gear 3 nstall the kick starter lever temporally to remove
119. the teflon coating metal on the piston Replace O rings with new ones Replace the teflon coating metal by cutting off the old one and sliding the new one onto the piston if necessary REAR SUSPENSION 17 9 17 10 REAR SUSPENSION REAR SHOCK ABSORBER REASSEMBLY Apply the rear suspension oil to the O rings and the teflon coating metal Insert the damper rod assembly 1 and install the new circlip Q Pull up the damper rod assembly 7 until it is stopped by the circlip Install the stopper to the shock absorber body Fill the specified rear suspension oil in the rear shock absorber 17 7 99000 99001 S25 SUZUKI REAR SUSPENSION OIL SS 25 Oil capacity Approx 195 ml 6 6 6 9 US Imp oz e Reinstall the compression adjuster assembly 7 17 8 Pressure the rear shock absorber unit with nitrogen gas to 1 000 kPa 10 kgf cm 142 psi 17 8 Reassemble the spring and adjust the spring set length 2717 5 Tighten the valve e Remount the rear shock absorber to the frame 7 17 5 REAR SHOCK ABSORBER DISPOSAL High pressure nitrogen gas is sealed in the rear shock absorber unit Be sure to release gas before disposing the rear shock absorber unit Remove the valve cap Press the valve with screwdriver WARNING Releasing high pressure gas from the rear shock absorber unit can be hazardous Place a rag over the valve and push the valve with a screwdr
120. throttle grip forward and pull in clutch lever kick up gearshift lever while twisting back the throttle grip Now pick up speed on second Repeat this sequence to shift upward step by through third fourth and fifth to top BRAKING To slow down 1 twist throttle grip forward and 2 brake front and rear wheels Just before you come to a stop pull in clutch lever and shift down into NEUTRAL GENERAL INSTRUCTIONS 1 7 1 8 GENERAL INSTRUCTIONS An attempt to slow down by braking alone is dangerous par ticularly braking of the front wheel alone The front wheel may slide out front wheel braking or rear wheel might skid side wise rear wheel braking A WARNING Braking when making a turn can lose balance and control Brake only when riding straight STOPPING ENGINE Twist the throttle grip forward Pull in the clutch lever and shift into neutral Hold in engine stop switch until the engine stops Turn the fuel valve lever from ON to OFF BREAK IN RUNNING IN WHEN THE MOTORCYCLE IS NEW 1 Warm up the engine bofore starting off 2 Ride for 1 hour using less than 1 2 throttle opening with vari ous throttle opening 3 Ride for 1 hour using less than 3 4 throttle opening with vari ous throttle opening The break in running in period is the period of greatest wear The bolts and nuts of the new machine can loosen qu
121. ticularly throttle and brake Make sure the gearshift pattern and shifting sequence are perfectly memorized Smooth simultaneous brak ing front and rear is particularly important Rule 3 Learn the technique of standing start and stopping with brakes Practice makes perfect Let the young rider repeat following you many times until you sure he or she has learned the knack and technique throughly NOTE For practice choose a level ground free of traffic and spacious enough to permit driving several yards with the engine powered In short break in the young rider gradually CLOTHING Rule 4 Wear simple clothes Loose fitting clothes are unsafe for riding Loose belts and scarves loose trimming etc can be dangerous Rule 5 Avoid scanty clothes Do not ride wearing short pants or short sleeve shirt A large part of riding fatigue comes from loss of body heat due to wind Abrasive injuries can be avoided by protection clothing Rule 6 Avoid stiff clothes Make sure that knee and elbow actions are free and that torso bending is not interferred with Free body movements are essential for safe riding NOTE The helmet gloves boots goggles and jacket are essential items of clothing STARTING ENGINE STARTING COLD ENGINE Turn the fuel valve lever from OFF to ON Jerk the machine back and forth and be sure the gear is in neutral The machine will resist the jerking if the gear is not in neutral G
122. tires SUZUKI MOTOR CORPORATION COPYRIGHT SUZUKI MOTOR CORPORATION 2006 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 carry special meanings Pay special attention to the messages highlighted by these sig nal words WARNING Indicates a potential hazard that could result in death or injury CAUTION Indicates a potential hazard that could result in motorcycle damage NOTE Indicates special information to make maintenance easier or instructions clearer GENERAL CONSIDERATIONS Wear helmet and goggles A helmet is the most important piece of gear to wear Helmets do not reduce essential vision or hearing Generally helmets do not cause or intensify injury if you crash Helmets simply help your skull protect your intelligence your memory your personality and your life Your eyesight is equally valuable Wearing suit able eye protection can help keep your vision unblurred by the wind and help shield your eyes from branches and airborne matter like bugs dirt or pebbles kicked up by tires Wear a helmet and eye protection every time you ride Wear protective gear Wear proper clothing when you ride Avoid loose clothes or scarves which could get caught in moving parts Abrasion injuries can be minimized by wearing protective clothing including gl
123. touches the stopper and tighten the union bolt Ensure the brake hose has enough clearance to the rear suspension spring Brake hose routing 7 18 13 Refill brake fluid and bleed air from the brake system 15 3 15 14 FRONT AND REAR BRAKES BRAKE PEDAL BRAKE PEDAL REMOVAL AND REASSEMBLY REMOVAL Remove the nut from the brake pedal pivot Remove the cotter pin and pin from the push rod end Remove the return spring REASSEMBLY Reassemble the pin washer and cotter pin to the push rod end Install the return spring Apply grease to the brake pedal pivot shaft Install the washer and cotter pin NOTE Replace the cotter pin with new one e Adjust the brake pedal height 772 17 FRONT FORK AND STEERING 16 1 FRONT FORK AND STEERING CONTENTS CONSTRUCTION mka a 16 2 FRONT FORK AND STEERING 16 2 FRONT FORK dicet 16 3 16 3 DISASSEMBLY 16 3 INSPEGTION 16 5 ua EE 16 7 REINS TALLATION lae 16 11 STEERING 16 12 REMOVAL ec 16 12 INSPECTION d epp sare bu
124. tri gt Right NOTE Seat the snap ring in the groove and locate its end as shown in the illustration Replace the removed snap ring with a new one Apply transmission oil to the following parts driveshaft coun tershaft transmission gears bearings gearshift forks gear shift shafts gearshift cam Reassemble the driveshaft and countershaft with gears installed Thrust Sharp edge gt Washer 10 10 TRANSMISSION AND CRANKSHAFT Install the gear shift forks D Install the gear shift cam 3 and gearshift shafts NOTE Turn the gearshift cam to the neutral position and confirm that the driveshaft and countershaft turn without resistance CRANKCASE REASSEMBLY Install the new gasket D and dowel pins Install the right crankcase half on the left crankcase half Tighten the crankcase bolts V Crankcase bolt 10 1 0 kgf m 7 3 Ib ft NOTE Tighten the bolts gradually and diagonally to guide the crank shaft into the bearing If it is hard to tighten the bolts separate the crankcase and confirm that the transmission parts are assembled correctly Inspect the crankshaft for smooth movement Apply grease to the oil seal s lip Install the spacer to the crankshaft e 0 PRIMARY DRIVEN GEAR REASSEMBLY nstall the primary driven gear and washer onto the crank shaft
125. ust con tacts the float valve Standard float height amp 19 0 5 mm 0 75 0 02 in REASSEMBLY Reverse the sequence of removal NOTE Fit the projection of the carburetor to the depression on intake pipe REED VALVE REMOVAL e Remove the carburetor 7 11 3 Remove the four bolts Remove the intake pipe and reed valve INSPECTION Inspect the reeds for damage Inspect the reed valve stoppers for damage Inspect the valve seat rubber for damage NOTE Be careful not to damage the removed reed valve ass y 11 6 FUEL SYSTEM REASSEMBLY Reverse the sequence of removal COOLING SYSTEM 12 1 COOLING SYSTEM CONTENTS CONSTRUCTION 12 2 COOLING SYSTEM NEIGE ERE IRE 12 2 ENGINE COOLANT 12 3 ENGINE COOLANT REPLACEMENT 12 3 RADIATOR 12 3 RADIATOR CAP INSPECTION 12 3 RADIATOR REMOVAL gt 12 4 COOLING SYSTEM INSPECTION 12 4 RADIATOR INSTALLATION 12 4 WATER PUMP euuee suene ere
126. valve V Brake caliper air bleeder valve 7 5 N m 0 75 kgf m 5 5 Ib ft Pour brake fluid up to the UPPER line Reassemble the reservoir cap BRAKE FLUID REPLACEMENT Remove the reservoir cap Connect a transparent tube to the bleeder valve and set the other end into a receptacle Loosen the bleeder valve and pump the brake lever pedal until brake fluid stops coming out from the bleeder valve Pour brake fluid into the reservoir Bleed air from the brake system 15 3 Reassemble the reservoir cap BRAKE PAD REPLACEMENT FRONT BRAKE PAD Remove the caliper mounting bolts Remove the brake pads by removing the clip D and pad mounting pin 2 NOTE Replace the two brake pads as a set Install the new brake pads to the caliper NOTE When installing the inner pad seat it on the hating part 3 of the pad spring Tighten the caliper mounting bolts V Caliper mounting bolt 23 2 3 kgf m 16 5 Ib ft NOTE Pump the brake lever several times to seat the brake pads after reassembling REAR BRAKE PAD Remove the caliper mounting bolts FRONT AND REAR BRAKES 15 5 Remove the clamp 1 Remove the pad mounting pin NOTE Replace the two pads as a set Install the new brake pads to the caliper NOTE Make sure that the tip of the spring is fitted to the inner pad 3 Tighten the caliper mounting bolts V Caliper mounting bolt 23 2 3 kgf m 16 5

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