The SUZUKI GS250T has been developed as a companion motorcycle to the GS models. It features highly advanced design concepts including a forged one piece crankshaft assembl y, a full-transistorized ignition system and a new highl y efficient combustion system (TSCC). The GS250T provides excellent performance, precise control and handling plus outstanding riding comfort. This service manual has been produced primarily for experienced SUZUKI mechanics. Apprentice and do-it-yourself mechanics will also find this manual to be an extremel y useful repair guide. This manual contains the most up-to¡date information at the time of p ub lication. The rights are reserved to update or make corrections to this manual at anv time.
All GS model SUZUKI motorcycles that were manufactured after January 1, 1978 are subject to Environmental Protection Agency emission regulations. These regualtions set specific standards for exhaust emission output levels as well as particular sen/icing re¡ quirements. This manual includes specific information required to properly inspect and ser vice the GS250 T in accordance with all EPA regulations. It is strongly recommended that the chapter on Emission Control, Periodic Servicing and Carburetion be thoroughly reviewed before any type of service work is performed. Further information concerning the EPA emission regulations and U.S. SUZUKI'S emission control program can be found in the U.S. SUZUKI EMISSION CONTROL PROGRAM MANUAL/SERVICE BULL ETIN.
Service Department Overseas Operations Division
Quo ting, cop ying or otherwise using any par:l of this manual without exp licit authorization from Suzuf<i Motor Co., il. td. is not permitted as all rights to the publication are reserved under C(lpyrighl law.
VIEW OF SUZUKI GS250T
RIGHT SI DE
LEFT SIDE
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GROUP INDEX
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GENERAL INFORMATION
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PERIODIC MAINTENANCE AND TUNE. . UP PROCEDURES i
SERVICING ENGINE
3
FUEL AND LUBRICATION SYSTEM
4 •,
EMISSION CONTROL & REGULATIONS
ELECTRICAL SYSTEM
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CHASSIS
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SERVICING INFORMATION
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. GENERAL
INF~RMATION
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CONTENTS- -
SERIAL NUMBER LOCATIONS ........................................................................... 1~ 1 FUEL AND OIL RECOMMENDATIONS ............................................................ 1~ 1
BREAKJNGQIN PROCEDURES .............................................................................. 1Q2
C YLINDER IDENTJFICATION ................................................................................. 1Q2 SPECIAL FEA TURES ................................................................................................ 1~ 2 BLOW B Y GAS RECYCLING ........................................................................ 1Q2 COUNTER BALANCER ................................................................................. 1~ 3
CAMSHAFT DRIVE CHAIN TENSIO NER ............................................. 1- 8 TSCC ....................................................................................................................... 1- 9
FULL- TRANS IS TORIZED IGNITIO N S YS TEM .................................... 1Q13 SPECIAL MATERIALS ............................................................................................. 1-15 PRECAUTIONS AND GENERAL INSTRUCTIONS .................................... 1-17 SPECIFICATIONS ......................................................................................................1-18
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1-1
GENERA L INFOR MATION
SERIAL NUMBER LOCATIONS The frame number 1 is stamped on the steering head tube and steeri ng head 1. D. plate. The engine serial number 2 is located on the right side of the crankcase. These numbers are required especia lly for registering the machine and ordering spare parts.
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SAE
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40 30 20W/ 50 lOW/ 50 1OW/30 20W lOW -
Temp.
vc OF
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- 20 - 10 0 10 20 30 40 - 4 14 32 50 68 86 104
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BRAKE FLUID Specification and classification:
FUEL AND OIL RECOMMENDATIONS FUEL Use only unleaded or low-lead type gasoline of at least 85 - 95 pump octane (~method) 2 or 89 octane or higher rated by the Research Method.
ENGINE OIL Be sure that the engine oi I you use comes under API classification of SE and that its viscosity rating is SAE 10W/40. If SAE 10W/40 motor oi l is not avai lab le, select the oil viscosity according to the fo llowing chart:
DOT3 or DOT4
WARN ING: * Since the brake system of this motorcycle is fi lled with a glycol-based brake f luid by the manufacturer, do not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will resu lt. * Do not use any brake fluid taken from old or used or unsealed containers. * Never re-use brake fluid left over from the previous servicing and stored fo r a long period. _ __
FRONT FORK 01 L Use front for k oi I # 15.
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GENERAL INFORMATION
BREAK I NG-1N PROCE DURES
SPECiAl FEATU RES
During manufacture on ly the best possibl e materi 路 als are used and all mach ined parts are fi n ished to a very high sta ndard but it is sti ll necessary to allow t he movi ng parts to "BREAK -IN" before subjecting the engine to max imum stresses. The future performance and reli abil ity of the eng ine depends on the care and restraint ex ercised during its early life. The general rules are as fo ll ows:
BLOW SY GAS REC VCLI NG Blowby gases in the cran kcase are constantly drawn into the cha in chamber provided in the m iddle section of the cy li nde r block. The top section of t his chamber is connected with the air cleaner assembly t hrough a rubbe r tube. I n the clea ner, the gases merge w it h incoming ai r and t hu s are recycled to t he engine through the norm al inta ke system .
G
Keep to these break ing-in eng ine speed limits: Initial
500 mile
Be low 4, 000 r/ min -I---
Up to 1 000 m ile r -- --
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Over 1 000 mile
0
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Below 6,000 r/ m in --------~
Be low 10,000 r/ min
Upon reachi ng an odometer read ing of 1 000 mi les you can subject the motorcyc le to full thrott le operation. However, do not exceed 10,000 r/ min at any t ime. Do not maintain constant engine speed for an ext ended t ime peri od during any portio n of the Try to vary the throttle position. break -in.
C YLIN DER IDENTIFI CATION T he t wo cy li nde rs are ident ified as LEFT-HA N D CY LI N D ER l and RIGHT -HAND CY LI NDER
1路2
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GENEnAL li\JFORvll-\ T!O~I
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COUNTER BA LA J\JCER ENGJNE CYCLE Du r ing o ne engine cycle, power stroke occurs at unequal intervals, that is, intervals o'f 180° and 540° in terms of crank angl a.
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POWER EX. POWER
COii!IP.
IN .
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POWE R
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CRJ\i\JI<SHAF T CO UNTERBAU\NCER One of the disti nct fea tures of the GS?.50T engine is the counterbalancer; it is provided for the purpose of minimi zing engine vibr<ltion.
Co u n terbal ~nee (
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Count erweights
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GENERAL li\J FOR I\IATI::li\1
1·4
Thi s counterbal ancer operates on princip les quite differen t f rom t hose of conven ti onal counterbalanc ing devices often employed in reciprocat ing engines. Fo r one to understand its operation . one must reca ll several basic facts of dynamics: Co nsider a single rotating shaft having two equal weigh ts attached to it. The weights are 180° apart as is the case wit h the ru nn ing parts - incl ud ing the crankshaft- of the GS250T engine. As the shaft rotates, its ends, supported by bearings, tend to exhibit a grinding motion because of the two centrifugal forces.
Ends are held by support through bearings.
Axially unbalanced shaft
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(W = Win 180° crank arrangement}
Grinding motion of axial ly unbalanced shaft
The mass of a crank pin plus its connecting-rod big end, crank arms and others may be regarded sim ilar to such a weight. The centr ifugal force of such a mass (or weight) can be cancel led off by attaching a counterweight 180° opposite to the crank pin. This is done in practica ll y every engine. I n this sense, the crankshaft of the GS250T is properly ba lanced. There is another kind of vibration-inducing force w hich the running parts of a cylinder exert to compress and tension, alter nat ely, the connecting rod and thus tend to vibrate the engine as a whole in vertica l directi on. I t is the reciprocating component of t he w hole mass (inclusive, of course, of the piston, con· nect ing-rod sma ll end and piston rings) that produce this f orce occurring cyclica ll y in upward and downwa rd directions.
DOWNWARD STROKE Tensile at and near TDC due to acce leration. Compressive at and near BDC clue to deceleration.
NEAR TDC
UPWARD STROKE Tensile at and near TDC clue to decele ration. Compressive at and near BDC clue to accele ration.
(Fo rce due to fue l combustion is disregarded . l
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~ [_ _ _
BDC
Let a vector represent this vertical force, which increases and decreases alternately as the piston moves up and down between TDC and SOC. (Remember, the length of a vector signifies the magnitude of the force.)
1·5
GE~ER.\L
~FOR\IMIQ\J
Another method is necessary to counter and kill off this force - INER T IA FORCE . If not cance lled off, then the crankshaft system of, say, the GS250T wou ld cause the crankshaft to tend to rock up and down, and this would be felt by the rider as vertical vibrations. ~
i.---- T hese vec tors change = -
ij
their length, but the d irection remai n unchanged.
/ -
Roc kmg motion about the cen ter
I n the case of the GS250T cra nk shaft system, wh ich is balanced as far as centrifuga l forces are concerned, a clever method is used to counter and substantial ly cancel off the effect of the inertia fo rce. Here's the method: An additi onal counterweight is provided for each crankp in, at a position 180° opposite, on the crank· shaft to create, intentionally, a ce ntri fugal force. Thus, two extra centrifuga l forces occur when the crankshaft rotates in the GS250T engine: th eir directions are opposite to each other. Consider thi s extra centrifugal force for one cy linder. The extra force (existing at al l times when the crankshaft is running) and the up·and-down inertia force add to each other and produce a resultant force. The resultant force, like a ce ntri fugal force, ex ists ilt all times and revolves around crankshaft axis. Two very important things must be noted in th is scheme employed in th is engine: 1) the addi tional weight, mentioned above, is so sized and radia ll y located that the resu ltant centrifuga l (wh ich is the vector sum of the extra centrifuga l force and the varying inertia force) is practically constant in mag nitude, and 2) what is equally important, the resultant centrifugal force revo lves in the direction opposite to that of cranks haft ! This will be seen in the phased diag ram shown in next page.
GENERAL INFORM ATIO N
1·6
Crank ang le
F1 F3
= inertia force = extra centri· fugal force
-- ·----I
F I+FJ=F2 . resultant centri· fuga l force
---f'·-
18:-1
f--t~F ,
Since the resu ltant centrifugal force embodies the extra centrifugal force and inertia force at every crank ang le, it is obvious that canceli ng off the resultant force cancels off the two component forces. This canceli ng is accompl ished indirectly in the GS250T by providi ng a separate unbalanced shaft - the
COUNTER BALANCER.
1-7
GENERAL
li\IFORMATIO~I
Consider the GS250T crankshaft with two resultant centrifugal forces equal in magnitude and 180° aoart. With these forces, the crankshaft tends to "grind" and cause the engine to vibrate in a grinding manner. Now, the counterbalancer is sized and shaped to behave, dynamically, as a mirror image of the crankshaft and tend to vibrate the engine in a similar gr inding manner 180° out of phase with that of the crankshaft. This is illustrated in three phases schematically:
Crankshaft "grinds" due to the two resultant force. F 1 .
~~ .b Counterweight
y Counterbalancer gr inds similarly bu t 180° out of phase. Its coun terweights are sized to match F 2 .
The foregoing explanation is a simplified one and, for sake of brevity, disregards some essentia ls of dynamics such as revo lving speed (on which centrifugal force depends for its magnitude) , the breakdown of inertia force into primary force and secondary force, etc. Let it suffice here to add that the crankshaft counterbalancer built into the GS250T engine serves to minimize, not to eliminate, the engine vibration due to massimbalance in a crankshaft system by intentionally creating spec ial centrifugal forces and by counteracting to the effect (gr ind ing tendency of the engine) of these forces.
GENERAL INFQR,viATION
l-8
CAMSHAFT DRIVE CHAIN TENSlONER The chain tensioner used in the Model GS250T is of se l f-adj usting type in that it adjusts itself to apply a constant tensioning force to the chain by compensating for the stretch of the cha in.
PUSH ROD AND LOCK SCREW Lock screw is for lock ing push rod when removing or installing the tensioner, it is normally held away from push rod to allow it to slide toward the chain. Push rod is urged by co il spring toward ch ain to keep the chain in proper te nsion. As the chain in service stretches prog ressive ly, the push rod shifts to keep on exerting the tensioning force, which remains practically unchanged.
LOCK SHAFT In operat ion, the running cha in shak es more or less, ten ding to allow the spring-urged push ro d to move in and ou t. This tendency is countered by preventing push rod from backing away by means of stee l ball and lock shaft. St eel ball bears against the sl oped face of push rod. Lock shaft is preloaded with spring ..L and keeps bal l in contact w ith push rod by the acti on of this spring and the tapered contact l between lock shaft body and shaft. Thus, ball is capabl e of moving forward (in th e directi on of t he arrow) but not backward.
Lock screw Push rod
Lock shaft
L _____Ha~le
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CD
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1-9
GENERAL INFORMATION
TSCC (TWIN SWIRL COMBUSTION CHAMBER) SUZUK I has introduced a new breed of 4-valves-per-cylinder high-performance 4-stroke engines--the TSCC series. TSCC describes the heart of the engine, the Twin Swirl Combustion Chamber. What the TSCC engine series does better than conventional 4-stroke engir,es, either 2-valve or 4 -valve, is to improve on the two major factors wh ich affect engine performance, charge bu rning efficiency and int ake charging efficiency. First, charge burn ing efficiency. The TSCC* system consists of a subtle, yet un ique shape mach ined into the head. Each of the two intake valves is set into adjo ining sem i-hemispherical depressions in the head . During the intake stroke these depressions channel the incoming fuel / air mixture to form two separate high-speed swirls. During the compression stroke the squish areas machined in the front and the rear of the cylinder head's combustion chamber accelerate the speed of the swirls. Thus, w hen the spark plug ignites the mixture, the flame spreads rapidly and co mpletes the com busti on more quickly. To further aid burning efficiency, the spark plug is central ly located, the ideal location. This results in the shortest possible path for the flame to travel.
*U.S. PATENT NO. 3633577
GENERAL IN F0 RiviA Tl Q\J
1-10
The quick complet ion of burning results in more energy being developed while th e piston is in position to transmit max imu m power to the crankshaft. High burning efficiency results in more power, improved throttle response at all rpm's, more compl ete combustion of the air/ fuel mixtu re (cleaner combustion) and less chance of detonation. Second, cha rging efficiency. The be nefits of increased burni ng eff iciency are further multiplied if intake charging efficiency is also increased. Basicall y, increasing the charging efficiency resu lts in more fuel and air being drawn into the engine during each intake stroke. Thus, greater energy potential. To ac hi eve th is, the four va lve head was adopted. Two sma ll er diameter intake valves can flow more than one large valve. Additionally, two smaller va lves run cooler due to increased valve seat area and two va lve guides to increase heat transfer.
SOUISH HE IGHT
(A} : Wa ll (8 } : Wall
SQUISH AREA
TSCC PROFILE
SWIRL CY LINDER BORE PROF I LE â&#x20AC;˘ U.S. PATENT NO. 3633577
I¡ I I
GENE R!-\ L I \1 F0 R~,I !-\ T I 0 i\J
But, SUZUKI went one step further. The valves are set in at a much shal lower angle than other eng in es. The resul t is a smoother intake tract with less valve guide protrus ion than in conventional cylinder heads. Therefore, increased flow, and smoother, less turbulant flow which contributes to more power and im¡ proved throttle response at all engine speeds. There are several other benefits. Th is design is more efficient and will flow more air/ fue l mixture than a convent ional 4 valve head. Therefore, even smaller, lighter valves can be used with no decrease in power. Also, t he valves can be shorter due to the p lacement angle. This allows more prec ise valve contro l since shorter, lighte r valves are more easily contro lled--especially at higher rpm's. Yet another benefit of valves set at shallower angles is that the volume of the cylinder head com bustion area is decreased. This aliows the use of racing type flat-topped pistons since the desired compression ratio can be achieved without resorting to domed pistons. Flat topped pistons offer no restriction to the incoming air/ fuel mixture and a flat-topped piston exposes the minimum amount of surface area to the hot burning mixture. This means that the f lat piston absorbs less heat and therefore has to dissipate less heat through the rings and to the oil than a co nventional domed piston. The result is a coo ler ru nning engine. Flat-topped pistons can also be made lighter resulting in less vibration and stress. I ncreased burning efficiency. Increased charging effic iency. The resu It is more power throughout, from idle to redline. Throttle response is instant and clean. Displacement fo r d isplacement, no conventional engine, 2-valve or 4-valve, can compare. This could be enough, but SUZUKI went even fu rther to ensu re reliabili ty and ease of maintenance. A d irect acting rock er arm is utilized to activate the valves. Each rocker arm, when depressed by th e cam lobe, directly activates two valves at one time. With th is system, engine height is reduced and tappets are not necessary. This system allows more room for cool ing air flow and allows the use of larger valve springs which increases spring life by reducing stress. Va lve adjustment is accomp lished without special tools-qu ickly and easily. Special sintered steel valve seats are incorporated, manufactured from premium alloys to ensure even more reliability under higher heat loads. The paten ted TSCC com bustion system combined with SU ZUK I 's high efficiency charg ing design results in power and throttle response found only in this new generation 4-stroke engine. The SUZUKI TSCC engine series--performance without compromise.
GENERAL INFORiviATI0\1
I f valve pitch diameter
@ is
'1;
is the same , spri ng
TSCC valve ang le
Q
is smal ler tha n
J
la rger than ~
TSCC 4 -valve TSC C va lve angl e
Con ven tion aI 4-valve Convent iona l va l ve angl e
â&#x20AC;¢ U .S. PATENT NO. 3633577
1-12
FULL-TRAN SI STORJ ZED I GN!Tl ON SVST'EIVI DESCRIPTION A fully transistorized ignition system is now empl oyed on the GS250T. Its primary adva ntages are : * Trouble free o peration due to elimination of contact breaker points. * Ignition ti ming is precisely controlled at all times and requires no maintenance. * Prov ides th e igni t ion co il with stab le primary voltage . " Excel lent vib ration and mo isture resistance. TRANS ISTOR T ran sistor functions can be divided into four main functions : 1. 2.
ampl i fication switching
3. 4.
oscill ation modulation
These functions are utili zed in the ignition system employed on the GS250T . Transistors are d ivided into two groups, N PN and PNP types. The transistors used in the GS250T model are of the NPN type only, which work an ampl ifier and switching a device. ,----
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E
B C E
BASE COLL ECTOR EII.IITT ER
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Each transisto r has three terminals identified as the Base (B). Collector (C) , and Emitter (E). and opera tion is as foll ows : On a NPN type the base is the controlling terminal o f th e transistor operation. On this type, the base util izes only a positive or incoming signal to do the "ON", or "OFF" switch ing. The co llecto r is th e ter mina l wh ere vo ltage is supp lied to the transistor and the emitter is the term inal for passing thi s cu rrent on when the base has th e proper "signal " . Usually the voltage applied across the coll ect or to the emi tte r is much larger th an t hat needed at t he base. This allows a relatively low voltage at the base to control large working voltages across the collector to t he emitter . The transistor ign ition system used on the GS250T is the KOK USAN brand and consists of a !:ignal genera to r, w hich emp loys a rotor and two pick ¡up co ils, the tran sistor un it, ignition co il s, and spa rk plugs.
SIGNAL GENERATOR The signal genera to r is moun ted on the right hand side o f th e engine in the area co mmon ly used for the contact breaker points. It is comprised of a magnet embedded rotor attached to a mechanical advance mechan ism and two pick~up co ils, with iron plates at their bases, affixed to a p late. Each pick ¡up coil consi sts of a co il o f wire and a yoke or coi l and is mount ed, 180 ° apart on the pla te. As the rotor magnet is tu rned past the coils, AC current is produced and used for sw itching w ithin the transistor unit. The transi stor unit controls power to the ignition co il s and causes the spa rk plugs to fire at the proper time.
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SIGI\JA L GEN ER AT O R r~~2:1 -
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SPA R K PL UG
IGNITOR
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0
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bCIID mi Zl1 -~~~
IGN IT ION SWITCH
IGNI T ION COI L
<r----i}! SPARK PL UG
By
...: BATT ERY
..L
IGN ITION CO l L
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1-15
GENERAL li\JFOR .\ IATIOi\J
SPEC ! AL
~~ ATER J Al§
The materials listed be low are needed for ma intenance work o n the GS250T, and shou ld be kept on hand for ready use. They supplement such star1dard mate rials as c lean ing flu ids, lubricants, emery cloth and the lik e. How to use them and where to -use them are described in the tex t of th is manual.
Part
Mater ial ~
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\ --....______ ~:~,. J SUZUKI SU PER GREASE " A " 99000-25030
0 (!)
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Oi l seals
Page 3-53, 3-55 , 3-64
Throttle grip Cables (speedome ter and tacho meter ) Clutch re lease mecha nism Gearshift lever l inkage and shaft
!)
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a 0
0 0
a 0
Ca l ip er axle shaft
7-21
SU Z UKI SILICO N E GREASE 99000-25100 ~ Va l ve stem D
G
o o o a
Cam shaft jou rna l Ch ain tension er push rod Conrod big end beari ng Countershaft Cranks ha f t journa l bearing Counter ba lancer jou rna l bear i ng
3 -29 3-70 3-33 3-41 3-52 3 -57 3-57
SUZUKI MOLY P ASTE 99000 -25 140 Mating su rfaces o f upper and lower crankcase o Mating surfaces of cran kcase and oil pan ·:> Oi l pressure swi tch o Front f ork damper rod bo l t
Q
SU Z UKI BOND No. 12 15 99 104 -3 111 0
Part
3-57 3-58 3-64 7-33
Whee l bearings Sprocket moun ting drum bearing Swinging arm bearing an d dust seal Rear brake cam Brake pedal shaft Con tact poin ts cam Governor I ink Ce n te rstan d space r Stee ri ng ste m beari ngs
Page 7-5 7- 15 7-45 7- 15 7- 28
7-40
GFNERAL lt\J F0 R.\ IAT I 0 f-1
Material
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Part - - +-- l --0 Gearsh ift cam reta1ner screw 0 Cam sproc ket allen bolt 0 Cam chain gu1de screw ::> St arte r clutch al len bolt ') Co unter balancer gear set tin g bolt
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Page
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Part --
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3·61 3·3 1 3·34 3·48 3-45
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THREAD LOCK SUPER "136 1A" 99 104-32020 --
:>
Gearsh ift arm stoppe r
-- ·
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--
--.
--
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3·44
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-
--- ----·
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r&ffB ' -
1--
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TH READ LOCK SUPER "1363A" 991 04·32030
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a Carbu retor set screw ') Camshaft end cap screw \) Engme sprocket sp acer 1nner su rface ") Cl u tch spr 1ng bolt 'i) Front fork damper rod bolt
j I
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4-15 3·75 3·8, 3-52 3·63 7-33
-
·-- -
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THREAD LOCK ce ment 99000·32040 ----
-
/ffii\ I_-~
-·a Generator sta tor securing screw 0 Generato r lead wrre gurde screw '!> Gearsh rft cam stopper bol t () Countershaft bearrng retarner screw ·::> Engrne or l pump httlllg screw
THREAD LOCK " 1363C" 99 104-32050 1-()
- -Generator rotor bo lt
-
j_.
3-48
0 Q
3·48
-- -- Starter motor secunng bolt Gearshr ft fo rk shaft st oppe r screw
-
3·59 3-54
3-60 3·60 I
3-49, 3·62
-- --- · 3-59
----
--
----- ! I
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II
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I
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THREAD LOCK SU PER " 1332B" 99 104 -32090
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I I7
GENERA L INF0 R1\l A TI 0 N
PRECAUTIONS AND GENERAL ~NSTRUCTION S Observe the following items without fa il when disassembl ing and reassembling mot orcycles.
=Be sure to rep lace packings, gaskets, circlips, 0 rings and cotter pins with new ones. 0 Ti ghten cylinder head and case bolts and nuts beg inn ing w it h larger diameter and end ing with sm aller d iameter, and from inside to outside diagona ll y, to the speci fied tightening torq ue. 0 Use special tools where speci fied. 0 Use genui ne parts and recommended oi ls. 0 When 2 or more persons work together, pay attention to the safety of each other. 0 After t he reassembly, check parts for t ightness cond ition and operation . 0 Treat gasoline, which is extremely flammable and highly explosive, with greatest care. gaso line as clean ing solven t.
Never use
Wa rnin g, Caution and Note are included in th is manua l occasiona ll y, describing the fo ll owing contents. WA RNING . .. . .. . ... .. When personal safety of the rider is involved , disrega rd of the information could result in injury. CA UT ION . . ..... . .. . . For the¡ protection of the motorcycle, the instruction or rul e must be strictly adhered to. NOTE .. .. . ... .. . .. . . . Advice calcu lated to facilitate the use of the motorcycle is given under this heading.
USE OF GEi\JUl NE SUZUKI PARTS To replace an y pa r t of the machine, use a genuine SU Z U KI rep lacement part. Im itation pa rts or part s supp lied from any other source than SUZUK I , i f used to replace SU ZUK I par ts can reduce the machine's performance and, even worse, coul d induce costly mechanical troubles.
GENERA L I \I F0 Rt\1AT I 0 \
SPEC IFJCATJON S D IMEi\JS IOi\J S AND DRY IVIASS Overall length .... . . ..... ... .. .......... . . . .... 2 Overall width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overall height . . .. .. . ........ ..... ............. I Wheelbase ..... . ... . . .. . .. .. . ............ ... . . I Ground clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
075 885 155 370 140 158
mm mm mm mm mm kg
(8 1.7 in) (34.8 in ) (45.5 in) (53.9 in) ( 5.5 in ) (348 lbs)
ENGINE Type ......... . .... . . ..... .. .. . . . ... . ... . .... Fo ur-stroke, ai r-cooled, DOH C Number of cylinders ... . .. ... . ... .... ...... ... .. 2 Bore .. . ...... .. ... .. . . ... .. .. ..... . ... . ..... 60.0 mm (2.362 in) Stroke . .. ........ .... .. . ... . .. .... ...... . .. . 44.2 mm ( 1.740 in ) Pist on displacement ...... .. ... ..... . ........ . .. 249 cm 3 ( 15.2 cu -in) Compression ratio . . ....... .... .. ... . ....... . .. 10.5 : 1 Carburetor . .... .................. ... .... .. . . . IVll K UN I BS30SS, twin A ir cleaner ......... .... . . ......... .. ..... . ... Pol yur(' thane foam element Starter system . .. ......... . ......... .. ... ... .. Electric Lubri cat ion syst em ... . .... .. .... .. .... ..... .... Wet sump
TRANSM i SSl 01\J Clutch ....... . . .. ....... .. ....... . . .. .... . .. Wet multi-p late t ype T ra nsmissio n .... . . . .. .. ... . .. .. .. .. . . .. .. .. .. 6-speed con stant mesh Gearshift pattern ... . ......... ... . .... .... ..... 1-down, 5-up Primary redu cti on ....... . .. ....... ... ... . ..... 3. 125 (75/ 24) Fina l reudcti o n . ......... . ..... ... .. ... . .. . .. . . 3.133 (4 7/ 15) Gear rat ios,
Low ... .. .... . ...... ...... ..... .. 2.500 (30/ 12) 2nd ...... ... ..... . ..... .. ..... .. . 1 .625 (26/ 16) 3rd .. ........ .......... . .. . ... . .. 1 .210 (23/ 19)
4th ' ' ' ' ' ' ' ' ' ' ' ' ' ' .' ' ' ' ' ' . ' . 5th .. ' . ' ' . ' . ' . ' ' . ' . ' ' ' . ' .. ' Top ... ... ... . .. . . ...... . . . Drive chai n ........ .... ... . . . ...... ... ..
. ' ... ' 1.000 (2 1/ 2 1) ' ' ' ' ' ' 0.863 ( 19/ 22) .. . .. . 0.782 ( 18/ 23) ... . .. DAIDO DI D520DS or TAKASAGO RK520SM, 106 link s
I·I8
1-19
GEi\IE RAL
l f\J FO RMATIO~I
CHASSIS Front suspension .................... .. .. Telescopic, oil dampened Rear suspensi on ................... . . .. . . Swinging arm, oil dampened, spring 5-way adjustab le Steerin g ang le ... ................... . .... 42째 (right & left) Caster ..... .... ... . . . .. ............... . 62째 00' Trail ..... . ....... . .... .. . .. .... . .. . ... 104 mm (4.09 in) Turning radius ... .. .. ................... 2.3 m
(7.5 ft)
Front brake . . ... . .... ................ .. Disc brake Rear brake ... .. . .. . .................... Internal expanding Front tire size ........................... 3.00-18 4PR Rear tire size .. . ... . ...... . ..... . . ... . . . 3.50- 17 4PR Fron t tire pressure .. . . .. ....... . ..... .. .. 1.50 kg/cm 2 (21 psi) (Norma l solo riding) Rear t ire pressure ... .. ...... . . . .. . ....... 1. 75 kg/cm 2 (25 psi) (Norma l solo riding)
ELECTRlCAL Ignition type .... . .. .. ........ . . .... .... Transistorized Ignition timing .................... ... ... 20째 B.T .D.C. below at 1 650 r/m in and 40째 B.T.D.C. above at 3 500 r/m in Spark plug ..... .... .. .. . .. . ... . .. .... . . NGK D8EA or NIPPON DENSO X27ES-U Battery .. . . .. ..... ... . . ........ . . ...... 12V 43.2 k C (1 2 Ah) / 10 HR Generator . ....... . . . . .. . ........ .. . .... Three-phase A. C. gene rat or Fuse ......... . ... . ..... ............... 1 5A
CAPACIT IES Fue l tank
including reserve ... ... .... . . .... 11 .0 L (2.9 US gal) Reserve ... . . . . . ............ .. . 2.0 L (2.1 US qt)
Engine o il . . .. . . .. ..... . .. ..... ....... .. 2.0 L (2 . 1 US qt) Front fork oil (each leg) . .. . ......... .. . ... 150 ml (5 .07 US oz)
* These specifications are subject to change without notice.
---
--- CONTENTS
PEIROODOC MAJNTENAINCE SCHE!DUILE .........................................................2u 1 MAINTENANCE AND TUNEuUP PROCEDURES .......................................2° 3 AJR CLEAI'IER ....................................................................................................2° 3
'-..,_',-,- . ''·j '
I
BA ITERV ............................................................................................................2° 4
.
'
2
~
'
'
..
~ ~- /
?
l/AL l/E CLEARANCE.......................................................................................2o 5 SPARK PLUG......................................................................................................2a 5 FUfEL LJNES.........................................................................................................2a 7
ENGU\JE ·OIL AND FILTER ...........................................................................2° 7
CARBURETOR ................................................................................................... 2° 8 CILUTCH ............................................................................................................... 2° 9 !D!ffi~I!E
CMAiiV ...................................................................................................2° 10
BRAKES ............................................................................................................... 2° 11 TJfRES ..................................................................................................................... 2° 14
STEERli'JG ............................................................................................................2·15 C YUNDER HEAD BOLTS AND NUT$...................................................2~ 15 CHASSIS SOL TS AvVD NUTS ..................................................................2a 18
l
-
/
.;' ·~.r· ·. ,.. ' ' . '),l}tJo.'l'v,~ ",b .... '1.·~
2I
PERI ODIC iVIAJ NT EI\IAI\ICE AI\ID TUNE- UP PROCED URES
lPER~ODI C
MAl NTENAI\JCE SCHEDULE
IMPORTAI\JT:
The periodic maintenance intervals and service requ irements have been established in
accordance with EPA regulations.
Following these instructions will ensure that the motorcycle wil l not
exceed emission standards and i t w ill also ensure the reliability and performance of the motorcycle. ------- - - - -
- - - - - - - - · - - - - - -- - - --
NOTE :
More ·freq uent servicing may be pedormed on motorcycles that are used under severe conditions, however, it is not necessary for ensuring emission level compliance. L___
_ _ _ _ _ __
_
-
-
-
The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and to maintain proper em ission levels. Mileages are expressed in terms o f kilometers, miles and time for your convenience.
PER I ODIC IVlAlNTENANCE CH ART
IN T ERVAL: THIS INTERVA L SHOULD BE JUDGED BY ODOMETER READING OR MONTHS WH ICHEVER CO M ES F IRST
m il e
-
Air cleaner element
-
--
-
--
Cy lind er he ad nu ts and exha ust p ipe bo lts - -1---- - Battery -Val ve cl earance
- - - --
-
------ -
--
-
-
--
-
-
-
15
----
---
-
_ _ _ _I __
l
-
-
-I
c
R
---
----
I
--
I
c
---
-
R
I
I
-- -- -
-
-
---
-
NOTE: T = T ighten, I = Inspect, R = R ep lace, C = Clean
I
I
I
I
I
-
-
I
-
- I
I I T
-~--
I I --Re place every two years.
Chassis bolts and nu ts
I
-I
Steering
I
---Clean and lubricate every 600 mil es ( 1 000 km).
-
T ire
---1--- - -
--
I
-
Drive chai n
-
R
R
--·--
I
Cl utch
- - ·-
I
-
Replace eve ry tw o years .
-
·---- --
T
I
-
- -
c
--· T
-
_I
--
c - - --
I
-
R
Ca rbur etor
- -+-
I
---
-·
15 000 .. - - 45
---~
T
-
-
1------ - - -- - - - Brake - Brake hose
10 000 30
c
-
----
9 500
-·
-r----
-t
Engin e oi l an d oil f ilter
- - -- - -
6 000
_ _ L _ ___ _
-
--·-~-
Fuel line
I
5 000
T
- --- -
-
Spark plug
-
3 000
km 1 000 -· - - -· - -- - month 2
-
t---
600
-
I
I
-
I I T
I
i
- -
T
l
1 I
I
-I I
---~-
I
-j
-
-T
PERIODIC ,\I Aii'IJTE~,-\\ICE -\010 TU\Jt-LP PROCEOLiFES
2-2
LUBRI CATIO N CH A RT The mai ntenance schedule, which fo llows, is based on odometer indicat ion and is calculated to achieve t he ultimate goal of motorcy c le maintenance in the most economical manner.
-:~ I tem
Ini t ial an d eve ry 3 000 mi les (5 000 km )
Igni ti on ti m ing governor link - Throttle cable
---
Thrott le grip
Clu tch cable . C lu tch re lease
--
-
--
--¡
-
-----
Speedometer cable
-- - - ---
T achome ter cable Dri ve chain Brake peda l -Brake cam sha f t
-
Steer ing stem bear ings Swi nging arm bea rings
---
-
Every 6 000 miles ( 10 000 k m)
-
Grease
Motor oil
-
-
Grease
Motor oi l
Grease
-
--
Grease
-- - -
Motor ad eve1 y 600 miles ( 1 000 km)
Gr ease
Grease or o il
-
-
Grease
-----
--
Grease every 2 years or 15 000 mi les (24 000 km)
WARNIN G: Be carefu l not to apply too much grease to the brak e cam shafts. If gre ase ge ts on t he linings, brake slippage w i II resu It
Lubri cate exposed parts which are subject to rust, with either motor oil or grease whenever the motorcycle has been operated under wet or rainy conditions. Befo re lubricating each part, clean off any rusty spots and w ipe off any grease, oil, dirt or grime.
23
PE RIODIC \ I AI 1\JTEN ANCE A1\JO TU,\JE-UP PR OCE DURES
--------------------
1\JiiAI NTE NANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures fo r each item of the Periodic Ma intenance requ irements.
A l R CLEANER ELE MENT 3 000, 6 000 , 9 500 m iles 5 000, 10 000, 15 000 km
If the air cleaner is clogged w ith dust, intak e resistance will be increased w ith a resultant decrease in output and an increase in fuel consumption. Check and clean the element in the following manner. (j)
Remove the seat and cleaner case cover.
Take out air cleaner element 1 from the air cleaner case by remov ing guide 2 . a Fill a washing pan of a proper size with nonf lammab le c lean ing solvent. Immerse the element in the cleani ng solvent and w ash it clean. o Squeeze the cleaning solvent out of the washed element by press ing it between the palms of both hands: do not twist or wring the element or it will develop tears. ~> I mmerse the element in motor oil, and squeeze the oi l out of the element leaving it slightly wet with oil. o
o Fit the c leaner case cover properly.
CAU TI ON: * Before and during the clean ing operation, A torn inspect the element fo r tears. element must be replaced. * Be sure to posit ion the element snugly and correctly, so that no incoming air w ill bypass it. Remember, rapid wear of piston rings and cylinder bore is often caused by a defective or poorly fi tted element.
~
I
ce- L~E
10W/40 OIL
---------
------- - - - - - - - - - - - -
PERIODIC i\1I AINTE~JANCE AND TUNE-UP PR OCED URES
BATTERY 600, 3 000, 6 000, 9 500 miles 1 000, 5 000, 10 000, 15 000 km
a The battery must be removed to check the
electrolyte level and specific gravity. :il
Remove right and left frame covers to check battery.
o Remove battery - lead at the battery terminal. <>
3
Remove battery - lead wire from fuse box and starter motor relay . Remove battery from the frame.
a Check electrolyte for level and specific gravity . Add distilled water, as necessary, to keep the surface of the electrolyte above the LOWER level line but not above the UPPER level lin e. For checking specific gravity, use a hydrometer to determine the charge cond ition. 09900-28403
Hydrometer
Standard specific gravity An S.G. reading of 1.22 (at 20°C) or under means that the battery needs recharging off the machine: take it off and charge it from a recharger. Charging the battery in place can lead to fa ilure of the regu Ia tor / rectifi er. G
To install t he battery, reverse the procedure described above. WARNING : When installing the battery lead wires, fix t he - lead first and lead last.
o Make
sure that the breather pipe is tightly secured and undamaged, and is routed as shown in the figure. CAUTION: Be careful not to bend, obstruct, or change the routing of the air vent tube from the battery . Make certain that the vent tube is attached to the battery vent f itting and that the oppos ite end is always open .
(F CAUTION
II
MISE EN GARDE
Battarv ,.,.. ¡ breather pipe ~-----'
IWl1illMI da Ia banoria
2-4
2-S
PER I 0 OIC viAl \JTE \JANC E AN 0 TU1 \JE -UP PROC EOUR ES
VALVE CLEARANCE - - - - ¡-
---
600, 3 000, 6 000, 9 500 m iles 1 000, 5 000, 10 000, 15 000 km
The va lve c learance spec i fication is the sa m e for both- inta ke and ex haust valves. Too small a valve clearance may reduce the engine power; too la rge a valve clearance increases va lve noise and hastens va lve and seat wear. When the valve c learance
is
set to the specification, the
engine wi II run without excessive noise from the va lve mechanism and w ill del ive r full power. Va lve clea rance adjustment must be checked and adjusted 1) at the ti me of periodic inspection, 2) whe n the valve mecha nism is serv iced, and 3) when the ca m shafts are distu rbed by removing them for servicing. Valv e clea rance (wh en co ld)
0.08 - 0.13 mm (0.003 - 0.005 in )
r--
NOTE:
* The cam must be at position ~ or § in order to check the valve clearance or to adjust valve clearance. * The clearance specification is for COLD state. Check it when the engine is cold. * To t urn the crankshaft for clearance checking, be sure to use a 19-mm wrench and to rotate in normal running direction. Both spark plugs sh ould ba removed. o Turn crankshaft to bring the "T" mark on the advance governor of "R" cylinder and also t o bring the notches
1
in the both camshaft (Ex .
and ln.) of the right ends to the position as shown. In this condi t ion, read the valve clearance at the valves A (In. and Ex. of "R"-cylinder , and ln. of " L "-cylinder). Use th i ck ness gauge
be tween
tappet and
va lve.
If clearance is off the specificati on, bring it into the specified range by using tappet adjust driver 2 .
09900-20803
Th ick ness gauge
09917 -14910
Tappet adjust driver
PERIODI C tviAii\JTE fiANCE A~I O TUNE-UP PROCE0 Ui1ES
0
~ -6
Turn crankshaft by 360 ° (one rotation) to bring the "T" mark on " R"-side advance governor and notches l to the position as shown .
;) Read clearance at the valves :@ (Ex. of "L"cylinder) and adjust the clearance if necessary.
SPARK PLUG Clean and Adjust Every 3,000 miles and, (5,000 km) Replace Every 6,000 miles (10,000 km)
The plug gap is adju sted to 0.6 - 0. 7 mm (0.024 - 0.028 in) . The gap is co rrectly adjusted using a thickness gauge (special tool). When carbon is deposited on the spark plug, remove the carbon with a spark plug c leani ng machine or ca reful ly us in g tool with a pointed end. If electrodes are extremely worn or burnt, repla ce the plug. A lso replace the plug if it has a broken insulator, da maged thread, etc. 09930-13210
Socket wrench
09930-14530
Universal joint
09914 -24510
T hand le
09900-20803
Thickness gauge
NG K D9EA or N I PPON DEN SO X27ES-U listed in the table should be used as the standard plug. However, th e heat range of the plug should be selected to meet the requirements of speed, actual load, fuel, etc. If the plugs need to be replaced, it is recommended that the standard plugs listed in the table be selected. Remove the plugs and inspect the insulators . Proper heat range would be indicated if both insulators were light brown in If they are blackened by carbon, they co lor. should be replaced by a hot type NG K D8EA or N IPPON DEN SO X24ES-U.
NOT E : To check the spark plugs, first make sure that the fuel tank contains unleaded gasoline, and if both are sootv with carbon , replace them altogether. CAUTION: Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon wi ll be deposited on the screw portion o¡f the plug hole and engine damage may result . NGK
NIPPON DEN SO
REMARKS
D8EA
X27ES-U
I f th e standard plug is apt to get we t , rep lace w tth th is plug. Hot ty pe.
D9EA
X27ES-U
Standard
Gap 0.6 - - 0 .7 m m (0.024 - 0.028 in)
2-7
PERIODIC '.!,..\ I'HE \J,..\\ICE t-\1\IO fUi\IE-UP PROCEDURES
FUEL Ll i\JES Replace Every 2 years
ENGINE 01 L AND Fl LTER 600, 3 000, 6 000, 9 500 miles 1 000, 5 000, 10 000 , 15 000 km The o il should be cha nged with the eng ine hot. Oil fil ter rep laceme nt at the above interva ls shou ld be done together with eng ine oil change. The procedure is as follows: <> Keep the motorcycle upright, supported on the center stand. G Place an o il pan below the engine and drain the oil by removing drain plug 1 and filler cap 2 . o Remove three nuts 3 , and remove the oil filter cap 4 and drain oil. o Pull out old fi lte r 5 , replace with new one. o Rep lace cover, and secure nuts ~ . Fit d rain plug 1 securely, and add fresh oi l through the fi ller. The eng ine will hold about 2.6 L (2.7 US qt) of oil. Use API classification of SE oil with SAE 1OW/40 viscosity. Start up the engine and al low it to run for several seconds at idling speed. o Turn off the engine and wait about one minute, then check the oil level with the filler cap dipstick 6 . Do not sc rew in the cap when making If the level is below mark "F" , this check. supply oil to that level. 2>
PER IODIC iVIAINTE ·.~i\J CE '-'l t\10 T__, \i t ,P :.>ROCFOI.J1ES
NOTE:
*
*
Pour about 2.0 L (2.1 US qt) of engine oil into the engine on ly when changing oil. When performing engi ne overhaul, the amount o·f oil to be replenished is 2.6 L (2.7 us qt) . Be sure to take care of 0-ring to prevent any damage and be su re that filter spring is properly in place.
CARBURETOR 600, 3 000, 6 000, 9 500 miles 1 000, 5 000, 10 000, 15 000 km
- - - - --
THROTT LE CA BLE PLAY There shou ld be 0. 5 mm play A on the throttle cabl e. To adjust the t hrottle cable play: G Tug on the throttle cable to check the amount of play. o Loosen the lock nut
1
and turn the adjuster
in or out until the specified play is obtained. ~ Secure the lock nut while holding the adjuster in place. 2
Throttle cable play 'A.
0.5 mm (0.02 in)
IDLING ADJUSTME N T NOTE : Make th is adjust ment when the eng ine is hot. G
Start up the engine and set its speed at anywhere between 1, 150 and 1,350 r/ min by turning throttle stop screw I Engine idle speed
1,250
:t
100 r/ min
o Re-ad just the throttle cab le play, if required.
CA UT ION: T he pilot screw 2 is pre-set by the factory ut ilizing specia lized testing and adjusting procedures, and mu st not be tampered with.
·mt t'{
·~·-®
I I
23
2-9
PERIODIC 1\1IAINTENANCE AND TUNE-UP PROCEDURES
CLUTCH 600, 3 000, 6 000, 9 500 miles 1 000, 5 000, 10 000, 15 000 km
0
Loosen lock nut 1 and reposition adjuster ~ in place to introduce a necessary amount of play for the clutch cable.
8
Loosen lock nut 3 , and back adjusting screw j _ away two to three rotations.
o From that position of adjusting screw, slowly run it in u nti I it begins to feel high resistance to turning. From this position, back it away ~ Y2 rotation, and secu re it by tightening lock nut
I. .
o Set the adjuster 1 to provide a cl utch lever play ~ of 4 mm, and tighten the lock nut I .
PERIODIC 1viAINTEi\ANCE AND TUNE-UP PROCEDUF:S
DRIVE CHAJN 600, 3 000, 6 000, 9 500 miles 1 000, 5 000, 10 000, 15 000 !<m Visually inspect the drive chain for the possible malconditions listed be low. * Loose pins * Damaged rollers * Rusted links * Twisted or seized links * Excessive wear If any defects are found, the drive chain must be replaced. CHECKING ii> Loosen axle nut
1
after pulling out cotter pin
z; . " St retch the drive chain fully by tightening the adjusters e Remove the chain guard. Count out 21 pins (20 pitch) on the chain and measure the di stance between the two. If the distance exceeds following li mit, the chain must be replaced.
r.
SenJice Limit
324.3 mm ( 12.77 in )
ADJUSTING Loosen the adjuster ~ until the chain has 20 - 30 mm (0.8 - 1.2 in) of sag at the middle between engine and rear sprockets. The mark 4 on both cha in adjusters must be at the same position on the sca le t o ensure that the front and rear wheels are correctly alig ned. o After adjusting the drive chain, tighten the axle nut L securely and lock with cotter pin I; . Always use a new cotter pin. Rear ax le nut tightening torqu e
5.0 - 8.0 kg-m (36.0 - 58.0 lb-ft)
CLEANING AND LUBRICAT ING Wash the drive chain in cleaning solvent and lubri cate it w ith chain lu be or motor oi I. If the motorcyc le operates under dusty conditions, frequent rapid acceleration or at sustained high speeds, the drive cha in shou ld be cleaned and lubricated more often.
r
2-10
ill_ PERIODIC lviAINTENANCE AND TUNE -UP PR OCEDURES
BRAKES - - - - - -600, 3,000, 6,000, 9,500 miles 1,000, 5,000, 10,000, 15,000 km Replace hose e11ery 2 years
----,
BRAKE FLUID LE VEL o Support the motorcycle on the ce nter stand and p lace the handlebars stra ight . o Check the brake f luid leve l by observ ing the upper and lower limit lines on t he b rak e flui d reservoir. <>
When t he level is be low the lower lim it line, replenish w ith brake fluid that meets the fo llowing specificati on.
Specifica tion and Classifi cation :
DOT3 or DOT4
CA UT ION : The brake system of thi s moto rcycle is filled with a glycol-based brak e fluid. Do not use or m ix different type s of flu id such as sil iconebased and petroleum-based f luid for refil l ing the system, otherw ise ser ious damage wi ll be caused. Do not use any brake flui d taken from o ld or used or unsealed containers. N ever r e-use the brake f luid left over from the last serv icing and stored f or long periods.
'
--~
WARNING: Brake f luid, if it leaks, will interfere with safe running and d iscolor paint-ed surfaces. Check the brak e hose for crack s and hose joint for leakage before ri ding.
BRAKE PADS Wear condition of brak e pads can be checked by observing the red lim it line I marked on the pad. When the wear exceeds the li mit line, rep lace the pads with new ones. (see page 7-16)
PER IOD IC 1\iiAIN TENAi\JCE AND TUN E-UP PROCEDU RE S
2-12
AIR BLEEDING THE BRAKE FLUlD CIRCUIT A ir trapped in the fluid ci rcu it acts l ik e a cushion t o absorb a large proport ion of the pressure developed by the master cylinder and thus interferes w it h t he full braki ng perfor mance of the brak e cal iper. The presence of air is ind icat ed by "sponginess" of the brake lever and also by lack of brak ing force. Conside r ing the da nger to w h ich such trapped air exposes the machi ne and rider, it is essenti al that, after remou nting t he brake and restoring the brak e system to the normal condition, the brake f luid circuit be purged of air in the follow ing manner: a Fil l up the master cyli nder reservo ir to the " HI GH" level li ne. Rep lace the reservo ir cap to prevent entry of dirt. o Attach a pipe to t he cal iper b leeder valve, and insert the free end of the pipe into a receptac le. B Ieeder valve tightening tor que
Ill
0.7 - 0.9 kg-m (5.0 - 6.5 lb-ft)
Sq ueez e and release the brake lever several times in rapid succession, and sq ueeze the lever fu lly w ithout releasing it. L oosen the bleeder va lve by turn ing it a quart er of a turn or so so t hat the brake f luid runs into t he recep tac le; th is w ill remov e the tension of the brake lever causing it to touch the hand leba r gr ip. T hen, close the va lve, pump and sq ueeze t he lever, and ope n the va lve. Repeat this process until the oi l flowing into the receptacle no longer contains air bub-
~
bles. Close the bleeder va lve, and disconnect the pipe. Fil l the reservoir to the "HIGH" level line.
CAUTION: Check to be sure th at brake light comes on when front brak e lever is squeezed.
NOTE: Rep len ish the brak e fluid reservoi r as necessary while bleeding the brake system. Nlake su re that there is always some fluid vi sible in the reservoir .
CAUT I ON: Handle the brake fluid w ith care : the f luid reacts chemically with paint, plastics, rubber materials, etc.
2-13
PER IODIC MAINTENANCE AND T JNE-UP PROCEDURES
REAR Bring the brake pedal to a position about 20 mm (0.4 in) below the footrest. Th is is effected by turning the ad justing bolt ! . Be sure to tighten the lock nut 1 good and hard after setting the bolt. By repositioning the adjusting nut I on brake rod, set the peda l p lay to between 20 and 30 mm ÂŽ (O.B - 1.2 in) as measured at peda l tip.
Check to be sure that rear brake ligh t comes on when the pedal is depressed to take up the play. The rear brake light switch is located under the right frame cover. To adjust the brake light switch : raise or lower the switch so that the brake light will come on just before a pressure rise is felt when the brake pedal is depressed.
BRAKE SHOE WEA R This motorcycle is equipped with brake lining wear limit indicator on rear as shown in Fig. At the condition of norma l lini ng wear, the extensio n line of the index mark on the brake cam shaft shou ld be within the range embossed on the brak e panel with brake on.
The extension line of the in dex mark is with in the range.
PERIODIC MAINTENANCE M ID TUNE -UP PR OC EDURES
2-14
To check wear of the brake li ning, perform the fo ll owing steps. 0 First check if the brake system is properly adj usted. ~ IJVh i le operating the brake, check to see that the extens ion line of the index ma rk is within the range on the brak e pa nel. o If the index mark is beyond the range as shown in the Fig., the brake shoe assembly should be rep laced with a new o ne. (see page 7-26) Th e extens ion line of the inde x mark is beyond the range .
TIRE S -~ /
'
600, 3 000, ·6 000, 9 500 mi les 1 000, 5 000, 10 000,15 000 km ~~~r,
T I RE TREAD CONDIT I ON Operating the motorcycle w ith excessively worn tires wi ll decrease rid ing stabi li ty and consequently invite a dangerous situation. It is high ly recommended to replace th e tire when the remaining depth of t ire tread reaches the foll owi ng specifications. FRONT 1-- -- - - - 1.6 mm (0.06 in)
I
I
\
\lj
I
'~
I_ _
REAR
2.0 mm (0.08 in)
T l RE PRE SSURE I f t he tire pressure is too high or too low, steering will be adversely affected and tire wear increased. T herefore, ma inta in the correct tire pressure for good roadabi lit y or shorter t ire life will result.
CAU TWI\J:
The stardard tire f itted on this motorcycle is 3.00-18 4PR for front and 3 .50-17 4PR for rear. T he use o·f a t ire other than the standard
Co ld infl ation tire press ure is as follows.
may cause instab ility. It is high ly re commended to use a SUZUKl Genuine Tire.
FRONT ~
2
REA R - -kg/em ! psi
psi
kg /cm
Solo
21
1.50
--
25
Du al
25
1.75
32
..c "2 - -So lo
25
1.75
28
Dual
28
§"' 0
z C><l)
·- a. I
"'
'
-
--
2 .00
- --
2.25 2.00 ~--
32
1.7 5
----
--
2.25
2- 15
PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES
STEERlNG 600, 3 000, 6 000, 9 500 mi les 1 000, 5 000, 10 000, 15 000 km Check that there is no play in the front fork assembly by supporting the machine so that the front wheel is off the ground, with wheel straight ahead, grasp lower fork tubes near the axle and pull forward. If play is found, perform steering bea ri ng adjustment as described in page 7-35 of this manual.
CYLI NDER HEAD BOLTS Ai\JD NUTS 600, 3 000, 6 000, 9 500 miles 1 000, 5 000, 10 000, 15 000 km
a T ighten the eight 8 mm nuts to the speci fi ed torque with a torque wrench sequentially in ascending numeral order with the engine cold.
2.3 - 2.8 kg-m {16.5 - 20.0 lb-ft)
Cylinder head nut tightening torque
") A fter tightening the eight nuts fi rmly, tighten one 6 mm bolt 1 to the specified torque with a t orque wrench.
0.7 - 1.1 kg-m {5.0 - 8.0 lb-ft)
Cylinder head bolt tightening torque I
r----NOTE: It is necessary to remove 'the fuel 'tank and cylinder head cover when ti ghtening cylinder head nuts. - -- ---:D
Tighten four exhaust pipe clamp bolts
2
the specified t orque wi th a torque wrench . Ex haust pipe c lamp bo lt tightening torque
I
0.9 - 1.2 kg -m {6.5 - 8 .5 lb-ft)
to
2- 16
PERIOD IC 1\IIAINTENL\NCE AND TUNE-UP PROCEDUR ES
CHASSIS BOLTS AND NUTS -----600, 3 000, 6 000, 9 500 miles 1 000, 5 000, 10 000, 15 000 km The bolts and nuts listed hereunde r are important safety parts . They must be retightened, as necessary, to the specified torque with a torque wrenc h. (Refer to pa ge 2-17 for the position of the fo llowing bolts and nuts on th e motorcyc le.)
lb¡h
kg¡ m
26. 0 - 37.5
3.6 - 5.2
11 .0 - 18. 0
1.5 - 2.5
ITEM Front ax le nut
I
2 Front ax le holder nut 3 Disc plate bolt
'l Ca liper bo lt 5 Ca liper axle bolt
1.5- 2.5
11 .0 - 18.0
- -- -
-----
---
11 .0 - 14.5
-
- -
-
1.5 - 2.0
-+---- - -
- --
6 Front fork lower clamp bolt
18.0 - 29.0
7 Front fork upper clam p bolt
14.5 - 21 .5
2.0 - 3.0
29.0 - 36.0
4.0 - 5.0
9 Steering stem clamp bo lt
11 .0 - 18.0
1.5- 2.5
10 Steering stem head bolt
26. 0 - 37.5
3.6 - 5.2
8.5 - 14.5
1.2 -2. 0
2.5 - 4.0 t --
-
-
-- -
-
B Steering stem nut
II
-
-
-
--
Hnndlebars clamp bolt
---
3.5 -
12 Mast er cylinder clamp bolt 13
!3 rake pedal arm bolt
14
Sw ingin g arm pivot nut
16 Rear shock absorber fitting nut ~
Rear axle nut
18 Rear brake cam lever bolt
!9 Spoke nipple
6.0 -
--
L
-
0.5- 0.8
7.0 - 11 .0
1.0 - 1.5
36.0 - 42.0
5.0 - 5.8
14.5 - 21.5
2.0 - 3.0
------
15 Rear torque link nut
17
-~-
2.5 - 4.0
18.0 - 29.0
- ----14.5 - 21. 5 ----- -------36.0 - 58.0
r--- 3.5-- 6.-0- - - - 3.0 -
3.5
2.0 - 3.0 5.0 - 8.0 0.5 - 0.8 0.4 - 0. 5
-----
2-17
PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES
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- - COU\1TENTS- - - ENGINE COMPOIM!ENTS fREMOVAB!/.JE WJTiH ENGINE IN PLACE ... 3A 1 COMPRESSION ·CfkJECK ....................................................................................... 3Q 2 ENGINE REMOVAL Au'-JD REffNSTAl.LATJON ................................................ 3A 3
ENG/f\IE DISAS:SEM!Bl. V..........................................................................................3A 11 ENGINE COMPONENTS INSPECTION AND SERVICING .....................3A2 1 CYLINDER f<JEAD ............................................................................................. 3g2 1 VAL V'£.....................................................................................................................3-22
CAMSNAFT......................................................................................................... 3m29 CAM CHAJN TENSIONfER ........................................................................... 3A32 C YLJN!DE!R ............................................................................................................3Q34
PISTOf\J ................................................... " ............................................................. 3A35 :PISTON RING ................................................................................................... 3A36 COu\JNECTJ:ftiG ROD .........................................................................- ............ 3A38 ·CRAi\Jif.S'HAFT ...................................................................................................3A43
COUNTER BALAiVICE'R .................................................................................3-45 CLUTCH ...............................................................................................................3m46 STARTER CLUTCH..........................................................................................3u41 OdL PUfiJIP ............................................................................................................ :Jad!./8
TRAft.JSMDSSuOM GfE.ARS............................................................................,.3n50 Ef\JGUNE R!EA:SS!Efii/J!B!L Y .........................................................................................3a5JIJ CRANKC;ASE...................................................................................................... 3A55
STARTER CLUTCJ-'1.......................................................................................... 3u59 CLUTCH ............................................................................................................... 3u62 SJGNAL GEN!ERATDiff .................................................................................... 3-64
PISTON RING ................................................................................................... 3-65 C YL!fAfD!EfR ............................................................................................................3-61 CAMSHAFJ......................................................................................................... 3-69
• ' .
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2
The parts listed below can be r emoved and reinstalled without removing the engine from the frame. Refer to the page listed in this section for removal and r einstallation instructions.
G.) ~
2
m ENGINE CE NTER
ENG I NE LEFT SIDE
See page
See page Gear shifting lever . .. .. .... - . - Engine sprocket cover ....... . . Clutch cable . . ... . . . - . .... - - - · Engine sprocket and drive chain ... Neutral indicator switch body . .. .
---· . --· -·· .. .. . .. .
3333-
5 5 5 6
3-16
Generator cover .. . . . . ...... . . - - . . . 3- 16 Generator rotor .. . .... .. . - - - - - - - - - 3-17 Starter clutch .. . .. . . .. . ... - - - - .. - - 3-17
Air cleaner . . .... . .. .... . . ... - - - . Oil filter .... . .... . .. .... - .. -- - - -Fuel tank ..... . .. ..... . . - . - - - - - - Horn ...... .. .. . . ... . . . .... . . - - - Tachometer cable .. .... . .. .. . . . .. . . Exhaust pipe and muffler . ...... . .... Carburetor and throttle cab le . ....... . Cam chain tensioner .. . . . . . . .. . ... . . Cylind er head breather cover . ... ..... Cylinder head cover . ... . .. . . . . . . .. . Camshaft .... .. . . ..... . . - .. . . - - Cylinder head . . . . . .. . . .. . ..... - - Cylind er . .. .. .. ... .. .. .. . ...... . Piston .. ... . ... . ..... ....... . . . . Starter motor .......... . ........ . Oil pan . ..... .. ....... . .. - --- - -Sump filter .. . ...... . . . . ... . - . . . \:>)
n
ENG I NE RI GHT S mE 2333-
3 3 4 4
3- 4 3- 5 3- 7 3-11
3- 11 3-11
- 3-11 - 3-12 - 3-12 - 3-13 - 3-1 7 - 3- 18 - 3-18
0 See page
Clutch cover . . ....... Clutch plates ...... . . Clutch sleeve hub . . . . . Primary driven gear ...
-. -.. -.
-
-------· ----------------------
-· -· ---
3-14 3-14 3-14 3-1 5
Oil pump drive gear . .. - - - - - - - - - - - - - 3·15 Oil pump ass'y .... - - Clutch push rod ..... . Gear shifting shaft .. . . Primary drive gear . . ..
. - · - - - - · - - · - · 3-15 - . - - - - - - - - - - · 3- 16 ------------ · 3-16 - - . - - - · - - - - - - 3-15
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0 2
m
-:;.:;
"""---
4 00 A2J
m
~
0
< p 00
u m
s
~
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2
Generator cover and starter motor lead wire should be removed from th e star ting motor
Q
rel ay side.
h'l
~
2
~
2 '""\QJ
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~
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m
li z
Cl
SERVICING ENGINE
COMPRESS I ON CHECK
3-2
COMPRESSION TEST PROCEDURE
The compression of a cylinder is a good indicator of its in ternal condit ion. The decision to overhaul the cylinders is often based on the results of a compression test. Periodic maintenance records kept at you r dealership should incl ude compression readings for each ma intenance service.
NOTE * Before testing the compression of the engine, make sure that the cylinder head cation,
*
and
valves
are
set
to proper
clearance. Warm up the engine before testing.
Compression Limit ¡ - -- - -- 11 - 14 kg/ cm 2 10 kg/ cm 1 (142psi) ( 156 - 199 psi) Standard
DiHerence 2 kg/ cm 2 (28.4 psi)
~ Remove both spark plugs. o F it the compression gauge 1 in one of the plug holes, while taking care that the con nection is
t ight.
-a Twist the throttle grip full open. Low compression pressure can indicate any of the following cond itions: * Excessively worn cyl inde r wall * Worn-down piston or piston rings * Piston rings stuc k in the grooves
* Poor sea li ng of valves * Ruptured or othervv ise defective cy li nder head gasket Overhaul the engine in the following cases: " Compression pressure in one of the cylinders is less than 10 kg/cm 2 ( 142 psi). * Difference in compression pressure between the two is more than 2 kg/crn 1 (28.4 psi) . * Both compression pressures are below 11 kg/ cm 2 (sta ndard) even w hen they measure more th an 10 kg/cm 2 (142 psi).
a Crank the engiCle a few seconds with the starter, and record t he maximum gauge read ing of the compression in that cylinde r. a Repeat this procedure with the other cyl inder . 09915-645 10
Compress ion gauge
0991 5¡632 10
Adapter
3-3
SERV ICING ENGIN E
ENG ~ i\JE REMOVAL AND REI NSTALLATl ON
ENGJ NE REMOVAL Before taking the engine out o f the frame, wash the engine with a steam cleaner and drain engine oil etc. The procedure of eng ine removal is sequentially exp lained in the fo ll owing steps, and eng ine insta llation is eff ected by revers ing the removal procedure.
1. Place an oil pan under the engi ne and remove the o il filte r cap and oil drain plug to dra in out engine oil.
l
2.
Remove the two bolts by pu lling rearw ard.
and remove the seat
3.
Remove the left and rig ht frame covers and disco nnect vario us lead w ires. o Battery - and lead w ires 2 . o Starter relay lead w ire 1 :i) Genera tor lead w i res .1: . o Signal generator and oil pressure switch lead w ires [ .
4.
Set the fuel cock in the "ON" or "RES" position and shi ft the fuel hose c lip sideways to remove the fuel hose and vacuum hose from the fuel cock.
SERVICING E1\JG1 1\JE
5.
Remove the bolt at the rear of the fue l tank. Remove the fuel tank by moving it rearwards.
6.
Disconnect the neutra l switch lead wire.
7.
Remove the horn.
8.
Remo ve tachometer cable f rom the engine.
9.
Remove the left footrest, gears hi fti ng lever and engine sprocket cover.
3-4
3·5
SERVICING ENGINE
10. Remove the left and right mufflers by un· screwing muffler mounting bo lts 1 , exhaust pipe clamp bolts 2 , exhaust pipe and muffler clamp bolts and povver chamber se· cu ring bolts 3 .
11. Straighten the bent washer on the engine sp rocket with a chisel and remove the sprocket. Apply rear brake to remove the mounting nut and the sprocket together with the chain from the drive shaft.
12. Sh ift the breather pipe clip sideways and remove the pipe from the cylinder head cover cap.
SERVIC ING ENGINE
13. Loosen the carburetor in take clamp screws 1 and slide the air cleaner case rearward by removing air cleaner case fitt ing screws 2 .
14.
Loosen the respective clamps for carburetors insulator to remove the carburetors by pull ing them toward th e rear .
15. Remove the carburetor from right side after removing the throttle cable from the carburetor assembly.
3-6
3-7
SERV ICING ENGINE
16.
Pull out the spark plug caps from spark plugs.
17.
Remove the right footrest and rear. brake pedal.
18. Remove
th e eng ine mounti ng
bol t s and
brackets.
19.
Gradually lift up the eng ine and lower the eng in e ass' y on the right sid e making su re th at it does not make contact w i t h the rear bracket . Remove th e engine through the right side of the frame.
SERVICING ENGii\IE
ENG I i\JE REI i\JSTALLATI Ot\J Reinstall the engine in the reverse order of engine removal. o Temporarily fasten the th ree engine mou nting bracke t s befo re inserting t he engine mou nting bolts. o Coat thread lock cement lightly to the inner surface o f the engine sprocket spacer. 99000-32040 3
Thread lock cement
The engine sprocket and drive chain should be installed on the drive shaft, together, at the same time. If it is difficult to install the engine sprocket, remove the rear axle cotter p in and loosen the axle nut 1 , and chain adjuster bolt 2 to push the wheel f orward and give the drive chain some play. When replac ing the engin e sprocket nut, stepped
side should be faced ins ide. o Af ter inserting the eng ine mount ing bolts, tighten engine mounting bracket bolts and engine mounting bolts. Insert all four long bolts from the left side and insert the rear upper bo lt through the spacer 3 on the lett side of the engine. Tightening torque for engine mounting bolts lb-ft
kg-m
10 mm Dia .
25.5
3.5
8 mm Dia .
18 .0
2.5
-
3-8
3-9
SERVICING Ei\IGii\IE
i\JOTE A'ftsr complete tightening of 'the angina moun t· ing bolts, adjust the dri,,e chain play, (see page 2-10).
Tighteni ng torque
Engine sprock et nut f-- -
l b-ft
kg-m
36.0 - 50.5
5.0 - 7.0
36.0 - 58.0
5.0 - 8.0
14.5 - 21.5
2.0- 3.0
·-
f-· - -
--
Rear axle nut
-
Torque l ink nut
-- -
Firmly secure the carburetor with the respect ive clamps. If the car buretor is not firmly secured, gas leak age, incor rect fuel -air ratio and unsatisfactory engine running may result. e Route wires and cables cor rectly. 9
(See pages 8-7 and 8-8) Securely ti ghten each exhaust and muffl er clamp bolts to th e spec ified torque.
Power chamber bolt Muffler mounting bracket bol t
----
Footrest mounting bolt
lb-l t
kg-m
14.5-21.5
2.0- 3.0
19. 5- 3 1.0
2. 7- 4.3
-----10 mm 19. 5-31 .0 2.7- 4.3
8mm 11.0- 18.0 1. 5- 2.5 -- - - -- - - - - - - Exhaust pipe-muffler clamp 6. 5- 10.0 0.9- 1 4 bolt
f-::- -
.__
Exhaust pipe clamp bolt
6. 5- 8.5
0.9 - 1. 2
SERVIC ING ENG I\JE
?
Replace the plug caps on the spark plugs so that "L" side ignition coil goes to the "L" cylinder and "R" side to " R" cylinder respectively.
R
J
Pour 2.6 L (2.7 US qt) of engine oil SAE 10W/40 graded SE into the engine after overhaul ing engine. Several minutes after starting
and stopping
engine, insure that the oil level remain s between the marks of dipstick.
NOTE: The dipstick should be "set" back into the
hole but not threaded down tight to correctly check the oil level.
J
After remoun ti ng the eng me, foll owing adj u st me nts are necessary. Page ' Throt t le cabl e ........ .. .. . .. . · · · · 2- 8 ' Clutch . . . .. .. . . ... .... .. . . . · · · · 2- 9 ' Drive chain .. . ... .. ..... . .... · · · · 2-10 "' Brake ligh tandpedal . . . . . .. ... .. . 2-13
3- 10
3-1 1
SERVICI I\JG ENGINE
ENG l NiE DJSASSE i'V1BLV e> Remove tachometer drive gear
1
by pu lling it
off after removing its stopper (secured by a cro ssrecessed screw). 3
Remove four camshaft end caps.
o Remove cylinder head cover.
~ Remove the starter motor cover.
o Loosen the lock nu t
1
and t ighten the stop
screw ~ and then remove tensione r mounting bolts 3
two cam chain
i\JOTE: Screw
2
lock s the spring loaded te nsioner
push rod inside.
o Hold down eac h camshaft w ith vice plie rs, and be sure t o loosen the fo ur camshaf t holder bolts evenly by sh i fting the wrench diagonally . Then, remove the p l iers and tak e off two camshafts.
\
SERV ICING ENG INE
o Pull out chain guide
1
.
o Rem ove the 6-mm bolt
1
at th e fro nt o f the
cha in cavity .
o Remove the eigh t 8 -mm cy linder head nuts in
decending order by using specia l tool.
<>
09914-24510
T han dle
09911 -74520
Long socke t 12 mm
A f ter remov ing cy l inder head, t ake a fi rm gri p on the cylinder block at both ends, and l ift it straight up . I f the block w ill not come of f, li ghtly tap on the non-fi n port ions of the block w ith a plastic mall et to shake the gasketed joint loo se.
CAUT ION Be care¡ful not to damage the 'fins when rem ovi ng or handling the cylinder block . This precaut ion applies t o the cyl inder head, t oo .
3-12
3-13
'>
SERVICING ENGINE
--- -
------ -¡- - - - - - -- - - - -- - -
Put a rag around the connecting rod down in the crankcase to prevent parts from falling into the crankcase.
Remove the piston pin circlips
and the piston pins. o Remove both pistons and scribe letters " L " and "R" on the crowns of respective piston.
09910-34510
J
Remove signal generator
Piston pin puller
co,;er and gasket.
o Apply wrenc h to crank turning nut to remove automatic advancer mounting bol t and the crank turning nut.
o Rem ove the o il pre ssure sw itch lead w ire o Remo,;e mounting screws
2
I .
for signal genera -
tor and then remove th e assemb ly and t he auto mati c advancer.
SERVICING ENGINE
'1>
Remove cl u tch cover and gasket.
<>
Remove
clutch
spring
mounti ng bol ts and
remove springs and pressure p late.
~
Remov e clutch push pi ece from countershaft.
1 and need le bearing
o A f t er remova l of clutch drive and driven plates, flatten the l ock w asher and re move the clutch sleeve hub nut by using special tool.
09920-537 10
Clutch sleeve hub holder
3-1 4
3-15
SERVICING ENGINE
" Draw out thrus t washer gear from countershaft.
<>
and p rimary driven
Using special tool, remove oil pump driven gear.
09900-06107
Snap ring opener
J
a Remove three oil pump mou nting screws and remove oil pump body from crankcase.
NOT E: Do not misplace oi l pump dri 1te pin, washer and two 0-rings.
o Remove cam stopper.
SERV ICIi\1 G ENG I \J E
:>
Draw out gearshifting shaft.
~
Remove bearing holder.
<))
:l
<~
Push ou t clutch push rod and remove generator lead wire guide I and neutral indicator switch housing . Remove generator cover and its gasket. Remove starter idle gear and shaft.
3- 16
3-17
SERVICING Ei\IGINE
o Using special t ool, remove ro tor securing bolt. 09930-44510
Rotor holder
t
I ~
,/
.
a Using special tools, re move the rotor with sta rte r clutch . 09930-301 02
Rotor remover sli din g shaft
09930-33 710
A ttachement
~I..
II o Remove two bolts, and lightly tap the head of sta rter motor gear with p lastic hamm er to remove starter motor.
0 0 :} Remove uppe r crankcase t ighte ning bolt.
.:1
â&#x20AC;˘ I
""-''-
SERVIC ING ENGI\JE
0
Turn engi ne upside down and remove oil pan .
~
Remove crankcase t ightening bolts.
3- 18
NOTE : At this moment, it is not necessary to remove the oil sump ¡filter .
o Using special tool, remove two allen bolts.
09914¡25811
6 mm T type hexagon wrench
\ ~\
\
3-19
SERVICING ENGINE
CAUTION
Make sure that ail bolts are removed before using the crankcase seprating tool. o Using spec i al tool , separate the upper and lower crankcase halves.
099 12-345 10
Cylinder disassembling tool
o Remove the countershaft and drive shaft. NOTE:
Be care¡ful not to drop "C" rings and the like .
0
Remove crankshaf t ba lancer.
assembly
and
cou nter
l
NOT E:
Be careful not to drop chain guide.
'>
t i.N O
Remove cam guide bolt fork shaft stopp er screw 2
dampers
I
of cam
and gear sh if ting
SERVICING ENG INE
:>
Extract gear shifting
fork
shaft
from lower
crankcase .
3
Remov e neutral stopp er .
stopper holder, spr ing and
3-20
3·2 1
SERVICING ENG INE
EJ\JGJNE CDMPOl\~El\JTS l NSPE.CTJO~J AND SEFIVJCJN'G CYU i\1DER HEAD Dl SASSEl\JlBL V J
Using special tools, compress valve springs and take off two cotter halves I from valve stem.
099 16·1 4510
Valve lifter
09916·1491 0
Valve li fte r attachment
09916-8451 0
Fo rceps
Take out the spring retainer, inner and outer springs. o From the other side , pull out the va lve .
:>
CAUTlOJ\J: Be sure to ide nti·fy each removed part as to its location, and lay the parts out in groups designated as "R cylinder", "L cy linder", "E~<h aust", "l nlet", "R" and "L", so t hat each will ba restored to the original location during assembly.
NOTE : !t Removal o·f valves completes ordinary d isassembling work. J·f valva guides have to be remo,Jed for replacement a'f'ter inspecting re lated parts, carry out the steps shown in valve guide servicing. !t When removing rocker arm shaft, remove the rocker arm shaft stop scre1.11J 1 and screw Smm bolt into t he rocker arm shaft end and pull it out.
SERVICING E1\J GINE
CYL1 1JDER HEAD DISTORTION .j
Decarbonize the combustion chambers.
~ Check the gasketed surface of the cylinder head
for distortion with a straightedge and thickness gauge , taking a clearance reading at several places indicated. If the largest read ing at any positi on of the straigh tedge exceeds the I im it, rep lace the cylinder head .
09900-20803
Thickness gauge
Service Limit
0.1 mm (0.004 in)
I..,
â&#x20AC;˘
VALVE FACE WEAR 0
Visua lly inspec t each valve for wear o f its sea tin g face. Rep lace any valve wi th an abnormal ly
worn face. o The thi ckne ss
'E
decreases as th e wea r of the
face advances. Measure the th ickness and , if th e th ickness is found to have been reduced t o th e limit, replace it . Service Limit
0. 5 mm (0.02 in)
VALVE STEM RUNOUT :>
Support the valve with "V" bl ocks, as shown, and check its runout wi th a dial gauge. The val ve must be rep laced if th e run ou t exceeds the I im i t.
09900-20606
Serv ice Lim i t
D ial gauge (1/ 100 mm)
0.05 m (0.002 in )
3-22
3-23
SERVIC ING ENGINE
VALVE HEAD RADlAL RU i\JOUT ll
Place the dial gauge at right angles to the val ve head face , and measure the val ve head radial run out. If it measures more than li m it, replace th e va lve.
0.03 mm (0.001 in )
Service Limit
VALVE GUIDE CLEARANCE
VALVE STEM
Measure the clearance in two directions "X " and "Y", perpendicu lar to each other, by rigging up the dial gauge as shown. If the clearance measured exceeds the limit, specified below, then determine whethe r the val ve or the guide should be replaced to reduce the clearance to the standard ran ge: V alve
Service Limit
I ntake valves
0.09 mm (0.0035 in)
Exhaust valves
0. 10 mm (0.0039 in)
VALVE STEM WEAR If the valve stem is worn down t o the limit, as measured with a micrometer , where the clearance is found to be in excess of th e limi t indicated , replace the valve; i f th e stem is within the limit, then replace the gui de.
Afte r replacing val ve or
guide, be sure to recheck the clearnce.
09900-20205 Valve
M icrometer (0 - 25 mm) Standard
I ntake valves
5.460 - 5.475 mm (0.2150 - 0. 2156 in)
Ex hau st valve$
5.445 - 5.460 mm (0.2144 - 0. 2150 in)
SERVICii\I G ENGI \IE
VALVE GUIDE SERVJ CJ i\JG o Using valve guide remover
1 ,
drive the valve
guide out toward intake or exhaust camshaft side.
09916-4491 0
Val ve guide remover
NOTE: D iscard the removed valve gu ide sub-assemblies.
1>
Re-finish the valve gu ide holes in cylin der head w i th a 11 .2 mm reamer.
09916-34560 099 16-34540
Valve guide hole reamer
I
Reamer hand le
() Fit a ring to each valve guide . Be sure to u se new rings and valve guides. Use of ri n gs and valve guides removed during disassembly is prohibited.
The intake and exhaust va lve guides
used during production differ is shape.
The
intake and exhaust value guides available from spare parts however are identical in shape as are the oil sea ls and may be uti lized in either position .
1111 5¡ 11 4 70
Valve guide
09289-05003
Valve gu ide oil seal IN
~
Oi l the
stem hole of each valve guid e and
drive the guide into the guide hole with the valve gu ide remover and attachment.
09916-44910
Valve guide remover
099 16-44920
Valve guide installer attachement
CAUTION : Failur e to oil th e valve guide hole before driving the new guide into p lace many resu lt in
a damaged guide or head. -
-- - - -
EX
3-24
3-25
SERVICING ENGI NE
o Install valve spring lower seats
1 •
Be careful
not to confuse the lower seats with th e spring retainer 2 .
a Re -f inish the valve guide mner surface with a 5.5 mm reamer.
09916 -34550
Valve guide reamer
099 16-34540
Reamer hand le
a Oi l each oil seal , and drive them in to positi on with the valve guide r emover .
099 16-44910
Valve guide remover
NOTE: Do not use the o il sea ls removed in d is· assembly: use new sea ls.
I
f VALVE SEAT WIDTH :l
Coat the valv e seat with Prussian blue un if ormly . Fit the valve and tap the coated seat with th e valve face in a rotating manner, in o rder to obtain a cl ear impression of the seating contact. In th is operation , use the valve lapper to hold the valve head.
<:)
The r ing-li ke dye impression left on th e valve f ace must be continuous-without any break and, in addi ti on to this requ irement, the width of the dye ring, wh ich is the visua li zed seat "w idth ", must be within the fo ll owing speci fi · cat ion:
SERVIC ING EN GI NE
Valve seat width Seat width
Standard -t---
w
- - - -1
0.9 - 1.1 mm
When inspecting the valve and seat for condition and proper seat width, it is also important to note the position of the contact area on the valve face. 1\JOTE : The proper seating position is in the canter of the valve 'face.
If any requirement is not met, correct the seat position by servicing it as foll ows: Valve seat \
VALVE SEAT SERVJCING The valve seats for both the in ta ke and exhaust va lves are machined to two different angles. The seat contact surface is cut 45° and th e area above the contact service (closest to the combusti on cha mber) is cut to 15° . NOTE: The valva seat contact area must be inspected after each cut. - - - -- - -
o Insert the so lid pilot 1 with a sli ght rotation. Seat the pi lot snug ly. Install the 45° cutter, attachment and T handle . !.> Using the 45° cutter, descale and cleanup the seat with one or two turns. '> Inspect the seat by the previously described seat width measurement procedure. If the seat is pitted or burned, addit ional seat conditioning with the 45° cutter is required. NOTE: Cut only the mini mum amount necessary from the seat to prevent the possibi lity o·f t he valve stem becoming too close to the rocker arm for correct valve adjustment.
If the contact area is too high on the valve , or if it is too wide, use a 15° cutter to lower and narrow the contact area.
)
Contact area too low I and too n arrow on face ' o f valve
3-26
3·27
SE RVICI NG EN GINE
If the contact area is too low or too narrow, use the 45° cutter to raise and widen the contact area.
:>
---~
~-
·---,
-
Contact patch too h igh and too wide on face of valve
After the desired seat position and width is achieved, use the 45 j cutter very lightly to clean up any burrs caused by the previous cutting operations. DO NOT use lapping compound after the fina l cut is made. The finished valve seat shou ld have a velvety smooth finish and not a high ly po lished or shiny fin ish. This wi ll provide a soft surface for the final seating of the va lve which will occur during the first few seconds of engine operation .
., Clean and assemble the head and valve com · ponents. Fill the intake and exhaust ports with gasoline to check for leaks. If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from sealing. NOTE: * Always use extreme caut ion when hand ling ga sol ine. * After servicing the valve seats, be sure to adjust t he va lve cleara nce after the cy linder head has been reinsta lled. (see page 2·5) CAUTION: * Re·fac ing valve stem end 1ace is permissible where the length 1 will not be reduced to less than 3 .5 mm (0.14 in). If this length becomes shorter than 3. 5 mm (0.14 in), then the va lve must be replaced. * After insta lli ng t he valve whose stem end has been ground oH as above, check that the face 2 o·f valve stem end is abolfe t he va lv e co tter 3 .
CD
_L
1
3-28
SER VIC ING Ei\IGI\IE
_
VALVE SPRINGS a The fo rce of the two coil springs keeps the valve
sea ts tight. Weakened spr ings result in reduced engine power output, and often account fo r the chattering noise comi ng from the valve mecha nism. e Check the springs for strength by measuring their free lengths and also th e force requi red to compress them . If the limit indi cated is exceeded by the free length reading or if the measured fo rce does not fall within th e range spec i f ied, replace wi th a SUZUKI spring. CAUT I ON: Replace both of the valve springs, inner and outer, at a t ime, if any one of these is found to be beyond the limit. Va lve sp ring free length Spring
Service Lim it
INN ER
31.9 mm (1.26 in)
OUTER
35.5 mm ( 1.40 in)
Va lve spring tension Spr ing IN NE R
OUTER
Standard
4.4 - 6.4 kg/ 28.5 mm (9.7 - 14. 11 bs/ 1.1 2 in)
6.5- 8.9 kg/32.0 mm (14.3- 19.6 lbs/1.26 in)
4.4 - 6.4 kg (9.7 - 14. 1 lbs)
-0>
_j
3-29
SERVI CING ENGINE
RE ASSE M BLY i>
Insert the va lves, with their stems coated with high quality molybdenum disulfide lubricant (SUZUKI MOLY PASTE) al l around and along the full stem length without any break.
CAUT ION: Whe n insert ing eac h valve, tak e care not to dam age t he lip of t he stem seaL
99000-25140
SUZUKI Moly Paste
(;) I nsta ll the va lve springs w ith the sma ll pitch po rtio n ÂŽ facing cylinder head. ~ : Large-pitch portion.
o Put on t he upper valve seat and, using the va lve I i fter, press down the springs, fit the two cotter halves to the stem end, an d release the Ii fter to
ÂŽ
allow the cotter I to wedge in between seat and st em. Be sure that t he rounded lip 2 of the cotter fits sn ugly into the groove ~ in the stem tmd .
CAU TION : Be sure to restore each spri ng, va lve and spr ing ret ainer to their origina l pos itions.
TDC
CAM SHAFT Bot h camshafts should be checked for the wear of cams and journa ls if the engine has been noted as giving abnorma l noise or vibration or lack of power output. Any of these co nditions may be caused by cam of camshafts j ourna l worn down to be low the se rvice limit.
BDC J
SERVIC ING Ei\J GI 1\IE
3-30
The ex haust camshaft can be di stinguished from that of the intake by the em bossed letters "EX" (for ex haust ) as against letters " IN " (for intake). The ~ ight end can be dist ingui shed by the notches from the le ft end of each camshaft .
CAMSHAFT \NEAR Worn -down cams can be the cause of incorrect valve timing resulti ng in reduced power output. The limit of cam wear is spec if ied fo r bot h intake and ex haust cams in terms o f ca m height H , wh ich is to be measured w ith a micrometer. Rep lace camshafts if found worn down to the be low limi t. Cam he ight Height
8'
Intake cams
H Service Limi t
- - - -------
Exhaust cams
34.350 mm (1.3524 in) --- -34.350 mm ( 1.3524 in)
--
- - - ----'
CAMSHAFT JOURNAL \NEAR Insta ll the camshaft correctly, and using a Pl astigauge measure the camsha ft journal clearance.
NOTE: Instal l each cap t o its origi nal position.
Ca m shaft bearing cap Tightening torq ue
1.0 kg-m (7.0 lb-ft)
Camsh aft- Journal clearance ( 11\J & EX) Service Li m it
0. 150 mm (0.0059 in)
- - - ___ _j
3-31
S ER V I C I ~I G
ENG INE
If the camshaft journal clearance measured exceeds the limit, measure the inside diameter of camshaft bearing cap and outside diameter of camshaft. Rep lace either the cylinder head or the camshaft, whichever the greater.
difference from specification is
'
Item Camshaft journal holder 1.0. (In & EX) 1-- - - - - - Camshaft journal 0.0. (In & EX)
Standard 22,000 - 22,0 13 mm (0.8661 - 0.8667 in)
- - -- - - 21 ,959 - 21,980 mm (0.8645 - 0.8654 in)
C AM SPROC KET REASSElV1BL Y o It is very important that each sprock et be positioned angularly on its camshaft as ill ustrat· ed. Its correct posit ion is determined by arrow mark " 3" marks "1" located (as I in the pin .
(on I NT AKE sprocket) or arrow and "2" (on EXHAUST sprock et) shown) in reference to the notch camshaft right end and positioning
~
Apply THREAD LOCK CEM EN T SUP ER "1361 A" to the threads of bolts, and tighten them with the foll owing specification : o Bend up the lock washer properly .
Tightening torque
99104-32020
0.9 - 1.2 kg·m (6.5 - 8.5 lb·ft )
I
Thread lock super " 1361 A"
SERVI CI NG EN GiNE
CAM CHAI ~J TEl\JSl Ol\I'ER 0
Turn the handle 1 al l the way coun terc lock· wise after loosening the lock screw, and move the push rod 2 in place to see if it slides smoothly. If any st ick ness is noted, remove the rod for inspect ion. A bent or scratched push rod must be replaced .
:>
all the way counterclockwise Turn handle agai nst the force of its co il spring and then turn it back as assisted by spring force to see if the handle returns to the original position 2 with· out exhibiting any sticking. Repeat this process several times. If any excessive sticking is felt or if the self-adj usting action is faulty, replace the whole tensioner.
R'EASSEM BLI NG u Apply engine oil to the lock shaft
1 • Insert the shaft into the holder 2 and bring the two into the relative position indicated.
o Hook the spring onto the holder and hand le 3 , twist the spring by one complete rotation counterclockwise A , and fit the handle onto the shaft, then instal l the nut 4 .
3-32
3-33
SERVIC ING EN GINE
o After tightening the lock shaft nut 4 , install the lock shaft assembly '1 on the tensioner body ID . Be sure to adhere to the following torque specifications: Tightening torque kg-m
lb-ft Lock shaft nut --Shaft assembly
0
'
.
6.0- 7.0
---
22.5 - 25.5
0.8 - 1.0 L
3.1 - 3.5
Apply a high quality molybdenum disulfide lubricant (SUZUKI MO LY PASTE) to the push rod and engi ne o il . to the push r od guide hole.
99000-2 5140
SUZUKI moly paste
o Match the lock screw hole 1 t o the long groove 2 in the push rod, as shown. o Sli de the push rod spring onto the push rod.
0
While turning lock shaft handl e counte rclockw ise, pu sh in the pushrod all the way . Keep o n turn ing the hand le u ntil it refuses to turn furt her.
SER VICING ENGINE
:) Tighten the lock screw t o lock the push rod, so that the push rod will not plunge out.
CAiVI CHAIN 20 PlTCH LENGTH Pull t he cha in tight to remove any slack , then using vernier calipers, measure the 20 pitch length of cam chain. If it measures more than lim it, replace the cam chain. Service Lim it
157.80 mm (6.213 in)
NOT E: When replacing following chain guides, app ly
SUZUKI Th read lock cement "1361A" to screws thread .
CYLINDE R DI STORTION Check the gasketed surface of the cy linder for distort ion with a straightedge and thickness gauge, t aking a clea rance reading at several p laces ind icated. If the la rgest reading at any positi on o f the straightedge exceeds the limit, rep lace the cy li nder. Cy linder distortion spec if ication Serv ice L imit
0.1 mm (0.004 in)
'
3-34
3-35
SERVIC ING ENG INE
CVU l\JDiER BORE Measure the cy linder bore diameter at six places. If any one of t he measurements exceeds the lim it, overhaul the cy linder and replace the piston with an oversize, o r replace the cyli nder. If one cylinder is worn to the po int that it needs to go oversize, the other cy linder should go oversize at the same time. Otherwise the imbalance might ca use excess vibration.
'
Cylinder oore Service Limit
60.095 mm (2.3659 in)
09900- 20508
Cylinder gauge set
PI STON DlAMETER Using a micrometer , measure the piston outside If the diamete r at the place shown 1n Fig . measuremen t is less than the li mit, replace the piston. Pist on ove rsize
0.5, 1.0 mm
j" d) ~
Servi ce Lim it
09900-20203
59.880 mm (2.3575 in) Micrometer (50-75 mm)
Pi STON- CVLI NDER CLEARANCE As a resu lt of the above measurement, if th e piston clearance exceeds the li mit shown in the table below, rebore th e cylinder and use an overs ize piston, or replace both cylinder and piston.
Service Limi t
0. 120 mm (0.0047 in )
I
I
--
~-
-
f...--"
SERVICING ENGI\JE
PI STOi\J Rl NG-GROOVE CLEARANCE Using a thickness gauge, measure the side clearances of the 1st and 2nd rings. If either of tbe clearances exceeds the limit, replace both piston and piston rings. Measure the clearance at exhaust side. Thick ness gauge
09900-20803
Piston ring-groo11e clearance Piston ring 1-
1st 2nd
!
Service Limit
II
0.180 mm {0.0071 in) - -- -
0. 150 mm (0.0060 in)
Piston ring groove w idth Piston ring .
----
Standard -
-
1.21 - 1.23 mm {0.047 - 0.048 in)
1st
-----
-
1.21 - 1.23mm {0.047- 0.048 in)
2nd
-
2.5 1 - 2.53 mm {0.099 - 0.100 in)
Oil Pist on r ing thickness
Standard
Piston r ing 1st
1.175 - 1.190 mm {0.0463- 0.0469 in)
2nd
1.170-1 .190mm {0.0461 - 0.0469 in)
PISTON Rl NG FREE END GAP AND PISTON Rl l\JG END GAP Before installing piston rings, measure t he free end gap of each r ing using vernier calipers. Next, fit the r ing in the cylinder, and measure each r ing end gap using a thickness gauge. If any r ing has an excess end gap, rep lace the ring. Piston ring 'free end gap Piston ring 1- -
---
-f--
1st
~-nd ___ -
Service Li mit
5.2 mm {0 .20 in) J
6.8 mm {0-.-27- in-) - -----1
3-36
3-37
SER VICIN G ENGI NE
?iston ring end gap Service Limit
Piston ring
0.70 mm (0 .028 in )
1st&2nd
09900-20803
e>
Thickness gauge
Oversize piston rings The fo ll owing two types of oversize piston rings are used. They bear the following identification numbers.
l 0.5mm
1S't
I
2nd
I
50
1.0mm
50
100
100
I
l
0.5 mm O.S.
e Oversize oil rings T he fo llowing two types of oversize o i l rings are They bear the follow ing identification used. marks.
I
Size
Color code
¡-- - -
1.0 mm O.S.
---
-
STD
Painted red
0.5 mm
Painted blue
1.0 mm
Painted yellow
-
Oil ring spacer
Oversize side rail Just measure out side diameter. Paint
PISTON PI i\l -
PIN BORE CLEARANCE
Using a smal l bore gauge, measure the piston pin bore inside diameter, and using a micrometer, measure the piston pin outside diameter. If t he two measurements are outside of the limits, replace piston and p iston pin.
?iston pin bore
J.D.
Service Limit
16.030 mm (0 .6311 in)
SERVICING ENGI~1E
Using a micrometer, measure the piston pin outside diameter at three positions. Piston pin O.D. Service Limit
15.980 mm (0.629 1 in)
09900-22401
Small bore gauge (10- 18 mm)
09900-20201
Micrometer (0 - 25 mm)
-----------
CONNECT! NG ROD SMALL El\JD BORE I.D. Using a small bore gauge, measure the connecting ro d small end diameter. Connecti ng rod small end bore I .D. Service Limit
16.040 mm (0.6315 in)
., If the difference betvveen the connecting rod sma l l end bore inside diamete r and the piston p in ou tside diameter exceeds the abovementioned limit, replace both connecting rod and piston pin.
CONNECTI NG ROD BIG END THRUST CLEARANCE Check t he connecting rod thrust clearance by using thickness gauge. If the clearance exceeds the limit, replace connecting rod or crankshaft. Service Limit
0.3 mm (0.012 in) Standard
-Big end width
19.95 - 20.00 mm (0. 785 - 0.787 in)
Crank pin w idth
20. 10 - 20. 15 mm (0.79 1 - 0.793 in)
09900-20803
Thickness gauge
.._J
3-38
3-39
SERVICING E1\JGI1\JE
CONNECT! i\JG ROD-CRANK PI i\J BEARil\JG SELECT ION o Loosen bearing cap nuts and tap t he bolt end lightly with plastic hammer to remove bearing cap. Remove rods and mark them to identify the cy linder posit ion. o Inspect bearing surfaces fo r any sign of fusion, p itting, burn or f laws. If any, replace them with specified set of bearings. :> Place plastigauge axia ll y on the crank pin, avoiding the oil hole. ?
a Tighten the bearing cap with two-step torque values.
NOT E: When insta lling 'the connecting rod and bearing cap on the crank pin, insure t hat the cap is properly aligned with t he connecting rod, and that the rod is installed on the crankshaft f acing in the proper direction.
Initial tightening torque Final tightening torque
I
I
1.2 - 1.8kg-m (8.5 - 13.0 lb-ft) Fro nt
3.0 - 3.4 kg-m (21 .5- 24.5 lb-ft)
t'\
i
NOTE: Never rotate crankshaf¡t or connecting rocl when a piece of Plastigauge is in the clearance. Numeral figure pr nted
:} Remove the caps and measu re the width of comp ressed plastigauge with envelope scale. Thi s measurement should be taken at the widest part. Service Lim it
0.080 mm (0.003 1 in)
SERVICING EN GINE
-) If oil clearance has exceeded the service limit, select the specified bearings from the following table. :> Check the cor respond ing rod I. D. code number 1 ,"1"or"2". o Check the correspond ing crank pin 0.0. code number, "1", "2" or "3". '-' The crank pin 0.0. code number is on the inside of each flywheel. Bearing selection table
I Code 1
Conrod
I
Crank pin ~
2 Green
3
Black
Brown f
2
Black
Brown
Yellow
Oil clearance Standard
0.024 - 0.048 mm (0.0009 - 0.0019 in)
Crank pin code
Connecting rod I. D. specification Bearing thickness Code
1.0. Specification 35.000-35.008mm
Thickness
Color (Part No.) ~
2
35.008- 35.016mm
-
Green ( 12164-11400-01 0) - - Black (1 2164 -11 400-020)
1.484- 1.488mm
Brown ( 12 164-11400-030) -Yellovv ( 12164-11400-040)
1.492-1.496mm
--
Crank pin 0. D. speci ·f icati on Code
0. D. Specificat ion
- - --L
31.992-32.000mm
2
31. 984-31.992mm
3
31.976-3 1.984mm
CAUTION: Bearing should be replace as a set. --·
--
- --- - ----
NOTE: Under size bear ings are available as an option· al part, such as 0.25 and 0.50.
-
1.488 - 1.492mm
----
~
1.496-1.500mm
Code
6
3-40
3-41
SERV ICING ENGINE
BEARII'JG ASSEMBLY :1>
When fitt ing the bearings to the bear ing cap and co nnecting rod, be sure to fix the stopper part 1
'l)
first and press the other end.
Check the connecting rod oil hole
I
to align
with the bearing oil hole ~ .
Ill
Apply engine oil or SUZUKI Moly Paste to the crank pin and bearing surface.
99000-25140
SU ZUK I Moly Paste
NOT E: N ever try to remo,/e or loosen the connecting
rod big end stud, otherwise, it vvil l displace the stud and wi II not fit the bearing cap proper ly.
o When mounting connecting rod on the crank shaft, make sure that oil hole 1 of the connect¡ i ng rod faces rearwar d. ';) T ighten the connecting rod fitting nuts with spec ified torque. Tightening torque
!
3.0 - 3.4 kg-m {21.5 - 24.5 lb-ft)
~ Check the con necti ng rod for smooth turning.
SERV IC IN G ENG INE
3-42
CRAi'Jl<CASE - CRAI\JI<SHAFT AND COUNTER BALA NCER BEAR I l\JG SELECT! ON :i>
Inspect each bearing of upper and lower crank cases for any damage.
r
•
o Place plastigauge on each crankshaft and counter ba lancer shaft journal in the usua l manner. NOTE: Do not place ·the plastigauge on the oil hole and do not ro tate t he shafts when plastigauge is in.
.J
Mate the lower crank case with the upper crankcase and tighten the crank case securing bolts with spec ified torque value in the following order. Item
-
initial t ightening
2.0 - 2.4 kg·m (14.5- 17.51b-ft)
- .!!.
1.3 kg-m (9.5 lb- ft)
9- 1P
0.6 kg -m (4. 5 lb-ft)
I
0.6 kg- m (4. 5 lb-ft)
I
I
-
The other 6 mm bolt ----The other 8 mm bolt
Final tightening
I
0 .9 - 1.3 kg-m (6.5 - 9. 5 lb-ft) 1.0 kg-m (7 .0 lb-ft)
-- ~
1.3 kg -m (9.5 lb·ft)
2.0 kg-m ( 14.5 lb-ft)
/
.....
I
I
I I
I
3-43
SERVICI,\JG ENGINE
~ Remove the
lower crankcase and measure the width of compressed plastigauge in the usu al manner. Service Limit
0.080 mm (0.0031 in )
o If the width exceeds th e limit, rerlace the set of bearing with new ones by refer ring t o the selection tab le. o Check the corresponding crankcase journa l I.D. code number 1 "A" or "B" w hi ch are stamped on the rear of upper crankcase.
a Check
the
corre sponding
crankshaft
and
ba lancer shaft journal O.D. code number ''A'', ''B'' or ''C,'.
2
i\JOTE : T he 0 . D. code ¡for th e jou rnal ind icat ed by the arrow is marked on the journal ("spacer") bearing surface. I f the letter code is not visible, the journal 0 . D. must be checked with , a micrometer . Bearing selection table Crankshaft and Balancer shaft O.D. code J
. - - - --l-Crankcase . I. D. code 1
Cod e A B
c
B
A 1 --
Green I
Black
Black
Brown
Brown
Yellow
I
Crankc ase journal I.D. speci'fication
-
Code
- -1
I. D. Specificati on
A
35.000-35.008mm
B
35.008-35.016mm
---
Cran kshaft and balancer code
SERVICIN G ENG INE
Crankshaft and Balancer journal O.D. Speci'fica'tion Code
Code
O.D. Specification
1-
A
31.992-32.000Mm
8
31.984-31.992mm
c
I
31.976-3 1.984mm
I
Bearing thickness speci¡fication Color (Part number)
Thickness I
Green ( 12229- 11400-010) Black ( 12229- 11400-020) f-Brown ( 12229-11400-030) Yellow ( 12229-11400-040)
1.486- 1.490mm
1.490-1.494mm I
1.494-1.498mm
1.498- 1.502mm
CRAl\JKSHAFT THRUST CLEARA\\JCE J
Check crankshaft thrust clearance with thickness gauge. If it exceeds the service Ii mit, measure the crankcase vvidth A and crankshaft width B and replace crankcase or crankshaft, whichever the difference from specification is greater. 09900-20803
I
Thickness gauge
09900-20101
I
Vernier ca lipers
I
Thrust clearance Service Lim it
0.35 mrn (0.014 in)
Standard Crankcase A
53.90 - 54.00 mm (2. 122- 2.126 in)
Crankshaft lff
54.05- 54.15 mm (2. 128 - 2.132 in)
d
3-44
3-45
SE RVIC ii\1G ENGli\JE
CRANKSHAFT RUJJOUT Support the crankshaft with "V" blocks as shown, with the two end journals resting on the blocks. Rig up the dial gauge, as shown, and rotate t he crankshaft slowly to read the runout. Replace the crankshaft if the runout is greater than the limit. 1
09900-20606
Dia l gauge ( 1/1 OOmm)
Cranl<shaft runout spaci1ication Service Limit
0.05 mm (0.002 in)
COUNTER BALANCER DISASSEM8lY ~ Remove the counter balancer setting bolt.
" Press out the spacer and counter ba lancer dr ive gear.
CO UNTER BALANCER REASSEMBLY o Fix t he key in the groove, press-fit the cou nter balancer drive gear.
o Fix the spacer ("bearing journal" ) and washer 2 , tigh ten the counter balancer setting bolt with specified torque. Apply thread lock super " 136 1 A" to the bo lt. Tightening torque
3.5 - 4.5 kg-m (2 5.5- 32.5 lb-ft)
I I
991 04-32020
Suzuki thread lock super "1361A"
SERV ICIN G Ei\JGINE
CLUTCH S?Rl i\JG fREE LEJ\JGTH Measure the free length of each coi l spring w it h vernier ca lipers and compare the elastic strength of each with the speci ¡fied limit. Rep lace all the springs if any spring is not within the limit. Clutch spring â&#x20AC;˘free length 33.6 mm ( 1.32 in)
Serv ice Lim it
CLUTCH DRIVE PLATES AND DRIVEN PLATES Clutch plates in service rema in in oi ly condition as if they were lub ricated with oil. Because of th is condition, both drive and driven plates are subject to little w ear ing action and the refore last much longer. Their life depends largely on the quality of oi l used in the clutch and also o n the way t he clutch is operated.
Ch ecking thickness
These plates are expendable: they are meant to be replaced when found worn down or distorted beyond the respective limit: use a ca liper to check th ickness and a thi ckness gauge and su rface p late to check distortion. 09900- 20 10 1 09900-20803
I
Vernier ca l_ip_e_r_s -
-
-
-1
Thickness gauge
Checking dist ort ion
Unit: mm (in) Service Limit 1---
Drive plate
- -- -- - - --
Th ickness
------
D riven p late
--+- - -- - -
2.6 (0.10)
- - - -- - - - - --
D istortion
-
-
1
0.1 (0.004)
Claw width : 11 .0 (0.43)
Check ing c law width
3-46
3-47
SER VICii\IG EI\IGii\JE
ClUTCH RE LEASE BEARJN'G Inspect this thrust-type bearing for any abnor mality, particularly cracks, upon removal from the clutch, to decide whether it can be reused or should be replaced. Smooth engagement and disengagement of the clutch depends much on the condition of this beari ng.
STARTER CLUTCH Dl SASSEMBLY <>
Remove roller 1 , spring 2 from starter clutch .
and push piece
1
o Clam p t he rotor with a vise taking care not to damage it and remove the thr ee hexagon bolts usi ng the 6mm "T" type hex agon wrench.
09914-258 11
'T' type hexagon w rench (6mm)
ÂŽ I
CD I
SERVICING ENGINE
3-48
REASSEMBLY o Apply THREAD LCOK "1363C" (99104-32050) to the stator set and lead wire guide screws. NOTE:
f!
lN ipe oH o il and grease on scre\iv completely and then apply the screw lock.
,I
1/ {
) Mount the lead wire clamp as shown in the photo.
) Locate the shim
to the proper position.
o Apply thread lock super to allen bolts and t ighten w ith specified torque. 99 104-32020
Thread lock super "1361A"
099 14-25811
T -type allen wrench (6mm)
Tight ening torq ue
1.5 - 2 .0 kg-m ( 11 .0 - 14. 5 Ib- ft)
OIL PUM P o Remove one screw fastening oil pump body and ext ract tw o positioning pins from the o il pump case.
3-49
0
SERVICING ENG INE
Check oi l pump tip clearance, outer rotor clearance and side clearance by using thickness gauge and st raight edge.
Un it: mm (in)
,) I
Serv ice Limit Tip clearance r-- - Outer rotor clearance Side clearance
0.20 (0.008) 0.25 (0.01 0) 0. 15 (0.006) Checking ti p clearance
..
,
Check 1ng side clearance
Checking ou ter ro tor clearance
REASSF.I\JII8l 'I &
Thorough ly wash the oil pump, inner and outer rotors and oil pump case with solvent and apply engine o il to them before inserting them into case.
~
on both Since there are punched mark s inner and outer ro tor upper surfaces , the rot or should be inserted respective o f these port ions.
0
Insert drive shaft and drive pin, and apply thread lock " 1363C" to oil pump body fasten ing screw.
() Tap the two position ing pins.
99 104-32050
Thread lock "1363C"
\ l
~,
SERVICING ENGINE
3-50
TRA!\JSMI SS I Oi\J GEARS AND RELATED PART S
------------
(] ---
- - - - --------
3-51
SERVICIN G
E~IGINE
GEAR-SH I FTI i'JG FORK CLEARANCE Using a thickness gauge, check the shifting fork clearance in the groove of its gear. This clearance for each o f the three shifting forks plays an important role in the smoothness and positiveness of shifting action. Each fork has its prongs fitted into the annular groove provided in I n operation, the re is sl iding con tact its gear. between fork and gear and, when a shifting action is in itiated, the fo rk pushes the gear axially. Too much a clearance is, therefore, liable to cause the meshed gears to slip apart. I f the clearance checked is noted to exceed the limit speci fied, replac e the fork or its gear, or both.
09900-20803
Thickness gauge
Shift ¡fork -groove clearance Service Limit No. 1
f or 5th driven gear
No. 2
for 3rd / 4th drive gears
-
- - - - - - -- -- -
No . 3
0.50 mm (0 .020 in)
for 6th driven gear
Sh ift fo rk groove widt h
Standard
5.5-5.6 mm (0.217 - 0.220 in)
Sh ih fork th ick ness
Standard
5.3- 5.4 mm (0.209- 0.2 13 in)
COUNTERSHAFT DISASSEMBLY .>
Remove the 6th drive gear circl ip from the groove and slide circlip and washer toward the 3rd / 4 th drive gears.
09900-06 104
Circlip remover
SERVICIN G EN GI.\IE
o Slide the 6th and 2nd drive gears toward the
CD
3rd / 4 th dr ive gears and remove the 2nd drive gear circli p
1
NOTE: These cir clips should be replaced with new ones.
-- -------
L
COUN TE RSHAFT ASSEMBLY ;) Before installing gears, coat lightly moly paste t o the counte rshaft.
99000.25140
SUZUKI M ol y Paste
() When mounting circlip, pay attention to the direction of the circlip.
Fit it to the side where
the thrust is as shown in the figure. N OTE:
DRI VE SHAFT ASSEM BLY 1
to the drive shaft and apply
thread lock cement to the inner surface of engine sprocket spacer 2 .
99000-32040
u~
Sharp edge 1
Always use new circlip.
., Fix 0· ring
Thrust ----> ~
Thread lock cement
3·52
3-53
0
SER VICIN G EN GINE
Coat SUZ UKI super grease "A" to the lip of oil seal.
99000-25030
SUZUKI Super grease" A"
SERV ICING Ei\JG II\!E
3-54
ENG JNE REASSEJVIBL Y The engine is reassembled by carry ing out the steps of d isassembly in the reversed order, but there are a nu mber of steps which demand special descriptions or precau t ionary measures. On ly those steps will be set forth on th e componen ts of the power unit. NOTE: Apply engine oi l to each ru nning and sl iding part before reassembl ing .
., Refer to the following figure in regard to the cor rect posit ions and orientations of the forks when installing these parts. Gearshift fork for 5th driven gear. 2 : Gearshift fork for 3rd/ 4th drive gea rs. 3 : Gea rshift fork for 6th dr iven gear. I
:
o Before driving in the cam guide bolt 1 and fork sha ft stopper screw 2 , app ly T HR EAD LOCK " 1363C" to their threads. 99104-32050
T hread lock " 1363C"
3-55
?)
SERVICI NG Ei\JGINE
Install the gearsh ifting cam with the dent f or the neutra l stopper directed downwar d, and meet the neu tral stopper
1 w ith this dent
2 .
a App ly grease to each oil sea l of drive and
l
counte r shafts.
99000-25030
0
Suzuk i Super grease A
Place three " C" rings
1 and a knock p1n
2
and install drive and co unter shaft s.
CD
o Install the countershaft and drive shaft oil seals, pos it ioning as shown .
SERVICING ENGINE
'l
Check oi I orifice materials.
3-56
for clogging by foreign
" Seat washer and tighten oil pressure regulator I with specified torque. T igh tening torque
1.7 - 2.0 kg-m ( 12.5 - 14.5 lb-ft)
o Place cam chain gu ide 1 properly and fix two dam pers 2 so that iron side faces to the chain gu ide pin (ins ide) .
::>
The washer between primary d rive gear and nut is in dish form when it is in free state. When fitting this washer, be sure to face it s concave
r
Primary drive gear
Nut
side to the gear as shown.
Tigh teniny torque
5.0 - 7.0 kg -m (36.0 - 50.5 lb-ft)
' - - - - - - - - -- - -
Wash~r:_ _ _ _j
3-57
~
SERVICING ENG IN E
Apply engine oil or SUZUKI MOLY PASTE to each bearing and journal portions of crankshaf t and balancer. 99000-25140
SUZUKI Moly Paste
~
When mounting the counterbalancer, be sure to position it exactly 180° out of phase with crank shaft. This pos iti oning is accomplished by meshing the drive and driven gears in such a way that the two punch marks 1 meet each other, as shown.
:>
Clean the mating su rfaces of t he cra nkcases before matching the upper and lower ones.
~
Apply SUZUK I BOND No. 12 15 to the mating surface o f the lower crankcase in the f ollowing procedure. 99 104-31110
Suzuki Bond No. 1215
NOT E:
* Make sur¡faces free from moisture, oil, dust and other fore ign materials.
* Spread o n surfaces thin ly to form and even layer and wait for around 10 minutes before assembl i ng. * Take extreme care not to app ly any bond No. 1215 to the bearing sudaces. * Applicable on di storted surface as it forms a comparatively th ick f ilm .
SE RVIC ING EN GINE
o When secu r.ing t he lower crankcase, tighten the 8-mm bolts and t he 6-m m bolts in the ascending order of nu mbe rs assigned to these bo lts, tigh tening each bo lt a l ittle at a tim e to equalize the pressure. T ighten all the securing bol ts to t he specified torque values.
Item
I -
E
-
-
l
-
(~
--
Final In itial tightening t ighten ing - - - - -·-- - 1.3 kg-m 2.0 - 2.4 kg-m (14.5 - 17.5 1b-ft) (9.5 lb-ft ) -- - 0.9 - 1.3 kg -m 0 .6 kg -m (4.5 lb-ft) (6.5 - 9.5 lb-ft )
The other 6mm bolt
0 .6 kg -m (4.5 lb-ft)
T he other Sm m bolt
1.3 kg-m (9 .5 lb -ft)
1.0 kg-m (7 .0 lb-ft )
-~--
09914-2581 1
2.0 kg-m ( 14.5 lb- ft)
6mm T-type he xagon w rench
I
-
- - - - ----- --- - N OTE : Place the engine grou nd wi re to the posit ion A shown.
~
Fix oil sump fi lter wi th three screws.
·<>
A pply Suzuki Bon d No. 1215 t hin ly to t he respective porti on as shown . 99 104-3 11 10
<>
SUZ U K I Bond No . 12 15
Locate o i I pan and t igh ten 15 6- mm bolts w ith spec if ied to rqu e. T ight ening to rque
1.0 kg-m (7 .0 lb-ft )
N OTE: Place t he two clamps for signal generator and o il pressu re sw itch lead wi res to the p roper positions §' as show n.
3-58
3-59
0
SER VICi t\J G ENG INE
Mount starter motor and route the lead wire properly.
99 104-32050
Tighten ing torqu e
:>
Thread lock " 1363C"
0.4 - 0 . 7 kg-m
(3.0 - 5.0 lb-ft)
Degrease the tapered port ion of the rotor and also the crank shaft. Use non petroleum clean ing fluid to wipe off the oil y or greasy matter to make these surfaces co mpletel y dry .
o A ft er mounti ng the rotor, secure the rotor by
ti ghtening the center bolt to the specified torq u e value.
Tightenin g torqu e
6.0 - 7.0 kg-m (43. 5 - 50.5 lb-ft )
99104-32090
T hread lock super "1 3328"
09930- 445 10
Ro t or h older
SERVIC ING ENGINE
:>
Install the starter idle gear and its shaft.
" Fit generator cover gasket with extreme ca re o·f oil passage 1 •
o Remember, switch contact 1 , spring and "0" ring are provided for the neutra l indicator switch.
:>
:>
Route generator lead wire and clamp it w ith neutral indicator switch fitting screw. I nsta ll
bearing holder and cam stopper with
screws and bolt. NOTE: When tightening cam stopper bol·t, posit ion its spacer
1
properly .
- -- - - 99 104-32050
-
-----
Thread lock" 1363C"
3-60
3-6 1
~-
SERV ICING ENGIN E
-
-- -
- - - --
-
-----,
i\IOTE: Aft.er tigh't'ening the cam s·topper bolt, mo•1e the stopper back and ·forth with fingers to be sure that its movement is normal. (:) Install the gearshift shaft . lj)
Bring gea rshi fting cam to "NEUTRAL" position by inspecting neutra l cam stopper 1 •
Insert neutral cam pin into the closest pin hole to cam stopper 2 . a Install pin retainer 3 in such a way that t he recess 4 of pin retainer will admit the semicircle end of pin 1 .
3
a Tighten pin re tai ner securing screw after apply ing thread lock super " 1363A" . 99104-32020
Thread lock super " 1363A"
o Be careful not to leave out the two "0" rings 1 when fitting oil pump.
:i,)
Apply thread lock " 1363C" to oil pump fitting screws.
l ,, ~
I
J
SERVI CI NG ENGI\IE
'u Position the washer
and oil pump drive pin 2 and fix the oil pump driven gear with circlip 3 . I
NOTE:
Upon installing the oil pump in crankcase, rotate the pump gear by hand to see if it turns smooth ly.
99104-32050
Thread lock "1363C"
09900-06107
Snap ring opener
~
Be sure to position the oil pump drive gear so that its two notches 1 admit tongues 2 of the prima ry driven gear damper plate. Fix it with circlip 3 .
'D
Install primary driven gear and th rust washer I .
1>
3-62
3-63
9
SERVICING ENGINE
After tightening the clutch sleeve hub nut I , be sure to lock the nut by positively bending t he tongue o f the washer. Tightening torque for the nut is specified.
09920-504 10
T ightening torque
3
::~
Clutch sleeve hub holder
3.0- 5.0 kg-m (21 .5- 36.0 lb-ft)
Drive plate (co rk plate) is the first to go into the sleeve hub. Install push piece and thrust bearing 2 properly. NOTE : Bearing side should ·face the clutch push piece side.
L
~ App ly thread lock cement tb the clu tch spring
set bolts.
99000-32040
Thread loc k cement
NOTE: Using conra d stopper, tighten t he clutch spring set bolts in the indicated manner, making sure that they are tightened just a little at a time to t he same fina l tighteness.
:>
099 10-20115
Con rad stopper
Tighteni ng torque
0.4 - 0.6 kg-m (3.0- 4.5 lb-ft)
Positi on new gasket to align two holes
I
with
oil passage of crankcase. NOTE: Do no·t •forget to fix the two positioning pins.
I
II
SERV ICING ENG INE
3-64
a Apply grease to oil seal lip of the cran kshaft.
99000-25030
Suzuki Super grease "A"
I
o Apply Suzuki Bond i\lo. 1215 to oil pressure switch thread. 99 104-311 10
J
Suzu k i Bond No. 1215
Install the signal generator rotor to the advance governor properly .
o Install the advance governor after installing the clutch cover. Be sure to pos it ion the governor in place so that its groove 2 wi ll admit locating pin 1 provided on crankshaft .
:>
Hold the crankshaft turning nut and tighten the governor c enter bolt
with specified torque.
Tightening torque
1.3 - 2.3 kg-m (9 .5 - 16.5 lb-ft)
(
3-65
SERV ICING
E~IGINE
o Install the signal generator so that the index line I
aligns with the center 2 of the fitting screw.
o Route stator and o il pressure switch wires properl y after installing stator.
lead
n Top ring and middl e (2n d) ring di ffer in the
,---- - - - -- - - - - -- - -- - --
shape of ring face and the face o f top ring is chro me-p lated whereas t hat of 2nd ring is not.
/
/
/'
/
¡ ¡ ~/ :/
The color of 2nd ring appears darker than that
/;//
0
of the top one.
/
Top
_) 2nd
(\) Top and midd le (2nd) rings have let ter " 1\J" marked o n the side . Be sure to bri ng the marked side to top when fi tting them to the piston.
~----
-
SERVICING ENGI\1E
:} Bottom ring T he first member to go into the ring groove is spacer 1 â&#x20AC;˘ After placing spacer. fit the two side rails 2 . Side designations, top and bottom, are not applied to the spacer and side ra i ls : you can position each either way. CAUTIOi\J: If the spacer is insta lled, be carefu l not to allow its two ends to overlap in the grooâ&#x20AC;˘Je.
11\JCORRECT
~ Position the gaps of the three rings as shown.
Before inserting each piston into the cylinder,
EX
check that the gaps are so located .
11\1 .
0
The piston is in correct position when its arrow {on the c rown) points forward .
.:) Be sure to install the piston in the cyl inder from which it was taken out in disassembly, refer to the letter mark, "R" or "L". scribed on the piston crown.
Spacer
3-66
3-6 7
SERV IC11\1 G E\1 GIN E
) Have each piston oiled lightly before installing it. Place a cloth beneath the piston, and inst all the
:>
circl ip. o Be sure to use new circlips.
Check to be sure that two oi l orifices are not
J
c logged.
o Install the cyl i nder gasket properly. Fix t he two positioni ng pins .
1)
Install piston ring holders in the indicated
3
Some I ight resistance must be manner . overcome to lower the cylin der block .
099 16-74520
Holder body
099 16-74530
Band (bore 55 - 65 mm)
i\JOTE :
* Do not OIJerti ghten the special tool bands o r t he pist ons w ill not slide into the cy -
*
linders. Each band has a numb er punch-marl<&d on it . The number refers t o a particular range of piston di amet er.
1~¡
~r
SERVICING Ei\I GI\IE
:>
Be su re to replace cy li nder head gasket with new one to prevent gas leakage.
J
Fix two positioning pins properly .
<> Install eight crown nuts
1
and copper washers
2 to tighten cy I i nder head.
T
\_.,
::~ With
the head snug ly seated on the cylind er bl ock, secure it by tightening the 8 nuts sequen路 tia ll y in the ascending order of numbers. Tighten each nut just a I ittle at a time and shift the wrench in the indicated order to reach the same final t orque value specified. Cylinder head nut tighteni ng torque
2.2- 2.8 kg路m (16.0 - 20.0 lb路ft)
NOTE: Use the wrench (special tool) and a torque wrench 2 to tighten cylinder head nuts, as shown.
3路68
3-69
J
SERV ICI ,\JG Ei\I GI\JE
After t ightening the 8 nuts to spec ifi cation, run in the 6 mm bolt (indicated as 3 ) and tighten it to th is torque value. Head bolt t ightening torque
3
Place chain guide
I
0. 7 - 1.1 kg-m (5 .0 - 8.0 lb-ft)
1
proper ly.
o While ho ld ing down the timing chain, r otate the crankshaft in normal direction to bring the "T" ma rk (on "R" side of the advance governor) t o the timing mark.
CA UTION: To rotate crankshaft, use a 19 mm wrench on the large crankshaft turning nut 1 â&#x20AC;˘ Never try to rotate crankshaft by putting a 12 mm wrench to bolt 2 .
~- ---~--- -- - - ~ -- ....... ---~·--·--.... ---·-----~-
1\JOTE: Jusc t:Bfore plac ing the carnshcri t on the cylinLler head, apply high quCJiit'; molybdanum d isul·fi da lubricant to its journal.s, fully coating each journal 1 with the pasta taking care not to lea,,e any dry spot. ,t\pply engine oil to the journal bearings.
l J
----- ---·-~;:,~,/ICI~I G
~\I GI'.JE
...~-~--
C) I....v
T
'-'-"
n0 99000-25 140
Suzuk i 1'vloly Paste
To iclenti fy the exhaust camshaft from the intake, the letters "E)(" (-for exhaust} and "l1\l" (for intake } are cast on the ca mshafts . Also, the ri ght end of both camshafts are identified by a notch.
0 J
Wi th "T " mar k accurately lined up with the timing mark, hold the c ra nkshaft steady and lightly pull up the chai n to remove the slack between t he crank sprocket and exhaust spr o-
cket . .) Exh aust sproc!<et bears an arrow m ark " I " indicated as 1 • Turn over the exhaust cam shaft so tha t th e arrow poi nts f lush with the gasketed surface of the cylinder head. the timing cha in vvith this sprocket.
J
Engage
The other arrow mark "2" is now pointing straight upward .
Cou nt the cha in roller pins
toward the in take camshaft, starti ng from the ro ller pin directly above this arrow mark "2" and ending with the 20th roller pin. Engage the chain with in take sprocket, locating the 20th pin, at and above the arrow mark " 3" on the intake sprocket .
20th 1st
3- 70
3-71
SERVICii\IG Ei\IGINE
-------------------.
~~ -1
~OTE:
The timing chain is now riding on all three sprockets. Be care¡ful not t o disturb the crankshaft until four hold ers and cam chain tensioner are secured .
20th
1 1 9~F=h=:::;;======~
2nd 1st
_j
o Each camshaft holder is identified with a east-on A matching east-on letter with a triangle. symbol appears on the head. Install each holder at it's matching letter, w ith triangle symbols pointing forward. o Secure the four camshaft bearing holders evenly
by tightening the camshaft bearing holder bolts sequential ly. Try to equali ze the pressure by moving the wrench diagonally from one bo lt to another and from one camshaft bearing holder to another, to pul l shafts down evenly . NOTE : Damage to head or cam bearing holder thrust surfaces may result in cam bearing holders that are not drawn down evenly.
~
Tighten the camshaft bearing holder bo lts to the following torque value: ---------CAUTION : The camshaft bea~ing holder bolts are made of a special mater ial and much superior in strength compared with other type of high strength bolts. Take special care not to use other type bolts instead of these special bolts. To identifv these bo lts, each o¡f them has a figure "9"
on its head.
Camshaft bearing holder bolt tightening torque
0.8 - 1.2 kg-m (6.0 - 8.5 lb-ft)
~
While turning lock shaft handle counterclock wise, push in the pushrod all the way. Keep on turning the hand le until it refuses to turn further. a Tighten the lock screw to lock the pushrod, so that t he pushrod will not plunge out. ~ Secure the adjuster to the cy linder block. Tightening torque
0.6 - 0.8 kg-m (4.5- 6.0 lb-ft)
"'-,
3-73
SER VICI1\JG ENGINE
o If tensioner adjuster is not going in, turn the crankshaft slowly clockwide to get cha in slack at inlet side. o Wi thdraw the lock sc rew by one-quarter to half a turn: this separa tes the t ip of the screw from the pushrod, thereby all ovv ing the pushrod to advance under spring fo rce and press the ten¡ sione r agai nst the camshaft drive chain. Tighten the lock nut
1 â&#x20AC;˘
NOT E: When tightening the lock nut, take care to prevent the lock screw 'from turning.
;>
Whi le turning t he handle 2 coun terclockw ise, slowly rotate the crankshaft in reverse direct ion (thus causing the chain to pu sh back t he tens ioner).
3
Relea se the handle and slowly turn back the crankshaft in normal running direction (to slacken that po rtion of the cha in extending along the t ensioner). See if the handle rot ates by itself as the chai n becomes progressively slackened; if it does, then the pushrod inside is obviousl y moving forward under spri ng force as it should, thus signifying t hat the tensioner is in good operable condition. If the handle rotat es, but sluggishly, it means that the pushrod or lock shaft is sticking and, in such a case, remove the tensioner and servi ce the pushrod and lock sha ft to mak e them move smoothly. CAUTI ON : Aher installing the tens ioner and checking it in initially set condition for operation, do not attemp t to turn the handle in either di rection until the next overh au l.
"' Adjust valve cleara nce. (Refer to page 2 ¡5) . J In fitting the seal ring to the oil filter chamber cap, lightly coat grease on the seal ring
1
groove to avoid any chance of dropping or mislocating the ring during the installation work.
o Tighten eng ine oil drain plug.
â&#x20AC;˘) Pour 50 ml of engine oil in fou r oil pockets in the head.
J
Install cylinder head cover. Two longer bolt should be placed at two knock pin positions.
A
3·75
1)
SERVICING E\IGii\JE
Place gasket properly and fix head cover cap .
., Install the tachometer d rive gear. CAUTION: This is to be ef'fected after insta lling cylinder head cover. Insta lling th is gear before install· ing t he cylinder head co•1er may cause the teeth of gear and worm to break.
o Apply thread lock cement to the camshaft end
ca p screws . Fit the four camshaft end caps.
99000·32040
:>
Thread lock cemen t
Install the respective carbaretor insulator to the cylinder head with two screws. NOTE: * Each insulator has an identi'ficatio n mark, "R" or "L", and fix it so that the mark should be positioned up side . * Locate the O·ring in the insulator groove properly.
- . .-
.
~
e
.-.
.
.
'·1
FUEL AND LUBRICATION SYSTEM .
---------
;
.
CONTENTS- - - - - -
FUEL SYSTEM ............................................................................................................ 4- 1 FUEL COCK .................................................................................................................. 4· 2 CARBURETOR ............................................................................................................ 4· 3 DIAPHRAGM AND PISTON OPERA TION............................................. 4- 4 SLOW SYSTEM................................................................................................ 4g 5 MAJN SYSTEM ................................................................................................ 4- S STARTER SYSTEM ....................................................................................... 4- 7 FLOAT SYSTEM .....................................-...................................................... 4- 7 DISASSEMBLY ................................................................................................ 4- 8 FUEL LEVEL INSPECTION ........................................................................ 4-10 FLOAT HEIGHT ADJUSTMENT ...............................................................4-11
NEEDLE VALVE ................................................................................................4-12 REASSE~1BL Y ................................................................................................... 4-12
BALANCING CARBURETORS .................................................................. 4- 15 LUBRICATION SYSTEM .......................................................................................... iJ-17
-
-·---· - -
- • •
.
I
4 i'
__________ _____ .,.
FUEL SYSTE i\Jl When turning starter motor, negative pressure is generated in the combustion chamber. This negative pressu re works on the diaphr::~g m oi fuel cock through passageway pm'!ided in the carburetor mai n bore and vacuum pipe, and diaphragm builds up a negat ive pressure w hich i.> higher th an the spring pressu re. Fuel valve is forced to open due to di:mhragm operation, and thus all ow fu el to flow into carburetor float chamber.
FUE L AND LU8 -~ IC1-\ T I O~I SYST:\1
FUEL COCK
Fuel ·filter 2 lever 3 Fuel valve 4 0 -ritlg
5 Diaphi3gm 3 Vacuum hose 7 Spri ng 3 Fuel hose
A' i=ue l flow §' Vacuum
c
9
Diaphr agm cham ber Chamber
This fuel cock has provided three positions "01\I",
"RES" and "P R 1". When ·the engine is not running with the lever in the 0 1'1 or RES positi on, the valve i3 kept in the closed posit ion by appl ,; ing pressure utili zing a spring so that ;10 fuel wi ll iiO'N to the carburetors. Whe n the engine i3 engaged, a negative pressure is generated in the diaphragm chamber "C" through the vacuum lnega·ti'le pressure) pipe which is connected to the carburetor, and builds up a negative pressu re which is higher th an the spr ing press ure so that t he diaphragm is f orced to open the va lve and thus all ow the fue l to flow to the carburetors. When ·tu ming the le"er ~o P({I posit ion, fuel flows directly t o the car buretor t hrough RES side ·fil ter and chamber "0 " .
PRI
ON
RES
4-2
4-3 ~
FUEL A\JJ LUBRICU.TIQ\1 SYSTE~
ARBURETOR CARBURETOR
- - - ·- -
-----------------------
CONSTRUCT! Oi'J
3
I"~
J
II
i5
ttl e cable brack et 21 Thro T op cap 3
Sp ri ng
c·1rclip Guide holder 6 E-ring 7 Spacer
4. ~
8 Washe r 9 Spr ing 11 Je t needle II -
o·laphragm
12 Steel ball
L
15 Throttle lever 16 Synchronizi 11 ldl " ng screw lng adt"u st screw 18 T hrottle va l·'e 19 p·l 1 ot jet
20
J et needle
28
·-Jh
21 Main jet 22 0 ·r1ng 23 Fuel fi l ter z~ Needle valve 25 Needle valve g .d 26 Float Ul e
I_J Spring
21 0-ring
~~
28 Drain plug
Starter shaft
21 - @
_
_J
;: u EL AND LUBRIC..\TION SYSTE\1
~ -<!
DIAPHRAGM Ai\JD PI STON OPERATI Oi\J The carburetor is of a variable -venturi type, whose venturi cross section area is increased or decreased automatically by the piston accord ing to the vacuum present on the dow nstream side of the ven turi . Vacuum is adm i tted into the diaphragm chamber through an orifice provided in the p iston . Rising vacuum overcomes the spring force , causing th e piston to rise to increase the said area and thus prevent the ai r vel ocity from increasing. Thus, air velocity in the venturi passage is kep t re l atively constant fo r improved fuel atomization and for securing an optimum ratio o f fuel to air in the mix tu re.
L_-
4· 5
FUEL AN D LUBRI CATION SYSTE1vl
SLO'N SYSTEM This system sup pi ies f uel during engine oper ation vvith throttle valve closed or sl igh t opened. The fuel from float chamber is first passed and metered by pil ot jet where i t mixes w ith air comi ng in through pilot air jet. This mixture, rich w ith fue l, then goes up th rough pilot p ipe to pilot screw. J.\ part of the m ixture is discharged into the ma in bore out of bypass ports. The remainder is then metered by p ilot screw and sprayed out into the main bore thro ugh pil ot out let.
¢:J Air
¢:J
Fuel/ Air mix t ure
~ F ue l
-\\1~ - ~tl-:
,_.,\ fiO'I S'rST::\1
·------------------------·---------------------'-·_,c_____________
j.r)
MAIN SYSTEM As throttle valve is opened, engine speed rises, and this increases •/acu um in the ven turi. Conseq uent!'/ the piston valve moves upward. Meanwhile, the fuel in f loat chamber is metered by m ain jet, and the metered fuel enters needle jet. in which it m i xes with the air admitted through main air je t to form an emu l sion. The em ulsified fuel then passes throu gh the c learance between needle je t and je t need le, and is discharged into th e venturi , in which it meets main air stream being drawn by the eng ine. 1\il ix ture p roportioning is accomplished in needle jet; the c learance through which the emul sifi ed fue l must flow is large o r small, depending ultimately on throttle position .
=~~ ; I
I
I
I
I
I
I I I I
I 1
I
I
I :
: l -- - - - - - - - - - - - -j I L - -- -
• '=-:
-~-
- - -
A11
··.._"---· Fu el A.r m1xture ~Fu e l
- -'
4· 7
FUEL AND LUBRICATI ON SYSTE1vl
ST ARTEPl SYSTEM Pull ing out the ch oke lever sli des sta rti ng p lunger to d raw fue l .i nto the start er circuit from the f loat chamber th rough starte r j et. Starter jet mete rs this fuel, which then flows into starter pipe and mixes with the air com ing from the
fl oat cha mber.
The mi x ture, rich in fuel
content, reaches starting plunger and mixes again with the air coming through a passage exte nding
_L
from behind the diaphragm. Th e two successive mixings of fuel with air are such that a proper fuel / ai r mi xture for sta r ting is produced whe n the mixture is sprayed ou t through starter outlet into the main bo re.
¢::J
Air
¢:'J
Fuel/ A ir m1x ture
~Fue l
FLOAT SYSTEM Floats and needle valve are associated with the sam e mechanism, so that , as th e floats move up and down, the needle valve also moves likewise. Wh en fuel level is up in fl oat chamber, floats are up and needl e valve rema i ns push ed up aga inst valve seat.
Under this condition, no fuel enters
the float cha mber. As the fue l level falls, floats go down and need le valve unsea ts itsel f to admit fuel into the cham ber. In this manner, need le valve admits and shuts off fue l alternately to maintain a practically constant fuel level inside the float cha mber.
~Fue l
- -----
- - ·- --
- - -- - - - --'
FUEL Al\10 LUBRI CATION SYSTE1\JI
DISASSEM BLY n
o Remove lower bracket.
Loosen two screws out starter shaft 2 .
1
on starter shaft and draw
a Separate
-- - - -
--------------------------
CAUT I ON:
When pu ll ing out t he starter sha·h , be care·ful not to drop the steel ball 1 and spring 2 from the hole 3 .
-
s D
-
4-8
-----------
Re move the fuel pipe pipes g_ Loosen four screw ~ bracket.
and two breather and remove upper
two carburetors and remove two throttle valve scre'NS 1 and thro tt le valve by turning shaft 2 .
4-9
FUEL AND LUBRICATION SYSTE1 1,1
----------------·----------~·~· -···---~-------~~
?
Remove "E" ring and draw out throttle valve shaft
.) Remo,,e float
1 ,
mai n JeC ~ and pil oc jet
I.
1I OTE:
Do not rniss the 0- ring
J
D
-~
.
Remove the needle 'lalve I
Remove float chamber.
J
Take oH carburetor top cap and th rottle cable ho lder by unscrewing 4 screws.
f=UEL AND LUBRI CAT ION SYSTE1vl
o Remove the spring and piston valve from carbu -
retor body.
4-1 0
FUEL LEVEL I i\JSPECTI Oi\J o Remove carburetor dra in plug I and install the fuel level gauge 2 .
099 13-14540
0
Remove circlip
i
09900-061 08
Fuel level gauge set
from the piston. Circlip rem over 1.>
Run the eng ine at the idling speed (1, 150 1,350 r/m in) , and measu re t he distance ,-8 with the middle li ne of the leve l gau ge aligned with the mating surface of float bowl as shown in photo.
f; shou ld be with in the specif ied range.
Distance
~
NOTE: ldent ifv the two piston valves removed a.; "R" or "L", in order to make sura each will be restored t o tha carburetor from which i·t
I
was taken out ----------
.J
A
4.0 ± 0.5 mm (0.14 ± 0.02 in)
4· I I
FUEL t.\ N0 LU8 RICATI 0 t\J SYSTEVI
NOTE:
FLOAT HEIGHT ADJUSTM ENT
When refitting the screw, be sure to use the "0" r ing 2 .
To chec k the float heigh t, invert the carburetor body, holding the fl oat arm pi n so t hat the pi n will not sl ip off. With the float arm kep t free, measure the height 8 while float arm is just in contact w ith needle valve by usi ng the calipe r. Bend the tongue l as necessary to bri ng the
o When fu el level readjustmen t is necessary, see
th e following item for adjusting float height.
height
'B
to th is va lue .
Float height ~
2 '1.4 .t 1.0 mm (0.84 ± 0.04 in)
NOTE :
When measuring ·float heigh·t, be sure to remove the gasket. - - - -- - -
FUEL AND LUBR ICATION SYS-Ct\1
NEEDLE VA LVE
REASSEMBLY
I f foreign matter is caught between the valve seat
) Place tongue
and the needle, the gasoline will con tinue flowing and cause it to overflow.
4-12
of diaphragm to carburetor
body oroperly.
If the seat and needle
are worn out beyond the permissibl e limits, similar trouble will occur. Conversely, if the needl e sticks, the gaso li ne will not flow into the float chamber. Remove the car bu reto r, f loat cham ber and floats, and clean the float chamber and fl oat parts with gasoline.
If the needle is worn as shown below,
replace it together with a valve seat. Clean the fuel passage of the mixing cham ber with compressed air. -----------,
i)
When fitt ing throttle valve shaft oil seals, groove should be faced outside
:1)
Check
following
items
for
any
I .
damage or
c logging.
* Pi l ot jet * Main jet ~
Main air jet
• Pil ot air jet
* Needle jet air bleed ing hole * F Ioat * Needl e valve mesh * Diaph ragm • Gasket +
Th rattle valve shaft oi I seals
• Drain plug 0-ring
* Pilot outlet and bypass holes
a Wh ile turning the throttle valve shaft, place the throttle valve in the groove so that the I. D. number 1 of the thro tt le va lve faces downside.
Tighten the throttle va lve securing screws
wi t h applying thread lock cement .
99000-32040
SUZUK I Thread lock cement
4- 13
FUEL AND LUBRICA TION SYSTD1I
') When engaging two carburetors, be sure to fix fuel pipe
1
n When inserting the sta rter shaft install the spring and steel ball to the hole and push them down by small screw driver .
and position throttle valve control
lever 2 correctly.
<>
Apply thr ead lock cement to uppe r and lower bracket scre ws 1 .
j)
Wh en mou nt ing starter shaft, align sta rter va lve screw wi t h dent mark 2 on start er sha f t and grease sliding por tions.
99000-32040
Thread lock cement
CD
IÂŽ
FUEL AND LUBRI CATION SYST: 'vi
1)
Set each throttle valve in such a way that its top end I meets the foremost bypass 2 . This is accomplished by turning throttle valve stop screw 3 and balance sc rew 4 .
D
l>
4-1 4
Check to be sure that vacuum pi pe l is clamped properly and fuel hose ÂŁ; and two breather pipes -~ are connected.
Fix the mesh rings 'I) 10 the carburetor intake .
4-15
FUEL AND LUBRICATIOrl SYSTE ,\;1
BALANCJ l\JG CJ.\RBURETORS
1
The two carburetors must be balanced after disassembli ng the engine or the carburetors. As the first step, calibrate the carburetor balancer gauge, as follows:
099 13-131 21
Carburetor balancer
099 13-14910
Throttle va lve adjust wrench
Turn the air screw ~ of the gauge so that the vacuum acting on the tube of that hose will bring the steel bal l 4 in the tube to the center line
I. 'M"
,..
••
o Start up the engine and run it in idling con dition for wa rmi ng up. o Stop the wa rmed-up engine. Remove vacuum inlet screw 1 fo r "R" or " L" cylinder and insta ll adapter 2 wi th 0-ring.
0991 3- 13140
Adapter
After mak ing sure that the steel ball stays steady at the center line, disconnect the hose fro m th e adapter and connect the next hose to the adapte r . Turn air screw to bring the other steel ball
'>
£
to the center line.
Tie one of the four rubber hoses of the balancer gauge to th is adapter, and start up the engine, and keep it running at 1,750 r/ min by tu rn ing throttle stop screw. ~
Remove the vacuum in let screw for the other cyli nder, and insta ll the other adapter. , Have the two hoses, mentioned above, connected to the two, "R" and "L", adapters. Run the engine at steady 1,750 r 1min and, under this running condition, see if the two steel balls stay equally at the center level line, as they shou ld, to signify that the two carburetors, "R" and " L", are in balance. if not, loosen lock nut and tu r n t hrottle balance screw 1 to adjust the throttle valve setti ng in "L" carbu retor to bring its steel ball to the cen ter leve l l ine.
FUEL AND LUBRICATION SYSTE.\1
Turning the balance screw will tend to change engi ne speed; if any change is noted, restore the speed to 1,750 r/ min by turning the D
throttle stop screw. Having checked to be sure that the two carbu 路 retors are in balance, remove the adapters and restore vacu um inlet screws, thus completing the procedure. Remember, each time the carbu路 retors are balanced as above, the engine id li ng speed setting must be re-established in the man路 ner set forth under the title "IDLING ADJUST路 IVIEi\JT" (page 2-8).
1\JOTE: * Each vacuum in let screw has a gasket
4-16
2 .
Be carefu l not to leave out this gasket.
* If eng ine is run with fue l tank removed , be sure to plug the fue l cock lfacuum line.
4-17
FUEL AND LUBRICATION SYSTE\1
LUBRJCATJON SYSTE J\fl Oll PRESSURE Start the engine and check if the oil pump pressure indicator ligh t is turned on. If it keeps on lighting, check the oil pump pressure indicator light circuit. I f it is in good con dition, check t he oil pump pressure in the following manner: () Install the oil pressure gauge l in the position shown in the figu re. u Warm up the engine as follows: Summer 10 m in. or so at 2,000 rl min. Winter 20 min. or so at 2,000 r 1min. o After warming up operation, increase the eng ine speed to 3,000 r/ min , and read the oil pressure gauge. ~ The oil pump p ressure is specified below:
OI L PRESSURE SPECIFICATIOI\J Above 3 .0 kg/cm 1 (43 psi), Be low 5.5 kg/cm 1 ((78 psi) at 3,000 r/m in 099 15-745 10
Oi I pressu re gauge
099 15-77330
Gauge (0 - 10
kg/e m~)
If t he pressu re is too low, it means that the oil pump is internal ly worn or otherwise defective and needs to be overhauled. l'f inner parts are found to be worn down to or beyond the limit , replace the complete oil pump unit . (See page 3-48)
01 L SUMP Fl LTER At the same time wash the oil pan. Check to be sure that t he su mp filter is free of any sign of rupture and wash the sump filter c-lean perio dical ly.
4-18
FU EL AND LUBRICATIO i\J SYSTE1\1l
CAMSHAFT JOURNAL
CON ROD BIG END BEARING
TACHOMETER DR IVE GEAR
. - - - - -1 ROCKER
ARM SHAFT
I .-----'---~ i.l â&#x20AC;¢ , - - ---'--- - - , COUNTER BALANCER GEAR
CYLINDER WALL
~
COUNT ER BALANCER BEARING CAM FACE
CON ROD SMALL END
~ ~
CRANK SHAF T JOURNAL
t ~ ~
.
CAM CHA IN
\
4 J ~
'~
- - - ---- - -,
~BYPASS COUNTER SHAFT BEARING
COUNTER SHAFT GEARS
~ ~ CLUTC H PLATES PR IMARY DR I VEN GEAR
J
~
4- 19
FUEL Ai\10 LUBRICATION SYSTE 1\JI
• ..
..EMISSioN coN-iROL & REaUU noNs .
.
.
.
.
.
CONTENTS - - - - - - - EMJSSJON REGULATIONS .................................................................................... 5- 1 EMISSION CONTROL CARBURETOR COMPONENTS ........................ SQ 2 GENERAL EMISSION INFORMATIO N ............................................................5A 3
.·... ,:.]
5-1
E,\JISSI 0 i\J
CO~I TR OL
Al\1 0 REGU LA Tl 0 1 \JS
EM ISSl ON REGULATJOJ\JS On February 4, 1977, Federal Emiss ion Regulations for motorcycles that may be licensabl e took effect. Th e regu l ati ons provided for a gradual , mul ti -step application of stricter em ission lim its beginning w ith all effect ed motorcycles manufactured after Janua ry 1, 197 8, c lum inat ing with the present 1980 emi ssion leve l restrictions. For the 1980 and succeeding years one set of emission lim its is in effect. They are as follows:
1980 EiVII SSIOt\1 LIMJTS CATE GO RIE S
HY DROC ARBONS (HC)
CARBO N MONOXID E
5.0 Grams/ Kilometer (8.0 Grams/ Mile)
12 Gams/Kilometer (19.3 Grams/ Mile )
-------------------------
f--- - - - - - - - - - - - - - - - - -
All motorcycles 50 cc - Larger
----
Em ission-controlled motorcycl es wh ich are subject to the em1ss1on regulations are th ose motorcycl es wh ich ar e equ ipped with a headlight, tailligh t , stop light and wh ich have an engine displacement larger than 50 cc . Su zuki Motor Company performed all the necessary testing and certification of emiss ion -controlled models in strict comp l iance w ith the E.P .A. testing reg ul ations.
Suzuki motorcycle deal ers are not re-
qu ired to either test o r certi fy emiss ion levels on any motorcyc les as Suzu k i Motor Company is legally respons ible for the entire certification procedure. E.P .A. regu l ations also provide f ines fo r individ uals w ho al ter , render in operative or impr oper ly service em iss ion -controlled motorcycl es ranging up to $10,000.00 per motorcycle. dividual se rvi cing
this em ission-controlled
presented in th i s manua l.
I t is essential that the in-
moto rcyc l e review thoroughly all the service procedu res
Under no circumsta nces shou ld t he recommended service procedures be
deviated f ro m nor adj ustments made wh ich are not in accordance with th e factory specificati ons or servi ce procedu res.
EivllSSION CO NT RO L AND REG ULAT IONS
5-2
EM ISSION CO NTROL CARBURETOR GOlVlPONENTS GS250T motorcycles are equipped with precision, manufactured carburetors for emission level control. These carburetors require special mixture control components and other precision adjustments to function properly. There are severa l carburetor mixture control components in each carburetor assembly . Three (3) of these components are machined to much closer tolerances than standard machined carburetor jets. These three (3} particular jets - MAI I\J JET, 1\JEEDLE JET , PI LOT JET - m ust not be replaced by standard jets. To aid in identifying these three (3) jets a different des ign of letter and number are used . If rep lacement of these close tolerance jets becomes necessary, be sure to replace them w i th the same type close to lerance jets ma r ked as in the examples shown below. The jet needle is al so of special manufacture. Only one clip position is provided on the jet needle.
If
replacement becomes necessary the jet needle may only be replaced with an equivalent performing rep lacement component. Suzuki recommends that Genuine Suzuki Parts be utilized whenever ' possible for the best possible performance and durabil ity. Conventional Figures Used on Standard Tolerance Jet Components Emission Type Figures Used on Close Tolerance Jet Components
1 2 3 4 5 6 7 8 9 0 -I 2 3 Lf 5 5 7 B 9 0
The carburetor specification for the emission-controlled GS250T are as follows. Carburetor I.D. No. 11 420
Main Needle Jet Jet - - - -Left0- '7 =/IS Right0-8
Jet 1\Jeedle
Pilot Jet
Pilot Screw
5CT40
t;/'/.S
PRE-SET DO 1\JOT ADJUST
The pilot screw is pre-set by the facotry utilizing specialized testing and adjusting procedures. The pilot screw is not adjustable as the idle circuit is "sealed" after factory adjustment. Ad justing, in terfer ring with, improper replacement, or resetting of any of the ca rburetor components may adversely af fect car buretor performance and cause the motorcycle to exceed th e exhaust emission level limits. If persons, who are unaware of t hese special carburetor servicing requirements tamper w ith the car buretors the Suzuki dealer shou ld restore the carburetors to their origina l co ndi tion or if unab le to effect repa irs, contact the d istributors representa tive for further technical inform ation and assistance.
5-3
E1viiSSION CONTR OL AND RE GULATI ONS
GENERAL EIVli SSl ON I NFORM ATl OJ\J There are three different types of reg ulat ed exhaust emissions. T hey are: Hyd rocarbons (HC) Carbon Monoxide (CO) Oxides o f N itrogen (NOx) Automobiles must meet sp ecific emiss ion standards for all three of these pollutants. Motorcycles must only meet the requiremen ts fo r the fo l lowing: Hydr ocarbons ( HC) Carbon Monoxide (CO) HC exhaust emissions are basically unburned fuel vapors which have passed through the engine and escaped the combustion process. CO exhaust em issions ar e for med during an incomplete combustion cycle as a resu l t of a rich air/ fuel mixture. The on ly way that CO can be produced is by the combustion cycle. Total NOx emissions from all m otorcycles is considered neg ligible. The EPA states that total NOx emission from motorcycles by 1980 w ill on l y amount to appr ox imately 0.5%. NOx is fo rmed during the combustion process at high combustion chamber temperatures.
CARBO i\J M O N OX I DE Carbon monoxide is a product of an imcomplete combustion cycle. CO is measured in grams per mile or kil ometer and also in perce n tage (%). The most common cause of CO is r ich carburetion. As the mixture is ri chened excessively, th e CO amount increases proportionately. Engine oil is also a hydrocarbon, so engine problems which lead to oil burning increase carbon monox ide.
CARB U RET 10 N MALF UN CT ION 1. Air Cleaner - Dirty or over oiled. 2. Idle Mi xtur e -Ad justed incorrectly . 3. Idle Speed- Too high or low. 4. Fue l Level - Sticking float , leaki ng needle, incorrect sett ing . 5. Choke - Lea ki ng or linkage sticking. 6. Synchronization - Improper balance on multi cyl inders.
ENG IN E M ALFU NCT I ONS 1. Valve Seals- Leaking or torn. 2. 3.
Va lve Guide -Worn and leaking excess oil . Gaskets - Leaking oil into combustion chamber.
E¡"li SSiO \i CONTROL AND REG ULATIONS
5-4
HYDROCARSO i\I S Hydrocarbons are unburnt gasoline vapors and can be measured in two different vvays . The first is to measure the weight of the pollutants over a specific distance such as grams per mile or grams per kilometer. The second method is to measure the concentration of HC in the exhaust gas in parts per million (PPM). The most common cause of high HC emission are i~J nition system problems. If the ignition system fa ils to ignite the fuel mixture properly, then raw gasoline vapors '!Viii pass through the engine into the exhaust system. Listed are the most common i gnition problems wh ich occur and which can affect HC emission output
I GNI TION SYSTE M MALFUN CTIOi\JS
1. Spark Plugs - Fouled, dirty, improper type or improperly gapped. 2.
Ign ition Tim ing -
3. 4.
Timing Advance - Too fast or too slow an advance rate. Battery - Low charge or faulty.
Advanced or Re tarded.
Ca rburetion can also lead to high HC emissions if the mixture 1s either excessively rich or excessively lean.
MI XTURE-RELATED MAL FUNCTIONS
1. Air Cleaner - Dirty, over oiled or torn. 2. Jets - Clogged, restricted or incorrect size. 3. Float Level - Level too low (lean) or too high (rich ). 4. Choke - Leak ing choke plunger or sticking l1nkage. 5. A ir Leaks - Intake manifolds, engi ne gaskets and other seal ing surfaces. 6. Synchronization - Un balanced on multi-cylinder machines. 7.
Exhau st System - Restricted flow or improper exhaust system.
Engine wear or damage can also cause high HC emissions.
1.
Ring- Lovv compression, leakage into crankcase.
2. 3.
Valves - Improper adjustment, bent stem or burnt. Gaskets - Leaking, loss of compress ion .
4. 5.
Cran k Seals - Leaking. Oil Consumption - Worn valve guides, worn ri ngs, clogged crankcase breather.
6.
Oil -
Improper engine oil.
;! · . .
''"-Tif'"! .; .. :·','"; ' "' • ... -•--. c,>' '' ;~[~ ., '•'•'f'·V;.:,; ~: ''~j •,)t ~"'' ·, .
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·. ·.p; ··?'' '' "")' ~ _-., 0 - '7'7""''i"1F • '. •. ·> ·,o,r -::~·r.m ;, ·; .,,~- ' •' 1 ·_- .,-. ' ·:
.
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:· • _- . .
.,,
I
lltECttfiC:AL SYSTEM .• . . . . .· '!:.~,
~:·
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CONTENTS -
JGNdTJO!A1 SYSTE:Ail .......................................................................................... s~ 1
·CJa-.JA.RGING S YSTEhl .................................................................................... So 5 ST.ARTER SYSTEM ....................................................................................... 5~ 9 COMB:Jf!wlA TJO~l llllETER................................................................................. 6~ 14 SYI!JTC/ri:ES ......................................................................................................... So 17
BAITERY .............................................................................................................. 6~20 L.AM!PS.................................................................................................................... 6Q24 -
--
- - -- --
-
-
-
- --
'
6-1
ELECTRIC.-"L SYSTC:,\1
l GI\JJ TI ON SYSTE M DESCRJPTJ Ol\J A ful ly transistorized , non-contact points, ignition system is newly employed in the new GS250T. The new transistorized ignition system consists, as sown in the fol lowing figure , of a signal generator composed of one rotor and two coils, transistor un it, ig nition coils, and spark plugs.
<>-~
SIGNAL GENERATOR
F """""",..,...,.9 1 1 Br
i C:f'-~ 1I
J
0
o
IG NITOR r==-~=a==-,.,
G; W
IGNI T ION SWITCH
IGNITION COIL
1l
J
l C'~ J
SPARK PLUG
1
.,__~
be."""""""""......~
SPARK PL UG
b ZQ;:J1Q:JagD~
'i"
: BATTERY
..L
IGN ITION COl L
l
--------· A DVANTAGES OF THE TRANSISTOR IZED I GNI TIO N SYSTEM * Troub le free operation due to elimina tion o·f contact breaker points which can become contami nated . * Ign iti on timing is maintained properly at all times and require no mai ntenance. * Free from arcing and provides the ignition coil with stable secondary vo ltage. * Excellen t vibration and moisture resistance .
~--~~-__...._............,.
.:: U:CT ,11'~ .-\L SYST: \1
___
6·2
-'-"'-"'--~~---~- ~
I i\.J£PE CTI ON IGN I T I ON CO I LS (Checking with e lectro Tes·ter) Using the electro tester, test each ignicion coi l fo r spark ing performance . Test connection is as ind icated. ivlake sure that the three-needle spar k· ing distance is at least 8 mm (0.3 in). If no sparking or orange color sparki ng occures with this much gap, then it is defecti'Je and must be replaced.
[
09900-281 06 STD Spark performance
Electro tester 8mm
(0. 3in )
-~
__j
.._,
8 mm (0.3 in)
""
---1 I I
IGNITION CO l LS (Checking with Pocket Tester) A SUZUKI pocket tester or an ohm meter may be used, instead of the elec tro tester. In either case, the ignition coil is to be checked for conti nui ty in both primary and secondary wind ings. Exact ohmic readings are not necessary, but , i·f the vvindings are in sound condition, their conti nuity will be noted with these approximate ohm ic values.
09900-25002
L
Pocket tester
L ______~ Ignition coil r esis tance Primar y Secondary
0 / W - W or 8 / Y Approx 3.5 - 4.5.\1 ----~ ---·Appro;<. 23 - 25k.\1 Plug cap 1/1/ or 8 / Y 1
~-·-
r---- ---- -, I I
I
I I
I
: I I I
I I
l
l'>EB-: ________
-- - - -
\..
...)
·--------------'
6-3
ELE CTR ICAL SYSTE\1
SIGNAL GEi\JERATOR Measure the resistance between lead wires . If the resistance noted to show infinity or too low resistance value. signal generator must be rep laced.
09900 -25002
Pocket tester
STD resistance Bl - G
60 -
80~!
IGNITER Remove the spark plugs from the right and left cylinders. Re-fit the spark plugs to the respective plug caps and place the spark plugs against the cyl inder head.
Remove the right f rame cover and disconnect the lead wire reachi ng from the signal generator . T urn ON the ignition switch and connect the pin o f the pocket tester (x1Q range) to 8/ W, pin to Br and G/W and then connect the al ternately. If the right p lug sparks, with the pi n co nnected to Br, and i f the left one sparks, with the pin to G/W, the igni ter is good.
NOTE: This checking presupposes tha¡t the ignition coi I used for checking â&#x201A;Źl good one.
Main wire harness
S-gener ator
'----------
- - -- -- --
-
-------
-
---------
6-S
ELECTRICk_ S'(ST':\1
·-----
~--
____________
____.,.._..._
Cl-IA RG I l'JG SY STf iVl DESCR I PTI Of'J This motorcycle, the circuit of its charging s';stern is indicated in the figure, is composed of AC genen tor, rectifier/regulator unic and battery The AC current generated from AC generator is r9ctified by rectifier and i5 turned into DC current, then it charges the battery.
-
--- - - - - - r--- _
--- -
__ _
____
------~1
Light ing switch
I
.'\C.Gener3tor
Ragu latc r/R ect i fier
J
IG.switch
I
I
-;;
>
.::.
"' :3
> '-
...... _L Ill "' <II
-~ c
"0 0
I
I
"0
"'
"'0
_.l
_.l
W/ 8 1
---------+--L3}--I
L
_______ . .
== L_
Function of Regulator Whil e the engine r/min is low and the generated voltage of 1-\C generator is lower than the ad justed voltage of regulat or, the regulator does not function, incidentally the generated current charges the battery directly.
6-atL
AC. Generator - - - - -
·- -
wG I
I
; ~
-
I
r
-
9egulator Rect1fier -
- - - --
IG . SWitCh
~rr:--·>----) '--& )
>
"'
"0
"?
,. 0
_.l
I
L
... ~
~
'---- -- - - - -
J
. 'J
_.l
I
- -- - - - - - -
_J
ELECTRICAL SYST~ .I,I
6-6
When the engine r/ min becomes higher, the genera ted voltage o f AC generato r also becomes higher and the voltage between po ints A and B of regulator becomes h1gh accordingly , and when it reaches the adjusted voltage of reg ulator, ZD (Zener diode) sends signal to the gate of SCR (Th yr istor). Then the SCR becomes conduct ive to the direction from point c to point 6 . Namely at the state of this, the cu rrent generated from the AC generator gets through SCR witnoui cha rg ing the battery and returns to AC generator agai n. At the end of t his state, since th e AC current generated from AC generator flows into the point D , reverse current tends to flow to SCR, th en the circuit of SCR turn s to OFF mode and begins to charge the battery agai n. Thus these repetit ions maintain charging voltage to the battery constant and pro teet it from overcharging .
- -------Light ing sw1tch --- -AC Generator
~----
-----}l
-- - - - - - - --,
J
IG. switch
~ - -
WG~ > t ,_. ,_.
I ..)
B
L - - - - - - - - - -"
'L - -
I
-L.QJ"'
8
________
_
_.J
>-
E
~
-~
-o
"0
_J
..J
"'0
c
"' 0
6·7
ELECTRICAL SYSTE\1
JNSPECTJON CHARGI NG OUTPUT CHECK Start the engine and keep it running at 5 000 r/min wit h the dimmer switch turned HI position. Using pocket tester, measure the DC voltage between the battery termina ls.
i\JOTE: IJIJhen making this tes·t, be sure that the batterv is in a· fu lly-charged condition.
STD cha rging output 09900-25002
14-15V(DC) at 5 000 r/ min Pocket tester
AC GENERATOR 1\JO-LOAD PERFORMANCE Disconnect t he three lead wires from the AC gene rator terminal. Start the engine and keep it running at 5 000 r/min. Us ing the pocket tester, measure the AC voltage between the three lead wires. STD No- load performance
75 V (AC) or Over at 5 000 r/min
--
--------'
ELE CTRICAL SYSE,\1
Using pocket tester, check the continuity between the lead wires of the stator. Also check that the stator core is insulated. NOT E :
When making this test, i't is no t necessary to remove the AC generator.
09900-25002
Pocket tester
REG U LA TOR /RECT I Fl ER Using pocket tester (X1 r2 range), measure the resistance between the lead wi res in the following tab le. If
the resistance checked is incorrect, repl ace
the regul ator /rectifier .
o ,' ~j , .., \-
... <\)
0
Ql
J:J 0\-
a.
-,--
y
W/R
W/ BI
B/W
-~
R
VI
~
::: probe of tester to
-R
J ...___
00
00
-
'
W/ BI 5-6r2 W/ R
5-6S1
y
5-6n
00
-
.......____
00
- - --
00
00
co
00
00
' 00
00
00
-......,
~
'-"'
B/vV
35- 45.11
5-6S1
5-6.11 I
5-6S1
00
~
3-d
6¡9
ELECTRICAL SYSTE .\1
..
-----------...-.._..~
STARTER SYSTENl DESCRIPTJOi\l The starter system is operated by starter motor, starter relay, starter switch, ignition switcrr, and battery. The diagra m be low shows the electrical circui t of starter syste m. When the starter switch is "Oi\J", the plunger is forced to link the main contact points of the relay by the magnetic force of the coil. The current from the battery novv flows to the starter motor through these connected points, and next the starter motor makes the engine start to run.
Starter switch
L
IG . Switch
L~- ~l ~ Fuse ~rrv-r~
I
STARTER ivlOTOR
I 1 Battery I I -..I.-
1 -----~------
---------
----------
ELECT RIC A'L SYST E'l1l
o·IO
STARTER i'V10T OR Dl SASSE M B'L y
_j
6·11
ELECTRICAL SYSTE .\1
STARTER MOTOR I i'JSPECT I ON CJ..\RBOi'J BRUSHES When the brushes are worn, the motor wi II be unable to produce sufficient torque, and the engine will be difficult to turn over. To prevent this, periodically inspect the length of the brushes, and replace them when they are too short or chipping .
~ervice Limit
''
9 mm (0.35 in)
COMMUTATOR If the commutator surface is dirty, starting performance decreases. Pol ish the commutator with .:;400 or similar fine emery paper •Nhen it is dirty. After polishing, wipe the commutator with a clean dry cloth.
Measure the comutator under cut
I .
I ~rvice__L_im--it_________o_.2__m_m__(_o_.o_o__8i_n_l__~ I
/
" SEGIVIEI\IT
------ -t.\R MATURE COIL Using a pocket tester, check the coil for open and ground by placing probe pins on each com mutator segment and rotor core (to test for ground) and on any tvvo segments at various places (to test for open), with the brushes lifted off the comrnu tator surface. If the coil is found to be open-c ircuited or grounded, replace the armature. Continued use of a defective armature will cause the starter motor to suddenly fail.
''
..~ ''• , ..
··•
..
I'
,, . '
i,
ELECH1 1 C~L ------------------------------------------~~----------
-
09900-25002
- -·-----
SYSTE\1
6-1 2
- - - - - - -- --------,
I
Pocket tester
I
STARTER MOTOR REASSEIVlBL Y
AI ign the protrusion I of the housing with notch 2 of the top ca p and fit them together.
Fit the protrusion 1 of the housing to the dent 2 of t he end cap while pushing the carbon brus hes w i th fingers. Tighten the two screws securely.
/
6-13
ELE CTR ICAL SYS Tfl\11
STARTER RELAY li\JSP'ECTIOJ\J Disconnect lead wire of starter motor at the starter relay. Turn on the ignition switch, check the continuity between the terminals of the starter relay. If cont inuity is found when pushing the starter button, the starter relay is in sound condition.
Check the co il for "open", "ground" and ohmic resistance. The coil is in good condition if the resistance is as follows. STD resist ance
3 - 4D
''--==e====:=;===~
ELECTRICA L SYSTE\'
C O~;l B J
NJ.\ T l ON l\IJ ETER
REM OVAL Remove seat.
Take of f fue l tank. NOTE :
When tak ing o'f'f fuel tank, disconnect fuel hose and vacuum hose and turn 'the f uel cock lever to "Oi\J" or " RES" position.
Disconn ect the co uplers fro m combination meter.
Disconnect speedometer and tachometer cab les.
o¡ l -l
"" 1t- L t- c·rR·Ir -\L SYSTE\_1_- --~:...2_ ~-'J
Remove Combinati on me ter mou nti ng nuts and take off meter.
DISASSEMSL y
I
I
I I
I I
I
~LECTRICf\L
SYSThl
6- 16
I NBPE CTl Of\J Using pocket tester, check the continui ty between lead wires in the following diagram. If the con ti nu ity measured is incorrect , rep lace the resp ective part.
09900-25002
Pocl<et tester
lj\JOTE: When making this tes¡t, it is not necessary to rerno11e the combination rnetef.
f\IEWTRAL
M.L CD
~
C1>
..J
CD
OIL
C1>
..J
I
I I L
I
--~---J
6- 17
ELECTRICAL SYSTEt\1l
SVVJTCHE S Inspect each switch for cont inuity with the pocket tester referring to the chart .
09900-25002
~
It l
Pocket tester
IGNITIOt\J SWITCH Wire color
R
0
Gr
Br
~ ----------------------------------1 ~
OFF
-------------------------------~
o- --{)
ON p
--
o-------------<
ENGINE STOP SWITCH Wi re color
0
0/1/1/
-o
RUN OFF
-
STARTER SWITCH Wire color
----
-
ON (Push) OFF
0/W
Y/G
o- --- --o -----
------
- - - -- ----
l:NG I ~E.
--
STOP
~OFF
~RU~
-------,
ELECT8 1CAL SYSTE',I
DIMM ER SWITCH y
Wire color
w
Y/W
HI LO
TUR N SI GNAL L IGHT SW ITCH 1/1/ire co lor
Lbl
8
-
f-
R
()--
Lg .----()
-
)
·-L
0
---o
-
--
HORN SWITCH Wire color HORN 1-----
G
BYW
o-
0
---
OFF
,....
F ROi\J T BRAKE LIGHT SWI TCH Wire color ON 1-
OFF
\JV
0 ·I - - - . . . , - · _J__ _
o--~
I
STARTER DISCONNECT SWITCH Wire color ON OFF
Y/ G
o-
Y/G 0
v
'
6-1 8
6-19
ELEC TRICAL SYSTE,\1
REAR BRAKE LIGHT SWJTCH Wire color
0
w
1---------------------r-- - - - - - - - ---<0 ON of--- - - -
OFF
OIL PRESSURE S'JI/1TCH Continuity, when engine is stopped. No conti nuity, when engine is running. i\JOTE : Be·fore tes·ting the oil pressure switch, check the engine oil level. '--------· -
/
i\JEUTRAL INDICATOR LIGHT SWITCH Co ntinuity, when gear posit ion is neutral. No continuity , when the other posi tions.
I
ELECTRICr\L SYSE\,1
o-20
BATTERY DESCR IPTION YUASA YB1 OL-A2 vacuumsealed dry cell battery is furnished with every GS250T. All necessary information is contained in the instruct ions given under the heading of INITIAL CHARGING IVIETHOD. The battery's serviceable life depends mainly both on initial charge and on the attention it subsequently receives. Each GS250T user should be reminded of the importance of giving proper care to their batteries.
SPECIFICATIONS Type designation Battery val tage
Y[' 10L-A2
Capacity
schedule
12 val ts
---
Standard electrolyte S.G.
2. lntial charging duration The act:ng materials on the cell plates have a store of energy equ iva lent to 75% of the rated capacity if the battery is new manufactured recently . This stored energy, however, dissipates spontaneously and progressively with lapse of time, so that, after filling it with electrolyte, the charg ing duration must be extended if a period of more than 6 months has elapsed since the date of manufacture (which is indicated on each battery as shown in picture. The standard initial charg ing duration being 20 hours. The charging time is to be determ ined according to the following
----
1. 280 (at 20°C or 68°F) --12 Ah/ 10 H R
Age of d ry battery (since manufacture) -Up to 6 months
Charg ing time 20 hours
Over 6 months or up to 9 months
30 hours
Over 9 months and up to 12 months
40 hours
Over 12 months
50 hours
-
INITI AL CHARG IN G METHO D Each new GS250T motorcycle IS delivered with the battery in a "vacuum-sealed dry" condition. The battery can be used after conducting the four following steps:
is ind icated by a threeDate of munufacture part number, the leftmost part indicating for t he
1. Initia l electro lyte filling
months, the middle part the year, and the last part the day of the month.
Take the battery off the motorcycle, and place it on a battery servicing bench. Fill each cell to the upper level with electrolyte: Dilute sulfuric acid solution with acid concentration of 34.6% by weight, having a speci fie gravity of 1.28 at 20°C (68° F). Electrolyte temperature, at the time of filling, should not be higher than 30° C (86° F) . After filling, let the battery stand for about 30 minutes. Then, check electrolyte level in each ce ll and, if the leve l in any cell has fallen add more electrolyte to bring it back to the upper level.
--___
..
.
CD
6-2 1
ELECTRI CAL
SYS TE~,J
3. Initial charging current The constant-current method of charging is recommended for initial charging, and is carried out in the following manner. 1) Before turning on the charger, to which the filled battery is connected, remove the sea l cap 2 and cell caps 3 . Make sure that the polari ty marks are matched correctly.
BATTERY SERV ICi i\I G
Removal 1. Remove left and right frame cover. 2. Disconnect (- ) lead wi re from the starter relay and( +) lead wire. 3. Disconnect the breather hose and take out battery.
Installation Before mounting the battery, make sure that the exterior surface of the battery containe r is dry and free fro m electrolyte. Be careful not to forget to re-connect the battery breather hose. The insta ll ing procedure is the reverse o f removal .
2) Sta rt charging, wi th the charger set for a maxim um charging rate of 1.2 amperes. Whil e c harging, occasiona lly check the electrolyte S.G. (specifi c gravity) an d also the charg ing vo ltage, particularly towards the end of the cha rg ing time. 3) Towards the end of the charge, the electrolyte will start releasing gas bubbles and the voltage and S.G. wil l be up and leveling; if not, it is likely that the vacuum seal was damage during tra nsit or in storage. Continue cha rging, even in excess of the predetermined time, un til the voltage and S.G. stay level , fo r one or two hours, with the battery allowed to con¡ t inue releasing gas. 4. Elect rolyte adjus¡tment After charging re-check the electrolyte S.G. to make sure it is 1.280 corrected for 20° C (68' F) . Add dist iled water, if necessary, to adjust the S.G. of each cel l. Replace the caps, and wash the surfaces of the battery container with fresh water. Let the battery dry before mounting it on the motorcycle.
CAUTION MIS~
i MGARD~
EL ECTR IC AL SYSE \1
Inspection 1. Visually inspect the surface of the battery.
If
signs of cracking o·r electrolyte leakage from the sides of th e battery are noticed, replace the battery with a new one.
6·22
To read the S.G . on the hydrometer, bring the electrolyte in the hydrometer to eye level and read the graduat ion on the f loat sca le corresponding to t he meniscus (curved portion of electrol yte
3. Check the electro lyte level and add distilled
surface), as shown in fi gure. Check the reading (corrected for 20, C) with figure to determine the recharging time in hours by constant-curren t charging at a charging rate of 1. 2 amperes (which is a tenth of the capacity of th e present battery ).
water, if necessary, to ra ise the electrolyte in each cell to the upper leve l.
Do not permit the electrolyte temperature to exceed 45° C ( 1 I 3° F), at any time, during the
2. If the battery terminals are found to be coated with rust or an acidic white powdery substance, then this can be cleaned away with sandpaper or hot water, respectively.
recharging operation . In t errupt the operati on, if necessa ry, to let the electrolyte cool down. The battery is proper ly recharged if th ree conditions are met : Rechargi ng has been carried out to the specification indicated in the graph in Fig. A Electrolyte S.G. has risen to 1.28 or higher and has remained the re for at least one hour. The battery term inal vol tage has r isen to 15 ..
_____
__
16 volts or
higher and has remained there f o r at least one hour .
...._____
Gas bubbles are being released in every cell .
S.G. Reading to correspond ing temperature When reading spec ific gravity by using hydrometer, measure the temperature of the air firstly, and read the accurate specific gravity by the graph below .
If S.G. is less than normal range , recharge or
WARNING:
* Before charging a battery, remove the seal cap from each cel l.
* Keep fire and sparks away 'from a battery being charged. ---
~--
replace the battery .
- - - - - - - - - -,-
i\JOTE:
NOTE: It needs recharging when the grav ity readi ng is 1.22 at 20° C.
. 's j
,.J I
j
Recharge
I :3
' 'lj : :: ~echarge or Replace ')
15
10
:s
Tempe rature
.! D
JS
4.)
Cons·tant·lfoltage charging, otherwise called "quick " charging, is not recommended for recharging because i·t may shorten the li·fe of the battery .
6-23
ELECT RICAL SYSTE\1
()
'o N
T >
~ 1 . 1 6 -~~
~
I . 12 ---t--....._
--~--l.-~-----
'lJ
a. (/)
1.08 _ 0 F1g. A
Hydrometer
_l.__L----- L-~-..:..
2
4
6
8
10
12
Charging time (hour)
14
16
18
ELECTRICAL SYSTE'.I
LA NIPS HEADLIGHT
6·24
6·25
ELECTRICAL SYST Ei\,1
TURN SIGi\JAL LIGHT
TA IL/BRAKE LJGHT_ _ _ _ __
I
_
_ -
------------ -------,
I I
I I I
L __ _
_ _ _ _I
, · ~ • • ~ ;•
•
..
·-··,-~
~
,•''
,;
-~
••-
";
e . . . .·. . .
•I
'
,
'
•.r
,-,-
I
~
·~
'
CHASSIS
~-- CONTENTS ---
~--
.
'
-~
•
-~
•
.
-.
,.., ..-, ,
J
· .·
- - - --·- - -
FRO/liT WHEEL ................................................................................................ 7~ 1 REAR WHEEL ................................................................................................... 1~ 7 FRONT BRAKE .................................................................................................. 7Q15 REAR BRAKE. ..................................................................................................... 7-26 FRONT FORK .....................................................................................................7Q29 STEERING STEM ............................................................................................. 7 ~35 REAR SUSPENSiON ....................................................................................... 7 Q42 - - - - - ----------------
_, ,
,. --··--... . "'1 . ;·
,~,
,
,• 'x
. ,I
1
:·t '
I
' '
,;,
7-1
CHASSIS
FRONT W HEE L RE MOVA L Support the machine by center stand, and jack or block .
Pull off co tter pin and remove axle nut. CAUTIO N : Do not reuse the cott er pin.
Remo ve axle holder nuts and take off axle holder .
Draw out ax le shaft and take off front wheel . NOTE: Do not operate the brak e lever wh ile d ismoun tin g t he wh eel.
CH ASSIS
I 2
3
4
5
-: 6 7 8_
;I
2.
Hub cove r Ax le spacer Wh eel beanng Spacer . Wheel bean ng Disc plate G ar box dust seal e box Speed omete r gear Axle space r
I
I
8
6
Tig hte ning torque
k~m
--- -- 3.6 =-5.2 - -· ·1.5 - 2. 5
lb-ft 26 .0 - 37 .5_
- 11.o-=-1s.o
B
9
7-2
7-3
CHASS IS
Unlock the lock washers. Remove securing bolts and separate the d isc from wheel. CA UTION : Do not reuse the lock washers.
Drive out the wheel bearings right and left. NOTE: Removing the left side bear ing ¡first makes the job easier. CAUT I ON: The removed bearing should be reJ)laced .
L-
JNSPECTION WHEEL BEAR INGS Inspect the play of wheel bearing inner race by hand while fixing it in the wheel hub. Rotate the inner race by hand to inspect an abnormal noise and a smooth rotation. Replace the bearing if there is anything unusual.
CHASS IS
7-4
---------~
Pla y
I
______ _j AXLE SHAFT Using a dial gauge, check the axle shaft for runout and replace it if the runout exceeds the limit. 09900-20606
,--, . l
Dial gauge ( 1/ 100)
Service Limit
0.25 mm (0.01 in)
WHEEL RIM Make sure that the wheel rim runout checked as shown does not exceed t he service limit. An excess ive runout is usually due to worn or loose wheel bearings and can be reduced by replacing the bea rings. If bearing replacement fai ls to reduce the runout, adjust the tension of the spokes, and, if this proves to be of no effect, replace the wheel rim . Service Limit (Ax ial and Radial)
2.0 mm (0.08 in)
~----------
SPOKE i\JJ ?PLE Check to be sure that all nipples are tight, and retighten them as necessary using special tool. 09940-60 113
Spoke nipple wrench
I
Tightening torque
I I
0.4 - 0.5 kg-m (3.0 - 3.5 lb-ft )
---
7-5
CHASSIS
~~-------------------------------------¡----------
HEASSElVlBL Y Reassemble and remount the front wheel in the )
reverse order of disassembly and removal, and also carry out the following steps:
/
WH EEL BEARINGS Install the wheel bearings by using special tool. CAUTION: First install the wheel bearin g for left side.
09924-8451 0
Beari ng installer set
Left side bear ing
Righ t sid e bea r1ng
l__...- Bearing
- Bearing installer set
~
Rightside
Leh side
r
¡+
installer set
Wheel bear ing (11'-rr-m---,---rr-t"'l
fll JLJ
rn
rC
_./)LJ
-1
Wheel bear mg ~
:"~
Wheel hub
IL_ '-----' "-.. ----..
----
l
~ !
Right side
Spacer Left side
___)
I
___ j Apply grease before installing the bearings.
99000-2 5030
Suzuki supe r grease " A "
CHASSIS
BRAKE DISC Make sure that the brake disc is clean and free of any greasy matter. After securing it in place by tightening its bolts, be sure to lock each tongue.
Tightening torque
1.5 - 2.5 kg-m ( 11 .0 - 18.0 lb-ft)
SPEEDOMETER GEARBOX Befo re instal ling the speedometer gearbox gr ease it and align its groove
1 ,
2 , (for fitting to
the hub of two drive pawls) with the hub to insert the gearbox to the wheel side.
When t ightening the fro nt axle, check to be sure that the arrow mark of the speedometer gearbox is in the position shown.
A)(LE HOLDER When securing the axle holder, be sure to tighten the
nuts
on the holder in such a way that
clearances ahead of and behind the axle will become equalized.
Tighten ing torque
1.5 - 2.5 kg -m ( 11 .0 - 18.0 lb-ft)
7-6
7-7
CHASSIS
REAR \IVHEEL RE MOVAL Support the machine by center stand . Remove brake adjuster, and torque link nut after pulling off cotter pin.
CAUT I Oi\J : Do not reuse t he co tter pin.
Remove the bottom side of rear shock absorbers, right and left, from the swing arm.
Pull off cotter pin and remove axle nut. CAUTI ON: Do not reuse the cotter pin.
To remove the axle, raise the rear wheel high enough for the axle to clear the mufflers. Pull the axle from the rear wheel /swing arm and lower the and remove the drive chain from the sprocket. Pull the wheel backwards and remove the wheel from the swing arm assembly.
CHASSIS
7-8
4
,/ /
/
8
I
ÂŁ 3 4
~
i 7 ] 9 10
[ ___
Chain adjuster Spacer Sprocket drum bearing Rear sprocket Sprocket drum Sprocket d ru m retainer Rear drum shock abso rber Wheel bearing ( L) Spacer Wheel bearing (R)
Brake shoe Brake cam 1], Brake panel 1_1, 0 ring 11 Brake cam lever 16 Spacer 17 Ax le shaft
II
Tightening to rque
lJ
kg-m
A.
5.0 - 8.0
lb-ft - -36.0- 58.0
8
2.5 - 4.0
18.0- 29.0
0.5 - 0.8
3.5- 6.0
c
I
-
7-9
CHASSIS
Drive out wheel bearings, right and left. NOT E: Removing the r ight side bearing first makes the job easier .
~--
CAUTION: The removed bear ing should be replaced.
Unlock the lock wash ers. Remove securing bol t s and separate the sprocket from sprocket mounting drum. ---~
CAUT ION : Do not reu se th e lock washers.
I I
Draw out sp rocket mounting drum oil sea l by using special too l.
0991 3-501 2 1
Oil seal remover
Drive out sproc ket mounting drum bea r ings . CAUT I ON: The removed bearin g should be replaced .
..
.-
CHASSIS
I i\JSPE CTI ON
I
I
WH EEL AND SPROCKET MOUNTING DRUM BEARINGS
I I
(
d '
Inspect the play o f bearing inner race by hand w hile fi xing it in the w heel hub or sprocket mounti ng drum. Rotate the inner race by hand to inspect for abnorma l no ise and a smooth rotat ion. Replace the beari ng i·f th ere is something unusual.
Pla y
Play
~<>-
t T
AXLE SI-IAFT Using a dial gauge, check the axle shaft for run out and replace it if the runout exceeds the limit.
·;
.. '\ )
09900-20606
·->l:G.
Dial gauge ( I I 100)
~ if~
~
Serv ice Limit
.. ·.·.
.
,...
-/ ..
0.25 mm (0.01 in)
L
WHEEL RIM Make sure that the wheel rim runout checked as shown does not exceed the service limit. An excessive runout is usua lly due to worn or loose whee l bearings and can be reduced by replacing the bearings. If bearing replacement fai ls t o reduce the runout, ad just the ten sion of the spokes, and, if this proves to be of no effect, rep lace the wheel rim. Servi ce Limit (Ax ial and Rad ial )
/
2.0 mm (0.08 in)
--
7-1 0
7-11
CHASSIS
SPOKE NIPP LE
Check to be sure that all nipp les are tight, and retighten them as necessar y using special tool. 09940-60 113 Tightening torque
Spoke nipple wrench 0.4 - 0.5 kg-m (3.0 - 3.5 lb -ft)
L--------------------------------~
REAR DRU M SHOCK ABSORBERS Inspect the rear drum shock absorbers for damage. If they are damaged, replace the shock absorbe rs.
SPR OCKET
Inspect the sprocket teeth for wear. If they are worn as illustrated, replace the sprocket.
L
Proper wear
~-------------------
Excessive wear
CHASS IS
REAR BRAKE PANEL Dl SASSE MBL Y Take o ff brake shoes.
Remove f itt ing bolt and pull off brake cam lever.
Pull o ff brake cam, 0 r ing and washer.
0
7-1 2
7-13
CHASSI S
REAR BRAKE l NSP£ CTJOi'J BRAKE DRUM Measure the brake drum l.D. to determine the extent of wear and, if the limit is exceeded by the wear noted , replace the drum. The value of this limit is indicated inside t he d rum . Service Limit
I I
160.7 mm (6.33 in)
BRAKE SHOE Check the brake shoe and decide whether it should be replaced or not from the thickness of the brake shoe lining. Service Limit
1.5 mm (0.06 in)
CAUTION: Replace the brake shoe with a set, otherwise braking performan ce will be adversely af'fected.
-
REAR BRAKE PANEL REASSEMBLY Apply grease to the bra ke cam. CAUT ION : Be care·ful not to apply too much grease to the brake cam sha'fts . 1·1 grease gets on the linings, brake slippage will result.
99000-25030
Suzu ki Super Grease "A"
-
--------~
CHASSIS
REASSEMBLY Reassemble and remount the rear wheel in the reverse order of disassembly and remo,Jal, and also carry out the following steps: WHEEL BEARII\IGS Install the wheel bearings by usi ng special tool. CAUTIOi\l: First instal l the wheel bearing for right side.
09924-845 10
Bearing installer set
Left side bearing
Right side bearing Bear ing installer set
Bearing installer set Left side
~,..--1\"Tdv
/ Wheel bearing Whee I hub
I I
Right side
I I
L_ CAUTION:
Make sure to identify each bearing, the right side (rubber sealed type) 1 and leH side (iron plate sealed type) j .
f Rightside
2
Left side
7-14
7- 15
CHASS IS
SPROCKET MOUi\JTl i\JG DRUM BEAR ING Install the sprocket mounti ng drum bea ring by using speci al tool as shown.
[
09924-84510
Bea ring instal ler set
,_ - - · - - - - SPROCKET MOUNTI N G DRUM 01 L SEAL
I nstall the sprocket mounting drum o il sea l.
... Appl y grease to the sp rocket mounting d rum oil sea l .
99000-25030
Suzuki super grease "A"
REAR DRUM SHOCK ABSORBERS
NOTE: Wh en insta ll ing the rear drum shock absorbers and sprocket mounting dr um into the wheel hub, apply ing detergent soapy water makes the job easy. CAUTION: Ad just the d rive chain slack and rear brake pedal p lay after insta llat ion o·f the rear wheel. (See pages 2-10 and 2-13.)
CHASSiS
----------------------·-----------------FROJ\JT BRAKE BRAKE PAD REPLACEMENT Remove two bolts and take off caliper.
CAUT I ON : not operate t he brake lever when remov ing the caliper. Do
-- - - - - -
Pull out brake pads w ith pad shim .
CAUTIOi\J : Replace the brak e pads as a set, otherwise braking per·formance wil l be adversely a'lfected.
NOTE: Push in the p i ~ton all the way to the caliper when remount t he ca li per .
7- 16
7-17
CHASSIS
-- -
CALl PER RE IVlOVAL Aj\jD Dl SASSEMBL Y
----
1
A
I Pad set 2 Cal1per holde r 3 Dust cover 4 Piston se al
5 Pisto n 6 Cal1per axle No. 1 7 Cal1per axle No 2
Tightening torque
kg-m
lb-ft
2.0- 2.5
14.5 - 18.0
------+-. .ยง) ~--1.5 - 2.0
~
2.5 - 4.0
11.0 - 14.5 18.0 - 29.0
_ :J
CH ASSIS
Disconnect brake hose and catch the brake fluid in a suitable receptacle.
Slightly loosen the caliper axle bolts. Remove ca l iper mounting bolts and take off caliper.
Remove cal iper axl e bolts , separate the caliper mounting bracket and cal iper.
Pl ace a rag over the p iston to prevent popp ing up. Force out the piston by using air gun.
CAUT IOI\J: Do not use high pressu re air for preventing piston damage.
7- 18
7-18
CHASSIS
Remove caliper axles and dust boots.
Remove piston boot and piston sea l.
(
CALl PER AND Dl SC 11'JSPECT I ON Inspect the cylinder bore wal l for nicks, scratchs or other damage.
Inspect the piston surface for any fl aw or other damage.
I
CHASSIS
Inspect the rubber parts for damage and wear.
Usi ng a micrometer check the disc for wear . Its thick ness can be checked with disc and wheel in place. The service limit is spec ified fo r the thi ckn ess of the disc:
09900-20201
Micrometer (0 - 25 mm)
Service Li mit
4.5 mm (0. 18 in )
With the di sc m ount ed on the wheel, check th e disc f or f ace ru nout with a dial gauge, as shown.
09900-20606
0 ial gauge ( 1/100 mm)
Service Limi t
0.30 mm (0 .0 12 in)
7-20
7-21
CHASSIS
CALl PER REASSEMBLY Reassemble the caliper in the reverse orders of disassembly and by taking the fol lowing steps:
CAUTION: Wash the caliper components with fresh brake "fluid be¡fore reassembly. Never use cleaning solvent or gasoline to wash thern. Apply brake fluid to the caliper bore and piston to be insened into the bore.
Apply grease to the caliper axles.
99000-2 51 00
SUZUKI silicone grease
-~ ¡ ;
Install the brake pad as shown.
CAUTION: Bleed the air from the brake system after reassembling caliper (Sse page 2-11.).
----
-----~
CHASSIS
MASTER CYUl\JDER REMOVAL Al\JD DISASSEMBLY
l
I Reservoir cap 2 Diaphragm plate 3 Diaphragm 4 Rese rvoir 5 0 ring 6 Piston ard cup set
TightP.ning torq ue kg-m
lb·ft
0.5 - 0.8
3.5- 6.0
7-22
7-23
CHASSI S
Remove brake I igh t switch and brake lever.
Place a rag underneath the union bolt on the master cylinder to catch spilled drops of brake Unscrew the union bo lt and disconnect f lu id. the brake hose/ master cylinder joint. CAUT I ON : Complete ly wipe of"f any brake f luid adher ing to any part o¡f motorcycle. The fl u id reacts chemically with paint, plastics, rubber materials, et c.
Remove two fitting bolts and take off master cylinder.
Remove fi l ler cap, diaphragm plate , diaphragm, and drain brake fluid .
CHASSIS
Pull out the reservoir and 0 ring by removing two fitting screws.
Draw out dust seal boot .
Remove circlip by using special tool.
09900-061 08
Snap ring p liers
Pull out piston, primary cup and spring.
7-24
7-25
CHASSIS
MASTER CYLINDER I NSPE CTI Oi'l Inspect the cylinder bore wal l for any scratch or other damage .
Inspect the piston surface for scratches or other damage. I nspect the primar y cup, secondary dust seal boot f or damage.
cup and
''
MASTER CYLI NDER REASSE MBL V Reassemble the master cylinder in the reverse o rd ers of disassembly and by taking the following steps:
CAUTION: Wash the master cylinder components with fresh brake fluid be¡fore reassemb ly . Never use cleaning so lvent or gasol ine to wash them. Apply brake fluid to the cylinder bore an d all the internals to be inserted in to t he bore. Mast er cyli nder
When remounting the master cy linder to the handlebars, first tighten the cl amp bolt for topside as shown .
UP CAUTION: Ad just the front brake light switch after in¡ stallation. Bleed the air from the brake fluid circuit after reassembling master cyl inder.
Hand lebar
Cleara nce
REAR BRAKE -
---
~
8
A
~5
9
c
k<> pedal Bra ~ d arm Brake pedal r~ Brake rod Ass Y Brake cam lever 0 ring To rque lin!< ~ Brake panel ~ Brake cam rg Brake shoe I 2 3 4 5 S
I
!
T igh tening tor~ue
kg -m A
[_
lb¡ ft
1.0- 1.5
7.0 - 1 ~0-
0. 5- 0.8 2.0 - 3.0
3.5 -
6.0 -
14.5 - 21. 5
7-27
CHASSIS
REAR BRAKE DRUM When removing, inspecting and reassembling the rear brake dru m, refer to the section of the reat wheel in the pages 7-7 through 7- 15.
BRAKE PEDAL REMOVAL Pu l l off cotter pin and disconnect brake rod . Disconnect brake I ight switch rod .
CAUTION: Do not reuse the cotter pin.
Remove the brake pedal securing bo lt and pull off brake pedal.
NOTE: Unhook
the return spri ng when pulling
off brake pedal.
Draw out brake pedal rod arm.
CHASSIS
BRA I< E PEDAL REASSEMBLY Reassemb le the brake pedal in the reverse order of remo val and also ca rry out the following steps.
BR.L\KE PEDAL ROD AR M Apply grease to the b rake pedal rod ar m shaft.
99000-25030
Suzuki Super Grease "A"
BRAKE PEDAL Wh en installi ng the rear b rake pedal , align th e brake pedal groove w i th punched mark
1
pro ¡
vided on the end face of brake pedal shaft.
CAUTI 0 1\J : Adjust the brake pedal he ight and rear brak e light sw itch ah er rem ounting. (Refer to t he page 2-13) .
7-28
7-29
CHASSIS
FRONT FORJ< RiEMOVAL Remove front wh ee l (See page 7- 1). Take off front brake ca liper and disconnect speedometer cable guide.
Remove fron t fender.
Loosen the steer ing stem upper and lower clamp bolts.
NOTE : Slightly loosen t he front for k cap bolt to f acil ita¡te later disassembly. L._
- - - - -- - - -- - -- -- -
Pull down r ight and le-ft front fork assembl ies.
CHASS IS
7-30
Dl SASSEMBL Y
I
Cap bolt 0 r ing For k spring Damper rod ring Rebound spr ing -~ Damper rod 7 Inner tube ~ Dust seal l 9_,~ Stopper ri ng fQ) Oil seal fl) Oil sea l spacer 11) Oil lock piece ij) Outer tube Axle holder
2 3 41 5
L ~ - -
G-{~
,~CB
C--<@
Tig htening torque ~
1---
kg-m
-
~
g
c
lb -ft
1.5- 3 .0 -
1. 5-2.5
11.0 - 2 1.5 ----1 1.0 - 18.0
1.5-2.5
11 .0 - 18.0
--
-
7
/f-s
1
~
~
ly
7 31
CHASSIS
Remove fron t fork cap bolt and draw out fork spr i 119.
Invert the fork and stroke it several times to let out t he o il inside. Under this condition (inverted condition), hold the fork for a few minutes.
/
I
\\
ll~
Remove damper rod securing bo lt by using special tools.
09914-25811
"T" type hexagon wrench
09940-34520
T handle
09940- 34561
Attachment "0"
.] M
I
Pull out in ner tube. Draw out damper rod with rebou nd spri ng and ring.
F i
~.l~
CHASSIS
7-32
Remove dust seal and snap ring.
() Remove the oi l sea l by using special to ol. 099 13-50121
Oi l sea l remover
CAUT I Oi\1 :
The remoiJed oil seal shou ld be replaced .
I NSPECT1 Oi'J FORK SPR li\J G Measure the fork spr ing f ree lengt h. If it is shorter than service I imi t, repal ce it. 1_,
Upper
103 mm (4.1 in)
Lower
391 mm (15.4 in)
Service L im it
INNER TUBE AND OUTER TUBE Inspect bot h inner and outer t ubes slidi ng surfaces for any scuHing .
-
-
--
-
1 ~. ,).L'J}).f, ~. WNJI/HfHI!fl,'ntmmrrn·rmrm ·1;
7-33
CH ASSI S
DAM?ER ROD Rli\JG Inspect damper rod ring for wear and damage.
REASSEMBLY Reassemble and remount the front fo rk in the reverse order of disassembly and removal and also carry out the following steps:
· J
1
;/
DAMPER ROD BOLT
Apply Thread Lock Cement and Bond No. 1215 to th e damper rod bolt and t ighten with specified torque. 0991 4-258 1 1
"T" type hexagon wrench
99014-3111 0
SUZUK I BOND "12 15"
99000-32040
Thread Lock Cement ·- --
Tightening torque
1.5 - 2.5 kg-m (11 .0 - 18.0 lb-ft)
I Th read Lock Cement
OlL SEA L
Install oi l sea l to the outer tube by using special tool. 09940-533 11
Oi l seal install er
-
---
--
- - --l
lu~~ SU ZUKI 80ND "1 215"
CH ASSIS
7-34
FORK OIL For the "fork oi I, be sure to use a motor oi I whose viscocity rating meets specif ications below.
Fork oil
Capacity
Forkoil :r 15
\
150 ml (5.07 US oz)
Ad just the fork oil level with a special tool. N OTE:
When adj usting oil level, remove the ¡fork spr ing and compress the inner tuba ¡fully. 09943-741 11 Oil level
Fork oi l level gauge 186 mm (7.3 in)
1, II
FORK S?A l NG
------------------------------------.
When installi ng the fork spr ing, small diameter end should pos it ion in bottom.
Bottom.(), \
~~
7-35
CHASSIS
STEE.R l NG STEiVl RE 1Y lOVA L A ND DISASSEi'llBL Y
I
·-i}
I 2 3 4 5 6 7
Handlebar clamp Steering sta m upper bracket Head light bracket ( R) Headlight bracket ( L) Steering stem bearing (Upper) Steering stem bea ring (Lower) Steering stem lower b racke t
Tighten ing torque --
kg-m
lb-ft
1.2 - 2 .0
8.5- 14 .5
3.6- 5.2
26.0- 37 .5
-
1.5 - 2.5 D
E
I_
--------
2.0 - 3.0 2.5 - 4 .0
-
-
;
-
11.0- 18.0
-
14.5 - 21.5 18.0 - 29 .0
- - --- ----- - - - - - -
I
CHASSIS
Remove front wheel (See page 7¡1). Remove the right and left front fork assemblies. (See page 7-29). Remove seat.
Take off fuel tank .
i\JOTE: When taking o'f'f fuel tank, disc onnect fuel hose and vacuum hose with turning the fuel cock lever to "Oi\1" or "RES" position.
Disconnect meter.
lead
wires
from
Disconnect
tachometer
cable
cable.
the
combination
and speedometer
7-36
7-37
CHASSIS
Remove mounting bolts and combinati on meter.
Remove headlight assembly and d isconnect lead wires.
Remove headl ight housing with rig ht and left turn signal lights.
/
,., Remove ignition switch by using special tool.
09911-73730
T type hexagon wrench
t ,l
I
I
CHAss ,s
Remove
handl ebars
clamp bolts and take off
hand lebars. --- --
- - - - -- - - -
i\JOTE: Put ¡ths handlebars on ths fra me.
Remove
w~r~ng
harness clamp and brake hose
clamp bolt. Remove steering stem head bolt and loosen clamp bolt. Take off steering stem upper b racket.
Remove steering stem nut by using special tool.
~NOTE: Ho ld ~h0
steering
~¡tern
lowsr brlllcke't by
hand to prevent dropping. i
09940-1491 0
Steering nut socket wrench
Draw out bearing outer race and steel balls. Take down steeri ng stem lower bracket.
Number of ba ll s
Upper
I
18
~---------+-------~
Lower
18
7-38
7-39
CHASSI S
Remove bearing outer race by using a chisel .
--~
L_____________________________
~
Push out beari ng inner races, upper and lower.
INSPECTION Inspect and check the removed parts for the fo llowing abnormalities. 1.> Bearing race wear and brinelling. 1> IJI/orn or damaged steel ba ll s. Distorti on of steering stem.
CHASSIS
REASSEMBLY Reassemble and remount the steering stem in th e reverse order of d isassembly and removal and also carry out the following steps:
IJ\JN'ER RACE S Press in the upper and lower inner races by using special tool.
09941 -34 511
Steering inner race install er
OUTER RACE S Press in the lower beari ng oute r race.
I Outer race
STEEL BALL Apply grease w hen install ing the upper and lower steel ba lls.
99000-25030
Number o¡f ball s
Suzuk i super grease "A"
18
Upper
18
Lower I
2 Drift
7-40
7-4 1
CHASSIS
¡----¡-------
Tighten the steering stem nut by using special tool until resistance is felt, then loosen it 1/8 1/4 turn. Make sure that the steering turns smoothly and eas ily le ft to right. NOTE :
This adjustment will vary from motor cycle to motorcycle.
HAf\JDLEBARS Set the hand lebars to match its dent mark to the mating surface between steering stem and handlebars cl amp as shown.
Secure the handlebars clamp in such a way that the clearances A ahead of and behind the handlebars are equalized.
CHASSIS
7-42
-~~~--~-,~~--~--~---
REJ\R SUS.P.E i\l-Sl ON FlEi'JlOVAL ArJD Dl SASSEl'!l BL Y
Sh cc~< absorber Torque link ~ Swinging arm '!- Spacer ;) Swinging ar·n bearing 6 Spece r 7 Washer l! Dust saal coyar 3 ?i •tot shaft
L
'2
Ti2htening lorque
t
-
lb-ft
~
2.0- 3 .')
~ 4 . 5 -2 15
3
2.0-3 :J
14.5 - 21 5
c
5.0- 5.8
36 .0 - 42,0
LI
I
-
kg-m -
-
l _j
7-43
CHASSIS
------------------------------~-------------·
Remove rear wheel (See page 7-7). Remove chain case.
Draw o ut swinging arm pivot shaft after removing nu t.
Take off sw in g ar m.
Remove to rque link .
CHU.SS S
7-44
¡----------------------------~---------
Remove dust seal cover, washer and draw out spacers.
Draw out swing arm bearings by using special tools.
CAUTI ON: The removed bearing should be replaced.
0994 1-445 10
Swing arm bear ing remover
J i'JSPE CTl 01 J SWJi\I G ARM BEAR INGS
Swinging arm
Inspect the play of swinging arm beari ng inner spacer by hands while fixing it in the swinging arm. Rotate the spacer by hands to inspect
?la â&#x20AC;˘t
whether abnormal noise occurs or ro tating smoothly. Rep lace the bearing and spacer if there is something unusual.
SWING ARM PIVOT SH.O. FT Using dia l gauge, check the pivot shaft for run out and rep lace it if the runout exceeds th e limit. 09900-20606
Dial gauge (1/100)
Service Limit
0.30 rnm (0.0 12 in)
-.... Spacer
.l
7-45
CHASSIS
REASSEfvl8L Y Reassemble and remount the swinging arm and rear shock absorbers in the reverse order o-f disassembly and removal and also ca rr'/ out the following steps: S1Nii\JG AR1Vl BEARii\IGS Press in the bearings by using specia I too l.
0994 1-34511
Bearing installer
CAUTI Oi\J: When installing a set o¡f bearings, punchmarked side of each bear ing comes on outer side. -- ~------
CA UT ION: Apply gr ease to the installing 'che spacers .
bearing
be¡f ore
) 99000-25030
Suzuki Super Grease "A"
DUST SEAL COVER Apply grease to the dust seal lip when installi ng the dust seal cover.
99000-25030
Suzuki Super Grease"~\"
\ .
.
~1!
; - .~~ .. ·.
. '
'
'
'
'
., , •· ·••.. -
.· e ·. •
.•
·• .
i
.
•
• •
~- .. . .,. ·.:·""
". · . '
"
.
" · · • -- ~-
.
· · o· .•
SERVICING INFORMATION
. • •
. -. • "' ··;
.
••. I
• •
•
• •
.
•
• •
•
•
•
•
•
•
.
•
- CONTENTS - -
• •
..., . . ,
.. ·"
. •
-
TROU!E!J!LESJ<JOOTJNG................................................................................................8- 1
WIRING .DUAG!RAM...................................................................................................... B- 13 WIRE ROUTJNG ......................................................................................................... 8a 7 CABLE ROUTING ...................................................................................................... B~ B SPECJAL TOOLS ...................................................................................................... 8- 9
TJGHTEMING TORQUE............................................................................................. 8·15 SERVJCE DATA ......................................................................................................... 8- 17 -----
··c,". ~ · - · . •·- N · ~l
.:·:i . , -i • •
•
.
.jj
8-1
SERVICI ·'IG INFO R,\1-\TI0\1
TRO UBLESHOOT! NG ENGI i'J E Co mplaint Eng ine will not start, or is hard to >tan.
Engine sta lls easily
Symptom and possible causes Compression too low 1. Valve clearance out of adjustment. 2. Worn valve guides or poor seating of valves. 3. Va l•1es mistiming. 4 . Piston rings excessively worn . 5. Worn-down cylinder bores. 6. Starter motor cranks but too slowly
Remedy
-----------------4 Adjust. Repair, or replace. Adjust. Replace. Replace , or rebore. Consu It "elect rical complaints".
Plugs not sparking 1. Fouled spark plugs. 2. Wet spark plugs. 3. Ig nition timing out of adjustment. 4. Defective igniti on coil. 5. Open or short in high-tension cords. 6. Ruptured condenser. 7. Defective signal generator or transistor unit
Clean. Clean and dry. Adjus t. Rep lace. Rep lace. Rep lace. Rep lace.
No fue l reaching the carburetors I. Clogged hole in the fuel tank cap. 2. Clogged or defective fuel ccck . 3. Defectiv e carbu retor float valve. 4. Clogged fuel pipe or suction cock pipe. 5. Defective fuel cock diaphragm .
Clean. Clean or replace. Rep lace. Clean. Rep lace .
1. 2. 3. 4. 5. 6.
Fou led spark plugs. Ignition tim ing out of adjustment. Defective signal generator or tran;istor unit. Clogged fuel prpe . Clogged jets in carburetors Valve claarance out of adjustment
Clean. Adjust . Replace. Clean. Clean Adjust.
-
No isy engine.
Excessive 'Jai•Je chatter I. Valve clearance too large. '2. Weakened o r bro ken valve spr ings 3. Camshaft journal worn and bu rnt.
Ad just . Replace. Replace.
Noise appears to come from pistons I. Pistons or cylinders worn down. 2. Combustion chambers fouled wit h carbon . 3. Pi ston pins worn.
Replace Clean . Replace.
Noi se seems to come from t iming chain 1. Stretched chain . 2. Worn spwckets. 3. Tension adjuster not work ing .
Replace. Replace. Repair or replace.
Noise seems to come ·from clutch I. ·worn spl ines of c ounte r sh<~ft o r hub. 2. Worn teeth of clutch plates. 3. Distorted clut ch plates, d riven <1nd drive
Replace. Replace. Repa ir or rap lace .
i\loise seems to co me from crankshaft 1. Rat tiing bearings due to wear. 2. Big-end bearings worn and burnt. 3. Journal bearing worn and burnt.
Rep lace . Replace. Replace.
Noise seems to come from transm ission 1. Gears worn or rubbing. 2. Badly worn spl ines. 3 Primary gears worn or rubbing. 4. Counter balancer gear worn or rubbing.
Replace. Replace . Rep lace Replace.
SE R VICI~IG INFQR ,\J!AT IO~I
---------------------------------------------------------Co mpl aint 1---~--
-·
---~
3. Wor n or d istorted pressu re plate. 4 . Distorted clutch plates, driven and dr ive .
1. 2. 3.
Dr agging clutc h
---
---
- - - --
- - ----------- - - -- - - - ----1
- ----
Clu tch co ntro l out of ad justment or to o much p lay . Some clu tch sp rings w eakened w hil e o t hers are no t. D istor ted p ressure pla te or clu tc h pl at es.
T ransmi ss ion w ill not shift
1. Br oke n gearshift cam . 2. D istorted gearshift forks .
Transmission w ill not shih bac k.
I. Broken return spring on shift shaft. 2. Shi ft shafts are rubbing or st ic ky .
--- ---------------- -
·------ - -- ---Adj ust. Replace. Rep lace. Rep lace.
I . Clutch control out of adju stmen t or lo ss of play.
2. INeakened clutch spri ngs .
~------- -----
-·- =1 Remedy
. Symptom and possihle cau ses
- - - - - - -·
Slipping clutch
8-2
Ad just. Replace . Replace. Replace. Replace .
- --- ----- ---- - - - - -- - - - Rep lace. Repai r.
-- 1. Worn sh ifting gears on driv e shaft or cou ntersha ft.
-·--------
T ransmission jumps out o1 gear.
2. Distorted or wo r n gearshift fo r ks. 3. Weakened stopper spri ng o n gearsh ift stopper.
1--- - - - - - - - - - - - -- ' --
Engine idl es poo rly .
lEngine run s poorly in high speed range.
Diny or hea•1y ex haust smo k e.
-
-
---- --
-
2. 3. 4. 5. 6. 7. 8.
I
--- - -- - -
----
1. V alve clearance out of adju stment.
I
--
Poor seating of valves. D efec t ive val ve guides. Igni tion ti m ing out of adju stme n t. Spark plug gap s too w ide. Defecti ve igni ti on coi l . Defective signal generator or transistor u n it. Float-chamber fuel level out of adjustmen t in car bu retors. 9. Clogged jets or imbalance of carbaretor s.
1. Valve springs weakened. 2. Va lve timing out of adj ustmen t. 3. Spark plug gaps too narrow. 4 . Ign ition not advanced sufficientl y due to poor ly w orking advancer . 5. Defective ignition coil. 6. Defective signal generator or t ransistor unit. 7. F !oat -c hamber fuel level too low. 8. Clogged air cleaner element. 9. Clogged fuel pipe, resu l ting in inadequate fuel supp ly to carb u reto rs. 10. Clogged suction cock pipe.
- - -- - -- --1. Too much engine oil in the engine. 2. 3. 4. 5. 6.
Worn p ist on rings or cy linders. Wor n va lve gu ides. Cylinder wall s scored or scuffed. Wo r n va lves stems. Defectiv e stem sea l.
Re p lace. Replace . Rep lace.
---· " - -- -- - - - - --
- ----1
A d just. Replace. Rep lace. A d just. Adjust or re place. Replace. Rep lace . Ad just. Clean or adjust.
--- - -- --
Replace. Adj ust. Adj ust. Replace. Rep lace. Rep lace. Ad jus t. Clean . Clean, and prime . Clean. Chec k with level gauge drain out excess oi l. Replace. Replace. Rebore or repl ace. Repla ce. Rep lace
8-3
SERVICING 11\JFOR,'vlAT IOl\l
------------------------------
Com plai nt
Remedy
Symptom and possible causes
- - - --- - - -- ---Engi ne lacks power
1. Loss of valve clearance. 2. Weakened valve springs. 3, Valve timing ou t of adjustmen t
Adjus t. Replace. Ad jus t. Replace. Repair. Adjust . Adjust or replace . Clean. Adjust. Clean. Retighten. Retigh ten or replace . Drain ou t excess oiL
4. Wom piston r ings or cylinders. 5. Poor sea t ing of val ves. 6, l gnitio.l t iming out of adjustment. 7. Spark plug gaps incorrect. 8. Clogged jets in carburetors. 9, Float-chamber fuel level out o f adjustment. 10. Clogged air cleaner el ement. 11. Carburetor balancing sc rew loose. 12, Sucking air f rom i ntake pipe . 13. Too much engi ne o il in the engin e. Engi ne overheats.
- - -- --- --
4, Fuel level too low in float chambers.
Clean. Add oil. Replace or clean. Adjust.
5. Suck air from intake pipes. 6, Use incorrect eng ine oiL
Retighten or replace. Change.
1. Heavy carbon deposit on piston crowns. 2. i\Jot enough oil in the engi ne. 3, Defective oil pump o r clogged oil circuit.
ELECTRJCAL
r--------------------------------------------------------------------------Complain¡t
Sy mp tom and possibl e causes
Remedy
1- -
1. Defectiâ&#x20AC;˘1e igniti on coil
i\Jo sparking or poor spark ing
Rep lace. Replace. Replace.
2. Defect ive spark plug s. 3. Defec t ive signal generator or trans is tor uni L ----
Spar k plugs soon bec om e f ouled w i t h car bon .
1. 2. 3. 4. 5,
- --- - - - -
Mixture too rich. Idling speed set too high. Incorrect gasol ine. Dirty element in air clean er. Spark plugs too cold.
Adjust carburetors . Adjust carburetors . Change. Clean . Rep lace by hot type plugs.
! - --
Spa rk plugs become fou led too soon .
1. Worn piston ri ngs.
Replace _ Replace. Rep l ace. Replace.
2. Pistons or cyl inders worn. 3. Excessiv e cl eara nce of valve stems in va lve guides. 4. Worn stem oil seaL --+-
Spark plug electrode s overheat or burn.
1. Spark plugs too hot. 2. The eng ine overheats. 3. Ignition tim ing out of adjustment. 4. Spark plugs loose. 5. M ixture too lean.
Gener ato r does not charge .
I . Open or short in lead wires, or loose lead co nnections. 2. Shorted, grounded or open generator coils. 3 . Shorted or panctu;ed regulato r/ rectifier.
I
--
Replace by cold type pl ugs. Tune up. Adjust. Ret ighten. Adjust carburetor s. - - t - - -- -- -- - - -- - - - - l Repa1r or replace or re t igh ten. Replace. Repla ce.
SERVICING I \JFOR.\IAT ON
Complaint Generator does charge, but charging rate is below the specification.
1. Lead wires tend to get shorted or open-
circ uited or loosely connected at term1nals. 2. Grounded or open-circuited stator co ils of generator. 3. Defective regulator/ rectifier. 4. Not enough electrolyte in the battery. 5. Defective ce ll plates in the battery.
Gene rator 0 â&#x20AC;˘Jercharge3.
Unstable chargi ng
Starter button is not effective.
8attary "sulfa tion"
1. Internal short-circuit in the battery 2. Res1stor element in the regulator/rectifier damaged or defective. 3. Regulator/rectifier poorly grounded.
1. Lead wire insulation frayed due to vibration. result ing in intermittent shorting. 2. Generator internally shorted. 3. Defective regulator /rectifier.
l
Repair, or reti ghte n. Replace. Replace. Add dist1lled wate r to the upper level. Replace the battery . Replace the battery. Replace. Clean and t1ghten ground connection . Repair or rep lace. Replace. Replace.
I . Battery run down. 2. Defective switch contacts. 3. Brushes not seati ng properly on commutator in starter motor. 4. Defective starter relay.
Recharge or replace. Replace. Repair or replace.
1. Charging rate too low or too high .
Replace the ba ttery.
(When not in use batteries should be recharged at least once a month to av oid sulfat1on.l 2. Ba ttery electrolyte excessive or Insuff icien t. or its specific gravity too h1gh or too low .
3. The battery left unused for too long in cold climate.
8attery discharge> too rapidl y.
Remedy
Symptom and possible causes
I. D1rty container top and sides. 2. Impurities 1n the electrolyte or electrolyte S.G. is too high
Rep lace.
Keep the electrolyte up to the prescribed level, or ad just the S.G. by consulting the battery maker's directions. Replace the battery, 1f badly su lfated. Clean. Change the electrolyte by consulting the battery maker's direct ions.
8-4
3-5
SERVICI1\JG li\JFOR."IATION
CHASS IS Com plaint
Symptom and possible causes
Heavy steering
--
1. Steering stem nut overtigh tened.
-
Adjust. Replace. Rep lace . Adjust. Adjust.
2. Broken bearing in steering stem . 3. Distorted steering stem.
4. Not enough pressure 1n tir es . 5. Overtightened steering stem nut. -
Wobbly handle
-~
1. Loss of balance between right and left suspe ns ion .
.
3. Distorted front ax le or cocked tire. -
2. Worn-down front wheel bearings.
-
5. Loose nut on axle. -
1. Weakened sprr ngs. 2. Not enough fork oi l.
-
-
Front suspension too st iff
-
1\Joisy fr o nt suspension Wobbly rear wheel
I. Fork o il too VISCOUS.
2. Too much for k oi l.
--
-
-
2. loose nuts o n suspens ion.
-
- ---
Noi sy rear suspension
.
---- -loose nu ts on suspension.
-
·- - - - Poor braking (FRONT and REAR)
-
1. Weakened springs.
2. Rear suspension ad justers improperly set. -- Rear suspension adjusters Improperly set.
Rea r suspension too st iff
-
4 . Defective or incorrect tire. -
-
--
--
~-
·---
-
-
Re tighten.
-
-
-~
I. Not enough brake fluid in the reservoir.
2. Air t ra pped in brake flu id circu it. 3. Pads or linings worn down . 4. To o much play on brake peda l.
Re fi ll. Re t ighten.
Rep lace. Rep lace. Retighten. Replace. . Replace. Adjust. . - -Adjust.
2. Worn·down rear wheel bearings.
-
----
----
- - -·
- -- - -
-
I. Distorted wheel rim. 3. loose wheel spokes.
Rear suspension too soft
-
·-
1. Not enoug h fork oil.
-
---
Repla ce. Rep lace . Retighten. Replace. Retigh ten. - - - - -·-Rep lace. Re fill. - ---Replace. Drain excess oil.
3. Loose wheel spokes. 4. Defective or 1ncorrect tire .
Front suspension too soft
-
-·
1 Distorted wheel ri m.
- - - -- -
-
Replace. Repair or rep lace. Replace.
2. Distorted front fork. Wo bbly fro nt wheel
Remedy -
--
I
- - ---
-
Refill to level ma rk. Bleed air out. Rep lace. Adjus t .
----
-------------·-· -~----·-~~£A_Y~CI 1\ G I~JFOFl,\1,.\TIJN
'vVJRl NG Dl AGRA J'vl
.
•
®
Q) ©
--- ...
;
'
'
'
00 co '
.g_ . ·-- ) ~
~d~dh1ni
·o 0 - -~
~
~F-?
,--) ~
...
I
-~
.
©
(' 8·o
s
'C...
,~
::0
(/)
-
Clamp handle switch lead wire
m
JO
0
c
u
Neutral position indicator lead wire Neu t ral indicator lead wire
Clamp main wiring harness and neutral switch lead wire
---4 2
G>
Clamp main wiring harness
NOTE: ¡1 : Clamp the 1gnition coil lead wire under the frame pipe. ¡2: Do not touch the generator lead wire with the chain case. ~ 3: Do not block the air intake of the cleaner case.
z
C)
-
z .,., 0 :rJ ~
-;
z
To tail/brake I ights
To crankcase bolt
Clamp neutral switch lead wire, starter motor lead wire and generator lead wire
-
0
To turn signal light
Clamp signal generator lead wire
\
<
n
)>
Regulator /rectifier
Brake cable
m :rJ
To crankcase bolt / Screw it With battery holder bolt
-----~~--~------·-----------....:;.:SE::.!.R.:..:V:..!.::ICING
I'IFQR ,\ IAT IOi\1
Signal generat or and oi l pressure lead wire
CABLE ROUT ING
Throttle cable should be routed left side of the breather pipe. Clamp clu tch cable with wiring harness
8-8
8-9
SE RV IC I1\J G I i\IFORt\IA Tl 0 ~I
SPEC IAL TOOLS Item
1 2 3
4 5
Part i\Jame
Part i\Jo.
09900-061 04 09900-06105 09900-061 07 09900-06108 09900-09002
Snap ring pl iers (opening type ) Snap ring pliers (closing type) Sna p ring p li ers (opening type) Snap ring pliers (closing type) Shock driver set 1\, 09900-09 10 1 Body (for untightening)
@ 09900-09 102 Bo dy (for tightening) 6 7
19 20
09900-20101 09900-20201 09900-20202 09900-20203 09900-20508 09900-20606 09900-20803 09900-211 02 09900-211 03 09900-25002 09900-28 106 09900-28403 0991 0-1 071 0 09910-20115 09910-3451 0 099 11-73730 099 14-258 11 099 12-34510 09913-131 21
21
~ 0991 3- 144 10
8 9 10 11 12 13 14 15 16 17 18
~ 099 13-1451 1
22 23 24 25 26 27 28 29 30 31 32
*0991 3-1491 0 09913-50121 09913-61110 09913-70122 09913-80112 099 1 5-64510 ¡o9915-6321 0 09915-74510 *099 15-77330 099 16-14510 " 09916-1491 0 09900-21 110
~ 09900-09202 Bit Vernier calipe r (200 mm) Micrometer (0 - 25 mm ) M icromet er (25- 50 mm) Micrometer (50 - 75 mm) Cylinder gauge set Dial gauge ( 1/ 100 mm) Thickness gauge Torque wrench (0 - 1.2 kg-m) Torque w rench ( 1.0- 9.0 kg-m) Pocket tester Electr otester Hydrometer Stud bo lt installer (8 mm ) Con rod stopper Piston pin puller " T" type hexagon wrench (5 mm) "T" type hexagon wrench (6 mm ) Cylinder d isassembling tool Carburetor balancer gauge set 099 13-13140 Ada pter Attachment ( 16 mm x P1.0) Gauge body (6 mm x P0 .75) Th rottle valve ad just wrench Oil seal remover Bearing puller Bearing inst al ler Bearing inst aller Comp ression gauge Adapter Oi l pressure gauge Meter (0 - 10 kg/c ml) Va lve lifter Valve lifter attach ment Valve seat cutter set
SER VICING l i\I FOR,\ IATIOI'I
Item
Part J\Jo.
33
'099 16-34560 '09916-34540 ·o991 6-34550 ·• o99 '16-449 1o
34 35 36 37 38 39 40 41 42
43
44 45 46 47 48 49 50 51 52
"09916-44920 09916-74520 099 "16-74530 09916-84510 *099 17-1491 0 09920-53710 09923-74510 09924-8451 0 09930-14511
09930-132 10 09930-30102 09930-337 10 09930-40113 09930-44510 09940- 1491 0 09940-34520 09940-34561 09940-60113 0994 1-34511 09943-74111
Part Name A Valve gu ide reamer {11 .2 mm) 8
Reamer han ale Valve guide reamer {5.5 mm) Valve guide remover Valve guide installer attachment A Piston ring holder body 8 Band (Bore: 55-65 mm ) Forceps Tappet adjust driver Clutch sleeve hub holder Bearing puller {10 : 20-38 mm) Bearing installer set Cylinder head nut and spark plug wrench set A 099 14-24510 " T " handle §.' 09911-745 10 Long socket 14 mm c 09911 -7 4520 Long socket 12 mm B' 09930- "14530 Unive rsa l joint E 09930-14520 Spark plug wrench 21 mm Spark p lu g socket wrench 19 mm
c
Rotor remover slid ing shaft Attachment Rotor and engi ne sprocket holder Rotor holder St eering nut socket wren ch A Front fork assembling " T " ha ndle §' Attachment "0" Spoke nipple wrench Steering race installer Front fork oil level gauge
Note: ( * )Mark shows newly applied for GS250T.
8-1 0
8- 11
SERVIC I ~~ G I t\1 F0 R\I 4TI 0 N
2
9
7
-
\..-.,_,...._. -
----"
12
/
I
--
13
!
--1I
I
II
SER V I C I ~J G 1 ,\JF OA~,J A T IO i\J
I3
I7
8-12
~
~ ~
', ~
--1~
---~
20
fl
~
22
23
24
26
27
A
I
- 1 28
29
30
SERV I CI~I G
8-13
31
IN FORMA. TJQ ,\J
3~
37
,, I
rrr---------.
j
, -, ......... """' -- ' \.;., .!0 Jv h
33
35
36
38
39
I I
46
47
SERV ICJ,'JG IJ\1 FO R,"IATl J,\J -~
8-14
~~
l
48
I
I
~c y
I I
L
I
I
49
I
50
51
.......
~
........
'
.
A 52
-,
~~' W'~
~-
"
~//''
'~
8·15
SERVIC IN G li\IFOi11\iiATIOi\l
TIGHTE NING TOP1QUE ENGI1 JE ITEM Cyli nder head cover bolt
kg·m
ib·f"t 6.5- 7.0
0.9 - 1.0 -
-
Cam sha f t journal holder bolt
6.0- 8.5
0.8- 1.2
Cam shaft sprocket bo lt
6.5- 8.5
0.9 - 1.2
Rocker arm shaft stopper bolt
6.0- 7.0
0.8- '1.0
Va lve clearance adjuster lock nut
6.5- 8.0
0.9- 1.1
Cylinder head bolt
5.0- 8.0
0. 7- 1.1
16.0- 20. 0
2.2- 2.8
Cy linder head nut -
Cam chain tensioner adjuster fitti ng bol t
- -
--
4.5- 6. 0
0.6-0.8
22.5- 25.5
3. 1 - 3.5
Cam chain tensioner adjust er lock nut
6.5- 10.0
0.9- 1.4
Cam cha in tensioner shaft lock nu t
6.0 -
7.0
0.8- 1.0
Starter motor bo lt
3.0 -
5. 0
0.4-0.7
43.5- 50.5
6.0- 7.0
11.0 - 14. 5
1.5-2.0
Primary dr ive gear nut
36.0- 50. 5
5.0 -- 7.0
Counter balancer center bolt
25.5-32.5
3.5 - 4.5
Con rod nut
21.5-24.5
3.0- 3.4
Oil pressure regulator
12.5-14.5
1.7-2.0
Governor center bolt
9.5- 16.5
1.3- 2.3
Pressure switch
9.5- 12.5
1.3- 1.7
13.0- 20.0
1.8-2.8
3.0- 4. 5
0.4 - 0.6
Clutch sleeve hub nut
2'1.5- 36.0
3.0- 5.0
Gearshifting arm stopper
11 .0 - 16.5
1.5-2.3
7.0
1.0
Cam chain tensioner shaft assy
--
Gener ator rot or bol t -
~
----
----
Starte r clutch al len bolt -
Neutra l stopper housing Clutch spring bolt
-
Oil pan bolt Crankcase bolt
1 -
a
14.5- '17 .5
2.0 - 2.4
9 -
12
6.5- 9 5
0.9- 1.3
6 mm bolt
7.0
1.0
8 mm bolt
14.5
2.0
36.0 - 50.5
5.0- 7.0
8 mm
18.0
2.5
10 mm
25.5
3.5
Engine sprocket nut Engine mounting bolt
Exhaust pipe clamp bol t
6.5- 10.0
0.9 - 1.4
- ----i
-------..·- --------..
______ _____________ __ ____ ... ,. SERVICii'I G li'IFOl\1.\TiG',
....,.,._....._....._.
·-...__~_.
a-1 6
CHASSIS ITE~tl
Front axle nut Front .::.Jxle holde r nut Front fork damper rod bolt Disc plate bol t Caliper bolt Caliper axle bolt Caliper bleede r Front fork lower clamp bol t Front fo rk upper clamp bo lt Front fork cap bol t Steeri ng stem nut Steering stem clamp bolt Steering stem head bolt -Han dlebars clamp bolt Brake hose union bolt Master cylinder clamp bolt -Brake peda l arm bol t Swinging arm pivot nut Front f oo trest bol t Front footrest bolt
10 mm 8 mm
Mu-ffl er bracket mounting bo l t Rear footrest bolt Muffl er bracket bol t Rear t orque link nut Rea r shock absorber fitting nut Rear ax le nut Rear sprocket nut Rear b ra k e cam lever bolt Spoke nipple
lb-ft
kg-m
26.0- 37.5 '11.0- 18.0 11.0- 18.0 11.0 - '18.0 18.0-29.0 11.0-14.5 5.0 - 6.5 '18.0 - 29 .0 14.5- 21.5 11 .0-21.5 29.0- 36.0 11.0 -18.0 26.0- 37.5 8. 5- 14.5 14.5- 18.0 3.5- 6.0 7.0- 11.0 36.0 - 42.0 19.5-31.0 11 .0- 18.0 19.5 -3 1.0 '19.5 - 31.0 14. 5-2 1.5 14.5-2 '1.5 14.5- 21.5 36.0 - 58.0 18.0- 29.0 3.5- 6.0 3.0- 3.5
3.6 - 5.'2 1.5- 2.5 '1.5 - 2.5 1.5 - 2.5 2.5 - 4. 0 1.5 - 2.0 ' 0.7 - 0.9-· 2.5 - 4.0 2.0 - 3.0 1. 5- 3.0 4.0 - 5.0 1.5 - 2.5 3.6 - 5.2 1.2 - 2.0 2.0 - 2. 5 0.5 - 0.8 1.0- 1.5 5.0 -- 5.8 2.7 - 4.3 I 5-2 5 2.7 4.3 2.7 - 4 3 2.0 - 3.0 2.0 - 3.0 2.0 - 3.0 5.0 - 8.0 2.5 - 4.0 0.5 - 0.8 0.4 - 0.5
-- -
Tl GHTEI\Jl i\J G TORQUE CHART For other bolts and nuts not listed above, refer to this char t. Tigh tening torque Thread Diameter (mm)
Conventional or " 4" l'llark ecl Bo l·t
lb·'lt
1.5 - 3.0 3.0 - 5.0 7.0 - 11 .5 16.0 - 25.5
5 6 8 10
r .,,,TTT ' ,,,
'7'' Marked Bolt
kg-m -
lb-H
0.2 - 0.4 0.4 - 0. 7 1.0-1 .6 2.2- 3.5
2.0- 4.5 6.0- 8.5 13.0 - 20.0 29.0- 43.5
kg-m
0.3 0.8 1.8 4.0
f 1 _: j 'C.:.,)
C0rwent anal Bolt
' '-1 '
1\i l ail<~d
Bolt
· 7" •Vhr ked Bolt
-
0.6 1.2 2.8 6. 0
8-1 7
SERVIC II\JG J,\JFOR .\;I ATIO \i
SERV ICE DATA VALVE+ GU IDE -
Un1 t: mm (in)
,--
ITENl
;----
Valve diam.
-
Valve lift
Valve clearance or Tappet clearance (when cold)
Valve guide to Valve stem clearance
Valve guide I . D.
L
Valve stem 0.0.
IN.
20.90 ( 0.823 -
21.10 0.831
EX.
17.90 0.705 -
18.1 0 0.713
-- -
lf\l.
7.0 0.28
EX.
7.0 0.28
IN. & EX.
0.08 - 0.13 0.003 - 0.005
IN.
0.025 - 0.052 ( 0.0010- 0.0020 )
0.090 ( 0.0035)
EX.
0.040 - 0.067 ( 0.001 6- 0.0026)
0.100 ( 0.0039)
11\1. & EX.
5. 500 - 5. 512 ( 0.2 165- 0.2 170 )
IN.
5.460 - 5.475 ( 0.2150-0 .2 156)
EX .
5.445 - 5.460 ( 0.2144-0.2150 )
I
Valve stem runout
L IMI T
STANDARD
IN . & EX
0.05 ( 0.002 )
IN . & EX .
0.5 ( 0.02
11\1. & EX
3.6 ( 0. 14
r----
Valve head thickness Valve stem end length
L-
Va1ve seat width
0.9 1.1 0.035- 0.043
11\l.&EX.
>---
Valve head radial runout Valve spring free length ( IN. & EX.)
Valve spring tension (IN . & EX.)
-
--·-
0.03 ( 0.001
11\J. & EX. INNER
31.9 1.26
OUTER
35.5 1 40
INNER
4.4 - 6.4 kg 9.7 - 14.1 lbs) at length 28.5 mm ( 1.12 in)
OUTER
6.5 - 8.9 kg 14.3 - 19 .6 lbs) at length 32.0 mm ( 1.26 in) (
SER V I Cl ,\IG IN FOR I,IATI 0 \1
8- 18
--------------·--------CAJ\tlSHAFT + CYL l i\JDER + HEAD
.
Unit: rnm (in)
--------, L IM IT
ST Ai\JD.L\ R D
I TEi'/1 Cam height
l i\1. EX.
Ca mshaft journ al oil c learance Camshaft journal holder 1.0. Camshaft j ou rnal O.D . Camsh aft runout Cam ch a1n
------ --
li\1 . & EX.
34.650 - 34.690 ( 1.3642 - J.3657 )
34.350 ( 1.3524)
34.650 ( 1.3642 0.020 ( 0.0008 -
34.350 ( 1.3524)
34.690 1.3657 ) 0.054 0.002'1 )
l i\1. & E><.
22.000- 22.013 ( 0.8661 - 0.8667 )
li\1. & EX.
2 1.959 - 2 1.980 ( 0.8645 - 0.8654 )
0.150 ( 0.0059) - -
-
-
0.10 ( 0.004 ) - ----· 157.80 ( 6.2 13 )
l i\1. & EX.
20 pitch length
-
Cam cha in pin (at arrow
"3")
20th p in -
Rocker arm I .D . Roc k er arm shaft 0.0.
Cy l inder head distortion
l i\1. & EX.
12.000 - 12.018 ( 0.4 724 - 0.4 731 )
IN . & E X.
11 .973 - 11 .984 ( 0.47 14 -0. 47'18)
--
.
.
----- - ·--
0.10 ( 0.004 )
-. -~
8-19
SERVICI.\IG IM09\IATIQ\l
·---~·-------
ST 0 N + R I- N G + CY L l f\J--D ER -Pl - -·
Unit. mm (in} L I ~1 I I T
STA i'JD,t.\RD 1 I -- 14
Compress ion pressure
156 - 199
kg/em" psi)
IO kg/ cm: 142 psi} 2 kg/em: 28.4 psi )
Comp ression pressure difference Piston to Cylinder clearance
0.035 - 0.04 5 ( 0.001 4 -0.0018)
0. 120 ( 0.0047)
Cylinder bore
60.000- 60.015 ( 2.3622- 2.3628)
60.095 ( 2.3659)
Piston d ia.
59 .96 0 - 59.975 ( 2.3606 - 2.36 12} Measu re the 15 ( 0.6 from piston sk irt end.
0.10 ( 0.004
Cyl inder distortion Piston ring free end gap
Piston r ing end gap
Piston ring groove clearance
Piston ring groove width
59.880 ( 2.3575)
I st
i\1
Approx.
6.5 ( 0.26)
5.2 0.20
2nd
i\l
A pprox.
8.5 ( 0.33)
6.8 0.27
1st
0. 10 - 0 .25 ( 0 004 -0.0 10
0.70 ( 0.028 )
2nd
0.10 - 0.30 ( 0.004 - 0.012
0.70 ( 0 .028 )
1st
0. 180 ( 0.0071)
2nd
0.150 ( 0.0060)
1st
1'2 1 - 1.23 ( 0.047 - 0.048
2nd
1.2 1 - 1.23 ( 0.047 - 0.0..:18
-- - - - - - - - Piston ring thickness
Oil
2.51 - 2.53 ( 0.099 - 0. '100
I st
'1. 17 5 - 1. 190 ( 0.0463- 0.0469 )
2nd
1' 170 - I. 190 ( 0 .0461 - 0.0469 )
Piston pin bore
'16.002 - 16.008 ( 0.6300 - 0.6302 )
16.030 ( 0.63 11)
Piston pin 0.0.
15.995 - 16.000 ( 0.6297 - 0.5300 )
15.980 ( 0.6291)
______________________ ,
CRANK SHAFT + COUi\JTER BALANCER+ CFL~d'JK CASE ITEM
--~·-------
Un it :
rnm (in)
L 1~11 rr
ST J\J\JDARD
Conrad small end I.D.
16.006 - 16.014 { 0.6302- 0.6305 )
16.040 ( 0.6315)
Conrad big end sid e clearance
0.10 { 0.004 -
0.20 0.008 )
0.30 ( 0.0'12 )
Conrod b ig end width
"19. 95 { 0.785 -
20.00 0.787 )
Crank pin width
20.10 ( 0.791 -
20. 15 0.793 )
Conrad big end oil clearance
0.024 ( 0.0009 -
0.048 0.0019)
Crank pin 0.0.
3 1.976 - 32.000 ( "1.2589 - 1.2598)
Crankshaft journal oil clearance
0.020 { 0.0008 -
Crankshaft journal 0.0.
31.976 - 32.000 ( 1.2589 - 1.2598)
Crankshaft thrust clearance
0.05 { 0.002 -
Crankshaf1 journal holder width (crankshaft)
54.05 - 54.15 { 2.1 28- 2. 132)
Crankshaft JOurnal w idth (crank case)
53.90 ( 2.122 -
0.044 0.0017 )
0.25 0.01 0 )
0.080 ( 0.003 1)
0.080 ( 0.0031)
0.35 { 0.0 I <~ )
54.00 2.126) 0.05 ( 0.002 )
Crankshaft runout
-
Balancer journal oil clearance
0.020 - 0.044 ( 0.0008 - 0.0017 )
Balancer j ournal 0.0.
31 .984 - 32.000 ( 1.2592 - 1.2598 )
OIL PUMP
0.080 ( 0.0031)
Unit :
ITEM Oil pump reduction ratio Oil p ressure {at 60C, 14CfF)
L II' ll IT
STAN DARD 1.905 ( 75 I 24 3.0
Above
43
Below at
X
mm (in)
25 I 4 I ) kg/em! psi )
5.5 kg/em~ 78 psi) 3000 r/m in.
Tip clearance
0.20 ( 0.008 )
Outer roto r clearance
0.25 ( 0.010 )
Side clearance
0.15 ( 0.006 )
8-21
SER\f!Cit\JG INFOR ,\ Ir\T!Oi\1
-----------------
CLUTC H
r··-------
i
r------ -·-
Unit: mm (In }
- - - - ---r- - -
JTE1VI
--------
STANDARD
4.0 0. 16
Clutch cab le play Clutch release screw
LIIVIJT
~ Y2 turn back
2.9 0.11
Drive plate claw width
11 .8 - 12.0
11.0
0.46 - 0.47
0.43
Driven plate thick ness Driven plate distortion
- 3.1 - 0.12
2.6 0.10
Drive plate thickness
'1.60 :t 0.06 0.063 ± 0.002 0.1
0.004 Clutch spring free length
33.6 1.32
}
T RA i'J SM J SS I 0 N ITEM
----------Primary reduction
F ina I reduct ion Gear rat tos
Unit: mm (in) -
3. '125 3.133
-
Low 2nd
3rd 4th 5th Top
75 -
I 47 I
--
----24 ) -----) 'l 5
I I 23 I 21 I 19 I 18 I
2.500 1.625 1.210
30 26
1.000 0.863 0.782
' Shift f ork to Groove clearance
0. 10 - 0.30 0.004 - 0.0 '12
路 Shift f ork groove width
5.5 - 5.6 0.217 - 0.220
- - - - ----,
Type
19 21 22 23
-路-)
) -
-- - - -- - - - 0.50 ( 0.020 )
106
J24.3 12.77 )
20 - 路 30 0.8 - 1.2
-~
------ --1
0 .1.0.: 520DS T AKAS ,t..\GO: R K520S~II
20 pitch lenqth
I
-- - -- 1
12 16
5.3 - 5.4 0.209 - 0.213
Links
Drive chain sl ack
-
路-
Sh i ft fork th ick ness Drive chain
-
---~~',lrf
STAt\JOAR D
--
-- -r
-
8-23
SERV ICI\I G I\I FOR .\IATI 01\l
--- ------------ · ~
CJ.\RB UFlETOH Unit: m rn (in) I T E~1I
Carburetor type
SPEC IF IC!-\TI Oi\1
1\1111< Ui\11 8 S30SS
Bore size
30(1.18)
I. D. 1\J o.
11 420
Id le r/mi n.
100 r, mi n.
±
1250
Fuel level
4 .0 (0 . 16
± ±
0.5 0.02)
Float height
21.4 (0.84
.!
1.0 0.04}
(1\11. j.)
.t
:;: I I S
IVlain jet -Mai n air jet
(M.A. J.)
Jet needle
(J. N .}
5C HT40
1\Jeeclle jet
(i\J . J .}
Left 0 -'7, Ri ght 0- B
Pilot jet By pass
(P. J.}
# 1'7.5
(B. P.)
0.9, 0.8, 0.7
Pi lot outlet
(P. 0 .)
0.8
Valve seat
(\/ . S.)
2.0
Starter jet
(G . S.)
35
Pil o t screw
(P. S.}
PRE -SET
Throttle cable play
-l
1.0
0 .5
-
1.0
(0 .02
-
0.04)
I I
I
SE"IVICi\IG 1\IFOn.\,I-\TI'J'.
--------------------------------------ELECTR ICA L ITHtl
SPEC I F ICAT ION
tl OTE
-·
'
Spark plug
Type
-
D9EA i\1. D.: X27ES-U
0 .6 - 0.7 ( 0 .024 - 0 .028 ) Ove r 8 (0.3) at 1 atm
Spark performance Signal coil resi st ance
--
Ignition coil resistance
Pr im ary
Of\J\1 3.5
n
-
'IV or 8/ Y 25 k n
75 V (AC) at
5000
r ' min.
14 - 15 V at
5000
. r,I m1n .
Brush length
Approx. Type designation Capacity Standa rd electrolyteS. G. M ain
W or 8/Y 4.5
Plug cap Approx. 23
N. D.
Limit:
Commutator under cut Starter re la'f resistance
Br - 8 W G/ W - B. W
n
80
Approx .
tVIore than
Regulated voltage Starter motor
60
Approx.
Second ary Generator No-Load voltage
-
i\JGK:
Gap
Fuse size
Unit: mm (i n)
20° B.T.D .C. Below 1650 .t 100 r/mi n and 40° B.T.D.C. A bov e 3500 ± 100 r/ min.
Ign ition timing
Bat tery
r -
3 - 4
Limit: (
9 0.4
)
0 ~068 J
0.. .
YB"IOL-A2
12V 43.2kC( 12.L\h) / IOHR 1.28 at 20°C (68°F) 15A
8-24
B-25
SE RV IC/,\JG li\J FOR .\IATION
BRAKE + WH EE L -- -~--
~~-----
-
- - - r-
IT EM ---- - -- ------ --- - -Rear brake pedal fr ee travel
1
-~-
·---- -
- - --------
-
-
-------- -----
ST ANDARD
--
--~--
(
20 0.8 -
30 1.2
20 0.8
Brake drum J.D.
160.7 ( 6.33 )
Rear -------- _ _ _ _ _L___ Brake lining thick ness Brake d isc thickness
- - - - - -- Brake disc ru nout
-
Brake ca l iper cyl inder bore
Front -
--~--
Front Front
-
------- -
-
14.000 - 14.043 ( 0.5512 -0.5529) - - - - - -- -13.957- 13.984 (0 .549 5- 0. 5506)
Front
1.5 ( 0.06
)
4.5 ( 0.18
)
0.30 ( 0.012 )
-
42.850 - 42.926 (1 .6870 -1 .6900)
-- - -
-
Wheel axle runout
( 0. 20 ± 0.004
_ __ _ _ _ _ j _ _ _ _ _ _ _
Brake ca li per piston dia. Wh eel rirn runout
5.0 ± 0.1
F rant
---+---
Master cylinder bore ~--
L IMIT
I
- ~- -~-------~~--
Rear bra ke pedal heigh t
-- 1\ll aster cylinder piston dia.
Unit: mm (in)
-·- · -
42.770-42.820 (I .6839- 1.6858) --
-
-
Axial
2.0 0.08
Radial
2.0 0.08
Front
0.25 ( 0.010 )
Rear
0.25 ( 0.010 )
Tire size Front
3.00- 18 4PR
Rear
3.50-17 4PR
I
r- T ire tread depth
Front
1.6 ( 0.06
Rear
2.0 ( 0.08
---------------------------_:_ S :..:ER_:...\:_:/I.::..C_:...II\~JG:_:_:I~.·I.:..:..FO R I\;IAT I O ' I
SUSPENSJON
Unit : mm (in)
ITEIVI
STA NDARD
Front fo rk stroke
i\IOTE
L IM IT
140
5.5 Front f o rk spring free length
103
Upper
4. 1
391
Lower Front fork oi I level
15. 4 )
- - -
186 7.3
Rear wheel travel
100
3.9 Swinging arm pivot shaft runout
0.3
-
r I
0.012
FUEL + 0 1L CAPA CITY IT EM Fuel type
NOTE
SPEC I FICAT ION Usa only unleaded or low·lead t ype gasol ine of at least 85 - 95 pu mp octane JR; ili1 method) or 89 oc tnne or higher r ated by the Research i'vlethod.
Fuel tank including reserve
11 .0 2.9
L US gal)
reserve
2.0 2. 1
L US gal )
Engine oil type
SAE 10\JV '40 -
Engine oil capacity
-
Front fork oil type -
-
--
Front fork oil capacity (each leg) Brake flui d type
8·26
Change
2000 2. 1
ml
Fi Iter change
2600 2.7
ml
Overhaul
2600 2.7
rn l
us qt) us qt) us qt)
Fork oil .:r 15
150 5.07
ml US oz)
SAE J 1703 or DOT3, DOT4
-- -
- - --
T l RE PRESSURE CO I'ITi f\IUO US HIGH SPEE D RI DING
NOR 1'vlAL RIOING
CO LD li\IFLATI Oi\1 TIR E PRESSURE
SOLO RIDING
DUAL RIDING
-----kPa
FRO NT
-
150
1
psi --- ----- --
kg/cm
21
1.50
kPa -
~-
---~-
kg/cm
1
SOLO RIDI NG
------ -- 路--psi
kPa
:<g/cm
25
175
1. 75
175
1.75
25
2
psi
- --路-
175
1 75
- - - - - - - - --- REAR
DUA L RIDING
-~~--- 路
25
200
2.00
28
225
2.25
32
-------
225
2.25
32
200
2.00
28
~-------~---------~-----------~-------------
WATTAG E
l (W}
IT EM
SPEC I Fl CAT I Oi\l
T
Ta il/ Brake light
8/ 23
~J
Turn si gnal li gh t Speedometer light
23 3.4
l
Tachometer l ight
3.4
Turn signal indicator light
3.4
High beam indi cator light
3.4
Neu t ral indicator light
3.4
Oil pressure ind icator light
3.4
Headlight
<--
Parking or c ity light
-路-
-
HI
45
LO
40
-
3.4
I 1 I
--I
I
Prepared by
Service Depa rt ment Overseas Opera tions Division Novembe r, 1980 ,\¡lanual No. 99000-8 555 1-0£ 3 Printed in Japan
y
IJS[ 路n路ll':) iVIANUAL WITII : \ GS2GOT SERVICE MANUAL (HH500-321)'10路03C)
'-
I
9D501 :l202 0
I. -.. ..<.,, ,\{1/.(; A.I.II0/"01~
OJ.. I. II> I'IU\TF/l I\ .f,l/'-1 \
.lui~路.
't:2
T
>
O '~E
This supplementary service manual has been produced to aid Suzuki mechanics in properly maintaining and repairing the 1982 "Z" model. This manual has been written primarily for the experienced Suzuki mechanic but will also be very useful even for the apprentice mechanic and do-it-yourself mechanic. The entire manual should be thoroughly reviewed before any servicing is performed. Please also refer to the GS250T'T " MODEL (1980 MODEL) Service Manual (9950032010-03ÂŁ) for all other areas of information not covered in this publication.
UM/fPJOJ!RTANT All Suzuki motorcycles manufactured on or after January 1, 1978, were subject to Environmental Protection Agency emission regulations. These regulations set specific standards for emission control, and also set new servicing requirements. This manual contains pertinent information that should be carefully studied. Other, vital emission information is also contained in the GS250T"T" MODEL Service Manual and should also be carefully reviewed. Complete information concerning the EPA emission regulation and U.S. Suzuki's emission control program can be found in the U.S. SUZ UKI EMISSION CONTROL PROGRAM MANUAL. NOTE: 1. How the manual is compiled. - This supplementary service manual lists only the points relating to maintenance work which differ from those applying to the GS250T"T" model. - However, in order to make this manual easier to use, some parts have the same information as provided in the service manual (99500-32010-03ÂŁ) lor the GS250T model. - Any differences in service data, service specifications and tightening torque tables with those that apply to the GS250T'T " model is clearly indicated with an asterisk ('~). 2. How to use the manual - Give precedence to this supplementary service manual when using it as the service manual for the GS300L " Z " model. - Refer to the sefllice manual for details which are not given in this supplementary service manual.
$11!Jtz MM o !F.f!Uf)) 1!@flfl
rc ({)) ., fL rr (JJ).
Administration Department Overseas Service Division
Quoting, cop ying or otherw ise using any psrt of this manual without explicit authorization from Suzuki Motor Co., !Ltd. is not permitted as all rights to the publication are reserved under copyright law.
~--------------CONTENTS ------------------~
VIlEW OF SUZUKI GS300LZ · · · · · · · · · · · · · · · ·· · ·. · · ·· · ·· · · · · · · · · · ·· · · · · ·· ·· · 1 SPECIAL FEATURES·· ··········· ········ ........ ...... ... ........... ... ·· · · · · 2
SPECI!FUCATIONS· · ·· · · · ·· · · · · · · · · · · · · ·· · · · · · · .... ...... ... . · · · ·· ... ·· · · · · · · · ·· · 3 !PERUODUC MAINTENANCE SCHEDULE · · · · · ·· · ·· ·· · ·· · ·· · ·· · · · · · · · ·· · · · 5 MODIFICATIONS ·· · · · · · · · · · · · · · · · · · · · · · ·· · · · · · .... · .. .. · · ·. ·· · · ·· ·· · · · · · ·· · · · ·· 6
ENGINE REMOVAL·········· ··· ·· ······· ······· ·· ······· ······· ···· ··· ···· ····· 8 SERVICING ENGINE · · · ·· · · · · · · · · · · · · · · · · ·· · · · · · · ·· · · · ·· · · ·· · ·· · ·· · ·· · · · · ·· · ·· 12 C YLINDER HEAD· ····· ···················· ··· ··· ···· .· ·· ···· ·········· ··· ····· ·1 6 C~nil Tl~l~<3 ~l)~ll~1f~f:~~· ·· ··· ······ · ········ ·· ·· ····· ···· · ····· ····· ···1 E)
FUEfL SYSTEM·· ···· ········ ··· ··· ··· ··········· ····· ······ ········ ·········· ··· 18 8GNIT805\J SYSTEfNJ · · · ·· · · · · · · · · · · · · · · · · · ·· · · ·· · · · · · · · · ·· · ·· · · · · · · · · · · · · · · · · · · · 20 ~f:C»t!l.Jl~()~J'~~(;1rl~lf:fl
... ...... ... ... .... ..... .. .. ....... .... ...... .... ..~2
COMBINATION METER········· ····· ·· ·· ·· ········ ·················· ·········23 SVI!UTCHES · · · · · · ·· · ·· · · · · · · · ·· · · · ·· · · ·· · · · ·· · · ·· · · ·· · · ·· · · · ·· · · ·· · ·· · · ·· · · · · · · · · · 26 FRONT WMEIEL AND fJ/RAKE · · · ·· · · · · · · · ·· · · · · · · · · · ·· · · · · · · · · · · · · · · · ·· · · · · 27 !R!EAR WHEEL · ·· ·· · · · · · · · · ·· · ·· · · · · · · · · · · · · · · · · · · · · · ·· ·· · · · · · ·· · · ·· · ·· · · · · · · · · · 35 FRONT !FORK · · · · · · · · · · ·· · · · · · · · · · · · · · · · ·· · · · · · · ·· · · · · · ·· · ·· · · · · · · · · · · · · · · · · · · · · 38
STEERING STEM··········· ··· ······ ·· ···· ··· ··· ··· ····· ····· ··· ·· ·· ·········· 44 REAR SUSPENSION · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · · · ·· · ·· · · ·· · ·· · · · · · ·· · · · ·46 TRO!JJ/8/LfESHOOTING · · · ·· · · · · · · · ·· · · · · · · · · · · · ·· · · · · · · · · · · · · ·· · · ·· · · · · · · · · · · ·· 4 7 WIRDNG ffJIAGAM · · · · · · · · · · · · · · · · ·· · · · ·· · · · · · · ·· · · ·· · · ·· · · · · · · · · · · · · · · · · · ···· ···52 MIIRE A/MD CABLE ROUTING · ·· · · · · · · · · · · · · · · · · · · ·· · · · · · ·· · · · · · · · · · · · · ·· · ·53
TIGHTENING TORQUE ··· ····· ······· ·· ···· ·· ······ ············ ·········· ···· 56
S/E!R'VUC!E DATA· ···· ·· ··· ······ ··· ······ ················· ···· ······ ··· ····· ··· · ··58
I
GS300 LZ
RIG~IT
SIDE
I"'' .
liEfT SIDlE
GS3Li0LZ
.... L
T R A1~SJ STO Ri llE D ~G!\WinON SVS"iffEM W~Tfr,~ IE l EC TR O N~C A DVANCE On the Model GS300L, the t iming advance character istics o·f the ignition timing have been changed f rom the hitherto-employed mechanical timing advance system incorporati ng an advance governor to an electronic timing advance system. This system consits of a signal generator, ignitor and ignition co il as shown in Fig. 1.
IGN ITI ON SWI T CH
SIGNAL GENERATOR
~r·~ ·~
I
I
' - - ' - - - - (!
I
PI CI<-UP CO IL
IGI\JITOR UI'JIT
BATIE RY :
L-.... !1=-=~=
SPAR I<
PLUG
I
1l
_ I_
1
Fig. 1
When the signal rotor is rotated in the system block diagram above, the signa i "A" is generated in the pickup coi l. The thus-generated signal w ill be converted to the signal waveform "8" in side of the ignitor unit and ignition timing is control led in response to t he engine speed as shown in Fig. 2. That is, timing
t
controll ed in the igni tor unit becomes X when the engine speed is lower than N 1, and it becomes when t he eng ine speed is N 1 ~ N2. The advanced angle when ignited w ith g) is 0 1 . When higher than N2 , t iming i s~ , and the t iming does not advance higher than the above . The maximum advanced angle is 02 . 360°
I
~~--------~~
A ===='-;"-=~
[1
\1 [~1 i1
=vr
I
Pick-up coi l signal
lfF==
rL
i
~!:=====:~
CD
l
II
T
~ ~
_£
-
- - - - - -_., 8 1
82
r
II I
I
-
1 Engine speed ) \ below N1
slow-speed revolution
-~-
8
Engine start ·speed revolution
@
l
82
~
3' Fig. 2
8J
Medium·speed revol ut ion
( Between ) N 1 and N2
High-speed revolution
l Over N2 I
" NJ = 1650 r / min l'h = 4500 r / min
0 2 = 25°
3
GS300LZ
D~MIENSGONS
AND
D~V
MASS
Overall length . . ... ... . .......... . . .............. .. Overall width .............. . .................... . . Overall height .. . ......... . .. . .. . ..... . .... ... .. .. . Whee lbase . . . ....... . . ....... . .. . . .. ....... . ... ... Ground clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry mass ........... .. .... .. ......... ...... . . ....
;'2020 mm .., 840 mm '" 1100 mm -:~ 1 4 10 mm 140 mm " 159 kg
(79.5 in) (33.1 in) (43.3 in) (55.5 in) ( 5.5 in ) (351 lbs)
ENGU\HE Type .. .... .......... .. ... .. .... . . . ....... . ..... . Four-stroke, ai r-cooled, DOHC Number of cy linders . . . . .. . . . ..... . . . ........ . . ..... 2 Bore ........................................ .. .. '1 62.0 mm (2.44 in) Stroke .... .. .... ....... . . .. . .. . .. . . .... ....... .. '1 49.6 mm ( 1.95 in) Piston displacement .. . ... . . ... ... . ..... . . . .... ... .. '1 299 cm 3 (18.3 cu . in ) Compression ratio .... . ... ... . ............. .. .... .. '1 8.9 : 1 Carburetor . . .. . .. . .. . .... . .. .. ..... ..... ... .. .... MIKUNI BS30SS, twi n Air cleaner .. .. ..... . ..... ... ...... ... . .. . ...... .. Polyuretha ne foam element Starter system .. .. .. . . . ........................... Electric Lubrication system . . . ................. ...... ....... Wet sump
TRANSM ~ SSHON Clutc h ....... . ....... . .... . ......... ... ...... . .. Transmission .......... . . . .... ..... .. . .... .. .... . . Gearshift pattern ..... . ... .. . ..... . .. . ... . . . . ...... Primary reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Final reduction .... .... . . . . . ....... ...... . . . ..... .. Gear ratios, Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4th . ...... . .... .. . .. . ........ . ....... Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive chain . .......... . .... ... ... .. .... . ... .. . ....
Wet mult i-plate type '1 5-speed constant mesh -:< 1-down, 4-up 3.125 (75/24) 'â&#x20AC;¢2.800 (42/15) 2.500 (30/12) 1.625 (26/16) 1.2 10 (23/ 19) 1.000 (21 /2 1) 0 .863 (19/22) " OAIDO DID520UB or TAI<ASAGO R 1<520SU, 108 links
GS300LZ
CC HASS~ S Front suspension .. ..... ... ... . . ... .. ... . ... . .... . . ·~Telescopic, coil spring oil dampened Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swinging arm, oil dampened, spring 5-way adjustab le Steering angl e .. . ........... . . . . . . . .. . . . . . .. . ... .. . 42° (right & left) Caster . . ... .... . . . .. . . . . .. . . .. . . ....... . . .... . . . . 62° 00' Trail . . .... . ... . . . . . .. . .... ... . .. . . ....... . ... . .. 104 mm (5.51 in) Turning radius .. . ........ . .. . .... .. . . .. . . . .. . .. ... 2.3 m (7.5 "ft) Front brake ... . . . . . . . ..... . . . . . .. .. . . . . . . .. .. . .. . '1 lnternal expanding Rear brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal e'<panding Front t ire size ...... . ... . .... ...... . . . ..... ... .... . *3.60S18 4PR Rear tire size . .... ... . . . . . .. ...... . . . . ...... .. ... . "4.60S16 4PR Front tire pressure . . ... ... . . .. .... . . .... .. ...... . .. ·~ 1.75 kg/cm 2 (24 psi) (Normal solo ridi ng) Rear tire pressure .. . . . . ..... . . . . . . .... . . . .. .. .. .. . . '~ 2.00 kg/cm 2 (28 psi) (Normal solo riding)
EliECTFUCAl Ignition type ... . ..... ... . ... . . . . . . ... . . ... .. .. .. . Transistorized Ignition t im ing .. .. . . . ... . . . . . . .. . ... . . . . . . ... .. .. . ·:1 15° B.T.D .C. below at 1 650 r/min and 40° B.T.D.C. above at 4 500 r/min Spark plug .... . . . .. .. . ... . . . ... . . . . . ... . ........ . NGK D9 EA or NIPPON DENSO )( 27ES-U Battery .... . ..... ... . .. . . .... . .. .. . . . . . .. . .. .. . . . 12V 43 .2 kC (1 2 A h) /1 0 HR Generator . ... .. . . ... . . . . .. . . . .. . .. .... . .. . .. .. .. . Three-phase A.C. generator Fuse .. . .. . . ... .. . .. . ... ... ... . . .. .. .. .. . .. ... .. . 15A
CAPACr ru:s Fuel tank
including reserve .. . . Reserve . . . . . . . . . . . Engine oi l . . . . . . . . . . . . . . . . . . Front fork o il (each leg) .. .. ...
. ... . . . ....... ....... . . .. ...
. . . .
.. .. .. ..
. . . .
. . . .
.. .. .. ..
.. .. .. ..
. .. . .... .... . . ..
. . " 13.0 L (3.43 US gal) . . 2.0 L (2.1 US qt) . . 2,000 ml (2.1 US qt) .. ·~ 153 ml (5 .17 US oz)
These specifications are subject to change w it hou t notice. o Specifications marked with asterisks (":1 ) are e)( elusive to GS300LZ. G
4
5
GS300LZ
IMPORTANT: The period ic maintenance interva ls and serv ice requirements have been established in accord· ance with EPA regulations. Fo llowing these instructions wi ll ensure that the motorcyc le wi ll not exceed emission standards and it wi ll also ensure the rel iabi lity and performance of the motorcycle. NOTE: Vehicles operated under severe conditions may requ ire more frequent servicing . The chart be low lists the recommended intervals fo r all t he requ ired period ic service work necessary to keep the motorcycle operating at peak per·formance and to maintain proper emission levels. Mileages are expressed in terms of k ilometers, miles and t ime for your conven ience.
PEFHO[O)iC MAU\JTENANCE CHART mil es Interval : This int erval should be juded by odometer reading or months, whichever comes first.
km months
600
4,000
7,500
11,000
15,000
1,000
6,000
12,000
18,000
24,000
2
12
24
36
48
c
c
c
c
T
T
Battery (Specific grav ity of elect rolyte) A ir cleaner element ___c _y l_in_d_e_r _he_a_d_n_u_ts_8_t _ex_h_a_u_st_P_ip_e_b_o_lt_s______+-___r_____ 1 Valve cl earance I
~____T _______~1 ---~ ~ 1
1
c
c
R Spark plugs R r---------------------------------+----~----4-----~----+----~ ----+,----~----~----~--- Fuel line Repl ace every four years. Engine oil and o il fi l ter
R
R
R
R
R
----~------~--------4-------~
Carburetor idle rpm
I
I
Clutch
I
I
Drive chain Cl ea n and lu bricate every 600 m il es (1,000 k m ) Brakes l----------------------------------+-------~-------------------~,-------4--------~
Tires
I
I
I
I
I
r---------------------------------+--------+--- -------------- -,--------~------~
Steering st em Chassis bolts and nuts Front fork
NOTE: T = Tighten, I = Inspect, R = Repl c:ce, C =Clean
I
T
T
I
T
I
I T
T
GS3(tJLZ
The following number of refinements have been carried out on the GS300LZ (1982 model) and new mechanisms adopted. ~
The displacement has been increased.
--------
GS300LZ I GS250TT
Cylinder bore
62 .0 mm
60.0 mm
Piston stroke
49.6 mm
44.2 mm
Piston displacement
I
299 cm
3
249 cm 3
o The eng ine cover screws have been replaced with bolts and the following specia l tools have been newly provided for eJ<tra convenience in mounting and removal.
o The transm ission has been changed from 6 speeds to 5 speeds.
o A new com binatio n meter is being used. A gear position indicator is provid ed, so that the gear position can be seen at one glance.
6
7
GS300LZ
o An interna l e:<pand ing brake of the two- leading shoes type is being used for the front brake. Front brCJI<e adjustment
Squeeze the front brake lever firm ly and measure the distance between the lever and the throttle grip. The distance CD should be 20- 30 mm (0 .8 - 1.2 in). If adju stment is necessary, slacken t he cab le by screw ing the adjuster @ on the front brake lever ho lder all the way in. Turn the front brake adju ster @ in or out to acquire the specified distance.
Bral<e lining wear limi-t This motorcycl e is equipped with brake lining wear limit indicators. As shown in Fig., at the condition of normal lining wear, an extended line from the inde:< mark on the brake camshaft should be w it hi n the range embossed on t he brake panel with brake on. To check wear of the brake lining, fo llow the steps below. (1) First check i¡f the brake system is properly adjusted. o While operating the brake, check to see that the extension I ine from the index mark is w ith in the range on the brake panel. 0 If the index mark is outside the range as shown in the Fig., the brake shoe assembly shou ld be rep laced to ensure sa¡fe operation.
The el<tension l ine of the index mark is w ith in the range.
The el<tension I ine of the index mark is outside of the range.
GS300LZ
Before taking the engine out of the frame, wash the engine with a steam cleaner and dra in engine oil etc. The procedure of engine removal is squentially el<p lained in the fo llowing steps, and engine installation is effected by reversing the remova l procedure. G Place an oil pan under engi ne and remove the oi l filter cap and oil drain p lug to drain out engine oil.
o Remove the two bolts by pu lling rearward.
0
CD
and remove the seat
Set the fuel cock in the "ON " or "RES" position and shift the fu el hose cl ip sideways to remove the fuel hose and vacuum hose from the fuel cock .
o Remove the bolts at t he rear of the fuel tank. Remove the tank by moving it rearwards.
8
9
GS300 LZ
o Remove the left and right frame covers and disconnect various lead w ires. - Battery 8 lead w ire ·1\ - Battery ~ lead w ire ·1:·. - Signa l generator and oil pressure switch lead w ires :~ .
e
- Starter relay lead wire I . - Generator lead wires ~ . - Gear position and neutral switch lead wires ]: .
Pu ll out the spark plu g caps from spark plugs . o Shift the breather pipe cl ip sideways and remove the p ipe from the cylinder head cover cap. 0
0
0
Remove the bolt J:; and pu II oH the gea rshi ft lever lin k arm I . Remove the eng ine sprocket cover .
GS300LZ
o Stra ighten the bent washer on the engine .::prod<¡ et with a chisel and remove the sprocket. Apply rear brake to remove the mounting nut and the sprocket together wit h the chain 'from the drive shaft.
o Remove the air cleaner case fitting screws.
0
Loosen the carburetor clamp screws <:C¡ , slide the air cleaner case rearward and remove the carbu retors.
o Remove the throttle cab le from the carbu retor assembly.
10
11
GS300LZ
o Remove the left and right mufflers by unscrewing pil lion ¡footrest mounting bolts CD and e;<haust pipe clamp bolt sŽ.
o Remove the rear brake pedal.
o Remove the engine mounting bolts and brackets. o Gradually lif t up the engine and lower the engine ass'y on the right side making sure that it does not make contact w ith the rear bracket. Remove the engine t hrough the right side o¡f t he frame.
GS300LZ
VAlVIE SP!Rl~NGS 11.7 - 15.3 kg
o The valve springs for intake and exhaust valves were composed of inner and outer spring on the GS250T, but only one va lve spring per va lve is installed for GS300L. Together with this, the valve spring tension and the shape of the va lve spring seat were changed.
.[}
Valve spring free lengt h Service Limit
36.1 mm (1 .42 in)
Valve spring tension Standard 0
I
11 .7- 15.3 kg/32.5 mm (25.8- 33.7 lbs/1.28 in)
Insta ll the valve springs with the small pitch portion ® down. ® : Large-pitch portion.
CAM §IHIAIFT
GS300LZ
o Beasically this model's engine is a up-sized bore version of the GS250T engine. With the up-sizing, the intake and exhaust cam shafts have been changed. Along with the differences in the intake and exhaust cam shafts, valve timing has been changed.
TOG
BOG
I
GS250TT
1f TOG
12
13
GS300LZ
o The dimensions o·f the counterbalancer shaft and the driven gear of the balancer were changed as shown in the illustration on the right. Together with this, the spacer was abolished, and the number "119" was marked on the counterbalancer shaft.
Balancer shaft 34 mm
Driven gear
/ L -
--
ClUTCIHI [))~~VfE PlATIES, ID~~VlEN
PlATtE$ AN!D
S~~U~G~
o The transmission of GS300L is a 5-speed transmission on the basis of the tra nsmission of GS250T. Together w ith this, the clutch drive and driven plates and the clutch spring were changed.
Unit: mm (in) GS300LZ
GS250TT
Drive plate
8 pieces
7 pieces
Driven plate
7 pieces
6 pieces
STD
2.7 -2.9 (0.10 - 0.11)
2.9 -3. 1 (0.11 - 0.12)
Service Limit
2.4 (0.09)
2.6 (0.10)
STD
1.20 ± 0.05 (0.04 7 ± 0.002)
1.60 ± 0.05 (0.063 ± 0.002)
Service Limit
29.5 (1 .16 )
33.6 (1.32)
Drive plate thickness
Driven plate thickness Clutch spring free length
GS300LZ
14
() The transm ission of GS300 L is based on the transm ission o¡f GS250T and has been changed "from 6 speeds to 5 speeds. The main differences between the correspond ing parts of the transmissions of GS300LZ and GS250TT are as shown below. GS300LZ [ 1st driven gear
GS250TT
[iii driven ge-ar I
I
Bushing
Bushing
A: 11 mm 8: 17 mm C: 21 mm l 3rd driven gear
I
Bushing
Washer
l 3rd driven gear
A: 12 mm B: 17 mm C: 19mm
I
A: 22 mm
A: 22 mm
8: 24 mm
ISliding dog wheel !
I6th driven gear I
ISpacer I
I6th drive gear I
15
GS300LZ
GS250TT
GS300LZ
IDrivesha'ft I
IDriveshaft I 190 mm
k: s===--
181.5 mm
~
IGearshift cam I
E
us
~
JGea rsh ift cam I
(Development of the lead groove shape)
TRANSM~S ~ ~ON
I
-
"1
~1111 ~
~3
.,
(Development of t he lead groove shape)
GEARS AND RElATED PARTS
00
0 []
GS300LZ
C VUNID IE ~
HIEAD
The cylinder head nut and its washer consists o'f two types. When the cylinder head has been re moved , reinstallation should carried out accord ing to the illustrat ion right. If a @ type nut and its washer is used on the ® section of th e cylinder head, it may cause oil leakage . Therefore, t he cylinder head should be fitted with the correct set of nut and washer.
Cylinder head nut t ightening torque
Front
@
@
2.2 - 2.8 kg-m ( 16.0 - 20.0 lb-ft)
CD . . ._ ®
Tightening order
@Type
@ Ty pe:
Iro n washer
® CAM TH\iUNG ADJUSTMENT o With R"T" mark accurately lined up w ith the timing mark, hold the crankshaft steady and lightly pu ll up the chain to remove the slack bet~ ween the crank sprocket and exhaust sprocket. 0 Exhaust sprocket bears an arrow mark " 1" indicated as CD . Turn over the exhaust camshaft so that the arrow points flush with the gasketed surface of the cylinder head. Engage the t iming cha in with this sprocket.
o The ot her arrow mark " 2" is now po1nt1ng straight upward . Count the chain roll er pins toward the intake camshaft, starting from the roller pin directly above th is arrow mark ,;2 " and ending with the 20t h roller pin. Engage th e chain wit h intake the arrow mark " 3" on t he intake sprocket.
16
20 th 1st
17
GS300LZ
NOTE: The 1iming chain is now riding on all three sprockets. Be careful not to disturb the cranl<shaU until four holders and cam chain tensioner are secured .
20th 19th
GS30fiLZ
18
When the starter motor is engaged, a negative p ressure (vacuum) is generated in t he combustion chamber. This vacuu m is then transmitted to the diaphragm o-f t he fue l cock through a passageway in t he main carburetor bore and a vacuum pipe. When the vacuum applied to t he diaphragm becomes greater than t he spring pressure holding the diaphragm controlled "fuel va lve closed, t he fuel va lve is faced open , allow ing f uel to flow into the carburetor float chambers.
19
GS300L Z
"ON"
(})
®
f\
~
When the eng ine is not running and the valve is in the ON or RES position, the fuel va lve is kept in the closed position by applying pressure utilizing a spring so that no fue l w ill flow to the carburetors. When the engine is started, a negative pressure is generated in the diaphragm chamber "C" through the vacuum (negative pressure) pipe which is connected to the No. 2 carburetor, and builds up a negative pressure which is higher than the spring pressure so that the diaphragm is forced to open the fuel va lve and thus allow the fuel to f low to the carburetors .
Fuel valve Spring Vacuum
®
® ~
0 -ring ® Diaphragm One way valve Fuel fl ow
"RES"
When the lever is set to PR I position, the protru sion ® located on the lever end pushes back the fuel va lve mechanically against the spring force and it allows fuel to flow to the carburetors direct ly, whether the engine is running or not, through the RES side fuel fi lter and fuel va lve clearance.
® "PRJ"
GS300L Z
20
DESCRI :?TI ON The fully t ransistorized ignit ion system consists of a signal generator, ignitor unit, ignition coils, and spark plugs. The signal generator comprises one rotor and two pickup co ils. The signal generator is mounted at t he r ight end of the cranksha ft . The output o"f the signal generator goes to the ign itor unit, where it turns ON and OF F the transistor alternatel y . As t he t ransistor is tu rned ON and OFF, the current passing through the primary w indi ng of the ign it ion coil is also turned OFF and ON accordingly, thus it induces the secondary current on the ignition coi l secondary windings and produce the spark between spark plug gaps. IGNITION SWITCH r------ O~N------~----------~
SIGNA L GENERATO R
r
a:a
CID lliZII a:Dc:IICi c;J
I
I
I I
II
I i
D
i
i I
I I I
I
Br
~ "j
B/81
SPA R I< PLUG
Control circui t
II
L~~---~..1
â&#x20AC;˘
I 1
BATTERY
I I
[~B/Y
IG N ITOR UI\JIT
i
~~
I
o l I
I I I
b ===..J IGN ITION COIL /
21
GS300LZ
~ GN31'80N
COHlS
A SUZUI<I pocket tester or an ohm meter may be used, instead of the electro tester. In either case, the ign ition coil is to be checked for cont inu ity in both primary and secondary w indings. Exact ohmi c readings are not necessary, but, if the windings are in sou nd cond it ion, t heir cont inui ty will be noted with these approxi mate ohmi c valu es. 09900-25002
Pocket tester
Pri mary term inal @ (- ) Primary termi nal @ (+)
Plug cap
Ignition coil resistance
ÂŽ
Primary
Terminal (f) - Terminal Approx. 3- 5 D
Secondary
Terminal @ Plug cap Approx . 22- 33 kD
@
8
9 -
S ~GNAl GIEU\IlERAlOffl Measure the resistance between lead w ires. If th e resist anc e noted to show inf inity or too low resistance va lue, the signal generator must be replaced . 09900-2500 2
Pocket tester
Signal coil resistance B/BI- Br B/81 - G/W
Approx. 200 - 280
n
Br --;t--a ~
B/ 81 ---''...___,,
~
J
GS300LZ
0
Using pocket tester, check the between t he lead w ires as shown.
09900-25002
continuity
Pocket tester
RIEGUlATOIR / IRlEC1r~ IF ~ ER C IH ECK~NG
CHART o Using pocket t ester ( X 1n range), measure t he resistance between t he lead w ires in the following tabl e. l¡f the continuity checked is incorrect, rep lace the regu later/rect ifier .
1\Jormal direction: Co ntinu ity
8
¡3:) probe of tester
probe of tester
y W/8 1 R
VV/R 8/W
y i
B/W
W/8 1 W/R Reverse direction: No continu ity
r3:) probe of tester
r9 probe of t ester
y
W/B I
R
W/R 8/W W/8 1 8/vV
IN/R y
22
23
GS300L Z
~IEMOVAl a Remove seat. i>
Take ol'f fuel tank.
i\JOTE: When taking off fuel tank, disconnect fuel hose and vacuum hose and turn the 'fuel cock lever to "ON " or " RES" position.
0
Disconnect meter.
the
couplers
o Remove frame head cover
'from
CD .
o Disconnect speedometer cab le.
combination
GS300LZ
~
. nuts and Remove combinat .lon me ter mou ntmg take off meter.
D~ SASS !EM lBl~V_ _ _ _ __
24
25
GS300LZ
H\1 SPlECT ~ON
Using pocket tester, check ·the continuity between lead wires in t he fo llowing diagram. l·f the continuity measu red is incorrect, replace the respective part. 09900-25002
Pocket tester
1\JOTE : When mal<ing this test, it is not necessary to remove the combinat ion metsr.
NEUTRAL
SPEEDOM ETER
~ T~N
~
oiil
<.!>oo
~.3'o +
PROBE
BIW
B Lg y
(+)
BIW
(-)
(+)
8 /W
(-)
(+)
8/W
(-)
0
(+)
81
(-)
0
(+)
G/Y
(-)
(lg/R)
TURN LEB (B)
Low (W/ Y)
TURN R Ef> (Lg)
2nd (R/ 8 )
NEUTRAL 8 (BI)
3rd (G / 81)
H IGH BEAM EB !Yl
Top (Br/ R)
SPEE DOM ETER Ef> (Gr ) SPEEDOMETER , TUR N HIGH BEAM 8 (8/W) O I L 8 (G/Y )
PROBE
(+)
GEAR INDICATOR , OIL, NEUTRALEB (O)
4th (Y/81)
-
Gr
(- )
GS30DLZ
~
y
Y/ W
n
IN
HI LO
-o
0
T URN S IGNAl UG HT SVVrfC!l-1
~ n
Lbl
8
Lg
R
e
L
o--- - ( )
HORN SWI TCH
~
G
p
B/ W
HORN
.()
OFF
Wire co lor
G/Y - Ground
0 Cont inu ity, when engine is stopped . o No. cont inuit y , when engine is running.
CAUT I ON : Before test ing t he o il pressure switch, checl< the engine o il level.
GIEAR POSiTiON UGHT SWiTCH
~dto ~ CATOR Wire co lor
Gear posit ion 1st Neutral
W/Y Bl
2nd
R/ B
3rd
G/ BI
4 th
Y/B I
Top
Br/R
Ground
26
27
GS300LZ
f~O~u
W!HIIEtEl AND r8~A!l{tE
IRIEMOVAlL AN[))
D~SASS>IEM IBHLV
o Support the machine by center stand, and jack or block .
~ Remove
the
speedometer
and
front brake
cables.
o Pull out cotter pin
CD
and remove axle nut ®.
CAUTION : Do not reuse t he cotter pin. a Loosen the a)<le holder nuts
®.
o Draw out axle shaft and t ake off front wheel.
GS300LZ
l I
Spacer Bearing spacer '[ Bearing d Bearing spacer ~ Bearing 6 Oil seal Circlip ~ Washer 9 Drive plate @Speedometer drive gear 11 Washer 0-ring 1] Washer
f
a
Tighte ning torque kg- rn
lb-ft
®
3.6 - 5.2
26 .0 - 37.5
@
0.5 - 0.8
3.5 -- 6.0
FRONT Wt-IEEL G Push out the whee l bearings, right and left. NOTE: Drawing out the left side bear ing ·first makes the job easier.
CAUTION : The removed bearing should be replaced.
~"i
~·
,
28
29
GS300L Z
FRONT BRAI<E o Take off brake shoes.
o Remove fitting bolts and pu ll of'f brake cam levers .
o Pul l off brake cams .
o Remove circlip, and pu ll off drive plate and drive gear. Snap ring pliers
09900-06107
J J I
-/
()
0
J
GS300LZ
o Remove oil sea l by using spec ial t oo l. Oi I sea l remover
1
0991 3¡5~
~ NSPECT~ O N FR ONT WH EEL Wheel bearings <> Inspect t he play of bearing inner race by hand
w hile "fix ing it in the w heel. Rotate t he inner race by hand to inspect an abnormal noise and a smooth r otation . Replace t he bea ring if there is anyth ing unu sual.
Piay
Ax le shaH o Using a d ial gau ge, check th e E1X It: shet h fo r runout and replace it if t he runout e;<ceeds the limit .
09900-20606
Service Limit
Dial gauge (1 / 100)
0.25 mrn (0.010 in )
30
31
GS300LZ
Wheel rim ~ Make sure t hat the wheel r im runout checked as shown, does not e:<ceed the servi ce lim it. An eJ<cessive run out is usually due to worn or loose whee l bearings and can be reduced by replac ing the bearings. If bearing replacement fa ils to reduce the runout, rep lace the wheel r im. Serv ice Limit
2.0 mm ( 0.08 in )
(Axial and Radial)
FRONT BRAI<E Brake drum ltl
Measure t he brake drums 1.0. to determine t he extent of wear and, if the limit is exceeded by t he wea r noted, replace the drum. The va lue of this lim it is indicated inside th e drum. 180.7 mm (7 .11 in)
Service Lim it
Bral<e shoe o Check th e brake shoes and decide whether it should be rep laced or not hom t he th ickness of t he brake shoe linings.
[
1.5 mm (0.06 in)
Service Limit
CAUTION: Replace the brake shoes as a set, otherwise performance bral<ing affected.
will
be
~dversely
Oil seal o Inspect the lip o¡f the oi l seal for damage.
GS300LZ
RIEASS!EMBlV Reassemble and remount t he "front wheel and brake in the reverse order of disassemb ly and removal, and also carry out the ¡fo ll owing steps:
WHE EL BEARINGS o Instal l t he wheel bearings by Llsing specia l tool. CAUTION : First install the wheel bearing ¡for left side.
09924-8451 0
Bearing install er set
Left side beari ng
Right side bearing
Bearing installer set - --~
I
Bear ing ( L) 1
Left side
<1Jic==
Right side =="i n[\>
o Apply grease to t he bearing before insta ll ing the bearings.
09900-25030
Suzuki super grease " t-\''
Left sida
Right side
~
~
32
33
GS300LZ
BRAKE CAMS o 1-\pply grease to th e brake cams. Suzuki super grease "A"
99000-25030
J
WARNI NG: Be careful not t o apply to much grease to the bral<e cam shafts. H grease gat on ·~he linings, brake slippage w ill resuH.
SPEEDOME TER GEAR o App ly grease to t he speedometer dr ive gear. Suzu k i super grease "A"
99000-25030
OIL SEAL o Apply grease to t he oil seal before install ing. Suzuk i super grease "A"
99000-25030
o Insta ll t he oil seal.
BRAKE PANEL o Install ing t he brake pane l, ali gn groove Q) on t he whee l hub w it h the two dr ive pawls @ on speedometer gearbox.
CAUTIOI\J: Adjust the 1ro nt brake lever p lay after insta ll<r~ ion of t he 'front wheel.
GS300LZ
BRAKE CANI LEVER o Loosen the lock nut J) and adjust the connecting rod to the dimensions shown in the illu stration on the right. o Tighten the lock nut J:; .
o Insta ll the brake cam lever after matching the pumch mark on the cam lever w ith t he inde)< mark on the cam.
AX tE 1-lOLDER o When securing the axle holder, be sure to tighten the nuts on the hol der in such a way that clearances ahead of and beh ind the ax le w ill become equa lized.
Tightening torque
1.5- 2.5 kg-m ( 11.0 - 18.0 lb-ft)
.A.pprox.143.2mm
34
35
GS300LZ
1 Chain adjuster supporter
~ Space r
~ Washer
'4' 0 -ring
rs:
~ "'-"
Bearing Bearing . spacer
T
Bean ng
ÂŽ
Bea rmg
tainer
'-.!./ '8' Sproc. I<e t d rum re ~
@ Oil seal
1] Spacer
GS300LZ
RfEMOVAll o Support the machine by center stand. o Remove brake adju ster, and torque link nut after pul ling out cotter pin.
CAUTION: Do not reuse the cotter pin.
o Pull out cotter pin and loosen ax le nut.
0
Loosen the two f itting bolts and take off chain case.
o Pu ll the rear wheel rearward and push down chain adjusters. o Remove chain adjuster supporter by loosening bolt -D.
36
.37
GS300L Z
o Push the rear wheel ·foreward and dismount the drive ch<l in ·from rear sprocket.
o Take oH rear w heel rearward .
o Remove a>de nut and draw out axle shaft.
DISASSEMBLY o Refer to page 7-9 of GS250T service manual .
I NSPECTI 01\l o Re'fer to page 7 ·10 of GS250T service manual.
REASSEMBlY o Reassemble and remount the rear wheel in t he reverse order of disassembly and removal, and refer to page 7-14 of GS250T service manua l.
GS300LZ
R!EMOVAl o Remove ¡front wheel (See page 27). o Remove front fender.
o Loosen the steering stem upper and lower clamp bolts.
NOTE: Slightly loosen t he front ¡fork cap bolt to
facilitate later disassembly.
o Pull down r igh t and left front fork assemb li es.
38
39
GS300LZ
-I
~
~/1- ~
·.·...,.
.1
1 1 .1
5'
~
.:=/
(
i; .__________
'9
Tightening t orque kg-m
lb·ft
~
1.5 - 2.5
11.0 - 18.0
@
1.5 - 2.5
11 .0 - 18.0
ffi \J
[Z JjJ
Cap Stopper ring Spring seat 0 -ring Damper rod ring Rebound spr ing Dam per rod Inner tube Dust seal Stopper ri ng Oi l seal Oi l sea l spacer Oi l lock piece
GS300LZ 40
o Remove the front fork cap, stopper ring Q) and spring seat @ , and draw out fork spring.
NOTE: * To remove the s¡topper r ing Q) , it will be necessary to push the spring seat @ inwards, to remove spring pressure from the stopper ring. ;t The removed stopper ring Q) should be replaced .
~ Invert t he fork and stroke it several times to re-
move the oi l. o Ho ld the fork inverted for a few minutes.
o Remove damper rod bolt by using the special tools.
09940-34520
"T" handle
09940-34561
Attachment " D"
09914-258 11
" T " type heJ<agon wrench
o Separate the inner tube from outer tube. o Remove oil lock piece and damper rod with rebound spring and damper rod ring.
41
0
GS300LZ
Remove dust seal and stopper r ing.
o Remove the oi l sea l by using spec ial tool.
[
Oil seal remover
09913-501 2 1
CAUTION: The removsd oil seal should be replaced .
1 ~M ~PfECTijON
FORK SPRING o Measure the fork spring free length. If it is shorter than serv ice li mit, replace it. Serv ice Limit
[
INN ER TU BE AND 0
494 mm (19 .5 in)
OUTER T UBE Inspect both inner and outer tubes sli ding surfaces for any scuffing.
GS300LZ
DAMPER ROD Rli\IG Inspect damper rod ring ·for wear and damage.
fRIEASSfEM BlY Reassemble and remount the front fork in the reverse order of disassemb ly and removal and also carry out the foll owing steps : DAMPER ROD BOL 1f Appl y Thread Lock Cement and Bond No. 12 15 to the damper rod bolt and tighten w it h spec ified torqu e. 09914-25811
"T' ' type hexagon wrench
990 '14-3 11 10
SUZUI<I BOND No. 1215
99000-32040
Thread Lock Cement
Tightening torqu e
1.5 - 2.5 kg-m (11 .0 - 18.0 lb-ft)
~ --..,......-
Thread Lock
OIL SEAL Install new oil seal t o t he outer tube by using special tool . 09940-50 '11 2
Oil seal install er
Ce~ent
/ SUZU:<I 8ond No. 1215
42 ·
43
GS300LZ
FORK OI L o For the 'fork oil, be sure t o use a fork oi l whose viscocity rating meets specifications below. Fork oil
Capacity
Fork oil # 15
153 ml (5.17 US oz)
o Adjust the fork oi l level with a spec ial tool. NOTE: When adjusting oil level, remove the fork spring and compress the inner tube fully. 09943-74 '111
Oi l level
Fork oi l level gauge
186 mm (7 .3 in)
FOR I< SPRING o When insta lling the 'fork spring, sma ll diameter end shou ld position in bottom.
o To install a new stopper ring, it will be necessary t o push the spring seat inward.
CAUT ION : 1 ' Always use a new stopper ring. * After installing a stopper ring, always insure that i¡1 is completely seated in its groove and securely f itted.
INNER TUBE o When insta lli ng t he front fork assembly,align the t op X of inner tube to the upper surface X' of t he steering stem upper bracket.
Bottom.(} !
-
:
GS3COLZ
CD
Cushion Seat @ Steering stem nu t ® Dust seat :ID Steering outer upper race ® Steering inner upper race (J) Steering inner lower ® Steel ball ® Steering outer lower race
®
Tightening torque
~ rA
kg-m
lb-ft
1.2 - 2.0
8.5
14.5
~
3.6 - 5.2
26.0
37.5
f'
1.5 - 2.5
11.0
18.0
:9
2.0 - 3.0
14.5
21 .5
1:' "''
2.5 - 4.0
18.0
29.0
44
c15
GS300L Z
~ IE M OVAl
A N[))
D ~ SAS§lEMBl V
o Please re¡fer to the GS250T service manual page 7-35. ~ N S f?IEC J'~ 01\:1
o Please re'fer to the GS250T service manual page 7-39 .
fFlrEASSlE fl.fii!Bl LV o Please re'fer to the GS250T service manua l page 7-40 . HANDLEBARS
o Install the steering head cover on the hand lebar a-fter matching the punch mark at the lower side of the hand lebar center with the center ho le of the bracket.
o Set the handlebars to match its dent mark to the mat ing surface between steering stem and hand lebars clamp as shown.
STEE RING HEAD
COV ER
GS300LZ
Tighten ing torque
-----
kg·m
l
2.0 - 3.0
~
2.0 - 3.0
19
5.0 - 5.8
I
I
lb-ft
14.5 - 21.5 14.5 - 21.5
!
36.5 - 42.5
Spacer Bearing ]) Spacer 1:, Washer ® Dust seal ~ Washer
::0 Cl'
~
E.
@
NOTE : Please re1er to the rasr suspension section o·f GS250T service manual (Sera
p~ue
7-43 - 7-45).
46
47
GS300LZ
IENGHNIE Complain路t Engine will not start, or is hard to start.
Remedy
Symptom ancl possible causes Compression too low 1. Valve clearance out of adjustment. 2. Worn va lve guides or poor seating of valves. 3. Valves mistiming. 4. Piston rings excessively worn. 5. Worn-down cylinder bores. 6. Starter motor cranks but too slowly.
Adjust. Repair, or replace. Ad just. Replace. Replace, or rebore. Co nsult "electrica l complaints".
Plugs not spar!<i ng 1. Fouled spark plugs. 2. Wet spark plugs. 3. Defective ignit ion coil. 4. Open or short in high -tension cords. 5. Defective signal generator or ignitor un it.
Clean. Clean and dry. Replace. Replace. Replace.
No fuel reaching the carbure路tors 1. Clogged hol e in the fuel tank cap. 2. Clogged or defective fuel cock. 3. Defective ca rburetor float va lve. 4. Clogged fuel pipe or vacuum pipe. 5. Defective fue l cock diaphragm.
Clean. Clea n or replace. Replace. Clean. Replace.
Engine stalls easily.
1. 2. 3. 4. 5.
Noisy engine.
E"cessive valve chatter 1. Va lve clearance too large. 2. Weakened or bro ken va lve springs. 3. Camshaft journal worn and burnt.
Fouled spark plugs. Defective signa l generator or ignitor uni t. Clogged fuel pipe. Clogged jets in ca rburetors. Valve clearance out of adjustment.
Clean. Replace. Clean. Clean. Ad just. Ad just. Replace. Replace.
Noise appears to come 'from pistons 1. Pistons or cylinders wo rn down.
2. Combustio n chambers fouled with carbon. 3. Piston pins wo rn.
Replace. Clean. Replace.
1\Joise see ms to come 路from ~ iming c hai n 1. Stretched chain. 2. Worn sprockets. 3. Tension adjuster not working.
Replace. Replace . Repa ir or replace.
Noise seems to come 路from clutch 1. Worn splines of countershaft o r hub. 2. Worn teeth of clutch plates. 3. Distorted clutch plates, driven and driv e.
Replace. Replace. Repa ir or replace.
Noise seems to co me from cra nkshaft 1. Ratti ing bearings due to wear. 2. Big-end bearin gs worn and burnt . 3. Journal bearing worn and bu rnt.
Replace. Replace. Replace.
Noise seems to come from transmission 1. Gears worn or rubbing. 2. Badly worn splines. 3. Primary gears worn or rubbing. 4. Counter balancer gear worn or rubbing.
Replace. Replace. Replace. Replace.
GS300LZ
Complaint
Remedy
Symptom and possible ca uses
Slipping clutch
Adjust. Replace. Replace. Replace.
1. Clutch control out of adjustment or loss of play.
2. Weakened clutch springs. 3. Worn or di storted pressure plate. 4. Distorted clutch plates, driven and drive.
Dragging clutch
I
-I
1. Clutch control out of adjustment or too much play.
2. Some clutch springs weakened wh ile others are not. 3. Distorted p ressure plate or clutch plates.
Transmission will not shift
2. Distorted gearshift forks.
Tra nsmission will not shi-ft back.
2. Shift shafts are rubbing or stic ky.
1. Broken return spring on sh ift shaft.
1. Worn shifting gears on driveshaft or countershaft.
2. Distorted or worn gearshi·ft forks. 3. Weakened stopper sp ring on gearshift stopper. 1. Valve clearance out of adjustment. I
I
Engine runs poorly in high· s.peed range.
I
I I I Dirty or heavy e><haust smoke.
Replace. Replace.
1. Broken gearshift cam.
Transmission jumps out of gear. Engin e idles poorly.
-
I
2. Poor seating of valves. Defective valve guides. Spark plug gaps too wide. Defect ive ignition co il. Defect ive sig nal generato r or igniter unit. 7. Float·chamber fue l level out of adjustment in carburetors . 8. Clogged jets or imbalance of carburetors. · ----1. Valve springs weakened. 2. Va lve t iming out of adjustment. 3. Spark plug gaps too narrow. 4. Defective ignition coil. 5. Defective signal generator or ignitor unit . 6. Float·chamber fuel level too low. 7. Clogged air cleaner element. 8. Clogged fuel pipe, resulting in inadequate fuel suppl y to carburetors. 9. Clogged vacuum pipe to fuel cock. 3. 4. 5. 6.
1. Too much engine oil in the engine.
2. Worn piston rings or cylinders.
I
3. 4. 5. 6.
Worn valve guides. Cylinder wa lls sco red or scuffed. Wo rn valves stems. Defective stem seal.
Adjust. Replace. Replace .
I
Replace. Repair. Replace. Replace. Replace. Adjust. Replace. Replace. Adjust or replace. Replace. Replace. Adjust. Clean or adjust.
--
Replace. Adjust. Adjust. Replace. Replace. Adjust. Clean. Clean, and prime. Clean.
-
Check with level gauge dra in out excess oil. Replace. Replace. Rebore or replace. Replace. Replace.
48
49
GS300LZ
Complain¡~
Svm!Ytom and possible causes
Engin e lacks power
1. Loss of valve clearance. Weakened va lve springs. Va lve timing out of adjustment. Worn piston rings or cylinders. Poor seating of va lves. Spark plug gaps incorrect. Clogged jets in carburetors. Float-chamber fuel level out of adjustment. Clogged air cleaner element. 10. Carburetor bal anc ing screw loose. 11. Sucking air f r om intake pipe. '12. Too much engin e oil in the engine.
2. 3. 4. 5. 6. 7. 8. 9.
Engine overheats.
1. 2. 3. 4. 5. 6.
Heavy carbon deposit on piston crowns. Not enough o il in the engine. Defective oil pump or clogged oi l circuit. Fuel level too low in f loat chambers. Sucking air from intake pipes. Incorrect engine oil used.
Remedy Adjust. Replace. Adjust. Replace. Repair. Ad just or replace. Clean. Ad just. Clean. Retighten. Retighten or replace. Drain out excess oil.
I
I
I
I
Clean. Add oil. Replace or clean. Ad just. Retighten or replace. Change.
I
fE l iECTIRl ~ CAl Compla in1
Symptom and possible causes
Remedy
1\lo sparking or poor spar!dng.
1. Defect ive ignition coi l. 2. Defective spark p lugs. 3. Defective signal generator or ign itor unit.
Replace. Replace. Replace.
Spark plugs soon become fouled wHh carbon.
1. 2. 3. 4.
Ad just carburetors. Ad just carburetors. Change. Cl ean. Replace w ith hot type plugs.
Spar i< plu gs bGcome fouled t oo soon.
1. 2. 3. 4.
Mixture too r ich. Idl ing speed set too high. Incorrect gasoli ne. Dirty element in air cleaner. 5. Spark plugs too cold. .
I Spar!c plug elec¡~rodes overheat or burn.
Genera1or does not charge.
I
Worn piston ri ngs. Pistons or cylinders worn. Excessive clearance of va lve stems in valv e gu ides. Worn stem oil seal.
Replace. Replace. Replace. Replace .
1. Spa rk plu gs too hot. 2. The engi ne overheats. 3. Spark plu gs loose. 4. Mixture too lean.
Replace with cold type plugs. Tune up. Retighten. Ad ju st carburetors.
1. Open or short in lead wires, or loose lead con nections. 2. Shorted, grounded o r open generator c oi ls. 3. Shorted or open regu lator/rectifier.
Repair or replace or retighten. Repl ace. Replace.
GS300LZ
Complaint
Generator Overcharges.
Remedy
Symptom and possible causes
Generator does charge, but charging rate is below the specification.
50
1. Lead wires tend to get shorted or open· circuited or loosely connected at te rminals. 2. Grounded or open-circuited stator coils of generator. 3. DeJect ive regulator/rect ifier. 4. f\Jot enough electrolyte in the battery.
Repa ir, or retighten. Replace. Replace. Ad d distilled water to t he upper level. Replace the battery.
i
5. Defective cell plates in the battery.
I
1. Internal short·c ircuit in the battery. 1 2. Resistor element in t he regu lator/rectifier damaged • or defect ive. 3. Regula tor/rectifie r poorly grounded.
I
Replace the battery. Replace. Clean and tighten grou nd connection.
r---------------~----------------------------------------·-+---------------------------4
Unstab le charging.
Starter button is not effective.
Battery "sul·fatio n"
I
1. Lead wire insulation frayed due to vibration, resulting in intermittent shorting. 2. Generator interna lly shorted. 3. Defective regu lator/ rectifier.
Repair or replace.
1. Battery run down. 2. Defective switch contacts. 3. Brush es not seating properly on commutator in sta rter motor. 4. Defective starter relay.
Recharge or replace. Replace. Repair or replace.
1. Charg ing rate too low or too high. (When not in use batteries should be recharged at least once a month to avoid sulfation.) 2. Battery electrolyte e;<cessive or insufficient, or its specific gravity too high or too low.
3. The battery left unu sed for too long in cold climate.
Repl ace. Replace.
Replace. Replace the battery.
-+
~--------------+-------------
Battery disc harges too rap idly.
1. Dirty container top a nd sides. 2. Impurit ies in the electrolyte or elect rol yte S.G . is too high.
Keep th e electrolyte LIP to the prescribed level, or adjust the S.G. by consul t ing the battery make r's direct ions. Replace the battery, if badly sulfated. -----------------------~
Clean. Change the electrolyte by consu lting t he battery maker's directions.
51
GS300LZ
Compla int
Remedy
Sym ptom and possible causes
Steering feels too heavy.
1. Steering stem nut overtightened. 2. Broken bea ring in steering stem. 3. Distorted steering stem. 4. Not e nough pressure in t ires.
Ad just. Replace. Replace. Adjust.
Wobbly handling.
1. Loss of balance between right and left suspension. 2. Distorted front fo rk. 3. Distorted fro nt ax le or cocked tire.
Replace. Repair or replace. Replace.
Wobbly front wheel.
1. Distorted wheel rim. 2. Worn -down front wheel bearings. 3. Defective or incorrect t ire. 4. Loose nut on axle.
Replace. Replace. Replace. Retighten.
1---
-- r--
Front suspe nsion too soft.
1. Weakened springs. 2. Not enoug h fork oil.
Front suspension too stiff.
1. Fork oil too viscous. 2. Too much fork oil.
Noisy front suspension.
1. Not enough fork oil. 2. Loose nuts on suspension.
Ref ill . Retighten.
Wobbly rea r wheel.
1. Distorted wheel. 2. Worn-down rear wheel bea rin gs. 3. Defective or incorrect t ire.
Replace. Rep lace. Replace.
Rear suspension too soft.
1. Weakened springs. 2. Rea r suspension adjusters improperly set.
Replace. Ad just.
Replace. Refill . Replace. Drain excess oi l. -
Rea r suspension too stiff.
I
---
Rear suspension adjusters improperly set. Adjust. -¡--~=t-
Noisy rear suspension.
Loose nuts on suspension.
Poor bra kin g (FRONT and
1. Linings worn down. 2. Too much pla y on brake peda l and lever.
Retighten. -- r---¡
REAR)
Repl ace. Ad just.
n
~
ICNIII ON COil
~
~
- -
HIGHT HANDLEBAR $WITCH
N
=
--
~
. . ...."TI.. .
:JgJ
o
=
~
lUHN SIGNA L H ~lA V
~ A. T HHY
~ Q! =
j)>
FRONT I"UHN SI GNAL LICIH 11«1
,
II I tT~
""' OK
~~
=
...--•"" 8t::i:"'M=
n • v ICr l8r
~
IGNiriONSW ITCH
t
1
..1Ill J nnnp
nt tH1~ ~ 0
~
~Lo-
l
]
.-+-=---• YI-+HJ~
I
w-
J
0
T
II
j
1
A~
!
;>
!:t l AH r~K D ISCONNECT
~ W if C tt
M ~~
'Yill!J
FRONT TU RN SIGNA l LICHT II I
1-H
.a eL.IL. '-EJ " H()RN $WITCH
WIRE COLO R B . ... . .... .. BI:Jck
Bl .. ........ Blue Br .. ........ Brown G ........ . .. Green Gr .......... Gray Lbl. .. .... . . Light blue Lg .. ...... .. Light green
- --
~
..
- -
lEfT HAND LEBAR SWITCH
O .. .. . ... ... Or::mge R .... .. ..... Red W .. .... ... . W hite Y .. ...... .. . Yellow B/ BI ....... Black with Blue t racer B/W ...... . Black with W h ite t racer B/ Y .. ...... Black w ith Yellow tracer
'T
G[ AR POSITION LIGHT SWITCH
~
I!
~ C)"i!'>G)- l;
N~ I
~
TURN SIGNAL liCH.ts::'r cH
H:t:AH fU HNStGNAl l lf..HI IHJ
l
0
~
~
1
·-=-· 1_L. J6-<o;~ l
w- - = -w
"'"l -----~:> w-'-<-=-
Ill I I IIHII II rc-r tllll I II ll
H()HN
w-L~
-
I ll
~
I
-
._
~
_J
I
l
~
<V"{J~
<V : : ~ =
1!u1I I H!,1Il l - ::iii~
~i 11 n1 1 1 111 1111
G)
O(') Q) II!I
U~l
RE AR fUAN ~IGNAl l iGHT I U
I i
:,IGNAL Gt.Nl i«ATOR O IL
Pkf~UH(
fUS E R liGULA TOFi/11£(; 1 lf i i:.R
1
A C GENHIAI OH IC NI10R
_II
~--~--~ ---~_j
Br/ R .. ..... Brown with Red trac.:r G/ BI . ... .. . Green with Blue t racer G/ R ... ..... Green with Red t racer G/W .... .. . Green with White tracer G/Y ...... .. Green with Yellow trac er 0 / W .. . .. .. Orange w ith White tracer R/ 8 ....... . Red w it h Black tracer
SWITC.H
~ TAR TE R M()T 0 h
$ TARTER H(l A V
W / el . .. Whil e with ell ro tr<oc0r W/G .. ... .. White with Green tracer W/R ...... .Whi te w ith Red tracer W /Y ...... . White with Yellow tracer Y / BI ....... Yellow with Blue t racer Y / G .... .... Yellow with Green t race r Y /W ...... . Yellow with Whit e tracer
C1 C/) (,,;)
0
c::>
r
N
(]1
N
53
GS300LZ
To igni tion coil CLAMP (Tail/brake lights and . . . / To turn s1gnal light turn signal lights)
Gear position ind icator lead wire
/
Wiring harness
'
To tur n signa l light
To meter Signal generator and oil pressure lead wire
Signal generato r and oil pressu re lead wire
CLAMP (Wiring harness and magneto)
\
\
\
CLAMP (Gea r position indicator lead wire and wiring harness)
Wiring harness
CLAM P (Starter motor, ge nelator lead wire and gear positio n Starter re lav
1 Frame ground
CLAM P (Wiri ng harness and brake light switch lead wi re
CLAMP (Signal generator, oil pressure and wi ri ng \ ha rness lead wi re)
To signal generato r
o
Engine grou nd : to crankcase bol t
GS300LZ
Signal generator and oi l pressure lead wi re
0
Front
54
55
GS300LZ
Throttle cable
Clutch cable
Thrott le cable
Clu tch cable
Speedometer cable
Brake cable
GS,iOOL Z
E N G ~N E
ITEM
kg-m
Cam chain tensioner adjuster fitting bolt
lb-H
0.6 -
0.8
4 .5 -
Cam chain tensioner adjuster lock nut
0.9 -
1.4
6.5 - 10.0
Cam chain tensioner shaft ass'y
3.1 -
3.5
22.5 - 25. 5
Cam chain tensioner shaft lock nut
0.8 -
1.0
6.0 -
7.0
0 .8 -
1.2
6.0 -
8.5
" 1.7 -
1.9
'-1 12.5 - 13.5
Clutch sleeve hub nut
3.0 -
5.0
21.5 - 36.0
Clutch spring bo lt
0.4 -
0 .6
Con rod nut
3.0 -
3.4
21 .5 - 24. 5
Counter balancer center bolt
3.5 -
4.5
25.5-32.5
0.9 -
1.3
2.0 -
2.4
0.7 -
1.1
-
Cam shaft journal holder bolt Cam shaft sprocket bolt
Crankcase bo lt
I
6 mm 8mm
- -
Cy linder head bolt
--
-:• 1.0
Cylinder head cover bolt Cylinder head nut
2 .2 8mm
Engine mounting bolt
10 mm
3.0 -
6 .5 -
6.0
4. 5
9.5
14.5 - 17.5 5.0 -
8.0
'J 7.0 2.8
16.0 - 20.0
2. 5
18.0
3.5
25.5
------
Engine sprocket nut
5.0 -
7.0
36.0 - 50.5
El<haust pipe clamp bolt
0 .9 -
1.4
6.5- 10.0
Gearshifting arm stopper
1.5 -
2.3
11.0-16.5
;•9.0 - 10.0
-:• 65.0 - 72.5
---
Generator rotor bolt Neutra l stopper housing
1.8 -
Oil pan bolt
2.8
13.0 - 20.0 7.0
1.0
Oil pressure regu lator
1.7 -
2.0
12.5 - 14.5
Pressure switch
1.3 -
1. 7
9.5-12.5
Primary drive gear n'ut
5.0- 7.0
36.0 - 50.5
Rocker arm shaft stopper bolt
0.8 -
1.0
6.0 -
Signal generator rotor bolt
1.3 -
2.3
9.5 - 16.5
1.5 -
2.0
11.0 - 14.5
Starter motor bolt
0.4 -
0.7
3.0 -
5.0
Valve clearance adjuster lock nut
0 .9 -
1. 1
6.5 -
8.0
" Starter clutch all en bolt
" Speci'fications marked with
asterisks( '~ )
are exclusive to GS300LZ.
7.0
56
57
GS300LZ
ITEIVl
lb-ft
kg-m
Brake pedal arm bolt
1.0 - 1.5 '}1.5 - 2.0
Chain adjuster support bolt
I I
7.0 - 11.0 ;, 11.0 - 14.5
Front axle holder nut
1.5 - 2.5
11.0 - '18.0
Front ax le nut
3.6 - 5.2
26.0 - 37.5
0.5- 0.8
~
8mm
1.5 - 2.5
11 .0 - 18.0
10 mm
2.7 - 4.3
19.5 - 31.0
Front fork damper rod bo lt
1.5 - 2.5
11 .0 - 18.0
Front fork lower clamp bolt
2.5 - 4.0
18.0 - 29.0
Front fork upper clamp bo lt
2.0 - 3.0
14.5 - 21.5
Handlebars clamp bolt
1.2 - 2.0
8.5 - 14.5
Muffler bracket bo lt
2.0 - 3.0
14.5 - 21 .5
Muffler bracket mounting bo lt
2.7 - 4.3
19.5 - 31.5
Rear axle nut
5.0 - 8 .0
36.0 - 58.0
Rear brake cam lever bo lt
0.5 - 0.8
Front brake cam lever bo lt Front ¡footrest bo lt
Rear shock absorber fitting nut
'
__j__
1
2.0 - 3.0
3.5 -
3.5 -
6.0
6.0
14.5 - 21.5
¡---
-
Rear footrest bolt
2.7 - 4.3
19.5 - 31 .5
Rear sprocket nut
2.5 - 4.0
18.0 - 29.0
Rear torque link nut
2.0 - 3.0
14.5 - 21.5
Steering stem clamp bolt
1.5 - 2.5
11.0 - 18.0
Steering stem head bo lt
3.6- 5.2
26.0 - 37.5
Swing arm pivot nut
5.0 - 8 .0
36.0 - 58.0
" Specifications marked with asterisks (.. ) are exclusive to GS300LZ.
GS200LZ
VA LVE+
GU~DE
Unit: rnm (in)
ITEM
LIM IT
STANDARD I
Valve d iam .
I N.
I
E><. Va lve li ft
(
(
I N.
I
I
(
I
I
Valve c learance or tappet clearance
EX.
JI
/ IN. & EX.
(when cold) Va lve guide to va lve stem clearance
I
I I
I
I N.
I
I
-
I
Va lve guide I. D.
EX.
·11\J. & EX.
Valve stem 0. D.
EX.
I
(
)
I
)
I
i
) )
0.08-0.13 0.003-0.005
I )
0.025-0.052 ( 0.0010 - 0.0020 ) 0.040 - 0.067 ( 0.00 16-0.0026 ) 5.500 - 5.512 ( 0.2 165 - 0.2170 ) 5.4 60-5.475 ( 0.2 150 - 0.2 156 ) 5 .445 - 5.460 ( 0.21 44- 0 .2 150 )
IN.
Valve stem runout
(
i
21 0.827 18 0.709 7 0.28 7 0.28
Va lve stem end length Va lve seat w idt h
I
lf\1. & EX.
I I N. &
EX.
(
0.9 - 1.1 0.035-0.043
I I
)
0.03
I
( 0 .00 1 )
·• 36. 1 ( 1.42
(IN. & EX.) (IN. & EX.)
I
'
Valve spring free length Valve spring tension
·•o. 35 ( 0 .0 14 )
0 .5 ( 0.02 ) ·• 3.7 ( 0.15 )
I
11\1. & EX. 11\J . & EK
~ o.35
( O.O 'ILI )
( 0 .002 )
I
I
Va lve head rad ial runou t
I I
0.05
IN. & EX. ·-·
Valve head t hickness
I
I
· ' 11.7 - 15.3 kg ( 25.8 - 33.7 lbs) at length 32.5 mm ( 1.28 in)
" Specificat ions mar ked w it h asterisks('' ) are e'<clusive to GS300LZ .
)
58
59
GS300LZ
CAMSHAFT + CYLI NDER HE AD
Unit· mm l in)
I
ITEM Cam height
STANDARD I
I IN. 8t EX.
Camshaft journal oil clearance I
I
( 0.0013 - 0.0026 )
0.150 ( 0.0059)
22.012 - 22.025 ( 0.8666 - 0.8671 ) 21 .959-21 .980 ( 0.8645 - 0.8654 ) I
IN. & EX .
( 0.004 )
I
( 6.213 )
157.8 I
Cam cha in p in (at arrow " 3 " )
I
Rockerarm I. D.
I I
Rocker arm shaft O.D.
20th pin 12.000 - 12.018
11\J. & EX.
( 0.4724 - 0.4731
)
11.973 - 11.984 ( 0.47 14 - 0.4718 )
I IN. & EX .
I
1 I
I
I
I
l
I
CYLI N DER + PISTON+ PISTON RING ITEM
; (
" 12 - 15 170 - 213
kg /cm psi)
1
T
I
Compression pressure difference
I I
I
* 61.950- 61 .965
1 10 kg/ crn psi ) ( 142 2 2 kg /ern ( 28.4 psi !
" 62.085 ( 2.4443)
( 2.4409 - 2.4415 )
Piston diam.
LIMIT
0 .120 ( 0.0047)
" 0.045 - 0.055 ( 0 .0018 - 0.0022 )
* 62 .000 - 62.015
Cylinder bore
0.10 ( 0.004 )
Unit· mrn (in)
I
STANDARD
Compression pressure
Piston to cylinder clearance
0.1
I
Cam chain 20 pitch length
Cylinder head d istort ion
" 34.16 ( 1.345 )
·:t
IN . & EX . IN. & EX.
Camshaft runout
LIM IT
)
'' 0 .032 - 0.067
I
Camshaft journal 0 . D.
'' 34.42 - 34.46 1.355 - '1 .357
(
IN. & EX.
Camshaft journal hold er I. D.
I
I
" 61.880 ( 2.4362)
( 2.4390 - 2.4396 ) Measure at 16 ( 0.6 ) from the skirt end . Cy li nder distortion
I
·:tSpeci·ficat ions marked w it h asterisks (" ) are eJ<clusive to GS300LZ.
i
0. 10 ( 0 .004 )
GS300LZ
60
Unit· nrm (in)
ITEM Pi ston rin g f ree end gap
1 1\l
A pp ro;<.
R
,6,pprox.
N
Apprm<.
R
Approx .
(
1st
I I 2nd I I
Pi sto n ring end gap
N R
2 nd
'' 7.5 0 .30
(
(
'' 0 .10 - 0 .30 0 .004 - 0.0 12
(
0 .10 - 0. 30 0 .00<!.- 0 .0 12
(
1st
1st 2nd Oil
Pist o n ring t hickness
Pi sto n pin bore Pi sto n pin 0. D.
~
(
" 7.5 0 .30 ) '' 9 .5 ( 0.37 ) ) )
)
I
" 7.6 ( 0.30
I
0.7 ( 0 .02 8 )
I
)
0 .7 ( 0 .028 ) 0.7
~
( 0.0 28 )
0 .180 ( 0.007 1 ) 0. 150 ( 0.00 60 )
2nd Piston r ing groove w idth
'' 6.0 0 .24 ) '' 6.0 ( 0.24 ) .. 7.6 ( 0.30 )
)
(
'' 9.5 0 .37 0 .10 - 0 .2 5 0 .004 - 0 .01 0
1st
Pisto n ring to groove cleara nce
LI MIT
ST AI'JDA RD !
·-
1.2 '1- 1.23 _ ( - 0.047 -0.048 1.21 - 1.23 ( 0 .04 7- 0.04 8 2.5 1- 2. 53 ( 0.0 99 - 0 .100
) )
)
1st
1.1 75-1. 190 ( 0 .0463- 0 .0469 )
2nd
1 .1 70 - 1.190 ( 0 .0461 - 0 .0 469 ) 16.0 0 2 - 16.008 ( 0. 6300 - 0 .6 302 )
16.030 ( 0 .6311 )
15.995 - 16.000
15.980 ( 0 .629 1 )
( 0 .6 297 - 0 .6300 )
·" Specif icat ions marked w it h asterisks ( '~ ) are exclu sive to GS300LZ .
61
GS300LZ
CONROD +CRANKSHAFT+ BAlANCER STAI\JDARD
LIMIT
16.006 - 16.014
16.040 ( 0.6315) 3.0 ( 0.12 )
ITEM Conrad sma ll end I. D.
Unit · m m (in)
( 0.6302-0.6305 )
Conrod deflection Conrod b ig end side clearance I
(
Conrod big end width
I
(
Crank pin width (
Conrod big end oil clearance ( i
Crank pin 0. D.
I
(
Crankshaft jou rnal oil clearance (
Crankshaft jou rnal 0. D. (
Crankshaft thrust clearance (
Crankshaft journal holder w idth (
Crankshaft joumal w idth (
0.10 - 0.20 0.004 - 0.008 19.95 - 20.00 0. 785 - 0.787 20.10 - 20.15 0.791 - 0.793 0.024-0.048 0.0009 - 0.0019 31.976-32.000 1.2589- 1.2598 0.020 - 0.044 0.0008 - 0.0017 31 .976-32.000 1.2589 -- 1. 2598 0.05-0.25 0.002 - 0.010 54.05 - 54.1 5 2.128 - 2.132 53.90- 54.00 2.122 - 2.126
1.0 ( 0.04
) ) )
0.080 ( 0.0031 )
) )
0.080 ( 0.0031 )
) )
I
)
)
I I
Balancer journal 0. D.
I
0 .020( 0.0008 31 .984 ( 1.2592 -
0.35 ( 0.014 )
)
Crankshaft runout Balancer journal oil clearance
)
0.0440.0017 ) 32.000 1.2598 )
1--
I
Oil PUMP
0.05 ( 0.002 ) 0.080 ( 0 .0031 ) - --
Unit · mm (in)
ITEM Oil pump reduction ratio Oil pressure (at 60° C, 140° F)
LIMI T
STANDARD
1.905 (
I I
Above Below
75/24 (
(
at
X
25/41
kg/cm 2 psi) 2 kg/cm 5.5 psi) 78 3000 r/ min.
)
I
3.0 43
I
I
GS300LZ
CLUTCH
62
Unit: rYrm (in)
ITEM Clutch cable play
---I Clutch release screw Drive plate thickness
LIMIT
STANDARD 4 ( 0.16 )
--
1/4 - 1/2 Turn back
~ I
" 2.7 - 2.9
I
(
0.106 - 0. 1 1£~
1 '1.8 0.46 " 1. 20 ± ( 0.04 7 ±
Drive plate claw w idth
(
Dr iven plat e thickness Driven plate distort ion
12.0 0.4 7 0.05 0.002
" 2.4 0.09 )
)
(
)
( 0 .43
11.0 )
--
--
)
0. 1
---
( 0.004 )
--
* 29.5
Clutch spring free length (
1. 16 )
TR AN SM ISS !ON + DRI V E CHA ~!\J ITEM Primary reduction ratio
LIMIT
STANDARD i
3.1 2 5
(
75/24
)
" 2. 800
(
4 2/ 15
)
1. 2 1o
(
23/19
)
~_ ___ 1.000
(
21/21__
0.8 63
(
19/22
--------------------------------------------4-------------
Final reduction ratio
l
Gear ratios
Low
3rd
1
--1 - __4_t_h__ Top
-
1
0 .1 0 - 0.30 mm 0.04 - 0. 12 in )
Shift fork to groove clearance Shift fork groove w idth
5.5 - 5.6 mm ( 0.127 - 0.220 in )
Shift fork thick ness
5. 3 - 5.4 mm ( 0. 209 - 0.2 13 in ) D. I.D. : ' 520UB TA I<ASAGO : 'RI<520SU
Drive chain
Type I
~--------I
~ · ' - - - - - - -- )
~
I
0.50 mm ( 0.020 in)
T
Links
1
----·~
., .
1oa
- - - - - -- -- - - - - - - + -- -::--::--:-::------1
324.2 mm [__ ______ _ _______ ( 1_2_. 7 _7__irr__l ___ r-------------~1-----20 - 30 mm Dri ve chain slack ( 0.8 - 1.2 in I 20 pitch length
I
·:•specif ications marked with asterisks(':' ) are exclusive to GS300LZ.
63
GS300L Z
CAR BURETOR SPECIFICAT ION
iTEM I
Ca rburetor type
MII<UNI BS30SS
'
Bore size (
I. D. No.
" 1 1900 I
Idler/min. Fuel level
I
1250 ± 100 r/ min.
I
4.0 0. 16 21.4 0.84
(
Float he ight I
Main jet
30 mm 1.2 in )
(M . J.)
(
I
± 0.5mm ± 0.02 in ) ± 1.0mm ± 0.04 in )
# 115 1.0 mm ( 0.04 in)
Main air jet
(M .A. J.)
Jet need le
(J . N. )
Need le jet
(N . J.)
Pi lot jet
(P. J.)
By pass
(B. P.)
Pi lot out let
(P. 0.)
0.8 mm ( 0.03 in )
Valve seat
(V. S.)
2.0 mm ( 0.08 in )
Starter jet
(G . S.)
Pi lot screvv
(P. S.)
Pi lot air jet
(P. A. J.)
I
" 5C53
.• 0-'l
I I
I
# 1'7.5 0.9 mm ( 0.035 in). 0.8 mm ( 0.031 in), 0.7 mm ( 0.028 in)
0
I
•
# 25
PRE-SET
• # 147.5
Thrott le cable p lay (
" 1.0 - 2.0 mm 0.04 - 0.08 in )
·:•specifications ma rked wit h asterisks( " ) are exclusive to GS300LZ.
GS300LZ
ELECTRICA l ITEM Ignition timing Spark plug
Spark performance
SPEC IFICATION ·• 15 o B.T. D.C. Be low 1650 ± 100 r/ min and 40 ° B.T.D.C. Above4500 ± 100 r/ min. 1\JGK D9EA or Type NIPPON DENSO X27ES-U 0.6 - 0.7 mm Gap ( 0.024 - 0.028 in ) Over 8 mm ( 0.31 in) at 1 atm
Signal co il resistance Igni tion coil resistance
Primary
" Primary __,, Prim ary ,...._ rerminal ::.0 - terminal :::--' Q Approx. 3-5 ''Plug cap - Primary terminal 22-33 Appro x. krl
More than 75 V (AC) at 5000 r/ min.
Regu lated voltage Starter motor
14- 15 Vat Brush length
N.D.
Commutator under cut Starter relay resistance Battery
Fuse size
0.
·• 200-280
Approx.
Secondary Generator no- load vo ltage
NOTE
Approl<.
r/ min.
5000 Limit:
9mm ( 0.4 in )
Limit:
0.2 mm ( 0.008 in)
3- 4
n
Type designation
" Y8128-82
Capacity
12V 4 3. 2kC( 12Ah)/ 1OHR
Standard electro lyte S. G.
1.280 at 20° C (68° F)
Main
·*Specifications marked with asterisks (':') are exclusive to GS300LZ.
15
A
8/81-Br 8/81-G/W
64
65
GS300LZ
Unit : mrr: (in )
BR AKE + WHEEl (
20 -30 0.8 - 1.2
)
(
20 - 30 0 .8 - 1.2
)
Frant brake lever distance Rear brak e pedal free trave l Brake drum 1.0.
LIMIT
STAND.L\RD
ITEM
I I
- --
---
Front
(
Rear
(
Brake linin g th ickness
- --
Wheel rim runout
Whee l ax le runou t
Tire size
I T ire tread depth
A x ia l
-
Radial
--
Front
--
Rear
---
(
-
(
( (
160.7 6.33 1.5 0.06 2.0 0.0 8 2.0 0 .08 0. 25 0.010
) )
) ) )
0. 2 5 ( 0.010 )
Front
.,. 3.60 S18 4PR
--
Rea r
·" 4.60 S16 4PR
--
Front
---
Rear
·--
1.6 ( 0.06 ) 2.0 ( 0 .0 8 )
SUSPENSi ON
Un it · mm (i n)
I TE M
STAN DAR D 140 ( 5. 5 )
Fron t fork stroke
LIM lT
(
I
I
I
(
Rea r wheel travel (
186 7.3 * 90 ·3.5
NOTE
I
Front fork spring free length Front fork oi l level
'' 180.7 7. 11 )
" 494 19.4
)
I ) )
Sw ing arm pivot shaft runout
0.3 ( 0 .0 12 )
·:t speci fications marked w ith asterisks (" ) are exclusive t o GS300LZ.
I
GS300LZ
FUE L + O~l ITEM
SPECifiCATION
Fuel type
NOTE
Use only un leaded o r low-lead type gasoline of at least 85 - 95 pump octane (R;fi.·J rnethod) or 89 octane or higher rated by the Research Method .
Fuel ta nk inc luding reserve
I
" 13.0 L 3 .43 US gal
(
2.0
reserve (
2.1
Engi ne oil type
)
L
us qt
)
SAE 10W/ 40
Engine oil capacity
Change Fi lter change Overhaul
(
ml 2000 ) 2.1 USqt ml 2600 2.7 us qt )
(
ml 2600 ) 2.7 us qt
(
" Fork oil # 15
Front fork oil type Front fork oi l capac ity (each leg) (
Brake fluid type
" 153 ml 5. 17 us oz
)
DOT3 or DOT4
T IR E PR ESSURE NORMAL RIDING COLD INFLAT ION TIRE PRESSURE
SOLO RIDING
kg/cm 2 FRONT REAR ~fspeci'fications
CONTINUOUS HIGH SPEED RIDING
DU AL RIDING
SOLO RIDING
DUAL RIDI NG
psi
kg/cm 2
psi
kg/cm 2
psi
kg/cm 2
psi
1.75
~ 24
1.75
24
* 2.00
* 28
2.00
28
* 2.00
~ 28
2.25
32
, 2.25
" 32
" 2.50
'36
~
marked w ith asterisks (" ) are exclusive to GS300LZ.
66
67
GS300L Z
Unit
WATTAGE ITEM Head light
SP EC IFICA TION
HI
45
LO
40
Tail/Brake light
8/23
Turn signal light
23
Speedometer light
3.4
Turn signal indicator light
3.4
High beam indicator light
3.4
Neutral indicator light
3.4
Oil pressure indicator light
3.4
¡:.Gear position indicator light " Specifications marked w ith asterisks ("" ) are e)< elusive to GS300LZ.
it
1. 12
VV
Prepa reu by
SUi.lUKU MOTOR CO, a..Tf!JJ.
Ad minist ration Department Overseas Service Division July, 1982 ~l a n ual
No. 9950 1-32020-03E
Prin ted in Japan