Suzuki Katana AY50 Scooter Shop Manual 1997 – 2014 – PDF DOWNLOAD by www.heydownloads.com

FOREWORD This manual contains an introductory description on the SUZUKI AY50/50W and procedures for its inspection/service and overhaul of its main components. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections as a guide for proper inspection and service. This manual will help you know the motorcycle better so that you can assure your customers of fast and reliable service. * This manual has been prepared on the basis of the latest specifications at the time of publication. If modifications have been made since then, differences may exist between the content of this manual and the actual motorcycle. * Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual motorcycle exactly in detail. * This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you. ! Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider and passenger.

GROUP INDEX GENERAL INFORMATION

PERIODIC MAINTENANCE

ENGINE

FUEL AND LUBRICATION SYSTEM

COOLING SYSTEM (AY50W)

CHASSIS

ELECTRICAL SYSTEM

SERVICING INFORMATION

AY50W/WW/WRW (’98-MODEL)

AY50X/WX/WRX (’99-MODEL) AY50Y/WY/WRY (’00-MODEL)

AY50K1/WRK1 (’01-MODEL) AY50K2/WRK2 (’02-MODEL)

AY50K3/SK3/WK3/WSK3 (’03-MODEL)

AY50K4/WK4 (’04-MODEL)

7-7

ELECTRICAL SYSTEM

STATOR COIL Measure the resistance between the lead wire and ground using a pocket tester. If the resistance is incorrect, replace the stator coil. ! 09900-25002: Pocket tester " Tester knob indication: × 1 Ω range Standard resistance 0.1 – 1.2 Ω

Y-Ground

REGULATOR/RECTIFIER Measure the voltage between the terminals with the multi circuit tester. ! 09900-25008: Multi circuit tester set # Tester knob indication: Diode test ($) Unit: V

- Tester prove

+ Tester prove A A B

✽

1.3 – 1.6 1.3 – 1.6

✽

1.3 – 1.6 1.3 – 1.6

0.8 – 1.2 0.8 – 1.2

✽

0.9 – 1.3 0.9 – 1.3

✽

0.4 – 1.1 0.6 – 1.1 0.2 – 0.5 0.2 – 0.5

✽ More than 1.4 V (tester’s battery voltage)

NOTE: If the tester reads under 1.4 V disconnect the tester probes from the wire leads, and then replace the multi circuit tester’s battery.

AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) 11-1

AY50K1/WRK1 (’01-MODEL) AY50K2/WRK2 (’02-MODEL)

This chapter describes specification, service data and servicing procedures which differ from those of the AY50Y/WRY (’00-MODEL). NOTE: * Any differences between AY50Y/WRY (’00-MODEL) and AY50K1/WRK1 (’01-MODEL) in specifications and service data are clearly indicated with the asterisk marks (*). * Please refer to the chapters 1 through 10 for details which are not given in this chapter.

CONTENTS SPECIFICATIONS ............................................................................. 11- 2 AY50K1 .......................................................................................... 11- 2 AY50WRK1 .................................................................................... 11- 3 SERVICE DATA ................................................................................. 11- 4 AY50K1 .......................................................................................... 11- 4 AY50WRK1 .................................................................................... 11- 8 THERMOSTAT (For AY50WRK1) ..................................................... 11-13 ENGINE COOLANT TEMP. SWITCH (For AY50WRK1) ................... 11-14 REGULATOR/RECTIFIER ................................................................ 11-16 CDI/IGNITION COIL .......................................................................... 11-16 WIRING DIAGRAM ........................................................................... 11-17

COUNTRY OR AREA P-02: UK P-04: France P-18: Swiss

P-22: Germany P-26: Denmark P-34: Italy

P-39: Austria P-53: Spain

11-2 AY50K1 K2/WRK1 K2 (’01 ’02-MODEL)

SPECIFICATIONS AY50K1 DIMENSIONS AND DRY MASS Overall length .............. 1 865 mm Overall width ............... 650 mm Overall height .............. 1 125 mm Wheelbase .................. 1 260 mm Ground clearance ....... 105 mm ... P-04, 22, 26, 39 120 mm ... The others Seat height .................. 790 mm Dry mass ..................... 77 kg

ENGINE Type............................. Intake system .............. Number of cylinders .... Bore ............................ Stroke .......................... Piston displacement ... Corrected compression ratio ..................... Carburetor ...................

Air cleaner ................... Starter system............. Lubrication system ......

Two-stroke, forced air-cooled Reed valve 1 41.0 mm 37.4 mm 49 cm3 6.5 : 1 ......... P-02, 22, 39 7.3 : 1 ......... The others KEIHIN PWS12 ........ P-34, 39 KEIHIN PWS14 ........ The others Polyurethane foam element Electric and kick SUZUKI “CCI”

TRANSMISSION Clutch .......................... Dry shoe, automatic centrifugal type Gearshifting ................ Automatic, variable ratio Reduction ratio ............ * Variable (2.768 – 1.005) ........ P-22 Variable (2.768 – 0.871) ........ P-02, 39 Variable (2.975 – 1.140) ........ The others Final reduction ratio .... 14.960 (51/15) × (66/15) ........ P-02, 22, 39 13.812 (51/15) × (65/16) ........ The others Drive system ............... V-belt drive

CHASSIS Front suspension ........ Inverted telescopic, coil spring Rear suspension ......... Swingarm type, coil spring, oil damped. Steering angle ............ 45° (right & left) Caster ......................... 25° 18’ Trail .............................. 76.7 mm Turning radius ............. 1.9 m Front brake .................. Disc brake Rear brake .................. Internal expanding Front tire size .............. 120/70-12 51L Rear tire size ............... 130/70-12 56L

ELECTRICAL Ignition type ................ Electronic ignition (CDI) Spark plug ................... NGK BPR6HS, DENSO W20FPR-U ............... P-02, 22 NGK BPR7HS, DENSO W22FPR ............. The others Battery ........................ 12 V 14.4 kC (4Ah)/10HR ........ P-53 12 V 10.8 kC (3Ah)/10HR ..... The others Generator .................... Magneto Fuse ............................ 10 A Headlight ..................... * 12 V 35/35 W Brake light/Taillight ...... 12 V 21/5 W Turn signal light ........... 12 V 10 W

CAPACITIES Fuel tank ..................... 6.8 L Engine oil tank ............ 1.2 L Final gear oil ............... 130 ml

These specifications are subject to change without notice.

AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) 11-3

AY50WRK1 DIMENSIONS AND DRY MASS Overall length .............. 1 865 mm Overall width ............... 650 mm Overall height .............. 1 125 mm Wheelbase .................. 1 260 mm Ground clearance ....... 105 mm ... P-04, 22, 26 120 mm ... The others Seat height .................. 790 mm Dry mass ..................... 83 kg

Air cleaner ................... Starter system............. Lubrication system ......

Two-stroke, liquid-cooled Reed valve 1 41.0 mm 37.4 mm 49 cm3 8.1 : 1 ......... P-02, 18, 22 8.0 : 1 ......... The others KEIHIN PWS12 ........ P-18, 34 KEIHIN PWS14 ........ The others Polyurethane foam element Electric and kick SUZUKI “CCI”

TRANSMISSION Clutch .......................... Dry shoe, automatic centrifugal type Gearshifting ................ Automatic, variable ratio Reduction ratio ............ Variable (2.975 – 0.781) ........ P-02, 18, 22 Variable (2.975 – 1.140) ........ The others Final reduction ratio .... 16.271 (51/15) × (67/14) ........ P-02, 18, 22 13.812 (51/15) × (65/16) ........ The others Drive system ............... V-belt drive

CHASSIS Front suspension ........ Inverted telescopic, coil spring Rear suspension ......... Swingarm type, coil spring, oil damped. Steering angle ............ 45° (right & left) Caster ......................... 25° 18’ Trail .............................. 76.7 mm Turning radius ............. 1.9 m Front brake .................. Disc brake Rear brake .................. Disc brake Front tire size .............. 120/70-12 51L Rear tire size ............... 130/60-13 M/C 53L

ELECTRICAL Ignition type ................ Electronic ignition (CDI) Spark plug ................... NGK BPR6HS or DENSO W20FPR ........... P-02, 18, 22 NGK BPR7HS or DENSO W22FPR ............. The others Battery ........................ 12 V 14.4 kC (4Ah)/10HR ........ P-53 12 V 10.8 kC (3Ah)/10HR ..... The others Generator .................... Magneto Fuse ............................ 10 A Headlight ..................... * 12 V 35/35 W Brake light/Taillight ...... 12 V 21/5 W Turn signal light ........... 12 V 10 W

CAPACITIES Fuel tank ..................... Engine oil tank ............ Final gear oil ............... Engine coolant ............

These specifications are subject to change without notice.

6.8 L 1.2 L 130 ml 1 200 ml

11-4 AY50K1 K2/WRK1 K2 (’01 ’02-MODEL)

SERVICE DATA AY50K1 CYLINDER + PISTON + PISTON RING ITEM Piston to cylinder clearance Cylinder bore Piston diam. Cylinder distortion Cylinder head distortion Piston ring free end gap Piston ring end gap Piston ring to groove clearance Piston pin bore Piston pin O.D.

Unit: mm STANDARD

LIMIT

0.06 – 0.07

0.120

41.005 – 41.020 Measure at 20 mm from the top surface 40.940 – 40.955 Measure at 15 mm from the skirt end ——— ——— 1st R Approx. 4.0 2nd R Approx. 4.3 1st & R 0.10 – 0.25 2nd 1st 0.03 – 0.07 2nd 0.02 – 0.06 10.002 – 10.010 9.995 – 10.000

CONROD + CRANKSHAFT ITEM Conrod small end I.D. Conrod deflection Crank web to web width Crankshaft runout

41.075 40.885 0.05 0.05 3.2 3.4 0.80 ——— ——— 10.030 9.980 Unit: mm

STANDARD 14.003 – 14.011 ——— 36.0 ± 0.05 ———

LIMIT 14.040 3.0 ——— 0.05

OIL PUMP ITEM Oil pump reduction ratio Oil pump discharge rate

SPECIFICATION 30.000 (30/1) 0.9 – 1.1 ml for 5 minutes at 3 000 r/min.

CLUTCH ITEM Clutch wheel I.D. Clutch shoe thickness Clutch engagement P-02,22,39 P-04,26, 34,53 Clutch lock-up P-02,22,39 P-04,26 34,53

Unit: mm STANDARD 110.00 – 110.15 3.0 3 300 ± 200 r/min.

LIMIT 110.50 2.0 ———

4 400 ± 200 r/min

———

4 500 ± 300 r/min.

———

6 000 ± 300 r/min.

———

AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) 11-5

TRANSMISSION

Unit: mm Except ratio

ITEM Reduction ratio

P-22 P-02, 39 P-04,26,34,53 P-02, 22, 39 P-04,26,34,53 P-02, 22, 39 P-04,26,34,53

Final reduction ratio Drive belt width Driven face spring free length

STANDARD * Variable 2.768 – 1.005 Variable 2.768 – 0.871 Variable 2.975 – 1.140 14.960 (51/15 × 66/15) 13.812 (51/15 × 65/16) 16.9 18.4 110

LIMIT ——— ——— ——— ——— ——— 15.9 17.4 104.5

CARBURETOR SPECIFICATION

ITEM Carburetor type Bore size I.D. No. Idle r/min. Float height Main jet Jet needle Pilot jet Air screw Throttle cable play

(M.J.) (J.N.) (P.J.) (A.S.)

ITEM Carburetor type Bore size I.D. No. Idle r/min. Float height Main jet Jet needle Pilot jet Air screw Throttle cable play

(M.J.) (J.N.) (P.J.) (A.S.)

P-04, 26, 53 KEIHIN PWS14 14 mm 35EE 1 900 ± 200 r/min. 5.1 ± 0.5 mm #70 N4WA-3rd #48 1¼ turns back 2 – 4 mm

P-22 KEIHIN PWS14 14 mm 35EJ 1 900 ± 200 r/min. 5.1 ± 0.5 mm *#65 *N5GJ-3rd *#40 *13/4 turns back 2 – 4 mm

SPECIFICATION P-34 KEIHIN PWS12 12 mm 35EG ← ← ← 6LQJ-5th #45 3 turns back ←

P-02 ← ← 35E2 1 700 ± 200 r/min. ← #60 ← #45 3 1 /8 turns back ←

P-39 ← ← 35EB 1 700 ± 200 r/min. ← #55 N5GJ-3rd #35 3 /8 turn back ←

11-6 AY50K1 K2/WRK1 K2 (’01 ’02-MODEL)

ELECTRICAL

Unit: mm

ITEM Spark plug Type Gap Type Gap Spark performance Ignition coil resistance Secondary Generator coil resistance

Charging Pick-up

Regulated voltage Generator Max. output Starter relay resistance Battery Type designation Capacity Standard electrolyte S.G.

SPECIFICATION NGK: BPR6HS DENSO: W20FPR-U BOSCH: WR7BC 0.6 – 0.7 NGK: BPR7HS DENSO: W22FPR 0.6 – 0.7 Over 8 at 1 atm. 4 – 10 kΩ *0.2 – 1.5 Ω 100 – 270 Ω 13.5 – 15.5 V at 5 000 r/min. *100 W at 5 000 r/min. 50 – 90 Ω FB4L-B YT4L-BS 12 V 14.4 kC (4 Ah)/10 HR 12 V 10.8 kC (3 Ah)/10 HR 1.280 at 20°C

Fuse size

NOTE P-02, 22, 39

P-04, 26, 34, 53

Plug cap – B/W lead wire terminal Y – Ground R – Ground

P-53 The others P-53 The others P-53

10 A

WATTAGE

Unit: W ITEM

Headlight

SPECIFICATION *35 *35 21/5 10 1.2 × 2 1.2 2 2 *1.7 2

HI LOW

Brake light/Taillight Turn signal light Speedometer light Fuel meter light Turn signal indicator light Oil level indicator light *High beam indicator light Trunk light

BRAKE + WHEEL ITEM Brake lever play Brake drum I.D. Brake disc thickness Brake disc runout Master cylinder bore Master cylinder piston diam.

Unit: mm Rear Rear Front Front Front Front

STANDARD 15 – 20 ——— 4.0 ± 0.2 ——— 11.000 – 11.043 10.957 – 10.984

LIMIT ——— 120.7 3.5 0.30 ——— ———

AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) 11-7 ITEM Brake caliper cylinder bore Brake caliper piston diam. Brake fluid type Wheel rim runout

Front Front Axial Radial Front Front Rear Front Rear Front Rear Front Rear

Wheel axle runout Wheel rim size Tire size Tire type Tire tread depth

STANDARD/SPECIFICATION 30.230 – 30.306 30.150 – 30.200 DOT 4 ——— ——— ——— J12 × MT3.50 J12 × MT3.50 120/70-12 51L 130/70-12 56L MICHELIN: DEXTER MICHELIN: DEXTER ——— ———

SUSPENSION

LIMIT ——— ——— ——— 2.0 2.0 0.25 ——— ——— ——— ——— ——— ——— 1.6 1.6 Unit: mm

ITEM Front fork stroke Front fork spring free length Rear wheel travel

STANDARD 77 124.7 60

LIMIT ——— 122 ———

TIRE PRESSURE P-26, 34 COLD INFLATION TIRE PRESSURE FRONT REAR

SOLO RIDING kPa kgf/cm2 psi 125 1.25 18 175 1.75 25

The others COLD INFLATION TIRE PRESSURE FRONT REAR

SOLO RIDING kPa kgf/cm2 psi 125 1.25 18 175 1.75 25

DUAL RIDING kPa kgf/cm2 psi 125 1.25 18 230 2.30 33

FUEL + OIL ITEM Fuel type Fuel tank capacity Engine oil type

Engine oil tank capacity Final gear oil type Final gear oil capacity

SPECIFICATION Gasoline used should be graded 91 octane or higher. An unleaded gasoline is recommended. 6.8 L Use SUZUKI CCI SUPER OIL. If they are not available, use a good quality 2-stroke oil rated FC under JASO classification. 1.2 L SAE 10W/40 130 ml

NOTE

11-8 AY50K1 K2/WRK1 K2 (’01 ’02-MODEL)

AY50WRK1 CYLINDER + PISTON + PISTON RING ITEM Piston to cylinder clearance Cylinder bore Piston diam. Cylinder distortion Cylinder head distortion Piston ring free end gap Piston ring end gap Piston ring to groove clearance Piston pin bore Piston pin O.D.

Unit: mm STANDARD

LIMIT

0.035 – 0.045

0.120

41.010 – 41.025 Measure at 20 mm from the top surface 40.970 – 40.985 Measure at 23 mm from the skirt end ——— ——— Approx. 4.5 1st & T 2nd N Approx. 3.0 1st & T&N 0.08 – 0.18 2nd 1st & 0.01 – 0.05 2nd 12.002 – 12.010 11.996 – 12.000

CONROD + CRANKSHAFT ITEM Conrod small end I.D. Conrod deflection Crank web to web width Crankshaft runout

41.105 40.890 0.05 0.05 3.6 2.4 0.80 ——— 12.030 11.980 Unit: mm

STANDARD 16.003 – 16.011 ——— 38.0 ± 0.05 ———

LIMIT 16.040 3.0 ——— 0.05

OIL PUMP ITEM Oil pump reduction ratio Oil pump discharge rate

SPECIFICATION 30.000 (30/1) 0.8 – 1.0 ml for 5 minutes at 3 000 r/min.

CLUTCH ITEM Clutch wheel I.D. Clutch shoe thickness Clutch engagement P-02,18,22 P-04, 26, 34, 53 Clutch lock-up P-02,18,22 P-04, 26, 34, 53

Unit: mm STANDARD 110.00 – 110.15 3.0 4 000 ± 200 r/min.

LIMIT 110.50 2.0 ———

4 400 ± 200 r/min

———

5 600 ± 300 r/min.

———

6 000 ± 300 r/min.

———

AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) 11-9

THERMOSTAT + RADIATOR + ENGINE COOLANT TEMP. SWITCH + ENGINE COOLANT ITEM Thermostat valve opening temperature Thermostat valve lift Radiator reservoir cap valve opening pressure Engine coolant temp. ON switch operating OFF temperature Engine coolant type

STANDARD/SPECIFICATION

LIMIT

*Approx. 65°C

———

*Over 3 mm at 80°C

———

100 kPa (1.0 kgf/cm2)

———

*Approx. 125°C

———

*Approx. 118°C

———

Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50:50.

———

1 200 ml

———

Engine coolant including reserve

TRANSMISSION

Unit: mm Except ratio

ITEM Reduction ratio

P-02,18,22,39 P-04,26,34,53 P-02,18,22,39 P-04,26,34,53

Final reduction ratio Drive belt width Driven face spring free length

STANDARD Variable 2.975 – 0.781 Variable 2.975 – 1.140 16.271 (51/15 × 67/14) 13.812 (51/15 × 65/16) 18.4 110

LIMIT ——— ——— ——— ——— 17.4 104.5

CARBURETOR ITEM Carburetor type Bore size I.D. No. Idle r/min. Float height Main jet Jet needle Pilot jet Air screw Throttle cable play

(M.J.) (J.N.) (P.J.) (A.S.)

P-04, 26, 53 KEIHIN PWS14 14 mm 35EC 1 900 ± 200 r/min. 5.1 ± 0.5 mm #68 N4WA-4th #48 1¾ turns back 2 – 4 mm

SPECIFICATION P-34 KEIHIN PWS12 12 mm 35EH ← ← #65 6LQJ-5th #45 2 turns back ←

P-18 ← ← 35EB 1 700 ± 200 r/min. ← #55 N5GJ-3rd #35 3 /8 turn back ←

11-10 AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) SPECIFICATION

ITEM Carburetor type Bore size I.D. No. Idle r/min. Float height Main jet Jet needle Pilot jet Air screw Throttle cable play

P-02 KEIHIN PWS14 14 mm 35E9 1 700 ± 200 r/min. 5.1 ± 0.5 mm #60 N4WA-3rd #45 3 1 /8 turns back 2 – 4 mm

(M.J.) (J.N.) (P.J.) (A.S.)

ELECTRICAL

Unit: mm

ITEM Spark plug

Type Gap Type Gap

Spark performance Ignition coil resistance Secondary Generator coil resistance Regulated voltage Generator Max. output Starter relay resistance Battery Type designation Capacity Standard electrolyte S.G. Fuse size

P-22 ← ← *35EA 1 900 ± 200 r/min. ← *#62 *N5GJ-2nd *← 1 *1 /2 turns back ←

Charging Pick-up

SPECIFICATION NGK: BPR6HS DENSO: W20FPR 0.6 – 0.7 NGK: BPR7HS DENSO: W22FPR 0.6 – 0.7 Over 8 at 1 atm. 4 – 10 kΩ *0.2 – 1.5 Ω 100 – 270 Ω 13.5 – 15.5 V at 5 000 r/min. *100 W at 5 000 r/min. 50 – 90 Ω FB4L-B YT4L-BS 12 V 14.4 kC (4 Ah)/10 HR 12 V 10.8 kC (3 Ah)/10 HR 1.280 at 20°C 10 A

NOTE P-02, 18, 22

P-04, 26, 34, 53

Plug cap – B/W lead wire terminal Y – Ground R – Ground

P-53 The others P-53 The others P-53

AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) 11-11

WATTAGE

Unit: W ITEM

Headlight

SPECIFICATION *35 *35 21/5 10 1.2 × 2 1.2 2 2 2 *1.7 2

HI LOW

Brake light/Taillight Turn signal light Speedometer light Fuel meter light Turn signal indicator light Oil level indicator light Water temp. indicator light *High beam indicator light Trunk light

BRAKE + WHEEL ITEM Brake disc thickness Brake disc runout Master cylinder bore Master cylinder piston diam. Brake caliper cylinder bore Brake caliper piston diam. Brake fluid type Wheel rim runout Wheel axle runout Wheel rim size Tire size Tire type Tire tread depth

Unit: mm Front Rear Front & Rear Front Rear Front Rear Front Rear Front Rear Axial Radial Front Front Rear Front Rear Front Rear Front Rear

STANDARD/SPECIFICATION 4.0 ± 0.2 4.0 ± 0.2

LIMIT 3.5 3.5

———

0.30

11.000 – 11.043 12.000 – 12.043 10.957 – 10.984 11.957 – 11.984 30.230 – 30.306 30.230 – 30.306 30.150 – 30.200 30.150 – 30.200 DOT 4 ——— ——— ——— J12 × MT3.50 J13MC × MT3.50 120/70-12 51L 130/60-13 M/C 53L METZELER: ME 7 TEEN METZELER: ME 7 TEEN ——— ———

——— ——— ——— ——— ——— ——— ——— ——— ——— 2.0 2.0 0.25 ——— ——— ——— ——— ——— ——— 1.6 1.6

11-12 AY50K1 K2/WRK1 K2 (’01 ’02-MODEL)

SUSPENSION

Unit: mm

ITEM Front fork stroke Front fork spring free length Rear wheel travel

STANDARD 77 124.7 60

LIMIT ——— 122 ———

TIRE PRESSURE P-26, 34 COLD INFLATION TIRE PRESSURE FRONT REAR

SOLO RIDING kPa kgf/cm2 psi 125 1.25 18 175 1.75 25

The others COLD INFLATION TIRE PRESSURE FRONT REAR

SOLO RIDING kPa kgf/cm2 psi 125 1.25 18 175 1.75 25

DUAL RIDING kPa kgf/cm2 psi 125 1.25 18 230 2.30 33

FUEL + OIL ITEM Fuel type Fuel tank capacity Engine oil type

Engine oil tank capacity Final gear oil type Final gear oil capacity

NOTE

AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) 11-13

THERMOSTAT (For AY50WRK1) REMOVAL • Remove the trunk. • Drain engine coolant. ! * Do not open the engine coolant reservoir cap when the engine is hot, as you may be injured by escaping hot liquid or vapor. * The engine must be cool before servicing the cooling system. * Engine coolant may be harmful if swallowed or if it comes in contact with the skin or eyes. If engine coolant gets into the eyes or contacts the skin, flush eyes or wash the skin throughly, with plenty of water. If engine coolant is swallowed, induce vomiting and call a physician immediately. • Remove the thermostat cover 1. • Remove the thermostat 2.

INSPECTION Inspect the thermostat for cracks or damage. If any damages are found, replace the thermostat with a new one.

Check the opening temperature of the thermostat valve. Pass a string between the flange as shown.

11-14 AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) Immerse the thermostat into a container of water and keep it suspended as shown.

Slowly heat the container and check the temperature on the thermometer when the thermostat valve begins to open. " Thermostat valve opening temperature: Approx. 65 °C

Continue heating the container until the water temperature is above 80 °C. When the water temperature reaches 80 °C, the thermostat valve should have lifted at least 3 mm. " Thermostat valve lift: Over 3 mm at 80 °C If the thermostat is faulty in either of these two checks, replace it with a new one.

INSTALLATION Install the thermostat in the reverse order of removal. • After installing the thermostat, be sure to add engine coolant.

ENGINE COOLANT TEMP. SWITCH (For AY50WRK1) REMOVAL • • • •

Remove the trunk. Drain engine coolant. Disconnect the lead wire 1. Remove the engine coolant temp. switch 2.

AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) 11-15

INSPECTION Check the operating temperature of the engine coolant temp. switch. • Place the engine coolant temp. switch into a container of oil. • Heat the oil and check the temperature on the thermometer when the engine coolant temp. switch is operated. # 09900-25008: Multi circuit tester set " Engine coolant temp. switch specification: →ON: Approx. 125 °C OFF→ →OFF: Approx. 118 °C ON→

INSTALLATION Install the engine coolant temp. switch in the reverse order of removal. Pay attention to the following points: • Apply SUZUKI BOND No. 1215 to the thread portion of the engine coolant temp. switch. $ 99000-31110: SUZUKI BOND No.1215 • Tighten the engine coolant temp. switch 1 securely and connect the lead wire.

11-16 AY50K1 K2/WRK1 K2 (’01 ’02-MODEL)

REGULATOR/RECTIFIER Measure the voltage between the terminals using the multi circuit tester, as indicated in the table below. If the voltage is not within the specified value, replace the regulator/rectifier with a new one. # 09900-25008: Multi circuit tester set % Tester knob indication: Diode test (& &) Unit: V

- Tester probe

+ Tester probe A

A B

0 0

1.0 – 1.2 1.0 – 1.2

0.9 – 1.1 0.5 – 0.7

1.2 – 1.4 1.2 – 1.4

1.0 – 1.2

0.5 – 0.7 0.5 – 0.7

0.4 – 0.6

More than 1.4 V (tester’s battery voltage)

NOTE: If the tester reads under 1.4 V, disconnect the tester probes from the wire leads, and then replace the multi circuit tester’s battery.

CDI/IGNITION COIL Measure the voltage between the terminals using the multi circut tester, as indicated in the table below. If the voltage is not within the specified value, replace the CDI/ignition coil with a new one. # 09900-25008: Multi circuit tester set % Tester knob indication: Diode test (& &) Unit: V - Tester probe

+ Tester probe A

1.2 – 1.4

0.8 – 1.0

C D

0.03 – 0.3 0.03 – 0.3

More than 1.4 V (tester’s battery voltage)

NOTE: If the tester reads under 1.4 V, disconnect the tester probes from the wire leads, and then replace the multi circuit tester’s battery.

Y B/W W

B B/W

DIMMER SWITCH

FRONT TURN SIGNAL LIGHT(L)

HEADLIGHT

Lg B/W

FRONT TURN SIGNAL LIGHT(R)

B/W

Gr Gr

Y/B Y/B

IGNITION SWITCH

Lb Lbl

Gr B/W

G/W G

HORN BUTTON

TURN SIGNAL LIGHT SWITCH

Y/W

W/B

B/W B/W B/W

Y/G R R

REGULATOR/ RECTIFIER

O Y/W B/W R Y W/Bl

TRUNK LIGHT SWITCH

HORN PTC

IGNITION COIL

P Y

W/B

GENERATOR

W/Bl

REAR BRAKE LIGHT SWITCH

STARTER BUTTON

B/R

: FUEL METER : SPEEDOMETER LIGHT : TURN SIGNAL INDICATOR LIGHT : OIL LEVEL INDICATOR LIGHT : HIGH BEAM INDICATOR LIGHT

O B/W Y/W

FUSE

Y/W

STARTER MOTOR

STARTER RELAY

Y/W Y

Y/W R/W R

BATTERY

RESISTOR

OIL LEVEL INDICATOR LIGHT SWITCH

TURN SIGNAL RELAY

CARBURETOR HEATER

GROUND

FUEL LEVEL GAUGE

Y/B Y/B

THERMO SWITCH

Lb Lbl R

FRONT BRAKE LIGHT SWITCH

Bl/W Bl/W B/W

B/W B/W

SPEEDOMETER

B/W

FU SP TU OI HI

Gr W Y

O O

B/R R/B B/W Bl/W O R Gr Br

B/W

Lg B Bl/W Lg B Bl/W

B/R R/B B/W Bl/W O R Gr Br

B/W

Y/G W/B R R/W

Y Y Lg

B B/W

B B/W B/W

REAR TURN SIGNAL LIGHT(L)

W/B B/W Br

BRAKE LIGHT/TAILLIGHT

REAR TURN SIGNAL LIGHT(R)

For P-02

B/W Y/W

AY50K1

P Y

WIRING DIAGRAM

R/W

G/W B/W

B/W B/W

LIGHTING SWITCH

AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) 11-17

Y B/W W

B B/W

Gr W Y

DIMMER SWITCH

FRONT TURN SIGNAL LIGHT(L)

HEADLIGHT

Lg B/W

FRONT TURN SIGNAL LIGHT(R)

O O

B/W B/W

Gr Gr

Y/B

IGNITION SWITCH

Lb Lbl

Gr B/W

G/W G

HORN BUTTON

TURN SIGNAL LIGHT SWITCH

Y/W

B/W B/W B/W

Y/G R R

TRUNK LIGHT SWITCH

HORN

W/B Y W/Bl

O B/W R

Y/W

REGULATOR/ RECTIFIER

PTC

IGNITION COIL

W/B

FUSE

Y/W

STARTER MOTOR

STARTER RELAY

GENERATOR

W/Bl

REAR BRAKE LIGHT SWITCH

B/R Y/G

STARTER BUTTON

BATTERY

TURN SIGNAL RELAY

: FUEL METER : SPEEDOMETER LIGHT : TURN SIGNAL INDICATOR LIGHT : OIL LEVEL INDICATOR LIGHT : HIGH BEAM INDICATOR LIGHT

B/W

W/B R R/W

Y/W Y

Y/W R/W R

RESISTOR

OIL LEVEL INDICATOR LIGHT SWITCH

Lb Lbl R

CARBURETOR HEATER

GROUND

FUEL LEVEL GAUGE

Y/B Y/B

THERMO SWITCH

Bl/W Bl/W B/W

B/W B/W

FRONT BRAKE LIGHT SWITCH

B/W

FU SP TU OI HI

Lg B Bl/W Lg B Bl/W

B/R R/B B/W Bl/W O R

Y Y

B/R R/B B/W Bl/W O R

O B/W Y/W B/W Y/W

B/W B/W

LIGHTING SWITCH

P Y P Y

B B/W

B B/W B/W

REAR TURN SIGNAL LIGHT(L)

W/B B/W Gr Br

BRAKE LIGHT/TAILLIGHT

REAR TURN SIGNAL LIGHT(R)

For P-39

R/W

G/W B/W

SPEEDOMETER

11-18 AY50K1 K2/WRK1 K2 (’01 ’02-MODEL)

Y B/W W

B B/W

Gr W Y

DIMMER SWITCH

FRONT TURN SIGNAL LIGHT(L)

HEADLIGHT

Lg B/W

FRONT TURN SIGNAL LIGHT(R)

O O

B/W B/W

Gr Gr

Y/B

IGNITION SWITCH

Lb Lbl

Gr B/W

G/W G

HORN BUTTON

TURN SIGNAL LIGHT SWITCH

Y/W

B/W B/W B/W

Y/G R R

TRUNK LIGHT SWITCH

HORN

W/B Y W/Bl

O B/W R Y/W

REGULATOR/ RECTIFIER

PTC

IGNITION COIL

W/B GENERATOR

W/Bl

REAR BRAKE LIGHT SWITCH

Y/W

FUSE

STARTER MOTOR

STARTER RELAY

B/R Y/G

Y Y

STARTER BUTTON

BATTERY

TURN SIGNAL RELAY

: FUEL METER : SPEEDOMETER LIGHT : TURN SIGNAL INDICATOR LIGHT : OIL LEVEL INDICATOR LIGHT : HIGH BEAM INDICATOR LIGHT

B/W

W/B R R/W

Y/W Y

Y/W R/W R

RESISTOR

OIL LEVEL INDICATOR LIGHT SWITCH

Lb Lbl R

CARBURETOR HEATER

GROUND

FUEL LEVEL GAUGE

Y/B Y/B

THERMO SWITCH

Bl/W Bl/W B/W

B/W B/W

FRONT BRAKE LIGHT SWITCH

B/W

FU SP TU OI HI

Lg B Bl/W

B/R R/B B/W Bl/W O R

Y Y

Lg B Bl/W

B/R R/B B/W Bl/W O R

O B/W Y/W B/W Y/W

B/W B/W

LIGHTING SWITCH

P Y P Y

B B/W

B B/W B/W

REAR TURN SIGNAL LIGHT(L)

W/B B/W Gr Br

BRAKE LIGHT/TAILLIGHT

REAR TURN SIGNAL LIGHT(R)

For the others

R/W

G/W B/W

SPEEDOMETER

AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) 11-19

B B/W

Y B/W W

DIMMER SWITCH

FRONT TURN SIGNAL LIGHT(L)

HEADLIGHT

Lg B/W

FRONT TURN SIGNAL LIGHT(R)

Gr Gr

Y/B Y/B

B/R

IGNITION SWITCH

Lg B

G/W Gr

G B/W

HORN BUTTON

TURN SIGNAL LIGHT SWITCH

Y/G

Y/W

DIODE

TRUNK LIGHT SWITCH

HORN

O G R B/W

REAR BRAKE LIGHT SWITCH

REGULATOR/ RECTIFIER

CDI UNIT & IGNITION COIL

O PTC

GENERATOR

FUSE

STARTER MOTOR

STARTER RELAY

WATER TEMP. GAUGE

TURN SIGNAL RELAY

B/W

Lbl Lb

O BATTERY

FUEL LEVEL RESISTOR GAUGE

Bl/W B/W GROUND

Bl/W B/W

FRONT BRAKE LIGHT SWITCH

Bl/B

STARTER BUTTON

B/G O

SPEEDOMETER

W/B

Y/W B/W R Y W/Bl

FU : FUEL METER SP : SPEEDOMETER LIGHT TU : TURN SIGNAL INDICATOR LIGHT OI : OIL LEVEL INDICATOR LIGHT WT : WATER TEMPERATURE INDICATOR LIGHT HI : HIGH BEAM INDICATOR LIGHT

Gr W Y

B/W O B/W O

B/W Bl/B O R Gr Br

Lg B Bl/W B/G Y B Lb Lbl Lg

Bl/W B/G Y

B/R B?r R/B B/W Bl/W O R Gr Br

W/B

B/W Y/W B/W Y/W

OIL LEVEL INDICATOR LIGHT SWITCH

B/W

CARBURETOR HEATER

G/W B/W

THERMO SWITCH

Y/G W/B

W/Bl B/R P B/W R R/W

Y/W Y/W

P Y

B/W Bl/W

R B/W

Y R/W R

Y/W Y

P Y

B B/W

B B/W B/W

REAR TURN SIGNAL LIGHT(L)

BRAKE LIGHT/TAILLIGHT

REAR TURN SIGNAL LIGHT(R)

W/B B/W Br Gr

For P-02

R/W

B/G R

Y/B B/W Y/B B/W

LIGHTING SWITCH

11-20 AY50K1 K2/WRK1 K2 (’01 ’02-MODEL)

AY50WRK1

B B/W

Y B/W W

FRONT TURN SIGNAL LIGHT(L)

HEADLIGHT

Gr Gr

Y/B Y/B B/R

DIMMER SWITCH

G/W Gr

G B/W

HORN BUTTON

TURN SIGNAL LIGHT SWITCH

IGNITION SWITCH

B/W

B/R R/B B/W

Lg B/W

Y/W TRUNK LIGHT SWITCH

HORN

Bl/B

DIODE

B/G O

STARTER BUTTON

Y/G O G R B/W

REAR BRAKE LIGHT SWITCH

REGULATOR/ RECTIFIER

CDI UNIT & IGNITION COIL

PTC

GENERATOR

FUSE

STARTER MOTOR

STARTER RELAY

WATER TEMP. GAUGE

TURN SIGNAL RELAY

B/W

Lb Lbl

O BATTERY

FUEL LEVEL RESISTOR GAUGE

OIL LEVEL INDICATOR LIGHT SWITCH

Bl/W B/W GROUND

Bl/W B/W

CARBURETOR HEATER

B/W

THERMO SWITCH

G/W B/W

FRONT BRAKE LIGHT SWITCH

W/B

Y/W B/W R Y W/Bl

SPEEDOMETER

B/W O B/W O Lg B

Bl/B O R

FRONT TURN SIGNAL LIGHT(R)

Gr W Y

Lg B Bl/W B/G Y B Lb Lbl Lg

Bl/W B/G Y

Bl/W O R

O B/W Y/W B/W Y/W

W/B P Y P Y

W/Bl B/R P B/W Y/G W/B

Y/W Y/W Y/W Y

R R/W

FU : FUEL METER SP : SPEEDOMETER LIGHT TU : TURN SIGNAL INDICATOR LIGHT OI : OIL LEVEL INDICATOR LIGHT WT : WATER TEMPERATURE INDICATOR LIGHT HI : HIGH BEAM INDICATOR LIGHT

B/W Bl/W

R B/W

Y R/W R R/W

B/G R

Y/B B/W Y/B B/W

LIGHTING SWITCH

B B/W

B B/W B/W

REAR TURN SIGNAL LIGHT(L)

BRAKE LIGHT/TAILLIGHT

REAR TURN SIGNAL LIGHT(R)

W/B B/W Gr

AY50K1 K2/WRK1 K2 (’01 ’02-MODEL) 11-21

For P-18

FRONT TURN SIGNAL LIGHT(L)

B B/W

Y B/W W

Gr Gr

Y/B Y/B B/R

DIMMER SWITCH

G/W Gr

G B/W

HORN BUTTON

TURN SIGNAL LIGHT SWITCH

IGNITION SWITCH

B/W

B/R R/B B/W

HEADLIGHT

B/W O B/W O Lg B

Bl/B O R

Lg B/W

Gr W Y

Lg B Bl/W B/G Y B Lbl Lb Lg

Bl/W B/G Y

Bl/W O R

FRONT TURN SIGNAL LIGHT(R)

Y/G O

Y/W

DIODE

TRUNK LIGHT SWITCH

HORN

G R B/W

REAR BRAKE LIGHT SWITCH

REGULATOR/ RECTIFIER

CDI UNIT & IGNITION COIL

PTC

GENERATOR

FUSE

STARTER MOTOR

STARTER RELAY

WATER TEMP. GAUGE

TURN SIGNAL RELAY

B/W

Lb Lbl

O BATTERY

FUEL LEVEL RESISTOR GAUGE

OIL LEVEL INDICATOR LIGHT SWITCH

Bl/W B/W GROUND

Bl/W B/W

CARBURETOR HEATER

B/W

THERMO SWITCH

G/W B/W

FRONT BRAKE LIGHT SWITCH

Bl/B

STARTER BUTTON

B/G O

Y/W B/W

SPEEDOMETER

W/B

R Y W/Bl

FU : FUEL METER SP : SPEEDOMETER LIGHT TU : TURN SIGNAL INDICATOR LIGHT OI : OIL LEVEL INDICATOR LIGHT WT : WATER TEMPERATURE INDICATOR LIGHT HI : HIGH BEAM INDICATOR LIGHT

B/W Bl/W

R B/W

O B/W Y/W B/W Y/W

W/B P Y

W/Bl B/R P B/W P Y

Y/W Y/W Y/W Y

Y/G W/B R R/W

Y Y R/W R RW

B/G R

Y/B B/W Y/B B/W

LIGHTING SWITCH

B B/W

B B/W B/W

REAR TURN SIGNAL LIGHT(L)

BRAKE LIGHT/TAILLIGHT

REAR TURN SIGNAL LIGHT(R)

W/B B/W Gr

11-22 AY50K1 K2/WRK1 K2 (’01 ’02-MODEL)

For the others

AY50K3/SK3/WK3/WSK3 (’03-MODEL)

12-1

AY50K3/SK3/WK3/WSK3 (’03-MODEL)

This chapter describes specifications, service data and servicing procedures which differ from those of the AY50K2/WRK2 (’02-MODEL).

NOTE: Please refer to the chapters 1 through 11 for details which are not given in this chapter.

CONTENTS SPECIFICATIONS ...............................................................................12- 2

AY50 AND AY50S............................................................................12- 2 AY50W AND AY50WS.....................................................................12- 3 SERVICE DATA ..................................................................................12- 4 AY50 AND AY50S............................................................................12- 4 AY50W AND AY50WS.....................................................................12- 8

WIRING DIAGRAM..............................................................................12-13 AY50 AND AY50S............................................................................12-13 AY50W AND AY50WS.....................................................................12-15 OIL HOSE ROUTING ..........................................................................12-17

COUNTRY OR AREA P-02: UK P-19: EU

12-2

AY50K3/SK3/WK3/WSK3 (’03-MODEL)

SPECIFICATIONS AY50 AND AY50S DIMENSIONS AND DRY MASS Overall length ....................................................... 1 865 mm (73.4 in) Overall width ........................................................ 650 mm (25.6 in) Overall height ....................................................... 1 125 mm (44.3 in) Wheelbase ........................................................... 1 260 mm (49.6 in) Ground clearance ................................................ 105 mm ( 4.1 in) Seat height........................................................... 790 mm (31.1 in) Dry mass.............................................................. 77 kg (169 lbs)

ENGINE Type ..................................................................... Intake system ....................................................... Number of cylinders ............................................. Bore ..................................................................... Stroke................................................................... Displacement ....................................................... Corrected compression ratio................................ Carburetor............................................................ Air cleaner............................................................ Starter system...................................................... Lubrication system ............................................... Idle speed ............................................................

2 stroke, Forced air-cooled Reed valve 1 41.0 mm (1.614 in) 37.4 mm (1.472 in) 49 cm3 (3.0 cu. in) 6.5 : 1 KEIHIN PWS14 Polyurethane foam element Electric and Kick SUZUKI “CCI” 1 900 ± 200 r/min

DRIVE TRAIN Clutch................................................................... Gearshifting.......................................................... Gear ratio, variable............................................... Final reduction ratio ............................................. Drive system ........................................................

Dry shoe, automatic, centrifugal type Automatic, variable ratio Variable reduction ratio (2.768 – 1.005) 14.960 (51/15 × 65/15) V-belt drive

CHASSIS Front suspension.................................................. Rear suspension .................................................. Front suspension stroke....................................... Front wheel travel................................................. Rear wheel travel ................................................. Caster .................................................................. Trail ...................................................................... Steering angle...................................................... Turning radius ...................................................... Front brake........................................................... Rear brake ........................................................... Front tire size ....................................................... Rear tire size........................................................

Inverted telescopic, coil spring Swingarm, coil spring, oil damped (SHOWA) 77 mm (3.0 in) 70 mm (2.8 in) 60 mm (2.4 in) 25° 20’ 76 mm (2.99 in) 45° (left and right) 1.9 m (6.2 ft) Disc brake Drum brake 120/70-12 51L, tubeless 130/70-12 56L, tubeless

AY50K3/SK3/WK3/WSK3 (’03-MODEL)

ELECTRICAL Ignition type......................................................... Ignition timing ...................................................... Spark plug ........................................................... Battery................................................................. Generator ............................................................ Fuse .................................................................... Headlight ............................................................. Brake light/Taillight .............................................. Turn signal light ................................................... Speedometer light ............................................... Fuel level gauge light .......................................... High beam indicator light..................................... Turn signal indicator light..................................... Oil level indicator light ......................................... Trunk light ............................................................

Electronic ignition (CDI) 14° B.T.D.C. at 4 000 rpm NGK BPR6HS or DENSO W20FPR-U 12V 10.8 kC (3Ah)/10HR Flywheel magneto 10A 12V 35/35W 12V 21/5W 12V 10W 12V 1.2W × 2 12V 1.2W 12V 1.2W 12V 2W 12V 2W 12V 2W

CAPACITIES Fuel tank ............................................................. Engine oil tank..................................................... Final gear oil,oil change ...................................... overhaul .........................................

6.8 L (1.8/1.5 US/Imp gal) 1.2 L (1.3/1.1 US/Imp qt) 120 ml (4.1/4.2 US/Imp oz) 130 ml (4.4/4.6 US/Imp oz)

12-3

12-4

AY50K3/SK3/WK3/WSK3 (’03-MODEL)

AY50W AND AY50WS DIMENSIONS AND DRY MASS Overall length ....................................................... 1 865 mm (73.4 in) Overall width ........................................................ 650 mm (25.6 in) Overall height ....................................................... 1 125 mm (44.3 in) Wheelbase ........................................................... 1 260 mm (49.6 in) Ground clearance ................................................ 105 mm ( 4.1 in) Seat height........................................................... 790 mm (31.1 in) Dry mass.............................................................. 83 kg (182 lbs)

2 stroke, liquid-cooled Reed valve 1 41.0 mm (1.614 in) 37.4 mm (1.472 in) 49 cm3 (3.0 cu. in) 8.0 : 1 KEIHIN PWS14 Polyurethane foam element Electric and Kick SUZUKI “CCI” 1 900 ± 200 r/min

DRIVE TRAIN Clutch................................................................... Gearshifting.......................................................... Gear ratio, reduction ratio .................................... Final reduction ratio ............................................. Drive system ........................................................

Dry shoe, automatic, centrifugal type Automatic, variable ratio Variable reduction ratio (2.975 – 1.033) 16.271 (51/15 × 67/14) V-belt drive

Inverted telescopic, coil spring Swingarm, coil spring, oil damped (SHOWA) 77 mm (3.0 in) 70 mm (2.8 in) 60 mm (2.4 in) 25° 20’ 76 mm (2.99 in) 45° (left and right) 1.9 m (6.2 ft) Disc brake Disc brake 120/70-12 51L, tubeless 130/60-13 M/C 53L, tubeless

AY50K3/SK3/WK3/WSK3 (’03-MODEL)

ELECTRICAL Ignition type......................................................... Ignition timing ...................................................... Spark plug ........................................................... Battery................................................................. Generator ............................................................ Fuse .................................................................... Headlight ............................................................. Brake light/Taillight .............................................. Turn signal light ................................................... Speedometer light ............................................... Fuel level gauge light .......................................... Turn signal indicator light..................................... High beam indicator light..................................... Oil level indicator light ......................................... Coolant temperature check light.......................... Trunk light ............................................................

Electronic ignition (CDI) 14° B.T.D.C. at 4 000 rpm NGK BPR6HS or DENSO W20FPR 12V 10.8 kC (3Ah)/10HR Flywheel magneto 10A 12V 35/35W 12V 21/5W 12V 10W 12V 1.2W × 2 12V 1.2W 12V 2W 12V 1.2W 12V 2W 12V 2W 12V 2W

CAPACITIES Fuel tank ............................................................. 6.8 L (1.8/1.5 US/Imp gal) Engine oil tank..................................................... 1.2 L (1.3/1.1 US/Imp qt) Final gear oil, oil change ..................................... 120 ml (4.1/4.2 US/Imp oz) overhaul ........................................ 130 ml (4.4/4.6 US/Imp oz) Coolant................................................................ 1 200 ml (2.5/2.1 US/Imp oz)

12-5

12-6

AY50K3/SK3/WK3/WSK3 (’03-MODEL)

SERVICE DATA AY50 AND AY50S CYLINDER + PISTON + PISTON RING ITEM Piston to cylinder clearance Cylinder bore Piston diam. Cylinder distortion Cylinder head distortion Piston ring free end gap Piston ring end gap Piston ring to groove clearance Piston pin bore Piston pin O.D.

Unit: mm

STANDARD 0.06 – 0.07 41.005 – 41.020 Measure at 20 mm from the top surface 40.940 – 40.955 Measure at 15 mm from the skirt end — — 1st R Approx. 4.0 2nd R Approx. 4.3 1st & R 0.10 – 0.25 2nd 1st 0.03 – 0.07 2nd 0.02 – 0.06 10.002 – 10.010 9.995 – 10.000

CONROD + CRANKSHAFT ITEM Conrod small end I.D. Conrod deflection Crank web to web width Crankshaft runout

LIMIT 0.120 41.075 40.885 0.05 0.05 3.2 3.4 0.80 — — 10.030 9.980 Unit: mm

STANDARD 14.003 – 14.011 — 36.0 ± 0.05 —

LIMIT 14.040 3.0 — 0.05

OIL PUMP ITEM Oil pump reduction ratio Oil pump discharge rate

SPECIFICATION 30.000 (30/1) 0.9 – 1.1 ml for 5 minutes at 3 000 r/min.

CLUTCH Clutch Clutch Clutch Clutch

ITEM wheel I.D. shoe thickness engagement lock-up

Unit: mm STANDARD 110.00 – 110.15 3.0 3 300 ± 200 r/min. 4 500 ± 300 r/min.

LIMIT 110.50 2.0 — —

AY50K3/SK3/WK3/WSK3 (’03-MODEL)

TRANSMISSION

12-7

Unit: mm Except ratio

ITEM Reduction ratio Final reduction ratio Drive belt width

STANDARD Variable 2.768 – 1.005 14.960 (51/15 × 66/15) 16.9 18.4 110

Driven face spring free length

LIMIT — — 15.9 17.4 104.5

CARBURETOR ITEM Carburetor type Bore size I.D. No. Idle r/min. Float height Main jet Jet needle Pilot jet Air screw Throttle cable play

SPECIFICATION KEIHIN PWS14 14 mm 35EJ 1 900 ± 200 r/min. 5.1 ± 0.5 mm #65 N5GJ-3rd #40 1! turns back 2 – 4 mm

(M.J.) (J.N.) (P.J.) (A.S.)

ELECTRICAL

Unit: mm

ITEM Spark plug

Type Gap

Spark performance Ignition coil resistance Secondary Generator coil resistance Regulated voltage Generator Max. output Starter relay resistance Battery Type designation Capacity Fuse size

Charging Pick-up

SPECIFICATION NGK: BPR6HS DENSO: W20FPR-U 0.6 – 0.7 Over 8 at 1 atm. 4 – 10 kΩ 0.2 – 1.5 Ω 100 – 270 Ω 13.5 – 15.5 V at 5 000 r/min. 100 W at 5 000 r/min. 50 – 90 Ω YT4L-BS 12 V 10.8 kC (3 Ah)/10 HR 10 A

NOTE

Plug cap – B/W lead wire terminal Y – Ground R – Ground

12-8

AY50K3/SK3/WK3/WSK3 (’03-MODEL)

WATTAGE

Unit: W ITEM

Headlight

SPECIFICATION 35 35 21/5 10 1.2 × 2 1.2 2 2 1.7 2

HI LO

Brake light/Taillight Turn signal light Speedometer light Fuel meter light Turn signal indicator light Oil level indicator light High beam indicator light Trunk light

BRAKE + WHEEL ITEM Brake lever play Brake drum I.D. Brake disc thickness Brake disc runout Master cylinder bore Master cylinder piston diam. Brake caliper cylinder bore Brake caliper piston diam. Brake fluid type Wheel rim runout Wheel axle runout Wheel rim size Tire size Tire type Tire tread depth

Unit: mm Rear Rear Front Front Front Front Front Front Axial Radial Front Front Rear Front Rear Front Rear Front Rear

STANDARD 15 – 20 — 4.0 ± 0.2 — 11.000 – 11.043 10.957 – 10.984 30.230 – 30.306 30.150 – 30.200 DOT 4 — — — J12 × MT3.50 J12 × MT3.50 120/70-12 51L 130/70-12 56L MICHELIN: DEXTER MICHELIN: DEXTER — —

SUSPENSION ITEM Front fork stroke Front fork spring free length Rear wheel travel

LIMIT — 120.7 3.5 0.30 — — — — — 2.0 2.0 0.25 — — — — — — 1.6 1.6 Unit: mm

STANDARD 77 124.7 60

LIMIT — 122 —

AY50K3/SK3/WK3/WSK3 (â&#x20AC;&#x2122;03-MODEL)

TIRE PRESSURE AY50S COLD INFLATION TIRE PRESSURE FRONT REAR

kPa 125 175

SOLO RIDING kgf/cm2 1.25 1.75

psi 18 25

kPa 125 175

SOLO RIDING kgf/cm2 1.25 1.75

psi 18 25

AY50 COLD INFLATION TIRE PRESSURE FRONT REAR

kPa 125 230

DUAL RIDING kgf/cm2 1.25 2.30

psi 18 33

FUEL + OIL ITEM Fuel type Fuel tank capacity Engine oil type Engine oil tank capacity Final gear oil type Final gear oil capacity

NOTE

12-9

12-10

AY50K3/SK3/WK3/WSK3 (’03-MODEL)

AY50W AND AY50WS CYLINDER + PISTON + PISTON RING ITEM Piston to cylinder clearance Cylinder bore Piston diam. Cylinder distortion Cylinder head distortion Piston ring free end gap Piston ring end gap Piston ring to groove clearance Piston pin bore Piston pin O.D.

Unit: mm

STANDARD 0.035 – 0.045 41.010 – 41.025 Measure at 20 mm from the top surface 40.970 – 40.985 Measure at 23 mm from the skirt end — — Approx. 4.5 1st & T 2nd N Approx. 3.0 1st & T& 0.08 – 0.18 2nd N 1st & 2nd 0.01 – 0.05 12.002 – 12.010 11.996 – 12.000

CONROD + CRANKSHAFT ITEM Conrod small end I.D. Conrod deflection Crank web to web width Crankshaft runout

LIMIT 0.120 41.105 40.890 0.05 0.05 3.6 2.4 0.80 — 12.030 11.980 Unit: mm

STANDARD 16.003 – 16.011 — 38.0 ± 0.05 —

LIMIT 16.040 3.0 — 0.05

OIL PUMP ITEM Oil pump reduction ratio Oil pump discharge rate

SPECIFICATION 30.000 (30/1) 0.8 – 1.0 ml for 5 minutes at 3 000 r/min.

CLUTCH Clutch Clutch Clutch Clutch

ITEM wheel I.D. shoe thickness engagement lock-up

Unit: mm STANDARD 110.00 – 110.15 3.0 4 000 ± 200 r/min. 5 600 ± 300 r/min.

LIMIT 110.50 2.0 — —

AY50K3/SK3/WK3/WSK3 (’03-MODEL)

12-11

THERMOSTAT + RADIATOR + ENGINE COOLANT TEMP. SWITCH + ENGINE COOLANT ITEM STANDARD/SPECIFICATION Thermostat valve opening temperApprox. 65 °C ature Thermostat valve lift Over 3 mm at 80 °C Radiator reservoir cap valve open100 kPa (1.0 kgf/cm2) ing pressure Engine coolant temp. switch ON Approx. 125 °C operating temperature OFF Approx. 118 °C Engine coolant type Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50:50. Engine coolant including reserve 1 200 ml

TRANSMISSION

— — — — — — —

Unit: mm Except ratio

ITEM Reduction ratio Final reduction ratio Drive belt width Driven face spring free length

STANDARD Variable 2.975 – 1.033 16.271 (51/15 × 67/14) 18.4 110

CARBURETOR ITEM Carburetor type Bore size I.D. No. Idle r/min. Float height Main jet Jet needle Pilot jet Air screw Throttle cable play

LIMIT

(M.J.) (J.N.) (P.J.) (A.S.)

SPECIFICATION KEIHIN PWS14 14 mm 35EA 1 900 ± 200 r/min. 5.1 ± 0.5 mm #62 N5GJ-2nd #45 1" turns back 2 – 4 mm

LIMIT — — 17.4 104.5

12-12

AY50K3/SK3/WK3/WSK3 (’03-MODEL)

ELECTRICAL

Unit: mm

ITEM Spark plug

Type Gap

Spark performance Ignition coil resistance Secondary Generator coil resistance

Charging Pick-up

Regulated voltage Generator Max. output Starter relay resistance Battery Type designation Capacity Fuse size

SPECIFICATION NGK: BPR6HS DENSO: W20FPR 0.6 – 0.7 Over 8 at 1 atm. 4 – 10 kΩ 0.2 – 1.5 Ω 100 – 270 Ω 13.5 – 15.5 V at 5 000 r/min. 100 W at 5 000 r/min. 50 – 90 Ω

NOTE

Plug cap – B/W lead wire terminal Y – Ground R – Ground

YT4L-BS 12 V 10.8 kC (3 Ah)/10 HR 10 A

WATTAGE

Unit: W ITEM

Headlight Brake light/Taillight Turn signal light Speedometer light Fuel meter light Turn signal indicator light Oil level indicator light Water temp. indicator light High beam indicator light Trunk light

HI LO

SPECIFICATION 35 35 21/5 10 1.2 × 2 1.2 2 2 2 1.2 2

AY50K3/SK3/WK3/WSK3 (’03-MODEL)

BRAKE + WHEEL

Unit: mm

ITEM Brake disc thickness Brake disc runout Master cylinder bore Master cylinder piston diam. Brake caliper cylinder bore Brake caliper piston diam. Brake fluid type Wheel rim runout Wheel axle runout Wheel rim size Tire size Tire type Tire tread depth

STANDARD/SPECIFICATION Front 4.0 ± 0.2 Rear 4.0 ± 0.2 Front & — Rear Front 11.000 – 11.043 Rear 12.000 – 12.043 Front 10.957 – 10.984 Rear 11.957 – 11.984 Front 30.230 – 30.306 Rear 30.230 – 30.306 Front 30.150 – 30.200 Rear 30.150 – 30.200 DOT 4 Axial — Radial — Front — Front J12 × MT3.50 Rear J13MC × MT3.50 Front 120/70-12 51L Rear 130/60-13 M/C 53L Front METZELER: ME 7 TEEN Rear METZELER: ME 7 TEEN Front — Rear —

LIMIT 3.5 3.5 0.30 — — — — — — — — — 2.0 2.0 0.25 — — — — — — 1.6 1.6

SUSPENSION

Unit: mm

ITEM Front fork stroke Front fork spring free length Rear wheel travel

STANDARD 77 124.7 60

LIMIT — 122 —

TIRE PRESSURE AY50WS COLD INFLATION TIRE PRESSURE FRONT REAR

kPa 125 175

SOLO RIDING kgf/cm2 1.25 1.75

kPa 125 175

SOLO RIDING kgf/cm2 1.25 1.75

psi 18 25

AY50W COLD INFLATION TIRE PRESSURE FRONT REAR

12-13

psi 18 25

kPa 125 230

DUAL RIDING kgf/cm2 1.25 2.30

psi 18 33

12-14

AY50K3/SK3/WK3/WSK3 (â&#x20AC;&#x2122;03-MODEL)

FUEL + OIL ITEM Fuel type Fuel tank capacity Engine oil type Engine oil tank capacity Final gear oil type Final gear oil capacity

NOTE

B/W

FRONT TURN SIGNAL LIGHT(L)

HEADLIGHT

B/W

Y/W

R/B

IGNITION SWITCH

P LOCK OFF C ON

DIMMER SWITCH

LO HI

B/R

Bl/W Bl/W B

B/W

HORN BUTTON

PUSH

B/G B/G

TURN SIGNAL LIGHT SWITCH

B/W

FRONT TURN SIGNAL LIGHT(R)

Y Y Lg

Lbl

HI PUSH

TRUNK LIGHT SWITCH

PUSH

HORN

ON OFF

W/Bl

B/W

Y/W

REGULATOR/ RECTIFIER

TU OI W/B Y

Bl/B Bl/W

Bl/W

Y/B

B/W

Y/W

B/W Br

Y/W

O O

Lg Lg

B B

FUEL ON OFF

PTC

CDI/IGNITION COIL

W/Bl

W/B

GENERATOR

R/W

Y/W

FUSE

STARTER MOTOR

STARTER RELAY

TURN SIGNAL RELAY

BRAKE LIGHT SWITCH (REAR)

ON OFF

BATTERY

B/W

GROUND

OIL LEVEL INDICATOR LIGHT SWITCH

Lbl R

ON OFF

CARBURETOR HEATER Bl/W

BRAKE LIGHT SWITCH (FRONT)

B/W B/W

O Y/W Y/W

SP : SPEEDOMETER LIGHT TU : TURN SIGNAL INDICATOR LIGHT OI : OIL LEVEL INDICATOR LIGHT HI : HIGH BEAM INDICATOR LIGHT Y/G R R

B/W B/W B/W

B/W B/W

Bl/W B/W

STARTER BUTTON

P P

B/R Y/G

FUEL LEVEL GAUGE

Y/B Y/B

SPEEDOMETER

Y Y

B/W R

W/B

Y/W Y

Y/W R/W R/W

B/W B/W

THERMO SWITCH

B/W

W/B

BRAKE LIGHT/TAILLIGHT

B Br G Gr Lbl Lg O P R W Y B/R B/W Bl/B Bl/W G/W R/B R/W W/B W/Bl Y/B Y/G Y/W

Black Brown Green Gray Light blue Light green Orange Pink Red White Yellow Black with Red tracer Black with White tracer Blue with Black tracer Blue with White tracer Green with White tracer Red with Black tracer Red with White tracer White with Black tracer White with Blue tracer Yellow with Black tracer Yellow with Green tracer Yellow with White tracer

WIRE COLOR

B B/W B/W

B B/W

REAR TURN SIGNAL LIGHT(L)

REAR TURN SIGNAL LIGHT(R)

AY50K3/SK3/WK3/WSK3 (â&#x20AC;&#x2122;03-MODEL)

WIRING DIAGRAM

AY50 AND AY50S

P-02

12-15

B/W

Y/W

Bl/W Bl/W B

B/W

HORN BUTTON

PUSH

B/G B/G

TURN SIGNAL LIGHT SWITCH

IGNITION SWITCH

ON C OFF LOCK

DIMMER SWITCH

LO HI

FRONT TURN SIGNAL LIGHT(L)

HEADLIGHT

Gr Y/W B/W

Y/B

R/B

B/W

O O

Bl/B Bl/W

B/W O O

Y Y Lg

Lbl

PUSH

TRUNK LIGHT SWITCH

PUSH

HORN

ON OFF W/B

ON OFF

PTC

CDI/IGNITION COIL

W/B

R/W

FUSE

Y/W

STARTER MOTOR

STARTER RELAY

GENERATOR

W/Bl

BRAKE LIGHT SWITCH (REAR)

W/Bl

B/W

Y/W

REGULATOR/ RECTIFIER

O R

TU OI

Lg Lg R

Bl/W

FRONT TURN SIGNAL LIGHT(R)

B/R

B B

FUEL

ON OFF

BATTERY

B/W

GROUND

OIL LEVEL INDICATOR LIGHT SWITCH

TURN SIGNAL RELAY

ON OFF

CARBURETOR HEATER

Lbl R

THERMO SWITCH

Bl/W

BRAKE LIGHT SWITCH (FRONT)

B/W B/W

O Y/W Y/W

SP : SPEEDOMETER LIGHT TU : TURN SIGNAL INDICATOR LIGHT OI : OIL LEVEL INDICATOR LIGHT HI : HIGH BEAM INDICATOR LIGHT Y/G R R

B/W B/W B/W

B/W B/W

Bl/W B/W

STARTER BUTTON

P P

B/R Y/G

FUEL LEVEL GAUGE

Y/B Y/B

SPEEDOMETER

Y Y

B/W R

W/B

Y/W Y

Y/W R/W R/W

B/W B/W

B Br G Gr Lbl Lg O P R W Y B/R B/W Bl/B Bl/W G/W R/B R/W W/B W/Bl Y/B Y/G Y/W

WIRE COLOR

B B/W B/W B/W

REAR TURN SIGNAL LIGHT(L)

Y/W

B/W

W/B

BRAKE LIGHT/TAILLIGHT

REAR TURN SIGNAL LIGHT(R)

12-16 AY50K3/SK3/WK3/WSK3 (â&#x20AC;&#x2122;03-MODEL)

P-19

B/W

Y/W

R/B

IGNITION SWITCH

P LOCK OFF C ON

DIMMER SWITCH

LO HI

FRONT TURN SIGNAL LIGHT(L)

B/W

Bl/B

B/W

HEADLIGHT

Bl/W Bl/W B

PUSH

B/W

HORN BUTTON

O PUSH

B/W B/W B/W

Bl/W

Y/G R R

TRUNK LIGHT SWITCH

Bl/B

W/Bl

REGULATOR/ RECTIFIER

Y/W

Lg Lg R

HORN

DIODE

B/G B/W

B L

B/G B/G

TURN SIGNAL LIGHT SWITCH

Y/B

Bl/W

B/W

Gr Y/W R

Y Y Lg

Lbl

ON OFF W/B Y

B/W B/W Y/W

FUEL

O O Br Br

FRONT TURN SIGNAL LIGHT(R)

B/R

PUSH ON OFF

PTC

CDI/IGNITION COIL

W/B

R/W

WATER TEMP. SWITCH

FUSE

Y/W Y

Y/W

STARTER MOTOR

STARTER RELAY

GENERATOR

W/Bl

BRAKE LIGHT SWITCH (REAR)

B/W B/W

O Y/W Y/W

TU OI WT HI

B/R Y/G

SP : SPEEDOMETER LIGHT TU : TURN SIGNAL INDICATOR LIGHT OI : OIL LEVEL INDICATOR LIGHT HI : HIGH BEAM INDICATOR LIGHT TURN SIGNAL RELAY

ON OFF ON OFF

BATTERY

Lbl R

BRAKE LIGHT SWITCH (FRONT)

B/G

B/W

GROUND

OIL LEVEL INDICATOR LIGHT SWITCH

Bl/W

STARTER BUTTON

P P

B/W B/W

Bl/W B/W

SPEEDOMETER

Y Y

B/W R

W/B

FUEL LEVEL GAUGE

Y/B Y/B

CARBURETOR HEATER

Y/W R/W R/W

B/W B/W

THERMO SWITCH

B Br G Gr Lbl Lg O P R W Y B/G B/R B/W Bl/B Bl/W G/W R/B R/W W/B W/Bl Y/B Y/G Y/W

Black Brown Green Gray Light blue Light green Orange Pink Red White Yellow Black with Green tracer Black with Red tracer Black with White tracer Blue with Black tracer Blue with White tracer Green with White tracer Red with Black tracer Red with White tracer White with Black tracer White with Blue tracer Yellow with Black tracer Yellow with Green tracer Yellow with White tracer

WIRE COLOR

B B/W B/W

B B/W

REAR TURN SIGNAL LIGHT(L)

B/W

W/B

BRAKE LIGHT/TAILLIGHT

REAR TURN SIGNAL LIGHT(R) Lg

AY50K3/SK3/WK3/WSK3 (â&#x20AC;&#x2122;03-MODEL)

AY50W AND AY50WS

P-02

12-17

B/W

Y/W

B/G B/G

Bl/W Bl/W B

B/W

HORN BUTTON

PUSH

Y Y Lg

Lbl

TURN SIGNAL LIGHT SWITCH

IGNITION SWITCH

ON C OFF LOCK

DIMMER SWITCH

LO HI

FRONT TURN SIGNAL LIGHT(L)

B/W

B/R

Y/B

Y/B B/W B/W

HEADLIGHT

O O

Bl/B

B/W

Gr Y/W

R/B

B/W B/W O O

Lg Lg R

Bl/W

FRONT TURN SIGNAL LIGHT(R)

PUSH

Bl/W

B/W B/W B/W

Y/G R R

TRUNK LIGHT SWITCH

PUSH

HORN

W/B Y

O R

ON OFF

PTC

CDI/IGNITION COIL

GENERATOR

W/Bl

BRAKE LIGHT SWITCH (REAR)

REGULATOR/ RECTIFIER

Bl/B Y/W

DIODE

ON OFF

B/G B/W

TU OI WT HI

W/Bl

B B

O B/W

W/B Y/W Y/W

B/W

FUEL

R/W

Y/W Y

Y/W

FUSE

WATER TEMP. SWITCH

STARTER MOTOR

STARTER RELAY

B/R Y/G

SP : SPEEDOMETER LIGHT TU : TURN SIGNAL INDICATOR LIGHT OI : OIL LEVEL INDICATOR LIGHT HI : HIGH BEAM INDICATOR LIGHT

TURN SIGNAL RELAY

ON OFF

B/G

ON OFF

BATTERY

B/W

GROUND

OIL LEVEL INDICATOR LIGHT SWITCH

Lbl R

BRAKE LIGHT SWITCH (FRONT)

CARBURETOR HEATER Bl/W

STARTER BUTTON

P P

B/W B/W

Bl/W B/W

SPEEDOMETER

Y Y

B/W R

W/B

FUEL LEVEL GAUGE

Y/B Y/B

THERMO SWITCH

Y/W R/W R/W

B/W B/W

B Br G Gr Lbl Lg O P R W Y B/G B/R B/W Bl/B Bl/W G/W R/B R/W W/B W/Bl Y/B Y/G Y/W

WIRE COLOR

B B/W B/W B/W

REAR TURN SIGNAL LIGHT(L)

Y/W

B/W

W/B

BRAKE LIGHT/TAILLIGHT

REAR TURN SIGNAL LIGHT(R)

12-18 AY50K3/SK3/WK3/WSK3 (â&#x20AC;&#x2122;03-MODEL)

P-19

AY50K3/SK3/WK3/WSK3 (â&#x20AC;&#x2122;03-MODEL)

12-19

OIL HOSE ROUTING

Oil hose

Clip

Filter Clip

to the oil tank Face the arrow mark on the filter, to the oil pump, when installing the filter.

Clamp

Oil hose

Clip

Clip Oil hose Oil hose Clip Oil pump

Oil hose

AY50K4/WK4 (’04-MODEL)

13-1

AY50K4/WK4 (’04-MODEL)

This chapter describes specifications, service data and servicing procedures which differ from those of the AY50K3/WRK3 (’03-MODEL).

NOTE: Please refer to the chapters 1 through 12 for details which are not given in this chapter.

CONTENTS SPECIFICATIONS ................................................................................13-2 AY50 .............................................................................................13-2 AY50W .........................................................................................13-3 SERVICE DATA ...................................................................................13-4 AY50 .............................................................................................13-4 AY50W .........................................................................................13-8

13-2

AY50K4/WK4 (’04-MODEL)

SPECIFICATIONS AY50 DIMENSIONS AND DRY MASS Overall length ...................................................................................... Overall width ....................................................................................... Overall height ...................................................................................... Wheelbase .......................................................................................... Ground clearance................................................................................ Seat height .......................................................................................... Dry mass.............................................................................................

1 865 mm (73.4 in) 650 mm (25.6 in) 1 125 mm (44.3 in) 1 260 mm (49.6 in) 105 mm (4.1 in) 790 mm (31.1 in) 77 kg (169 lbs)

ENGINE Type..................................................................................................... Intake system ...................................................................................... Number of cylinders ............................................................................ Bore .................................................................................................... Stroke.................................................................................................. Displacement ...................................................................................... Corrected compression ratio ............................................................... Carburetor ........................................................................................... Air cleaner ........................................................................................... Starter system..................................................................................... Lubrication system .............................................................................. Idle speed ...........................................................................................

2 stroke, Forced air-cooled Reed valve 1 41.0 mm (1.614 in) 37.4 mm (1.472 in) 49 cm3 (3.0 cu. in) 6.5 : 1 KEIHIN PWS14 Polyurethane foam element Electric and kick SUZUKI “CCI” 1 900 ± 200 r/min

DRIVE TRAIN Clutch .................................................................................................. Gearshifting......................................................................................... Gear ratio, variable.............................................................................. Final reduction ratio............................................................................. Drive system .......................................................................................

Dry shoe, automatic, centrifugal type Automatic, variable ratio Variable reduction ratio (2.768 – 1.005) 14.960 (51/15 × 65/15) V-belt drive

CHASSIS Front suspension................................................................................. Rear suspension ................................................................................. Front suspension stroke ...................................................................... Front wheel travel ................................................................................ Rear wheel travel ................................................................................ Caster ................................................................................................. Trail...................................................................................................... Steering angle ..................................................................................... Turning radius ..................................................................................... Front brake .......................................................................................... Rear brake .......................................................................................... Front tire size ...................................................................................... Rear tire size .......................................................................................

Inverted telescopic, coil spring Swingarm, coil spring, oil damped 77 mm (3.0 in) 70 mm (2.8 in) 60 mm (2.4 in) 25° 20’ 76 mm (2.99 in) 45° (left and right) 1.9 m (6.2 ft) Disc brake Drum brake 120/70-12 51L, tubeless 130/70-12 56L, tubeless

ELECTRICAL Ignition type......................................................................................... Electronic ignition (CDI) Ignition timing ...................................................................................... 14° B.T.D.C. at 4 000 rpm Spark plug ........................................................................................... NGK BPR6HS or DENSO W20FPR-U Battery................................................................................................. 12 V 10.8 kC (3 Ah)/10 HR Generator ............................................................................................ Flywheel magneto Fuse .................................................................................................... 10 A Headlight ............................................................................................. 12 V 35/35 W Brake light/Taillight .............................................................................. 12 V 21/5 W License plate light ............................................................................... 12 V 5 W Turn signal light ................................................................................... 12 V 10 W Speedometer light ............................................................................... 12 V 1.2 W × 2 Fuel level gauge light .......................................................................... 12 V 1.2 W High beam indicator light .................................................................... 12 V 1.2 W Turn signal indicator light .................................................................... 12 V 2 W Oil level indicator light ......................................................................... 12 V 2 W Trunk light............................................................................................ 12 V 2 W CAPACITIES Fuel tank ............................................................................................. Engine oil tank .................................................................................... Final gear oil, oil change ................................................................... overhaul ......................................................................

6.8 L (1.8/1.5 US/Imp gal) 1.2 L (1.3/1.1 US/Imp qt) 120 ml (4.1/4.2 US/Imp oz) 130 ml (4.4/4.6 US/Imp oz)

AY50K4/WK4 (’04-MODEL)

AY50W DIMENSIONS AND DRY MASS Overall length ..................................................................................... Overall width....................................................................................... Overall height ..................................................................................... Wheelbase ......................................................................................... Ground clearance ............................................................................... Seat height ......................................................................................... Dry mass ............................................................................................

1 865 mm (73.4 in) 650 mm (25.6 in) 1 125 mm (44.3 in) 1 260 mm (49.6 in) 105 mm (4.1 in) 790 mm (31.1 in) 83 kg (182 lbs)

ENGINE Type .................................................................................................... Intake system ..................................................................................... Number of cylinders ........................................................................... Bore.................................................................................................... Stroke ................................................................................................. Displacement...................................................................................... Corrected compression ratio .............................................................. Carburetor .......................................................................................... Air cleaner .......................................................................................... Starter system .................................................................................... Lubrication system ............................................................................. Idle speed ...........................................................................................

2 stroke, liquid-cooled Reed valve 1 41.0 mm (1.614 in) 37.4 mm (1.472 in) 49 cm3 (3.0 cu. in) 8.1 : 1 KEIHIN PWS14 Polyurethane foam element Electric and kick SUZUKI “CCI” 1 900 ± 200 r/min

DRIVE TRAIN Clutch ................................................................................................. Gearshifting ........................................................................................ Gear ratio, reduction ratio ................................................................... Final reduction ratio ............................................................................ Drive system.......................................................................................

Dry shoe, automatic, centrifugal type Automatic, variable ratio Variable reduction ratio (2.975 – 1.033) 16.271 (51/15 × 67/14) V-belt drive

CHASSIS Front suspension ................................................................................ Rear suspension ................................................................................ Front suspension stroke ..................................................................... Front wheel travel ............................................................................... Rear wheel travel................................................................................ Caster................................................................................................. Trail ..................................................................................................... Steering angle .................................................................................... Turning radius ..................................................................................... Front brake ......................................................................................... Rear brake.......................................................................................... Front tire size ...................................................................................... Rear tire size ......................................................................................

Inverted telescopic, coil spring Swingarm, coil spring, oil damped 77 mm (3.0 in) 70 mm (2.8 in) 60 mm (2.4 in) 25° 20’ 76 mm (2.99 in) 45° (left and right) 1.9 m (6.2 ft) Disc brake Disc brake 120/70-12 51L, tubeless 130/60-13 M/C 53L, tubeless

ELECTRICAL Ignition type ........................................................................................ Ignition timing ..................................................................................... Spark plug .......................................................................................... Battery ................................................................................................ Generator ........................................................................................... Fuse ................................................................................................... Headlight ............................................................................................ Brake light/Taillight.............................................................................. Turn signal light .................................................................................. License plate light............................................................................... Speedometer light .............................................................................. Fuel level gauge light.......................................................................... Turn signal indicator light.................................................................... High beam indicator light .................................................................... Oil level indicator light......................................................................... Coolant temperature check light ......................................................... Trunk light ...........................................................................................

Electronic ignition (CDI) 14° B.T.D.C. at 4 000 rpm NGK BPR6HS or DENSO W20FPR 12 V 10.8 kC (3 Ah)/10 HR Flywheel magneto 10 A 12 V 35/35 W 12 V 21/5 W 12 V 10 W 12 V 5 W 12 V 1.2 W × 2 12 V 1.2 W 12 V 2 W 12 V 1.2 W 12 V 2 W 12 V 2 W 12 V 2 W

CAPACITIES Fuel tank............................................................................................. Engine oil tank .................................................................................... Final gear oil, oil change................................................................... overhaul ..................................................................... Coolant ...............................................................................................

6.8 L (1.8/1.5 US/Imp gal) 1.2 L (1.3/1.1 US/Imp qt) 120 ml (4.1/4.2 US/Imp oz) 130 ml (4.4/4.6 US/Imp oz) 1 200 ml (2.5/2.1 US/Imp oz)

13-3

13-4

AY50K4/WK4 (’04-MODEL)

SERVICE DATA AY50 CYLINDER + PISTON + PISTON RING ITEM Piston to cylinder clearance Cylinder bore Piston diam. Cylinder distortion Cylinder head distortion Piston ring free end gap Piston ring end gap Piston ring to groove clearance Piston pin bore Piston pin O.D.

Unit: mm

STANDARD 0.06 – 0.07 41.005 – 41.020 Measure at 20 mm from the top surface. 40.940 – 40.955 Measure at 15 mm from the skirt end. — — 1st R Approx. 4.0 2nd R Approx. 4.3 1st & R 0.10 – 0.25 2nd 1st 0.03 – 0.07 2nd 0.02 – 0.06 10.002 – 10.010 9.995 – 10.000

CONROD + CRANKSHAFT ITEM Conrod small end I.D. Conrod deflection Crank web to web width Crankshaft runout

LIMIT 0.120 41.075 40.885 0.05 0.05 3.2 3.4 0.80 — — 10.030 9.980 Unit: mm

STANDARD 14.003 – 14.011 — 36.0 ± 0.05 —

LIMIT 14.040 3.0 — 0.05

OIL PUMP ITEM Oil pump reduction ratio Oil pump discharge rate

SPECIFICATION 30.000 (30/1) 0.9 – 1.1 ml for 5 minutes at 3 000 r/min

CLUTCH Clutch Clutch Clutch Clutch

ITEM wheel I.D. shoe thickness engagement lock-up

Unit: mm STANDARD 110.00 – 110.15 3.0 3 300 ± 200 r/min 4 500 ± 300 r/min

LIMIT 110.50 2.0 — —

AY50K4/WK4 (’04-MODEL)

TRANSMISSION

13-5

Unit: mm (Except ratio)

ITEM Reduction ratio Final reduction ratio Drive belt width

STANDARD Variable 2.768 – 1.005 14.960 (51/15 × 66/15) 16.9 18.4 110

Driven face spring free length

LIMIT — — 15.9 17.4 104.5

CARBURETOR ITEM Carburetor type Bore size I.D. No. Idle r/min Float height Main jet Jet needle Pilot jet Air screw Throttle cable play

SPECIFICATION KEIHIN PWS14 14 mm 35EJ 1 900 ± 200 r/min 5.1 ± 0.5 mm #65 N5GJ-3rd #40 1-3/4 turns back 2 – 4 mm

(M.J.) (J.N.) (P.J.) (A.S.)

ELECTRICAL

Unit: mm

ITEM Spark plug

Type Gap

Spark performance Ignition coil resistance Secondary Generator coil resistance Regulated voltage Generator Max. output Starter relay resistance Battery Type designation Capacity Fuse size

Charging Pick-up

SPECIFICATION NGK: BPR6HS DENSO: W20FPR-U 0.6 – 0.7 Over 8 at 1 atm. 4 – 10 kΩ 0.2 – 1.5 Ω 100 – 270 Ω 13.5 – 15.5 V at 5 000 r/min 100 W at 5 000 r/min 50 – 90 Ω YT4L-BS 12 V 10.8 kC (3 Ah)/10 HR 10 A

NOTE

Plug cap – B/W lead wire terminal Y – Ground R – Ground

13-6

AY50K4/WK4 (’04-MODEL)

WATTAGE

Unit: W ITEM

Headlight

SPECIFICATION 35 35 21/5 5 10 1.2 × 2 1.2 2 2 1.7 2

HI LO

Brake light/Taillight License plate light Turn signal light Speedometer light Fuel meter light Turn signal indicator light Oil level indicator light High beam indicator light Trunk light

Unit: mm Rear Rear Front Front Front Front Front Front Axial Radial Front Front Rear Front Rear Front Rear Front Rear

SUSPENSION ITEM Front fork stroke Front fork spring free length Rear wheel travel

LIMIT — 120.7 3.5 0.30 — — — — — 2.0 2.0 0.25 — — — — — — 1.6 1.6 Unit: mm

STANDARD 77 124.7 60

LIMIT — 122 —

AY50K4/WK4 (â&#x20AC;&#x2122;04-MODEL)

TIRE PRESSURE COLD INFLATION TIRE PRESSURE FRONT REAR

kPa 125 175

SOLO RIDING kgf/cm2 1.25 1.75

psi 18 25

kPa 125 230

DUAL RIDING kgf/cm2 1.25 2.30

psi 18 33

FUEL + OIL ITEM Fuel type Fuel tank capacity Engine oil type

Engine oil tank capacity Final gear oil type Final gear oil capacity

NOTE

13-7

13-8

AY50K4/WK4 (’04-MODEL)

AY50W CYLINDER + PISTON + PISTON RING ITEM Piston to cylinder clearance Cylinder bore Piston diam. Cylinder distortion Cylinder head distortion Piston ring free end gap Piston ring end gap Piston ring to groove clearance Piston pin bore Piston pin O.D.

Unit: mm

STANDARD 0.035 – 0.045 41.010 – 41.025 Measure at 20 mm from the top surface. 40.970 – 40.985 Measure at 23 mm from the skirt end. — — Approx. 4.5 1st & T 2nd N Approx. 3.0 1st & T& 0.08 – 0.18 2nd N 1st & 2nd 0.01 – 0.05 12.002 – 12.010 11.996 – 12.000

CONROD + CRANKSHAFT ITEM Conrod small end I.D. Conrod deflection Crank web to web width Crankshaft runout

LIMIT 0.120 41.105 40.890 0.05 0.05 3.6 2.4 0.80 — 12.030 11.980 Unit: mm

STANDARD 16.003 – 16.011 — 38.0 ± 0.05 —

LIMIT 16.040 3.0 — 0.05

OIL PUMP ITEM Oil pump reduction ratio Oil pump discharge rate

SPECIFICATION 30.000 (30/1) 0.8 – 1.0 ml for 5 minutes at 3 000 r/min

CLUTCH Clutch Clutch Clutch Clutch

ITEM wheel I.D. shoe thickness engagement lock-up

Unit: mm STANDARD 110.00 – 110.15 3.0 4 000 ± 200 r/min 5 600 ± 300 r/min

LIMIT 110.50 2.0 — —

AY50K4/WK4 (’04-MODEL)

13-9

TRANSMISSION

— — — — — — —

Unit: mm (Except ratio)

ITEM Reduction ratio Final reduction ratio Drive belt width Driven face spring free length

STANDARD Variable 2.975 – 1.033 16.271 (51/15 × 67/14) 18.4 110

CARBURETOR ITEM Carburetor type Bore size I.D. No. Idle r/min Float height Main jet Jet needle Pilot jet Air screw Throttle cable play

LIMIT

(M.J.) (J.N.) (P.J.) (A.S.)

SPECIFICATION KEIHIN PWS14 14 mm 35EA 1 900 ± 200 r/min 5.1 ± 0.5 mm #62 N5GJ-2nd #45 1-1/2 turns back 2 – 4 mm

LIMIT — — 17.4 104.5

13-10

AY50K4/WK4 (’04-MODEL)

ELECTRICAL

Unit: mm

ITEM Spark plug

Type Gap

Spark performance Ignition coil resistance Secondary Generator coil resistance

Charging Pick-up

Regulated voltage Generator Max. output Starter relay resistance Battery Type designation Capacity Fuse size

SPECIFICATION NGK: BPR6HS DENSO: W20FPR 0.6 – 0.7 Over 8 at 1 atm. 4 – 10 kΩ 0.2 – 1.5 Ω 100 – 270 Ω 13.5 – 15.5 V at 5 000 r/min 100 W at 5 000 r/min 50 – 90 Ω

NOTE

Plug cap – B/W lead wire terminal Y – Ground R – Ground

YT4L-BS 12 V 10.8 kC (3 Ah)/10 HR 10 A

WATTAGE

Unit: W ITEM

Headlight Brake light/Taillight Turn signal light License plate light Speedometer light Fuel meter light Turn signal indicator light Oil level indicator light Water temp. indicator light High beam indicator light Trunk light

HI LO

SPECIFICATION 35 35 21/5 10 5 1.2 × 2 1.2 2 2 2 1.2 2

AY50K4/WK4 (’04-MODEL)

BRAKE + WHEEL

Unit: mm

LIMIT 3.5 3.5 0.30 — — — — — — — — — 2.0 2.0 0.25 — — — — — — 1.6 1.6

SUSPENSION

Unit: mm

ITEM Front fork stroke Front fork spring free length Rear wheel travel

STANDARD 77 124.7 60

LIMIT — 122 —

TIRE PRESSURE COLD INFLATION TIRE PRESSURE FRONT REAR

13-11

kPa 125 175

SOLO RIDING kgf/cm2 1.25 1.75

psi 18 25

kPa 125 230

DUAL RIDING kgf/cm2 1.25 2.30

psi 18 33

13-12

AY50K4/WK4 (â&#x20AC;&#x2122;04-MODEL)

FUEL + OIL ITEM Fuel type Fuel tank capacity Engine oil type

Engine oil tank capacity Final gear oil type Final gear oil capacity

NOTE

Prepared by

7th Ed. February, 2004 1st Ed. March, 1997 Part No. 99500-10457-01E Printed in Japan

274