RM250 Owners Service Manual 1991
RM250 Owners Service Manual 1991
RM250 Owners Service Manual 1991
GENERAL I N S T R U C T I O N S 1
PERIODIC M A I N T E N A N C E 2
TROUBLESHOOTING 3
MACHINE TUNING
KICK STARTER 8
TRANSMISSION AND CRANKSHAFT 9
FUEL SYSTEM 10
COOLING SYSTEM 1 1 1 1
ELECTRICAL SYSTEM 12
FRONT AND REAR WHEELS 13
FRONT AND REAR BRAKES 14
FRONT FORK AND STEERING 15
REAR SUSPENSION 16
SERVICE DATA 17
SPECIAL TOOLS 18
WIRE, CABLE AND HOSE ROUTING 19
SPECIFICATIONS 20
1-1 GENERAL INSTRUCTIONS
LOCATION OF PARTS
2 Co)
0 C l u t c h lever
Engine kill s w i t c h
CD T h r o t t l e grip
LT F r o n t brake lever
Fuel t a n k cap
Carburator choke knob
0 G e a r s h i f t lever
0 K i c k starter lever
R e a r brake pedal
. - -
GENERALINSTRUCTIONS 12
FUEL
This motorcycle is of the two-stroke design, which requires
a premixture of gasoline and oil.
PERIODIC MAINTENANCE
INSPECTION BEFORE PRACTICE
-r&
PERIODIC MAINTENANCE 2-2
SPARK PLUG
Inspect t h e spark plug condition, electrode color, carbon
deposits, spark plug gap, and washer damage, after remov-
ing the spark plug.
NOTE: R e m o v e the dirt around the spark plug before remov-
ing the spark plug to prevent dirt from entering the combusi-
ton chamber.
Clean the spark plug with a brush or wire and check the spark
plug gap w i t h a thickness gauge.
Spark plug gap: 0 . 5 - 0 . 6 mm
(0.020-0.024 in)
A CAUTION
Changing the spark plug heat range improperly can damage
the engine.
Select the spark plug heat range only after adjusting the
ignition timing, carburetor settng and oil/gasoline mixture.
AIR CLEANER
Air Cleaner Element Removal
Remove the frame cover and seat.
Remove the air cleaner cap.
Remove screw CI).
Washing
Fill a washing pan large enough to hold the element with
a non-flammable cleaning solvent 'AD. Immerse the element t 7-
V
in the solvent and wash it.
,,_-_i!_, 1
Squeeze the element by pressing it between the palms of
t
both hands to remove excess solvent. Do not twist or wring --:- --- ----1
the element or it will develop cracks. 1\,,,.
D r y the element in a plastic bag, pour in some foam filter
.,,----'
oil S a n d w o r k the oil into the element. e,
Squeeeze the element to remove excess oil.
Installation
A p p l y grease to the element holder where it contacts the
element.
Install the inner and Outer elements onto the element holder
as triangle mark q ) faces upward.
a CAUTION
Improper element installation allows dust and dirt to enter
into the combustion chamber. It can result in piston and
cylinder wear.
TRANSMISSION OIL
Transmission Oil Level Inspection and Replenishment
Place the motorcycle on level ground and hold the motor-
cycle vertically.
Run the engine for a f e w minutes and stop it. Wait 2 - 3
millutes.
Remove oil level screw C h e c k that the oil comes out
of the hole.
I f the oil does not come out of the hole, open oil filler cap
and add the specified oil until the oil comes out of the
oil level hole.
Ti g h t e n t h e f i l l e r c a p a n d o i l l e v e l s c r e w f i r m l y.
Transmission Oil Change
Wa r m u p the engine.
Place t h e motorcycle o n t h e level ground and hold t h e
motorcycle vertically.
Remove filler c a p CI) a n d drain p l u g O . Drain t h e o i l
thoroughly.
Tighten the drain plug firmly.
Pour 6 5 0 ml (0.7 US qt) o f SAE 1 0 W- 4 0 motor oil.
S t a r t the engine and idle it a f e w minutes.
Inspect the oil level.
(Only for U.S.A.)
Suzuki recommends the use o f SUZUKI PERFORMANCE 4
MOTOR OIL or an oil which has 1 0 W - 4 0 viscosity rating.
COOLANT
Coolant Level Check
AWARNING
You can be injured by scalding fluid or steam if you open
the radiator cap when the engine is hot.
S
Do not open the radiator cap when the engine is hot. Wait
until engine cools.
ACAUTION
NOTE:
T h i s motorcycle does not have an overflow tank at the end
of breather hose. Therefore, coolant level man decrease
while riding. Check the coolant level every time before
riding.
W h e n replenishing coolant, be sure to use coolant mixed
with distilled water at the ratio o f 5 0 : 50. A d d i n g only
water wil dilute coolant and it may decrease cooling per-
formance.
Coolant MES
Use SUZUKI GOLDEN CRUISER 1200 or equivalent anti-freeze
and Summer coolant which is compatible with aluminum radi- 1
ta.da coltz.
ator at the ratio o f 5 0 : 5 0 .
SUZUKI G O L D E N CRUISER
NOTE: 1200NA
I N o n - A m m e tvpeI 1 2 . 0 0
The radiator, cylinder and cylinder head are made o f alumi- 99000-99032-10X
AWARNING
Coolant is harmful if swallowed or if it comes in contact
with your skin or eyes.
Keep coolant away from children and pets. Call your doc-
tor immediately if coolant is swallowed and induce vomit-
ing. Flush eyes or skin with water if coolant gets in eyes
or comes in contact with skin.
CLUTCH
Adjust the clutch cable play as follows:
Major Adjustment
Loosen lock n u t T .
Tu r n adjuster s o t h e c l u t c h c a b l e h a s 2 - 3 m m
( 0 . 0 8 - 0 . 1 2 in) play at the clutch lever holder before pres-
sure is felt.
Ti g h t e n lock nut
Minor Adjustment
Loosen lock n u t .
Tu r n adjuster 4 s o t h e c l u t c h c a b l e h a s 2 - 3 m m
( 0 . 0 8 - 0 . 1 2 in) play at the clutch lever holder before pres-
sure is felt.
Ti g h t e n lock n u t .
THROTTLE CABLE
Adjust the throttle cable play as follows:
Loosen lock n u t II).
Tu r n adjuster so the throttle cable has 0 . 5 - 1 . 0 m m
( 0 . 0 2 - 0 . 0 4 in) play.
Ti g h t e n lock n u t
FUEL LINE
Repalce fuel line every four years.
PERIODIC MAINTENANCE 2-8
Cylinder
Remove the cylinder. ( 6 - 2 )
Remove carbon deposits from t h e exhaust port.
Check for scratches and wear on the cylinder sleeve.
Piston
Remove the piston. ( J.
Remove carbon deposits from the top surface of the piston.
Check for scratches, cracks, and wear around the piston
bosses.
Remove minor scuffs with # 600 * 8 0 0 sand paper.
Check piston ring wear. Remove carbon deposits from the
piston ring groove.
EXHAUST VALVE
NOTE
Be careful not to bend the chain clip.
Inspect for wear and damage of the drive chain and replace
it i f necessary.
NOTE:
Reassemble the drive chain clip so the slit end faces opposite
the direction o f rotation.
7
-
PERIODIC MAINTENANCE 2-10
Sprocket Inspection
Inspect the engine sprocket and rear sprocket for wear and
cracks. Reprace the sprockets as necessary.
NOTE:
When replaceing a worn sprocket, i r i s likely t h a t the drive
chain w i l l need to be replaced as w e l l
NOTE:
The drive chain can hit a bent guide causing noise and drive
chain wear.
NOTE:
The drive chain can touch the swing arm directly if the chain
guide buffer is worn out. This will cause drive chain and swing
arm damage.
BRAKES
Brake Fluid Level
Inspect the brake fluid level in both front and rear reservoirs.
If the brake fluid level is lower than LOWER mark, replenish
the resrvoir with the specified brake fluid to the UPPER level.
Inspect brake pad wear and brake fluid leakage if the brake
fluid level decreases.
Brake fluid: D O T 4
2-11 PERIODIC MAINTENANCE
A WARNING
Brake fluid can be hazardous to humans and pets. Brake
fluid is harmful or fatal if swallowed, and harmful if it comes
in contact with your skin or eyes.
Keep brake fluid away from children. Call your doctor im-
mediately if brake fluid is swallowed, and induce vomiting.
Flush eyes or skin with water if brake fluid gets in eyes or
comes in contact with skin.
A CAUTION
The use of any fluid except DOT4 brake fluid from a sealed
containter can damage the brake system and lead to an ac-
cident.
A CAUTION
Spilled brake fluid can damage painted surface and plastic
parts.
Be careful not to spill any fluid when filling the brake fluid
reservoir. Wipe spilled full up immediately.
Brake Shoe
Inspect the brake shoes for wear. I f the brake shoes are
worn, replace them w i t h n e w ones. ( 1 4 - 3 )
Brake shoe wear limit: 1 . 5 mm ( 0 . 0 6 in)
NOTE:
P u m p the brake lever/pedal several times to restore the
brake pads after replacing the brake pads.
Replace both right and left pads together when replace-
ing the brake peads.
1.5 m m
PERIODIC MAINTENANCE 2-12
a CAUTION
Brake lever play less than 0.1 m m ( 0 . 0 0 4 in) can cause
brake dragging.
Do not adjust the brake lever play less than 0.1 mm (0.004
in).
FRONT FORK
M o v e the front fork up and d o w n several times and in-
spect for smooth movement.
Inspect for damage and oil leaks.
Inspect the bolts and nuts for tightness.
REAR SUSPENSION
M o v e the rear suspension up and d o w n several times
and inspect for smooth movement.
Inspect for damage and oil leaks.
Inspect the bolts and nuts for tightness.
2-13 PERIODIC MAINTENANCE
WHEELS A N D TIRES
Wheel Rim
Inspect the wheel bearing for rattles Replace the bearings
if necessary. ( 1 3 - 3 )
Inspect the wheel rim runout. ( = 13-3)
Tire Pressure
Inspect front and rear tire pressure.
Cold inflation tire 7 0 - 1 1 0 kPa
pressure: ( 0 . 7 - 1 . 1 kg/cm', 1 0 - 1 6 psi)
-
Inspect the steering by moving the front fork up and down,
and right and left. If the steering has play or binds, inspect
steering stern head n u t tightness and steering bearings.
( 15-7)
PERIODIC MAINTENANCE 2-14
LUBRICATION
Apply grease or oil t o the moving parts t o increase durability and prevent wear.
pf
,b4 I
1lo
11
Follow the schedule closely. The disassembly necessary to lubricate many components is in itself valu-
able preventative maintenance. It allows you to inspect for wear, fatigue, adjustment and fastener tight-
ness and i t allows you t o clean o u t the grit which otherwise cannot be gotten out.
2-15 PERIODIC MAINTENANCE
TIGHTENING TORQUE
Front fork upper clamp bolt (right and left) 20-30 2.0-3.0 14.5-21.5
Front fork lower clamp bolts (right and left) 20-30 2.0-3.0 14.5-21.5
80-100 8.0 10.0 58.0-72.5
Steering stem head nut
Front fork cap bolt 25-35 2.5-3.5 18.0-25.5
50-55 5.0-5.5 36.0-40.0
Front fork piston rod nut
5-8 0.5-0.8 3.5-6.0
Master cylinder set bolt (front)
8-12 0.8-1.2 6.0-8.5
Master cylinder set bolt (Rear)
Brake hose union bolt (front and rear) 15-20 1.5-2.0 11.0-14.5
15-20 1.5-2.0 11.0-14.5
Brake pad mounting bolt (front and rear)
Brake caliper mounting bolt (front) 18-28 1.8-2.8 13.0-20.0
6-9 0.6-0.9 4.5-6.5
Brake bleeder plug (front and rear)
Front axle holder nut 9 - 11 0.9-1.1 6.5-8.0
Front axle shaft 50-80 5.0-8.0 36.0-58.0
37-45 3.7-4.5 27.0-32.5
Engine mounting nuts
Rear axle nut 8 5 - 11 5 8 . 5 - 11 . 5 61.5-83.0
30-40 3.0-4.0 21.5-29.0
Rear sprocket nut
Spoke nipple 2-3 0.2-0.3 1.5-2.0
50-80 5.0-8.0 36.0-58.0
Rear swingarm pivot nut (engine mounting)
Rear shaock absorber fitting nut (upper and 40-60 4.0-6.0 29.0-43.5
lower)
Rear cushion lever center nut 80-120 8.0-12.0 58.0-87.0
Rear cushion lever front nut 60-100 6.0-10.0 43.5-72.5
Rear cushion rod n u t 80 120 8.0-12.0 58.0 87.0
PERIODIC MAINTENANCE 2-16
Bolt Conventional or " 4 " marked bolt " 7 " marked bolt
Diameter
(mm) N.m kg-m lb-ft N.m kg-rn lb-ft
4 1.0-2.0 0.1-0.2 0.7-1.5 1.5-3.0 0.15-0.3 1.0-2.0
5 2.0-4.0 0.2-0.4 1.5-3.0 3.0-6.0 0.3-0.6 2.0-4.5
6 4.0-7.0 0.4-0.7 3.0-5.0 8.0-12.0 0.8-1.2 6.0-8.5
8 10.0-16.0 1.0-1.6 7 . 0 - 11 . 5 18.0-28.0 1.8-2.8 13.0-20.0
10 22.0-35.0 2.2-3.5 16.0-25.5 40.0-60.0 4.0-6.0 29.0-43.5
12 35.0-55.0 3.5-5.5 25.5-40.0 70.0-100.0 7.0-10.0 50.0-72.5
14 500-800 5.0-8.0 36.0-58.0 110.0-160.0 11 . 0 - 1 6 . 0 7 9 . 5 - 11 5 . 5
16 80.0-130.0 8.0-13.0 58.0-94.0 170.0-250.0 17.0-25.0 123.0-181.0
18 136,0-190.0 13.0-19.0 94.0-137.5 200.0-280.0 20.0-28.0 144.5-202.5
3-1 TROUBLESHOOTING
TROUBLESHOOTING
ENGINE
Possible Cause Remedy
Complaint
Fuel deterioration Replace
Engine does n o t
start o r hard t o No fuel f l o w t o t h e carburetor
Clean
start Fuelcock clogged
Fuel hose clogged Clean o r replace
Fuel tank cap breather hose clogged Clean
Carburetor float valve malfunction Replace
Carburetor overflow pipe clogging Clean
Carburetor air v e n t pipe clogging Clean
Too rich fuel/air mixture in combustion chamber Scavenge
Incorrect ignition timing Adjust or replace
_,- 1 0-2
No spark at spark plug
Low compression
Piston ring w o r n o r stuck Replace
Cylinder w o r n Replace
A i r leak f r o m cylinder gasket Replace
A i r leak f r o m crankshaft oil seal Replace
CHASSIS
Carburetor Specifications
Bore 38 m m
Main j e t # 370
Jet needle 6AEL01-60-3rd
Needle jet (R-1) N o t adjustable
Cut-away 3.5
Pilot jet # 50
Air s c r e w 1-
Float height 16.0 1 .0 r a m ( 0 . 5 5
0 . 0 4 in)
# 3 5 0 , # 3 6 0 , # 3 8 0 and
Spare main jet:
#390
5. Starter plunger
6. * A i r screw
7. * M a i n j e t
1. T o p cap 8 . * P i l o t jet
2. Spring 9 . Float
3. * J e t needle 1 0 . N e e d l e valve ass'y
4. T h r o t t l e valve 11 . Clip
MACHINE TUNING 4-2
As shown below, each of the asterisk ( * ) marked parts is located between the air/fuel passage and
has its own air/fuel mixture adjustable range in terms of the throttle valve opening. The chart indi-
cates that the carburetor can supply correct air/fuel mixture to the engine in any range because o f
the overlapping adjustable range o f the each part.
JET NEEDLE
1111.1111
Va 1 /
THROTTLE OPENING
I I I I
0 M A I N SYSTEM a ) INTERMEDIATE SYSTEM P I L O T SYSTEM
When performing carburetor tuning first find Out Pilot Air Screw
in w h a t t h r o t t l e opening r a n g e a n i m p r o p e r
air/fuel mixture is supplied, by checking the color
of exhaust smoke, spark plug, throttle response,
power, etc. Second, replace or adjust the part(s)
related t o the throttle opening range b y refer-
ring t o t h e f o l l o w i n g instructions. T h e sizes
referred to in the illustrations are those of stan-
dard setting.
Pilot Jet
Lean
c
Rich 1 5
The jet needle is linked to the throttle valve by The main jet, like the pilot jet, meters fuel f l o w.
means o f the needle clip. I t s l o w e r part is ta-
pered and i t has five grooves c u t in the upper
part w h e r e the needle clip fits.
Jet Needle
EX. 6 A E . . 1 0 1 -64-3rd
6AEJ01 -65-3rd
6AEJ01-66-3rd
MACHINETUNING 4-4
1%1
100 100
90 9 0
0
< 80 8 0
uJ
0
0
>-
X
0 1 1 1 1 1 I I I I 1
-100 1 0 2 0 3 0 4 0 ["CI 5 0 0 1000 1500 2000 2500 1m] 20 4 0 6 0 8 0 1 0 0 1%i
10 3 0 5 0 7 0 9 0 11 0 1 Ifti
ATMOSPHERIC TEMPERATURE A LT I T U D E H U M I D I T Y
In the above graphs, oxygen concentration is graduated on the vertical axis while the temperature,
altitude and humidity are on the horizontal axis respectively. Oxygen concentration is set 1 0 0 % un-
der the cnditions o f 2 0 C ( 6 8 " F ) , 0 m ( 0 ft) and 5 0 % humidity. The standard carburetor setting
is chosen t o obtain the best engine performance under these conditions.
The graph at the left shows that the oxygen concentration changes about 1 0 % in the 0 " t o 4 0 C
temperature difference, the one in the center shows about 20"/0 change in the 0 to 2 0 0 0 m attitude
difference and the one at the right shows about 5')/o change in the 0 to 1 0 0 % humidity difference.
As for humidity, its normal range is from 2 0 to 9 5 % . Therefore the possible effect o f humidity on
the oxygen concentration is so little that it can be disregarded. Consequently, w e can say that the
oxygen concentration varies by as much as 209/o depending on the temperature and altitude under
normal riding conditions. On the other hand, different from the air, the fuel (gasoline) hardly changes
in volume even when such environmental conditions change. Therefore, increase in oxygen concen-
tration w i l l make the air/fuel mixture leaner and decrease w i l l enrich it.
As the carburetor mixes gasoline and air, w h i c h are metered b y each jet in varying proportions t o
suit throttle opening, the air/fuel mixture is affected if the air concentration itself aries as described
above. Then proper engine power output can n o t be attained and, should the mixture become too
lean, a piston seizure may result. To compensate for such change in the air concentration, i t is re-
quired to carry out carburetor tuning beforehand. This requirement applies to all models of motorcy-
cles and AT V s if they are used in areas where temperature and altitude range widely. The next section
describes the procedure o f the above tuning in detail.
4.5 MACHINE TUNING
Atomosphe-
ric tempera- 'C -10 0 10 20 30 40
ture
Altitude
0 14 32 50 68 86 104
A d j u s t m e n t o f main system
With the throttle opened 3 / 4 to full, make main
s' t e r n adjustment monitoring the air/fuel mix-
ture condition after completion of pilot system
setings.
* I f selection o f t h e main j e t is b e t w e e n t h e
columns, take the larger number main jet first Fine tune the intermediate system by changing
to prevent the piston seizure' the clip position.
* M a k e sure to adjust the main system before
adjusting t h e interrndiate system.
() A d j u s t m e n t o f intermediate system
Monitor the air/fuel mixture condition and ad-
just the intermediate system b y selecting t h e
r - ) e r needle size. Changing standard needle
wunin o n e size (larger o r smaller) w i l l c o v e r
almost any race condition. Size 5 5 and 51 are
rarely used.
-
MACHINETUNING 4-8
FRONT FORK
The front fork compression and rebound damping force, oil
level, air pressure and spring pre-set is adjustable for rider's
preference, riders w e i g h t and course condition,
NOTE:
Break-in new front forks before attempting adjustment.
-4)
B e sure to adjust both right and left front forks equally.
_,*__
, '
-
MACHINE TUNING 4-10
140 mm (5,5 iM
NOTE: A n oil level lower or higher than the above range 1 4 5 rnrin 4 5 . 7 i n )
will affect the front fork performance. Be sure to adjust the 150 rnrn 45.0 in/
Stroke ( mm)
NOTE:
When adjusting t h e f r o n t f o r k o i l capacity, m a k e sure t h a t t h e o i l level is w i t h i n t h e specified
range. A l s o , t h e capacity should be increased or decreased b y 5 m m (approx. 5 m 0 a t a time.
When adjusting the damping setting, a t t e m p t turning the adjuter 1 t o 2 click stops a t a time f o r
each adjustment.
." .17: -
MACHINE TUNING 412
REAR SUSPENSION
The r e a r suspension compression a n d rebound d a m p i n g
force, and spring preload is adjustable for rider's preference,
rider's weight and course condition.
R e m o v e t h e radiator cover.
T u r n t h e fuelcock lever to the " O F F " position and dis-
connect t h e fuel hose.
R e m o v e t h e t w o bolts and band f r o m t h e fuel tank.
R e m o v e t h e fuel tank.
Drain t h e transmission oil. (E..7' 2-5)
D r a i n coolant. 1 1 - 2 )
R e m o v e the m u ff l e r f i t t i n g b o l t s .
R e m o v e t h e exhaust pipe and muffler.
ENGINE MOUNTING
M o u n t the engine on t h e frame.
Ti g h t e n t h e engine mounting nuts.
Tightening torque
N.m kg-m lb-ft
' 37-45 3.7-4.5 27.0-32.5
( 37-45 3.7-4.5 27.0-32.5
37-45 3.7-4.5 27.0-32.5
50-80 5.0-8.0 36.0-58.0
2 . 5 - 3 . 0 kg-m A 4
2.6 3.0 kg-m
t c
3 . 7 - 4 . 5 kg-m
1207B
3 . 6 - 4 . 0 kg-m
CD
f 1303
ci) g q0 ,'
eo
' (,<2)gr'
V,
r),)'
, )
11 f ' q l /
---9 i
6-2 CYLINDER, PISTON AND EXHAUST VALVE
CYLINDER REMOVAL
R e m o v e the exhaust pipe. (E_T- 5-1)
R e m o v e the carburetor. ( 1 0 - 2 )
R e m o v e the exhaust valve rod cover.
U n h o o k the stopper and remove the exhaust valve rod.
R e m o v e the four cylinder nuts.
PISTON REMOVAL
R e m o v e the piston pin circlip.
CYLLINDER INSPECTION
Remove carbon deposits f r o m the exhaust port.
I n s p e c t the cylinder for cracks and replace the cylinder
if necessary.
I n s p e c t the cylinder bore f o r wear and scratches.
M e a s u r e t h e cylinder b o r e f o r w e a r a t p l a c e w i t h a
cylinder gauge at 2 0 m m f r o m t h e t o p surface.
Standard : 6 7 . 0 0 0 - 6 7 . 0 1 5 mm ( 2 . 6 3 7 8 - 2 . 6 3 8 4 in)
09900-20508 : Cylinder gauge set ( 4 0 - 8 0 mm)
Service Limit
Piston pin bore 18.030 mm (0.7098 in)
Piston pin O.D. 17.980 mm (0.6724 in)
t:
11111 4E10 I
CON
Measure the c o n
F i t the piston pin and bearing into the con-rod small end
and check the play.
NOTE:
Replace t h e piston pin circlip w i t h a n e w one.
P l a c e cloth on the crankcase t o prevent piston pin cir-
clip f r o m dropping into the crankcase chamber.
CYLINDER REASSEMBLING
F i t t h e n e w gasket. Fit the dowel pins.
F i t t h e reed valve t o t h e cylinder.
Move t h e piston t o t h e t o p dead center.
A p p l y engine oil t o t h e cylinder bore.
H o l d the piston and piston ring, and insert the piston into
the cylinder.
a CAUTION
If the piston pin end is not at the proper position, you can
not insert the piston into the cylinder properly and the
piston ring will be damaged.
Locate the piston ring end to the locating pin and insert
the piston into the cylinder.
OK
NG
CYLINDER, PISTON AND EXHAUST VALVE 6-7
Install t h e n e w 0-rings.
Install t h e cylinder head.
CLUTCH
OIL
OIL
7-2 CLUTCH
Service limit
Thickness 2.4 mm ( 0 . 0 9 in)
Claw width 15.3 m m ( 0 . 6 0 in)
Clutch Spring
M e a s u r e the clutch spring free length.
Service limit : 4 2 . 3 m m ( 1 . 6 7 in)
NOTE.
spring is beyond the service limit.
CLUTCH 7-3
H o l d the clutch sleeve hub with the special tool and loos-
en the nut.
KICK STARTER
-Gl
13338
8-2 KICK STARTER
8
V
-
1303
0 " R S I
1303
1303
1303 I C -
40
OIL
OIL
1333B
2 1
9-2 TRANSMISSION AND CRANKSHAFT
D i s m o u n t the engine. ( 5 - 1 )
R e m o v e t h e cylinder and piston. ( 6 - 2 )
R e m o v e t h e clutch. ( r 7 - 2 )
R e m o v e the kick starter. ( 117 8-2)
R e m o v e the magneto rotor and stator. ( 1 2 - 4)
R e m o v e t h e exhaust valve actuator.
CRANKCASE SEPARATION
R e m o v e t h e crankcase fitting s c r e w s .
1- "
TRANSMISSIONAND CRANKSHAFT 9-3
NOTE:
S e t the crankcase separating tool to the clutch side of
the crankcase.
Separate the crankcase gradually while hitting the crank-
case boss and countershaft softly with a plastic hammer.
TRANSMISSION REMOVAL
Remove the gearshift fork shaft and forks.
Remove the gearshift cam.
Remove the drive shaft assy and countershaft assy.
CRANKSHAFT REMOVAL
Remove the crankshaft by hitting with a plastic hammer.
TRANSMISSION INSPECTION
Inspect the gear teeth, dogs, and gearshift grooves for
abnormal wear and damage.
Inspect the bushes and splines for abnormal wear and
discoloration.
nommillmoommilmom
ititattifillintal011
CRANKSHAFT INSPECTION
a M e a s u r e the crankshaft runout w i t h V-blocks and dial
gauge.
Standard : 5 7 . 9 - 5 8 . 1 m m ( 2 . 2 8 - 2 . 2 9 in)
imon
OIL S E A L INSPECTION, R E M O VA L A N D I N S TA L -
LATION
I n s p e c t the oil seal lips f o r wear and damage.
0 9 9 1 4 - 7 9 6 1 0 B e a r i n g / O i l seal installer
BEARING INSPECTION, R E M O VA L A N D I N S TA L -
LATION
I n s p e c t t h e bearings f o r play, discoloration, w e a r and
seizure.
M o v e t h e inner race b y finger and inspect f o r smooth
inc yement.
R e m o v e t h e retainers.
R e m o v e the bearing w i t h t h e special tools.
1 Bearing puller
-t)9923-74510 Bearing puller
09930-30102 Rotor remover slide shaft
0 9 9 1 4 - 7 9 6 1 0 B e a r i n g / O i l seal installer
TRANSMISSION AND CRANKSHAFT 9-7
CRANKSHAFT INSTALLATION
F i t the crankshaft into t h e right crankcase half.
TRANSMISSION REASSEMBLY
_ 111 1- a
Ula.411
9-8 TRANSMISSION AND CRANKSHAFT
tv
confirm t h a t the driveshaft and countershaft turn w i t h o u t
resistance.
CRANKCASE REASSEMBLY
F i t t h e l e f t crankcase half on t h e right crankcase half.
Ti g h t e n t h e crankcase bolts.
lv
the crankshaft into t h e bearing. I f it is hard to tighten the
bolts, separate the crankcase a n d confirm t h a t the trans-
r ' c s i o n parts are assembled correctly.
F i t t h e gearshift r e t u r n s p r i n g t o t h e gearshift s h a f t
properly.
FUEL SYSTEM
-
10-2 FUEL SYSTEM
CARBURETOR
Carburetor Removal
T u r n the fuelcock to the " O F F " position and disconnect
the fuel hose.
Loosen the carburetor clamp screws and remove the car-
buretor.
Remove two screws from the carburetor top cap. Remove
the throttle valve.
R e m o v e t h e choke konb.
Clean t h e carburetor body w i t h pressurized air.
FUEL SYSTEM 103
Carburetor Inspection
I n s p e c t the following parts f o r damage.
Jet needle, throttle valve, f l o a t
I n s p e c t t h e following jets f o r clogging.
Main jet, p i l o t jet, starter jet
I n s p e c t t h e needle valve f o r wear.
rburetor Reassembly
Reverse t h e sequence o f removal.
-
Reed vale Removal
R e m o v e t h e carburetor. ( 1 0 - 2 )
R e m o v e t h e four bolts.
R e m o v e t h e intake pipe and read valve.
COOLING SYSTEM
q.11
11
'
'k..,?_1(22r -
-4131 OIL
1322
kel
11-2 COOLING SYSTEM
COOLANT REPLACEMENT
AWARNING
You can be injured by scalding fluid or steam if you open
the radiator cap when the engine is hot.
Do not open the radiator cap when the engine is hot. Wait
until engine cools.
RADIATOR
Removal
R e m o v e the seat and fuel tank.
Drain coolant.
D i s c o n n e c t the radiator hoses and over f l o w t u b e .
R e m o v e the radiator fitting bolts. Remove the radiator.
lssembly
Weverse the sequence o f removal.
COOLING SYSTEM 11-3
WATER PUMP
Removal
D r a i n the coolant. ( 1 1 - 2 )
R e m o v e t h e bolts and w a t e r pump cover.
0 9 9 2 1 - 2 0 2 0 0 B e a r i n g remover
0 9 9 3 0 - 3 0 1 0 2 R o t o r remover slide shaft
Reassembly
F i t the bearing and circlip. A p p l y transmission oil to the
bearing.
A p p l y thread lock " 1 3 0 3 " t o t h e outer surface o f the
oil seal. F i t the oil seal.
A p p l y grease t o the oil seal lip.
I n s e r t the water pump shaft. Fit the water pump driven
gear and circlip.
114 COOLING SYSTEM
ELECTRICAL SYSTEM
12
3 . 0 - 4 . 0 kg-nn
12-2 ELECTRICAL SYSTEM
ELECTRICAL CIRCUIT
Engine s t o p s w i t c h
B
Magneto Ignition coil
r r
BR
I. - - 1 r - - -
IN
Color code:
B : Black
B/R : B l a c k w i t h red tracer
B/W : B l a c k w i t h w h i t e tracer
BY B l a c k w i t h y e l l o w tracer
G : Green
: Red
R/W : R e d w i t h w h i t e tracer
WIBI: W h i t e w i t h blue tracer
09900-25002 P o c k e t tester
properly.
09900-28106 E l e c t r a Tester
3900-70210 C D I unit test lead
Checking with Pocket Tester
Measure resistance between the lead wires w i t h the pock-
et tester l x 1kf1 range).
09900-25002 P o c k e t tester
A CAUTION
Unit: A p p r o x . k9,
Posit've (I) probe pin Wire color
-------,.. B/R R/W R G B/Y W/BI B/W G : Green
R : Red
B/R ---------,.., 170 125 120 0 OFF 125 B/R : Black w i t h Red tracer
, R/W 14 11 6.2 14 OFF 6.2 B/W : Black w i t h W h i t e tracer
'a R 7 7 7 OFF 3
BlY : Black w i t h Ye l l o w tracer
R/W : Red w i t h W h i t e tracer
Q) G 2.8 2.8 3.2
'--------....,.. 2.8 OFF 0 W/BI : W h i t e w i t h Blue tracer
>/ BY 0 170 125 125 OFF 125
c' W/BI 8 8 7 2.6 8.2 2.6
a)
z
BIW 2.8 2.8 3,2 0 2.8 OFF
-------,....
12-4 ELECTRICAL SYSTEM
Black/RedRed/White 1 0 0 - 2 0 0 '2
RedGreen 8 0 - 2 0 0 c2
--4111;
1303 0 . 7 1.0 kg-m
13
.; e "
4 . 0 kg-nn
13-2 FRONT AND REAR WHEELS
REAR W H E E L R E M O V A L A N D R E A S S E M B LY
Rear Wheel Removal
Place the motorcycle on a block to lift the rear wheel o ff
the ground.
R e m o v e the c o t t e r pin and axle nut.
Loosen the chain adjuster lock nuts and chain adjusters.
R e m o v e the rear wheel.
NOTE:
Reasemble the left side (disc side) bearing first and then
reassemble the right side bearing.
P o s i t o n the bearing so sealed side faces out.
A f t e r reassembling the bearings, inspect the bearings for
smooth movement.
13-4 FRONT AND REAR WHEELS
F i t t h e circlips.
0 . 5 - 0 . 8 kg-m
o
S
Tr ,
0 . 8 - 1 . 2 kg-m
1 . 5 - 2 . 0 kg-m
1. 5
, 6
1 . 5 - 2 . 0 kg-rn
1 . 5 - 2 . 0 kg-m
4
c#
14
1 . 5 - 2 . 0 kg-m
41
.,e
1 . 5 - 2 . 0 kg-m .
1 4trz, 0 . 6 - 0 . 9 kg-m 2 . 0 - 2 . 5 kg-m '
z
,- 1111 T .--
2 . 0 - 2 . 5 kg-m ( -
<
'
1 . 5 - 2 . 0 kg-m
40
14-2 FRONT AND REAR BRAKES
AWARNING
Brake fluid can be hazardous to humans and pet. Brake
fluid is harmful or fatal if swallowed, and harmful if it
comes in contact with your skin or eyes.
Keep both fluid away from children. Call your doctor im-
mediately if brake fluid is swallowed and induce vomit-
ing. Flush eyes or skin with water if brake fluid gets in
eyes or comes in contact with skin.
AWARNING
The use of any fluid DOT4 brake fluid from a sealed con-
liner can damage the brake system and lead to an ac-
cident.
AlkWARNING'
Spilled brake fluid can damage painted surface and plas-
tic parts.
R e m o v e t h e reservoir cap.
C o n n e c t a transparent tube to the bleeder valve and set
the other end i n t o a receptacle.
Pour brake fluid u p t o the FULL line.
P u m p the brake lever/pedal until air bubles stop coming
out f r o m t h e reservoir.
P u m p t h e brake lever/pedal i n t h e squeezed position.
Open t h e bleeder valve and tighten t h e bleeder valve.
Release the brake lever/pedal. Repeat this sequence un-
til air bubbles stop coming o u t from the bleeder valve.
NOTE:
D o n o t release t h e brake lever/pedal while t h e bleeder
valve is opened.
R e m o v e t h e brake pads.
NOTE: Pump the brake pedal several times to seat the brake
pads a f t e r reassembling.
Service limit
Front 2.5 mm (0.10 in)
Rear 4.0 mm (0.16 in)
CALIPER
ILWARNING
The use of any brake fluid except DOT4 brake fluid from
a sealed container can damage the brake system and lead
to an accident.
AWARNING
Brake fluid can be hazardous to humans and pets. Brake
fluid is harmful or fatal if swallowed, and harmful if it
comes in contact with your skin or eyes
Keep brake fluid away from children. Call your doctor im-
mediately if brake fluid is swallowed, and induce vomit-
ing. Flush eyes or skin with water if brake fluid gets in
eyes or comes in contact with skin.
A CAUTION
A WARNING
Fingers can get caught between piston and caliper body
when removing the piston.
not place your fingers on the piston when removing
the piston.
AWARNING
Fingers can get caught between piston and caliper body
when removing the piston.
1the piston.
Caliper Inspection
Measure the caliper cylinder bore with a small bore gauge.
Front: 2 7 . 0 0 0 - 2 7 . 0 5 0 m m ( 1 . 0 6 3 0 - 1 . 0 6 5 0 in)
Rear: 2 7 . 0 0 0 - 2 7 . 0 5 0 m m ( 1 . 0 6 3 0 - 1 . 0 6 5 0 in)
I n s p e c t the caliper cylinder f o r scuffing.
Caliper Cleaning
Flush t h e Caliper ports w i t h pressurized air.
Wa s h t h e caliper piston and cylinder w i t h fresh brake
fluid.
MASTER CYLINDER
A WARNING
Brake fluid can be hazardous to humans and pets. Brake
fluid is harmful or fatal if swallowed, and harmful if it
comes in contact with your skin or eyes.
Keep brake fluid away from children. Call your doctor im-
meiately if brake fluid is swallowed, and induce vomit-
ing. Flush eyes or skin with water if brake fluid gets in
eyes comes in contact with skin.
A WARNING
The use of any fluid except DOT4 brake fluid from a sealed
container can damage the brake system and lead to an
accident.
ACALITION
Spilled brake fluid can damage painted surface and plas-
tic parts.
Be careful not to spill any fluid when filling the brake fluid
reservoir. Wipe spilled fluid up immediately.
R e m o v e t h e dust seal b o o t
R e m o v e t h e circlip '
R e m o v e the washer , piston a n d spring .
Al CAUTION
Improper brake hose routing can damage the brake hose.
Reassembly
Reassemble the pin, w a s h e r and c o t t e r pin.
a F i t t h e return spring.
A p p l y grease to the brake pedal pivot bolt. Tighten the
bolt.
F i t t h e washer and cotter pin.
A d j u s t the brake pedal height. ( 2 - 1 2)
1
FRONT FORK AND STEERING 15-1
4
2 . 0 - 3 . 0 kg-m
2 . 0 - 3 . 0 kg-m
2 . 5 - 3 . 5 kg-m
Ipsro
\\, e
3.0 kg-m
15
0 . 9 - 1 . 1 kg-m s
5 . 0 - 5 . 5 kg-m
152 FRONT FORK AND STEERING
L o o s e n t h e f r o n t f o r k cap bolt ,D
L o o s e n t h e upper bracket clamp bolts ,
L o o s e n t h e l o w e r bracket clamp bolts .
R e m o v e t h e f r o n t forks.
R e m o v e t h e f r o n t fork cap bolt from t h e outer tube.
Clean t h e f r o n t forks.
R e m o v e t h e piston rod.
FRONT FORK AND STEERING 15-3
R e m o v e the d u s t seal ( ! .
R e m o v e the snap ring (
' )il)!):If)1911400,iiiii)Viai
15-4 FRONT FORK AND STEERING
1
FRONT FORK AND STEERING 155
Steering Inspection
I n s p e c t t h e bearing races f o r wear.
I n s p e c t t h e needle bearings f o r wear.
I n s p e c t the steering stem f o r distortion.
i,40100.q.,
0 9 9 4 1 - 7 4 9 1 0 S t e e r i n g bearing installer
F i t the upper and lower outer races with the special tool.
Steering Reassembly
A p p l y grease t o t h e bearings.
F i t the steering stem, upper bearing, dust seal and steer-
ing stem nut.
Ti g h t e n the steering s t e m n u t t o t h e specified torque.
Tightening torque : 4 0 - 5 0 N-rn
( 4 . 0 - 5 . 0 kg-m, 2 9 . 0 - 3 6 . 0 lb-ft)
Tightening torque : 8 0 - 1 0 0 Nm
( 8 . 0 - 1 0 . 0 kg-m, 5 8 . 0 - 7 2 . 5 lb-ft)
REAR SUSPENSION
4 . 8 - 7 , 2 kg-m
t r
8 . 0 - 1 2 . 0 kg-m
8 . 0 - 1 2 . 0 kg-m
6 . 0 - 1 0 . 0 kg-m
,F
16
Ctrl
16-2 REAR SUSPENSION
A WARNING
Releasing high pressure gas from the rear shock absorb-
er unit can be hazardous.
Place a rag over the valve and push the valve with a screw-
driver to release nitrogen gas. Do not use your finger to
push the valve, and direct the valve away from your face
-
and body.
Bearing Replacement.
R e m o v e the d u s t seals.
R e m o v e t h e circlip.
S e t a pipe, washer, bolt (M10) and nut (M10) as shown.
Ti g h t e n the n u t and remove t h e bearing.
-
Swing Arm Removal
R e m o v e t h e rear wheel. r 13
Remove the brake pedal. ( r r 1 4 - 11 )
Remove the rear brake hose f r o m t h e guides.
Remove the rear caliper. ( 1 4 - 6 )
Remove the drive chain.
R e m o v e t h e chain guide.
0 0 0 0 tee4
t t
Swing Arm Inspection
M e a s u r e the pivot shaft runout with a dial gauge and V-
blocks.
Bearing Replacement
Remove the bearings and oil seals with the special tools.
09923-74510 Bearing remover
09930-30102 Rotor remover slide shaft
A p p l y grease t o t h e bearings.
F i t the bearings with the special tool and a pipe, 2 4 mm
(0.9 in) in diameter and 7 . 5 m m ( 0 . 3 in) in length.
0 9 9 1 4 - 7 9 6 1 0 B e a r i n g / o i l seal installer
Tightening torque : 5 0 - 8 0 Nm
( 5 . 0 - 8 . 0 kg-m, 3 6 . 0 - 5 8 . 0 lb-ft)
16-6 REAR SUSPENSION
A p p l y grease t o t h e bearings.
F i t the bearings with the special tool and a pipe, 2 8 w i n
11.1 i n ) in diameter and 4 m m ( 0 . 2 in) in length.
0 9 9 1 4 - 7 9 6 1 0 B e a r i n g / o i l seal installer
F i t t h e circlips.
REAR SUSPENSION 16-7
Tightening torque:
A: 4 8 - 7 2 Nm ( 4 . 8 - 7 . 2 kg-m, 3 4 . 5 - 5 2 . 0 lb-ft)
B: 4 8 - 7 2 Nrn ( 4 . 8 - 7 . 2 kg-m, 3 4 . 5 - 5 2 . 0 lb-ft)
C: 8 0 - 1 2 0 Nm ( 8 . 0 - 1 2 . 0 kg-m, 5 8 . 0 - 8 7 . 0 lb-ft)
D: 6 0 - 1 0 0 Nm ( 6 . 0 - 1 0 . 0 kg-m, 4 3 . 5 - 7 2 . 5 lb-ft)
E: 8 0 - 1 2 0 Nm ( 8 . 0 - 1 2 . 0 kg-m, 5 8 . 0 - 8 7 . 0 lb-ft)
0.1
1
SERVICE DATA 17-1
SERVICE DATA
RADIATOR
STANDARD LIMIT
ITEM
110 kPa(1.1 kigicm', 1 6 psi)
1 pressure
Unit: mm (in) Except ratio
TRANSMISSION
STANDARD LIMIT
ITEM
2.652 (61/23)
Primary reduction ratio
3.846 (50/13)
Final reduction ratio
Gear ratios Low 2.285 (32/14)
2nd 1.733 (26/15)
3rd 1.375 (22116)
4th 1.090 (24/22)
Top 0.863 (19/22)
0.10-0.30 0.50
Shift fork to groove clearance No. & (0.004-0.012) (0.020)
- 4.8-4.9
Shift fork groove width No. & (0.189-0.193)
4.6-4.7
Shift fork thickness No. & No. (0.181-0.185)
DRIVE CHAIN
STANDARD LIMIT
ITEM
D.I.D.: D.I.D 5 2 0 V S
Drive chain Type TAKASAGO: RK520SMO
Links 114
323.8
20-pitch length (12.75)
45-55
Drive chain slack
(1.8-2.0)
ITEM SPECIFICATION
MIKUNI NTM38SS
Carburetor type
38 mm
Bore size
28C20
I.D. No.
16.0:
Float height
(M.J. #370
Main jet
(J.Ni 6AEL1-60-3rd
Jet needle
(N.J.) (R-1)
Needle jet
(CA.) 3.5
Cut-away - .. 4 - -
P (P.J.) # 5 0
SERVICE DATA 17.3
ITEM SPECIFICATION
By-pass (B.P.) 0.7 mm (0.028 in)
Pilot outlet (P.O.) 0.6 mm (0.024 in)
Air screw (A.S.) 1
Throttle cable play 0 . 5 - 1 . 0 mm ( 0 . 0 2 - 0 . 0 4 in)
ELECTRICAL Unit: mm (in)
ITEM SPECIFICATION NOTE
Ignition timing 75' - 1 r
Spark plug Type NGK: B8EGV UK, Australia
Type NGK: BR8EV Canada, France
0.5-0.6
Gap (0.020-0.024)
Spark performance Over 8 (0.3) at 1 atm.
Ignition coil resistance Primary 0-1 Q Terminal Ground
Secondary , 5 - 8 kii. Plug capGround
Magneto coil resistance 80-200 Q RG
1 1 0 0 - 2 0 0 c2 R/WB/W
TIRE PRESSURE
Front 7 0 - 11 0 kPa
& 0 . 7 - 1 . 1 kg/cm'
Rear 1 0 - 1 6 psi
SPECIAL TOOLS
sn,
18
1
I
191 WIRE, CABLE AND HOSE ROUTING
Magneto lead w i r e
CDI u n i t lead w i r e
Engine kill s w i t c h lead w i r e
Magneto lead w i r e
Radiator o v e r f l o w h o s e
Magneto lead w i r e
Radiator o v e r f l o w h o s e
Magneto lead w i r e
Exhaust valve breather hose
Radiator o v e r f l o w h o s e
WIRE, CABLE AND HOSE ROUTING 19-2
CLAMP
Do not bend t h e hoses
Carburetor over f l o w h o s e
Do n o t clamp this hose
Fuel hose
Carburator o v e r f l o w h o s e
CLAMP
CLAMP
CLAMP
Breather hose
19
19-3 WIRE, CABLE AND HOSE ROUTING
163rrinn
(0.63 0.12 in)
t
Master cylinder
Caliper
WIRE, CABLE AND HOSE ROUTING 1 9
Throttle cable
\ C l u t c h cable
Throttle cable
Clutch cable
I
19-5 WIRE, CABLEAND HOSE ROUTING
Radiator
hose
\ \
Exhaust valve
breather hose
Magneto lead w i r e
WIRE, CABLE AND HOSE ROUTING 19-6
I
20-1 SPECIFICATIONS
SPECIFICATIONS
DIMENSIONS A N D DRY M A S S
Overall l e n g t h 2 1 6 5 mrn ( 8 5 . 3 in)
Overall w i d t h 815 m m (32.1 in)
Overall height 12 5 0 mm (49.2 in)
Wheelbase 1 4 6 5 mm (57.7 in)
Ground clearance 360 m m ( 1 4 . 2 in)
Seat h e i g h t 960 m m ( 3 7 . 8 in)
Dry mass 98 k g ( 2 1 6 lbs)
ENGINE
Type Two-stroke water-cooled
Intake s y s t e m Crankcase reed valve
Number o f c y l i n d e r 1
Bore 67.0 m m ( 2 . 6 3 8 in)
Stroke 70.8 m m ( 2 . 7 8 7 in)
Piston displacement 249 c m
Corrected compression ratio 8.6110.2 : 1 (Low/High)
Carburetor M U N I NITM38SS, single
Air cleaner Polyurethane f o a m element
Starter system Primary k i c k
Lubrication system Fuel/oil premixture o f 2 0 : 1
TRANSMISSION
Clutch Wet multi-plate t y p e
Transmission 5-speed constant mesh
Gearshift p a t t e r n 1-down, 4 - u p
Primary r e d u c t i o n 2.652 ( 6 i / 2 3 )
Final reduction 3.846 ( 5 0 / 1 3 )
Gear ratios, L o w 2.285 ( 3 2 / 1 4 )
2nd 1.733 ( 2 6 / 1 5 )
3rd 1.375 ( 2 2 / 1 6 )
4th 1.090 ( 2 4 / 2 2 )
Top 0.863 (19/22)
Drive c h a i n DAIDO O L D . 5 2 0 V S or TA K A S A G O
RK520SMO 11 4 links
SPECIFICATIONS 20-2
CHASSIS
Front suspension Telescopic, pneumatic/coil spring, oil damped
compression damping force 2 1 - w a y adjustable
rebound damping force 2 1 - w a y adjustable.
Rear s u s p e n s i o n New link suspension system, spring pre-load ful-
ly adjustable, compression damping force
18-way adjustable, rebound damping force
21-way adjustable.
Steering a n g l e 4 5 ' (right & left)
Caster 62 3 0 '
Trail 113 m m ( 4 . 4 in)
Turning r a d i u s 2.3 m ( 7 . 5 ft)
Front b r a k e Disc brake, hydraulically operated
Rear brake Disc brake, hydraulically operated
Front t i r e s i z e 80/100-21 5 1 M
Rear t i r e size 11 0 / 1 0 0 - 1 8 6 4 M
Front f o r k s t r o k e 3 1 0 nn nn ( 1 2 . 2 in)
Rear wheel travel 324 m m ( 1 2 . 8 in)
ELECTRICAL
Ignition t y p e SUZUKI " P E I "
Ignition t i m i n g 7 . 5 BT.D.C. a t 9 0 0 0 r p m
Spark plug NGK B8EGV U K , Australia
NGK BR8EV F o r Canada and France
CAPACITIES
Fuel t a n k 11.0 L ( 2 . 9 US gal)
Front f o r k o i l 619 ml ( 2 0 . 9 US oz)
Transmission oil 6 5 0 ml ( 0 . 7 US/Imp qt)
Coolant 8 5 0 ml ( 0 . 9 US qt)
20
INDEX
ITEM PAGE
AIR CLEANER 2-4
BEARING INSPECTION, R E M O VA L A N D INSTALLATION 9-6
BRAKE DISC INSPECTION 14-4
BRAKE FLUID A I R BLEEDING 14-2
BRAKE FLUID REPLACEMENT 14-3
BRAKE PADS REPLACEMENT 14-3
BRAKE PEDAL R E M O VA L A N D REASSEMBLY 14-11
BRAKES 2-10
BREAK-IN 1-4
CALIPER 14-4
CARBURETOR 10-2
CDI U N I T INSPECTION 12-3
CLUTCH 2-7
CLUTCH PLATE INSPECTION 7-2
CLUTCH PLATE REASSEMBLING 7-3
CLUTCH PLATE R E M O VA L 7-2
CON-ROD INSPECTION 6-5
COOLANT 2-5
COOLANT REPLACEMENT 11-2
CRANKCASE REASSEMBLY 9-8
CRANKCASE SEPARATION 9-2
CRANKSHAFT INSPECTION 9-5
CRANKSHAFT INSTALLATION 9-7
CRANKSHAFT REMOVAL 9-3
CYLINDER HEAD INSPECTION 6-3
CYLINDER HEAD R E M O VA L 6-2
CYLINDER HEAD, CYLINDER A N D PISTON 2-8
CYLINDER INSPECTION 6-3
CYLINDER REASSEMBLING 6-6
CYLINDER R E M O VA L 6-2
DISC PLATE REPLACEMENT 13-4
DRIVE CHAIN A N D SPROCKETS 2-8
DRIVE CHAIN GUIDE, BUFFER, TENSIONER ROLLER 2-10
ELECTRICAL CIRCUIT 12-2
ENGINE DISMOUNTING A N D MOUNTING 5-1
ENGINE MOUNTING 5-2
EXHAUST VA LV E 2-8
EXHAUST VA LV E INSPECTION 6-5
EXHAUST VA LV E REASSEMBLING 6-6
EXHAUST VA LV E REMOVAL 6-3
FRONT A N D REAR WHEEL INSPECTION 13-2
FRONT FORK 2-12
FRONT FORK DISASSEMBLY 15-2
FRONT FORK DISMOUNTING 15-2
FRONT FORK INSPECTION 15-3
FRONT FORK MOUNTING 15-5
FRONT FORK REASSEMBLING 15-4
FRONT WHEEL DISASSEMBLY A N D REASSEMBLY 13-2
FUEL 1-2
FUEL LINE 2-7
GEARSHIFT LINKAGE INSPECTION 9-3
GEARSHIFT LINKAGE REASSEMBLY 9-9
ITEM P A G E
GEARSHIFT LINKAGE REMOVAL 9 - 2
IGNITION COIL INSPECTION 1 2 - 2
INSPECTION BEFORE PRACTICE 2 - 1
INSPECTION BEFORE RACE 2 - 1
KICK STARTER INSPECTION 8 - 2
KICK STARTER REASSEMBLY 8 - 3
KICK STARTER REMOVAL 8 - 2
LOCATION OF PARTS 1 - 1
LUBRICATION 2 - 1 4
MACHINE TUNING, CARBURETOR 4 - 1
MACHINE TUNING, FORNT FORK 4 - 9
MACHINE TUNING, REAR SUSPENSION 4 - 1 2
MAGNETO ROTOR A N D S TATO R R E M O VA L A N D REASSEMBL 1 2 - 4
MASTER CYLINDER 1 4 - 8
OIL SEAL INSPECTION, R E M O VA L A N D INSTALLATION 9 - 5
OPERATING INSTRUCTIONS 1 - 3
PERIODIC MAINTENANCE CHART 2 - 2
PISTON A N D PISTON RING INSPECTION 6 - 4
PISTON RING A N D PISTON REASSEMBLING 6 - 5
PRIMARY DRIVEN GEAR A S S Y INSPECTION 7 - 4
PRIMARY DRIVEN GEAR A S S Y REASSEMBLY 7 - 4
PRIMARY DRIVEN GAER A S S Y R E M O VA L 7 - 3
RACK A N D PINION INSPECTION 7 - 3
RADIATOR 1 1 - 2
RADIATOR CAP INSPECTION 1 1 - 2
REAR SHOCK ABSORBER DISPOSAL 1 6 - 3
REAR SHOCK ABSORBER INSPECTION 1 6 - 3
REAR SHOCK ABSORBER REASSEMBLY 1 6 - 4
REAR SHOCK ABSORBER REMOVAL 1 6 - 2
REAR SUSPENSION 2 - 1 2
REAR SUSPENSION LINKAGE 1 6 - 6
REAR SUSPENSION LINKAGE REASSEMBLING 1 6 - 7
REAR WHEEL R E M O VA L A N D REASSEMBLY 1 3 - 2
REED VA LV E 1 0 - 3
SERVICE D ATA 1 7 - 1
SPARK PLUG 2 - 3
SPECIAL TOOLS A N D MATERIAL 1 8 - 1
STATOR COIL INSPECTION 1 2 - 4
STEERING 2 - 1 3
STEERING BEARING REPLACEMENT 1 5 - 6
STEERING REASSEMBLY 1 5 - 7
STEERING R E M O VA L 1 5 - 5
SWING A R M 1 6 - 4
THROTTLE CABLE 2 - 7
TIGHTENING TORQUE 2 - 1 5
TRANSMISSION 1 - 4
TRANSMISSION INSPECTION 9 - 4
TRANSMISSION OIL 2 - 5
TRANSMISSION REASSEMBLY 9 - 7
TRANSMISSION R E M O VA L 9 - 3
TROUBLESHOOTING, ENGINE 3 - 1
TROUBLESHOOTING, CHASSIS 3 - 4
ITEM PAGE
WATER PUMP
11-3
WHEEL BEARING R E M O VA L A N D REASSEMBLY 13-3
WHEELS A N D TIRES 2-13
WIRE, CABLE A N D HOSE ROUTING 19-1
r',57
x.;
Al October, 1990 C ) E N
Printed in Japan
- -4