- •Generalinformation
- •Informationlabels
- •Periodicmaintenance
- •Valveclearance...................................................................2-8
- •Valveclearance
- •Inspectevery24000km(15000miles,24months).
- •IrWtl09900-20803:Thicknessgauge
- •09913-10750:Adaptor
- •Ventitsshortoropencircuit.
- •Iacautioni
- •09900-22302:Plastigauge
- •09900-22403:Smallboregauge{18-35mm)
- •09916-34542:Reamerhandle
- •09916-43220:Attachment(2)
- •Initialseatcut
- •15Mm(0.6in)fromthepistonskirtend.
- •Installation
- •1Root109913-70210:Bearinginstallerset
- •Inspectionandcleaning
- •09900-20701:Magneticstand
- •09900-21304:V-block(100mm)
- •09900-22401:Smallboregauge(1o-18mm)
- •Inspection
- •Iacautioni
- •Initial:18n·m(1.8kgf·m,13.0lb-ft)Final:32n·m(3.2kgf·m,23.0lb-ft)
- •Becareful!nottodamagethecylinderwallbytheconrod.
- •1L1molybdenumoilsolution
- •Iacautioni
- •Initial:15n·m(1.5kgf·m,11.0lb-ft)Final:90°(1/.Iturn)
- •Inglightly.
- •Initial:18n·m(1.8kgf·m,13.0lb-ft)Final:32n·m(3.2kgf·m,23.0lb-ft)
- •Usethenewgaskettopreventoilleakage.
- •FlSystemandintakeairsystem
- •Voltagecheck
- •VoltageBetween:
- •VoltageBetween:
- •Injectiontime(injectionvolume)
- •Various
- •ISensors
- •IUltimate
- •Injectionstopcontrol
- •Injectiontiming
- •Intakeairsystem
- •Injection"yes""'yes"
- •Inspection
- •1Root109900-25008:Multicircuittester
- •1Rq109900-25008:Multicircuittester
- •Inspection
- •Irk!09900-25008:Multicircuittester
- •1Rkib09900-25008:Multicircutitester
- •Construction
- •Inspection
- •1Root109930-11960:Torxwrench
- •Inspection
- •Iapsensorinspection
- •Iapsensorremoval/installation
- •28ForTPsensorsettingprocedure.
- •Iatsensorinspection
- •Iatsensorremoval/installation
- •Inspection
- •Installation
- •Inspection
- •..Takespecialcarewhenhandlingthetemperature-sen• sor.Itmaycausedamageifitgetsasharpimpact.
- •Installation
- •Inspection
- •Installation
- •Inspection
- •Usethenew0-ringstopreventenginecoolantleakage.
- •Icamdrivechaini
- •Istarterclutchi
- •Chassis
- •Installation
- •Installation
- •Inspectionanddisassembly
- •09900-20701:Magneticstand
- •Inspection
- •Itemn·mkgf·mlb-ft
- •Inspection
- •09940-14960:Steeringstemnutwrenchsocket
- •Inspectionanddisassembly
- •09940-14960:Steeringstemnutwrenchsocket
- •09940-14960:Steeringstemnutwrenchsocket
- •Itemn·mkgf-mlb-ft
- •Inspectionanddisassembly
- •09900-20701:Magneticstand
- •Inspection
- •Inspectionanddisassembly
- •Ingsolventsuchasgasoline,kerosineortheothers.
- •Iw)lllllu.D
- •Inspection
- •Valveinspection
- •Valveinstallation
- •Electricalsystem
- •IIncorrectt
- •Ignitioncoil
- •Ignitionsystem
- •0 Sensor
- •ICorrectIncorrect
- •Inspection
- •Ventanelectricshockwhiletesting.
- •Ignitioncoiuplugcapresistance
- •1Riot109900-25008:Multicircuittesterset
- •Inspection
- •09930-11940:Bitholder
- •Initialcharging
- •Iacautioni
- •Iacautioni
- •Insideofthebodycowling
- •Itemstd/spec.Limit
- •Itemstd/spec.Limit
- •Itemstd/spec.Limit
- •Itemstd/spec.Note
- •Itemstd/spec.Note
- •11IiiIu
- •Iatsensor
- •Suzukimotorcorporation
Icamdrivechaini
.••.•..
,,,•,'•
SUB-GALLERY
Istarterclutchi
.•.•.
•\
i
OILHOSE#1PISTONCOOLING#2PISTONCOOLING13PISTONCOOLING~4PISTONCOOLINGOILJETOILJETOILJETOILJET
'.'....
....TENSIONADJUSTER
,••'
'•'
."••.
;•I
CAMCHAIN
I
111PISTONANO#2PISTONAND#3PISTONAND#4PISTONAND••
.
CYLINDERWALLCYLINDEAWALLCYLINDERWALLCYLINDERWALL'.''
',',
',,'',,'',,
n''
''
12CRANKSHAFT |
#3CRANKSHAFT |
#4CRANKSHAFT |
115CRANKSHAFT |
JOURNALBEARING |
JOURNALBEARING |
JOURNALBEARING |
JOURNALBEARING |
'''I
-
#1CRANKPIN
il2CRANKPIN
#3CRANKPIN
#4CRANKPIN
BEARING
BEARING
BEARING
BEARING
.
ORIFlCE',
''.'
....
GENERATOR,•,
MAIN-GALLERY
OILPRESSURESWITCH
OILPUMP
OILCOOLERCOUITTERSHAFT
~----~-----1LEFT-SIDE
BEARING
DAIVESHAFTRIGHT-SIDEBEARING
OILFILTER
CLUTCHPUSHPRIMARYDRIVEN
PIECEGEARBEARING......---~---.
...,,•.
COUNTERSHAFTGEARSANOBUSHINGS
DAIVESHAFTGEARSANDBUSHINGS
CLUTCH.PLATES••
..•.OILSTiRAINER
11
,,,,,IIt\;"
_----=iJr~'
r\-_.::--=-=--------==----O_::l::_:::L::--PA_N_---==--~--.........,.._..--==-=~=--
ENGINELUBRICATIONSYSTEM
J
....
-
VIEWOFA
Chassis
EXTERIORPARTS6-2
-
FASTENERREMOVALANDREINSTALLATION
6-
2
SCREEN........................................................................................
6-
2
BODYCOWLINGCOVER......
6-
3
RIGHTANDLEFTUNDERCOWLINGS
6-
3
BODYCOWLING........
6-
4
RIGHTANDLEFTAIRINTAKEPIPES
6-
5
COWLINGBRACE
6-
5
FRONTSEAT................................................................................
6-
6
REARSEATANDSEATTAILCOVER........................................
6-
6
FRAMECOVER.............................................................................
6-
6
FRONTWHEEL6-7
REMOVAL...................................................................................... |
6-8 |
INSPECTIONANDDISASSEMBLY............................................. |
6-8 |
REASSEMBLYANDREMOUNTING |
6-10 |
FRONTFORK...................................................................................6-13 |
|
CONSTRUCT/ON.......................................................................... |
6-13 |
REMOVALANDDISASSEMBLY................................................. |
6-14 |
INSPECTION |
6-17 |
REASSEMBLYANDREMOUNTING........................................... |
6-18 |
SUSPENSIONSETTING............................................................... |
6-23 |
STEERINGDAMPER |
6-24 |
CONSTRUCTION.......................................................................... |
6-24 |
REMOVAL...................................................................................... |
6-24 |
INSPECTION................................................................................. |
6-24 |
REMOUNTING............................................................................... |
6-24 |
STEERING |
6-25 |
CONSTRUCTION.......................................................................... |
6-25 |
REMOVALANDDISASSEMBLY................................................. |
6-25 |
INSPECTIONANDDISASSEMBLY............................................. |
6-27 |
REASSEMBLYANDREMOUNTING |
6-27 |
STEERINGTENSIONADJUSTMENT.......................................... |
6-29 |
HANDLEBAR................................................................................... |
6-30 |
CONSTRUCTION.......................................................................... |
6-30 |
REMOVALANDDISASSEMBLY |
6-30 |
REASSEMBLYANDREMOUNTING........................................... |
6-31 |
REARWHEEL |
6-33 |
CONSTRUCT/ON.......................................................................... |
6-33 |
REMOVAL...................................................................................... |
6-34 |
INSPECTIONANDDISASSEMBLY............................................. |
6-35 |
REASSEMBLYANDREMOUNTING |
6-37 |
REARSHOCKABSORBER............................................................ |
6-41 |
CONSTRUCTION.......................................................................... |
6-41 |
REMOVAL...................................................................................... |
6-42 |
INSPECTION |
6-42 |
REARSHOCKABSORBERSCRAPPINGPROCEDURE......... |
6-43 |
REMOUNTING............................................................................... |
6-43 |
SUSPENSIONSETTING............................................................... |
6-44 |
CONSTRUCTION..........................................................................6-7
-
REARSUSPENSION
6-45
CONSTRUCTION..........................................................................
6-45
REMOVAL......................................................................................
6-46
INSPECTIONANDDISASSEMBLY.............................................
6-48
REASSEMBLY..............................................................................
6-50
REMOUNTING...............................................................................
6-52
FINALINSPECTIONANDADJUSTMENT..................................
6-53
FRONTBRAKE................................................................................
6-54
CONSTRUCTION..........................................................................
6-54
BRAKEPADREPLACEMENT.....................................................
6-55
BRAKEFLUIDREPLACEMENT.................................................
6-55
CALIPERREMOVALANDDISASSEMBLY................................
6-56
CALIPERINSPECTION................................................................
6-57
CALIPERREASSEMBLYANDREMOUNTING..........................
6-57
BRAKEDISCINSPECTION.........................................................
6-58
MASTERCYLINDERREMOVALANDDISASSEMBLY.............
6-59
MASTERCYLINDERINSPECTION.............................................
6-60
MASTERCYLINDERREASSEMBLYANDREMOUNTING.......
6-60
REARBRAKE..................................................................................
6-62
CONSTRUCTION..........................................................................
6-62
BRAKEPADREPLACEMENT.....................................................
6-63
BRAKEFLUIDREPLACEMENT.................................................
6-63
CALIPERREMOVALANDDISASSEMBLY................................
6-64
CALIPERINSPECTION................................................................
6-65
CALIPERREASSEMBLYANDREMOUNTING..........................
6-65
MASTERCYLINDERREMOVALANDDISASSEMBLY.............
6-66
MASTERCYLINDERINSPECTION.............................................
6-67
MASTERCYLINDERREASSEMBLYANDREMOUNTING.......
6-67
TIREANDWHEEL............................................................................
6-68
TIREREMOVAL
6-68
INSPECTION
6-68
VALVEINSPECTION.....................................................................
6-69
VALVEINSTALLATION................................................................
6-69
TIREINSTALLATION....................................................................
6-69
BALANCERWEIGHT...................................................................
6-70
EXTERIORPARTS
FASTENERREMOVALANDREINSTALLATION
FASTENER@
REMOVAL
•Depresstheheadoffastenerscenterpiece1).
•Pulloutthefastener.
