Valveclearance

Inspectevery24000km(15000miles,24months).

•Removetherightundercowling.(c::::T6-3)

•Removethefrontandrearseats.(c::::T6-6)

•Liftandsupportthefueltank.(c::::T4-52)

•Removethesparkplugs.(c::::T2-5)

•Removethecylinderheadcovers.(c::J'3-15)

Thevalveclearancespecificationisdifferentforintakeandex•

haustvalves.

Valveclearancemustbecheckedandadjusted,1)atthetimeofperiodicinspection,2)whenthevalvemechanismisserviced,and3)whenthecamshaftsaredisturbedbyremovingthemforservicing.

~Valveclearance(whencold):

Standard:IN.:0.10-0.20mm(0.004-0.008in)EX.:0.20-0.30mm(0.008-0.012in)

_NOTE:

_{•Thecammustbeatpositions,®or@,inordertocheckthe}

_{valveclearance,ortoadjusttappetclearance.Clearanceread•}^®®

ingsshouldnotbetakenwiththecaminanyotherposition

thanthesetwopositions.

*TheclearancespecificationisforCOLDstate.

wToturnthecrankshaftforclearancechecking,besuretouseawrench,androtateinthenormalrunningdirection.Allsparkplugsshouldberemoved.

_{•Removethevalvetiminginspectioncap(D.}

-

•Turnthecrankshafttobringthe'Top"lineonthestarterclutchtotheindexmarkandalsotobringthenotches~ontheleft

_{endsofbothcamshafts(ExandIn)tothepositionsasshown.}

_®

•Inthiscondition,readthevalveclearanceatthevalves@(InandExofNo.4cylinder,ExofNo.3andInofNo.2).

•Iftheclearanceisoutofspecification,adjusttheclearance.(CT2-10)

IrWtl09900-20803:Thicknessgauge

•Turnthecrankshaft360degrees(onerotation)tobringthe

"TOP"lineonthestarterclutchtotheindexmarkofvalvetim•

inginspectionholeandalsotobringthenotches®tothepositionasshown.

•Readtheclearanceattheremainingvalves©andadjustthe

_{clearanceifnecessary.(CT2-10)}

Front

¢::i

Camposition

Notch®position

_{ExhaustCamshaftI}ntakeCamshaft

^@<-Front^@<-Front@

^t)<-Front@<-Front@

VALVECLEARANCEADJUSTMENT

Theclearanceisadjustedbyreplacingtheexistingtappetshimbyathickerorthinnershim.

•Removetheintakeorexhaustcamshafts.(c::::T'3-16)

•Removethetappetandshimbyfingersormagnetichand.

•Checkthefiguresprintedontheshim.Thesefiguresindicatethethicknessoftheshim,asillustrated.

•Selectareplacementshimthatwillprovideaclearancewithinthespecifiedrange.Forthepurposeofthisadjustment,atotalof25sizesoftappetshimareavailablerangingfrom1.20to

2.20mminstepsof0.05mm.Fittheselectedshimtothevalvestemend,withnumberstowardtappet.Besuretocheckshimsizewithmicrometertoensureitssize.Refertothetap•petshimselectiontable(c::::T'2-11,2-12)fordetails.

NOTE:

*Besuretoapplyengineoiltotappetshimtopandbottomfaces.

*Whenseatingthetappetshim,besuretofacefigureprintedsurfacetothetappet.

IACAUTIONI

Reinstallthecamshaftsasthespecifiedmanner.

(c:::T3-91)

•Afterreplacingthetappetshimandcamshafts,rotatetheen•ginesothatthetappetisdepressedfully.Thiswillsqueezeoutoiltrappedbetweentheshimandthetappetthatcouldcauseanincorrectmeasurement,thenchecktheclearanceagaintoconfirmthatitiswithinthespecifiedrange.

•Afterfinishingthevalveclearanceadjustment,reinstallthefol•

_lowingitems.

Page

•Cylinderheadcover3-96

*Sparkplugandplugcap2-7

*Valvetiminginspectionplug3-96

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ENGINEOILANDOILFILTER

(ENGINEOIL)

Replaceinitiallyat1000km(600miles,1month)andevery6000km(4000miles,6months)thereafter.

(OILFILTER)

Replaceinitiallyat1000km{600miles,1month)andevery18000km(11000miles,18months)thereafter.

Oilshouldbechangedwhiletheengineiswarm.Oilfilterreplace•mentattheaboveintervals,shouldbedonetogetherwiththeengineoilchange.

ENGINEOILREPLACEMENT

•Keepthemotorcycleupright.

•Placeanoilpanbelowtheengine,anddrainoilbyremovingtheoildrainplugG)andfillercap(2).

•TightenthedrainplugG)tothespecifiedtorque,andpourfreshoilthroughtheoilfiller.Theenginewillholdabout2.8L(3.0/

_I

2.5US/Impqt)ofoil.UseanAPIclassificationofSForSGoilwithSAE1OW/40viscosity.

(!)Oildrainplug:23N·m(2.3kgf·m,16.5lb-ft)

•Startuptheengineandallowittorunforseveralminutesatidlingspeed.

•Turnofftheengineandwaitaboutthreeminutes,thenchecktheoillevelthroughtheinspectionwindow.Ifthelevelisbelowmark"t,',addoilto"F"level.Ifthelevelisabovemark"P',drainoilto"F"level.

2·14PERIODICMAINTENANCE_-

OILFILTERREPLACEMENT

•Draintheengineoilasdescribedintheengineoilreplacementprocedure.

•RemovetheoilfilterG)usingthespecialtool.

1HiOt109915-40610:Oilfilterwrench

•Applyengineoillightlytothegasketofthenewoilfilterbeforeinstallation.

•Installthenewoilfilter.Turnitbyhanduntilyoufeelthattheoilfiltergaskethascontactedtheoilfiltermountingsurface.Then,tightentheoilfiltertwofullturnsusingthespecialtool.

NOTE:

Toproperlytightentheoilfilter,usethespecialtool.Nevertightentheoilfilterbyhand.

•Addnewengineoilandchecktheoillevelasdescribedintheengineoilreplacementprocedure.

E NECESSARYAMOUNTOFENGINEOIL:Oilchange:2.8L(3.0/2.5US/Impqt)

Oilandfilterchange:3.1L(3.3/2.7US/Impqt)Engineoverhaul:3.4L(3.6/3.0US/Impqt)

IACAUTIONI

ONLYUSEAGENUINESUZUKIMOTORCYCLEOILFIL•TER.

Othermanufacturer'soilfiltersmaydifferinthreadspeci•fications(threaddiameterandpitch),filteringperfor•manceanddurabilitywhichmayleadtoenginedamageoroilleaks.Also,donotuseagenuineSuzukiautomo•bileoilfilteronthismotorcycle.

_-

Aftercontactingthegasket,tighten2turns.

FUELHOSE

Inspectevery6000km(4000miles,6months).Replaceevery4years.

Inspectthefuelhose<Dfordamageandfuelleakage.Ifanydefectsarefound,thehosesmustbereplaced.

ENGINEIDLESPEED

Inspectinitiallyat1000km(600miles,1month)andevery6000km(4000miles,6months)thereafter.

NOTE:

Makethisadjustmentwhentheengineishot.

•Starttheengine,turnthethrottlestopscrewandsettheengineidlespeedasfollows.

~Engineidlespeed:1300±100rpm

THROTTLEVALVESYNCHRONIZATION

Inspectinitiallyat1000km(600miles,1month)(E-33only)andevery12000km(7500miles,12months).(O"4·73)

THROTTLECABLEPLAY

Inspectinitiallyat1000km(600miles,1month)andevery6000km(4000miles,6months)thereafter.

Adjustthethrottlecableplay®asfollows.

MINORADJUSTMENT

tststep:

•LoosenthelocknutCDofthethrottlereturningcable(2)andfullyturnintheadjuster®·

_-

2ndstep:

•Loosenthelocknut®ofthethrottlepullingcable@.

•Turntheadjuster®inoroutuntilthethrottlecableplay(atthethrottlegrip)®isbetween2.0-4.0mm(0.08-0.16in).

•Tightenthelocknut®whileholdingtheadjuster®·

6Throttlecableplay®:2.0-4.0mm(0.08-0.16in)

3rdstep:

•Whileholdingthethrottlegripatthefullyclosedposition,slowlyturnouttheadjuster®ofthethrottlereturningcable~untilresistanceisfelt.

•Tightenthelocknut(Dwhileholdingtheadjuster®·

AWARNING

Aftertheadjustmentiscompleted,checkthathandlebarmovementdoesnotraisetheengineidlespeedandthatthethrottlegripreturnssmoothlyandautomatically.

NOTE:

Majoradjustmentcanbemadeatthethrottlebodysideadjuster.

MAJORADJUSTMENT

•Liftandsupportthefueltankwithitspropstay.(L?"4-52)

•LoosenthelocknutsCDofthethrottlereturningcable(2).

•Turnthereturningcableadjuster®toobtainpropercableplay.

•Loosenthelocknuts@ofthethrottlepullingcable®·

•Turnthepullingcableadjuster@inoroutuntilthethrottlecableplay®shouldbe2.0-4.0mm(0.08-0.16in)atthethrottlegrip.

•Tightenthelocknuts©securelywhileholdingtheadjuster

®·

~Throttlecableplay®:2.0-4.0mm(0.08-0.16in)

•Whileholdingthethrottlegripatthefullyclosedposition,slowlyturnthereturningcableadjuster®toobtainacableslack@of1.0mm(0.04in).

•TightenthelocknutsCDsecurely.

.AWARNING

Aftertheadjustmentiscompleted,checkthathandle•barmovementdoesnotraisetheengineidlespeedandthatthethrottlegripreturnssmoothlyandautomati•cally.

CLUTCH

InspectEvery6000km(4000miles,6months).

•Removetheleftundercowling.(C76·3)

•TurnintheadjusterCDallthewayintotheclutchleverassem•

bly.

•Removetheclutchreleasecover.

•Loosenthelocknut(Z)andturnouttheadjustingscrew®twoorthreerotations.

•Fromthatposition,slowlyturnintheadjustingscrew®tofeelresistance.

•Fromthisposition,turnouttheadjustingscrew®J.irotations,andtightenthelocknut~-

^{•Loosenthelocknut@,andturnthecableadjuster(IDtoob•}

tain10-15mm(0.4-0.6in)offreeplay®attheclutchleverend.

•Tightenthelocknuts®·

~ Clutchleverplay@:10-15mm(0.4-0.6in)Clutchreleasescrew:1.4turnsout

COOLINGSYSTEM

Inspectevery6000km(4000miles,6months).Replaceenginecoolantevery2years.

ENGINECOOLANTLEVELCHECK

•Keepthemotorcycleupright.

•Checktheenginecoolantlevelbyobservingthefullandlowerlinesontheenginecoolantreservetank.

®Fullline@Lowerline

•Ifthelevelisbelowthelowerline,removetheleftundercowl·ing(c::::T6·3),andaddenginecoolanttothefulllinefromtheenginecoolantreservetankfiller.

ENGINECOOLANTCHANGE

•Removetheundercowling.(c::::T6-3)

•RemovetheradiatorcapCD.

•Drainenginecoolantbydisconnectingtheradiatorhose~

fromthepump.

AWARNING

*Donotopentheradiatorcapwhentheengineishot,asyoumaybeinjuredbyescapinghotliquidorvapor.

*Enginecoolantmaybeharmfulifswallowedorifit

comesincontactwithskinoreyes.Ifenginecoolantgetsintotheeyesorincontactwiththeskin,flushthoroughlywithplentyofwater.Ifswallowed,inducevomitingandcallphysicianimmediately!

•Flushtheradiatorwithfreshwaterifnecessary.

•Connecttheradiatorhose(2)securely.

•Pourthespecifiedenginecoolantuptotheradiatorinlet.

-m]Enginecoolantcapacity(withoutreservoir):

2150ml(2.3/1.9Us/Impqt)

•Bleedtheairfromtheenginecoolantcircuitasfollowingpro•

cedure.(c::::T2-19)

ENGINECOOLANTINFORMATION:c::::TS-2

AIRBLEEDINGTHECOOLINGCIRCUIT

•Addenginecoolantuptotheradiatorinlet.

•Supportthemotorcycleupright.

•Slowlyswingthemotorcycle,rightandleft,tobleedtheairtrappedinthecoolingcircuit.

•Addenginecoolantuptotheradiatorinlet.

•Startuptheengineandbleedairfromtheradiatorinletcom•

pletely.

•Addenginecoolantuptotheradiatorinlet.

•Repeattheaboveprocedureuntilbleednoairfromtheradia•

torinlet.

•LoosentheairbleedingboltCDandchecktheenginecoolantflowout.

(!JAirbleedingbolt:5.5N·m(0.55kgf·m,4.0lb~ft)

•Closetheradiatorcapsecurely.

•Afterwarmingupandcoolingdowntheengineseveraltimes,addtheenginecoolantuptothefulllevelofthereservetank.

IACAUTIONI

Repeattheaboveprocedureseveraltimesandmakesurethattheradiatorisfilledwithenginecoolantuptothereservetankfulllevel.

GEnginecoolantcapacity(Withoutreservoir):

2150ml(2.3/1.9US/Impqt)

RADIATORHOSES

•Removetheundercowlings.(c:::::7'6-3)

•Checktoseetheradiatorhosesforcrack,damageorenginecoolantleakage.

•Ifanydefectsarefound,replacetheradiatorhoseswithnewones.

DRIVECHAIN

Inspectinitiallyat1000km(600miles,1month)andevery6000km(4000miles,6months)thereafter.Cleanandlubricateevery1000km(600miles).

Visuallycheckthedrivechainforthepossibledefectslistedbe•low.(Supportthemotorcyclebyajackandawoodenblock,turntherearwheelslowlybyhandwiththetransmissionshiftedtoNeutral.)

*Loosepins*Excessivewear

*Damagedrollers*Improperchainadjustment

*Dryorrustedlinks*Missing0-ringseals

*Kinkedorbindinglinks

Ifanydefectsarefound,thedrivechainmustbereplaced.

NOTE:

Whenreplacingthedrivechain,replacethedrivechainandsprocketsasaset.

CHECKING

•Removetheaxlecotterpin.(ForE-03,28and33)

•LoosentheaxlenutG).

•Loosenthechainadjusterlocknuts(?.).

•Loosenthetorquelinknut(Rear)@.

_{•Tensethedrivechainfullybyturningbothchainadjusters@.}

•Countout21pins(20pitches)onthechainandmeasurethedistancebetweenthetwopoints.Ifthedistanceexceedstheservicelimit,thechainmustbereplaced.

•Drivechain20-pitchlength:

Servicelimit:319.4mm(12.57in)

123

r,J...t...l..~

ADJUSTING

•LoosenortightenbothchainadjusternutsG)untilthereis20

-30mm(0.8-1.2in)ofslackatthemiddleofthechainbetweentheengineandrearsprocketsasshown.Therefer•

^{encemarks®onbothsidesoftheswingarmandtheedgeof}

eachchainadjustermustbealignedtoensurethatthefrontandrearwheelsarecorrectlyaligned.

DDrivechainslack:

Standard:20-30mm(0.8-1.2in)

•Placethemotorcycleonitsside-standforaccurateadjustment.

•Afteradjustingthedrivechain,tightentheaxlenut(?)andthetorquelinknut(Rear)@tothespecifiedtorque.

•Tightenbothchainadjusternuts@securely.

(!]Rearaxlenut:110N·m(11.0kgf·m,79.6lb-ft)

......................ForE-03,-28,-33

120N·m(12.0kgf·m,86.8lb-ft)

......................Fortheothers

Torquelinknut(Rear):34N·m(3.4kgf·m,24.6lb-ft)

•Installanewcotterpin.(ForE-03,28,33)

•Recheckthedrivechainslackaftertighteningtheaxlenut.

CLEANINGANDLUBRICATING

•Cleanthedrivechainwithkerosine.Ifthedrivechaintendstorustquickly,theintervalsmustbeshortened.

IACAUTIONI

Donotusetrichloroethylene,gasolineoranysimilarsolvent.Thesefluidshavetoogreatadissolvingpowerforthischainandtheycandamagethe0-rings.Useonlykerosinetocleanthedrivechain.

•Afterwashinganddryingthechain,oilitwithaheavyweightmotoroil.

IACAUTIONI

*Donotuseanyoilsoldcommerciallyas"drivechainoil".Suchoilcandamagethe0-rings.

*ThestandarddrivechainisaRK525SMOZ6Suzukirecommendstousethisstandarddrivechainasareplacement.

20-30mm

(0.8-1.2in)

BRAKE

(BRAKE)

Inspectinitiallyat1000km(600miles,1month)andevery6000km(4000miles,6months)thereafter.

(BRAKEHOSEANDBRAKEFLUID)

Inspectevery6000km(4000miles,6months).Replacehosesevery4years.Replacefluidevery2years.

BRAKEFLUIDLEVELCHECK

•Keepthemotorcycleuprightandplacethehandlebarsstraight.

•Checkthebrakefluidlevelbyobservingthelowerlimitlinesonthefrontandrearbrakefluidreservoirs.

•Whenthelevelisbelowthelowerlimitline,replenishwithbrakefluidthatmeetsthefollowingspecification.

~SpecificationandClassification:DOT4

AWARNING

*Thebrakesystemofthismotorcycleisfilledwithaglycol-basedbrakefluid.Donotuseormixdifferenttypesoffluidsuchassilicone-basedandpetroleum•basedfluids.Donotuseanybrakefluidtakenfromold,usedorunsealedcontainers.Neverre-usebrakefluidleftoverfromthelastservicingorstoredforalongperiodoftime.

*Brakefluid,ifitleaks,willinterferewithsaferunning

andimmediatelydiscolorpaintedsurfaces.Checkthebrakehosesandhosejointsforcracksandfluidleak•agebeforeriding.

BRAKEPADSFRONTBRAKE

^{•Theextentofbrakepadwearcanbecheckedbyobserving}

thegroovedlimitline®onthepad.Whenthewearexceedsthegroovedlimitline,replacethepadswithnewones.(c::::t6-55)

.ACAUTIONI

Replacethebrakepadsasaset,otherwisebrakingper•

_{formancewillbeadverselyaffected.}

-rr-

_'

^'

REARBRAKE

•Theextentofbrakepadwearcanbecheckedbyobservingthegroovedlimitline®onthepad.Whenthewearexceedsthegroovedlimitline,replacethepadswithnewones.(c:::?'6·63)

IACAUTIONI

Replacethebrakepadsasaset,otherwisebrakingper•

_{formancewillbeadverselyaffected.}

_-

=

'

BRAKEPEDALHEIGHT

•Loosenthelocknut<D.

•Turnthepushrod(2)untilthebrakepedalis50-60mm(2.0

-2.4in)®belowthetopofthefootrest.

•Tightenthelocknut<Dsecurely.

~Rearbrakemastercylinderrodlocknut:

_{18N·m(1.8kgf·m,13.0lb-ft)}

RBrakepedalheight®:

Standard:50-60mm(2.0-2.4in)

BRAKELIGHTSWITCH

•Adjusttherearbrakelightswitchsothatthebrakelightwillcomeonjustbeforepressureisfeltwhenthebrakepedalisdepressed.

AIRBLEEDINGTHEBRAKEFLUIDCIRCUIT

Airtrappedinthebrakefluidcircuitactslikeacushiontoabsorbalargeproportionofthepressuredevelopedbythemastercyl•inderandthusinterfereswiththefullbrakingperformanceotthebrakecaliper.Thepresenceofairisindicatedby"sponqiness"ofthebrakeleverandalsobylackofbrakingforce.Consideringthedangertowhichsuchtrappedairexposesthemachineandrider,itisessentialthatafterremountingthebrakeandrestoringthebrakesystemtothenormalcondition,thebrakefluidcircuitbepurgedofairinthefollowingmanner:

FRONTBRAKE

•Fillthemastercylinderreservoirtothetopoftheinspectionwindow.Replacethereservoircaptopreventdirtfromenter•ing.

•Attachahosetotheairbleedervalveandinsertthefreeendofthehoseintoareceptacle.

_-

-

-

•Squeezeandreleasethebrakeleverseveraltimesinrapidsuccessionandsqueezetheleverfullywithoutreleasingit.Loosentheairbleedervalvebyturningitaquarterofaturnsothatthebrakefluidrunsintothereceptacle,thiswillre•movethetensionofthebrakelevercausingittotouchthehandlebargrip.Then,closetheairbleedervalve,pumpandsqueezethelever,andopenthevalve.Repeatthisprocessuntilfluidflowingintothereceptaclenolongercontainsairbubbles.

NOTE:

Whilebleedingthebrakesystem,replenishthebrakefluidinthereservoirasnecessary.Makesurethatthereisalwayssomefluidvisibleinthereservoir.

•Closetheairbleedervalveanddisconnectthehose.Fillthereservoirwithbrakefluidtothetopoftheinspectionwindow.

C!JAirbleedervalve:8N·m(0.8kgf·m,6.0lb-ft)

ACAUTIONI

Handlebrakefluidwithcare:thefluidreactschemicallywithpaint,plastics,rubbermaterials,etc.

-

REARBRAKE

•Bleedairfromtherearbrakesystemasthesamemanneroffrontbrake.

NOTE:

Theonlydifferencebetweenbleedingthefrontandrearbrakesisthattherearmastercylinderisactuatedbyapedal.

TIRES

Inspectevery6000km(4000miles,6months).

TIRETREADCONDITION

Operatingthemotorcyclewithexcessivelyworntireswilldecreaseridingstabilityandconsequentlyinviteadangeroussituation.Itishighlyrecommendedtoreplaceatirewhentheremainingdepthoftiretreadreachesthefollowingspecification.

n'&ili09900~20805:Tiredepthgauge

•Tiretreaddepth:

ServiceLimit:FRONT1.6mm(0.06in)REAR2.0mm(0.08in)

TIREPRESSURE

Ifthetirepressureistoohighortoolow,steeringwillbead•verselyaffectedandtirewearwillincrease.Therefore,maintainthecorrecttirepressureforgoodreadabilityandalongertirelife.Coldinflationtirepressureisasfollows.

~Coldinflationtirepressure

Soloriding:Front:250kPa(2.50kgf/cm2,36psi)Rear:250kPa(2.50kgf/cm2,36psi)

Dualriding:Front:250kPa(2.50kgf/cm2,36psi)

_{Rear:250kPa(2.50kgf/cm2,36psi)}

IACAUTIONI

Thestandardtirefittedonthismotorcycleisa120!70

ZR17(SSW)forthefrontanda180/55ZR17(73W)fortherear.Theuseoftiresotherthanthosespecifiedmaycauseinstability.Itishighlyrecommendedtousethespecifiedtires.

-TIRETYPE

DUNLOP(D207FU.....Front,D207U.....Rear)

..............................E-03,24,28,33

PIRELLI(MTR21Scorsa....Front,MTR22Scorsa....Rear)

..............................Theothers

STEERING

Inspectinitiallyat1000km(600miles,1month)andevery12000km(7500miles,12months)thereafter.

Thesteeringshouldbeadjustedproperlyforsmoothturningofthehandlebarsandsafeoperation.Overtightsteeringpreventssmoothturningofthehandlebarsandtooloosesteeringwillcausepoorstability.Checkthatthereisnoplayinthefrontfork.Supportthemotorcyclesothatthefrontwheelisofttheground.Withthewheelfacingstraightahead,graspthelowerforktubesneartheaxleandpullforward.Ifplayisfound,readjustthesteer•ing.(C:?6-29)

-

FRONTFORK

Inspectevery12000km(7500miles,12months).

Inspectthefrontforksforoilleakage,scoringorscratchesontheoutersurfaceoftheinnertubes.Replaceanydefectiveparts,

ifnecessary.(c::::?6-13)

REARSUSPENSION

Inspectevery12000km(7500miles,12months).

Inspecttherearshockabsorbersforoilleakageandcheckthatthereisnoplayintheswingarm.Replaceanydefectivepartsifnecessary.(c::::?6-41,6-45)

EXHAUSTPIPEBOLTANDNUT

Tighteninitiallyat1000km(600miles,1month)andevery12000km(7500miles,12months)thereafter.

•Tightentheexhaustpipebolts,mufflermountingboltandnuttothespecifiedtorque.

(!)23N·m

2.3kgf·m)^(16.5lb-ft

~(!]23N·m

2.3kgl·m)⁽¹6.5lb-ft

CHASSISBOLTSANDNUTS

Tighteninitiallyat1000km(600miles,1month)andevery6000km(4000miles,6months)

thereafter.

Checkthatallchassisboltsandnutsaretightenedtotheirspecifiedtorque.Thelocationsofthefollowingnutsandboltsonthemotorcycle.:c:::7'2-29

Item G)Steeringstemheadnut				N·m 90		kgt·m 9.0	lb-ft 65.0
i'.2)Steeringstemlocknut				80		8.0	58.0
:IDFrontforkupperclampbolt				23		2.3	16.5
©Frontforklowerclampbolt				23		2.3	16.5
,IDFrontforkcapbolt				35		3.5	25.5
@Frontaxle				100		10.0	72.5
J)Frontaxlepinchbolt				23		2.3	16.5
®Handlebarsetbolt				10		1.0	7.0
®Handlebarclampbolt				23		2.3	16.5
®)Frontbrakemastercylinder	mountinq	bolt		10		1.0	7.0
@Frontbrakecalipermountinabolt				25		2.5	18.1
@Frontbrakecaliperhousinqbolt				21		2.1	15.2
@'Brakehoseunionbolt(Front&Rear)				23		2.3	16.5
@Caliperairbleedervalve(Front&Rear)				8	0.8		6.0
@Brakediscbolt(Front)				23	2.3		16.5
(@Brakediscbolt(Rear)				35	3.5		25.5
@Rearbrakecalioermountinabolt				25	2.5		18.1
(@Rearbrakecaliperhousinabolt				30	3.0		21.5
Q$Rearbrakemastercvlindermountinabolt				10	1.0		7.0
12])Rearbrakemastercvlinderrodlocknut				18	1.8		13.0
®Frontfootrestbracketrnountincbolt				23	2.3		16.5
®Swinaarmoivotnut				100	10.0		72.5
(i.3}Swinaarmoivotlocknut				90	9.0		65.0
®Torquelinkboltandnut(Front)				28	2.8		20.0
'WTorquelinkboltandnut(Rear)				34	3.4		24.6
®'Rearshockabsorberbracketnut				115	11.5		83.2
®Rearshockabsorbermountingbolt/nut
(Upper&Lower)				50	5.0		36.0
®•Rearcushionlever/rodmountingnut				78	7.8		56.5
@RearaxlenutIForE-03,28,			33	110	11.0		79.6
IFortheothers				120	12.0		86.8
~Rearsprocketnut				60	6.0		43.5
~Steeringdamperbolt/nut				23	2.3		16.5

PERIODICMAINTENANCE2-29

COMPRESSIONPRESSURECHECK

Thecompressionpressurereadingofacylinderisagoodindicatorofitsinternalcondition.

Thedecisiontooverhaulthecylinderisoftenbasedontheresultsofacompressiontest.Periodicmainte•

nancerecordskeptatyourdealershipshouldincludecompressionreadingsforeachmaintenanceservice.

COMPRESSIONPRESSURESPECIFICATION

Standard^{LimitDifference}

^{1100-1500kPa900}kPa200kPa

₍

(11-15kgf/cm2)^9kgf/cm2)_(2kgf/cm2)

^{156-213psi128psi28}psi

Lowcompressionpressurecanindicateanyofthefollowingconditions:

•Excessivelyworncylinderwalls

*Wornpistonorpistonrings

•Pistonringsstuckingrooves

*Poorvalveseating

•Rupturedorotherwisedefectivecylinderheadgasket

Overhaultheengineinthefollowingcases:

*Compressionpressureinoneofthecylindersislessthan900kPa(9kg/cm2,128psi).

"Thedifferenceincompressionpressurebetweenanytwocyl•

indersismorethan200kPa(2kgf/cm2,28psi).

*Allcompressionpressurereadingsarebelow11ookPa(11kgf/cm2,156psi)evenwhentheymeasuremorethan900kPa

(9kgf/cm2,128psi).

COMPRESSIONTESTPROCEDURE

NOTE:

*Beforetestingtheengineforcompressionpressure,makesurethatthecylinderheadnutsaretightenedtothespecifiedtorquevaluesandthevalvesareproperlyadjusted.

*Havetheenginewarmedupbeforetesting.

*Makesurethatthebatteryisfully-charged.

Removetherelatedpartsandtestthecompressionpressureinthefollowingmanner.

•Liftandsupportthefueltank.(CT4-52)

•Removeallthesparkplugs.(CT2-5)

•Installthecompressiongaugeandadaptorinthesparkplughole.Makesurethattheconnectionistight.

•Keepthethrottlegripinthefullyopenedposition.

•Pressthestarterbuttonandcranktheengineforafewsec•onds.Recordthemaximumgaugereadingasthecylindercom•pression.

•Repeatthisprocedurewiththeothercylinders.

!r'OOli09915-64510:Compressiongaugeset