- •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
Itemstd/spec.Limit
CamshaftjournalO.D.
IN.&EX.I
23.959-23.980(0.9433-0.9441)
Camshaftrunout0.10(0.004)
Camchainpin(atarrow"3")14thpin
Cylinderheaddistortion0.20(0.008)
CYLINDER+PISTON+PISTONRINGUnit:mm(in)
Itemstd/spec.Limit
Compressionpressure1100-1500kPa900kPa
(11-15kgf/cm2)(9kgf/cm2)
156-213psi128psi
Compressionpressure200kPadifference(2kgf/cm2)
28psi
Pistontocylinderclearance0.010-0.0350.120(0.00039-0.00138)(0.0047)
Cylinderbore67.000-67.015Nicksor
(2.6378-2.6384)Scratches
Pistondiam.66.970-66.98566.880(2.6366-2.6372)(2.6331)
Measureat15mm(0.6in)fromtheskirtend.
Cylinderdistortion0.20(0.008)
Approx.
Approx. |
7.35.8 (0.29)(0.23) 9.2 7.4(0.36)(0.29) |
|||
0.06- |
0.18 |
0.50 |
||
(0.003- |
0.008) |
(0.020) |
||
0.06- |
0.18 |
0.50 |
||
(0.003 |
-0.008) |
(0.020) |
||
|
|
0.180 |
||
|
|
(0.0071) |
||
|
|
0.150 |
||
|
|
(0.0059) |
||
Pistonringfreeendgap1stR
2ndRN
PistonringendgaptstR
2ndRNPistonringtogrooveclearance1st
2nd
Pistonringgroovewidthtst1.01-1.03(0.0398-0.0406)
2nd0.81-0.83(0.0319-0.0327)
Oil1.51-1.53(0.0594-0.0602)
Pistonringthickness1st0.97-0.99(0.0382-0.0390)
--
2nd 0.77-0.79(0.0303-0.0311)
Piston |
pinbore |
14.002 |
-14.008 |
14.030 |
|
|
(0.5513 |
-0.5515) |
(0.5524) |
Piston |
pinO.D. |
13.995 |
-14.000 |
13.980 |
|
|
(0.5510 |
-0.5512) |
(0.5504) |
CONROD+CRANKSHAFT ITEM |
STD/SPEC. |
Unit:mm
LIMIT |
(in) |
|||
Conrodsmallendl.D. |
14.010-14.018 |
14.040 |
|
|||
|
|
(0.5516 |
-0.5519) |
(0.5528) |
||
Conrod |
bigendsideclearance |
0.10 |
-0.20 |
0.30 |
||
|
|
(0.004 |
-0.008) |
(0.012) |
||
Conrod |
bigendwidth |
19.95 |
-20.00 |
|
||
|
|
(0.7854 |
-0.7874) |
|
||
Crankpinwidth20.10-20.15
|
(0.7913-0.7933) |
|
|
Conrodbigendoilclearance |
0.032-0.056 |
0.080 |
|
|
(0.0013-0.0022) |
(0.0031) |
|
CrankpinO.D. |
30.976-31.000 |
|
|
|
(1.2195-1.2205) |
|
|
Crankshaftjournaloilclearance |
0.016-0.040 |
0.080 |
|
|
(0.0006-0.0016) |
(0.0031) |
|
CrankshaftjournalO.D. |
31.976-32.000 |
|
|
|
(1.2589-1.2598) |
|
|
CrankshaftthrustbearingRight |
side2.425-2.450 |
|
|
thickness(0.0955 |
-0.0965) |
||
Leftside2.350 |
-2.500 |
||
(0.0925 |
-0.0984) |
||
Crankshaftthrustclearance0.055-0.110(0.0022-0.0043)
Crankshaftrunout0.05(0.002)
OILPUMP
ITEM |
|
|
STD/SPEC. |
|
|
LIMIT |
Oilpressure(at60°C, |
140°F) |
(2.0- |
200-500kPa 5.0kgf/cm2,28- |
71 |
psi) |
|
|
|
|
at3000r/min. |
|
|
|
Clutchleverplay |
10- |
15 |
|
|||
(0.4- |
0.6) |
|||||
Clutchreleasescrew Driveplatethickness |
No. |
1,2 |
"!4turn |
back 2.92- |
3.08 |
|
CLUTCH Unit:mm(in)ITEMSTD/SPEC.LIMIT
and3(0.115-0.121)
DriveplateclawwidthNo.1,213.7-13.812.9and3(0.540-0.543)(0.508)
Drivenplatedistortion0.10(0.004)
Clutchspringfreeheight47.8045.4(1.882)(1.787)
-
-
TRANSMISSION+
ITEM
DRIVE
CHAIN
STD/SPEC.
Unit:
mm(in)Exceptratio
LIMIT
Primaryreductionratio
1.926
(79/41)
Finalreductionratio
2.812
(45/16)
Gearratios
Low
2.785
(39/14)
2nd
2.000
(32/16)
3rd
1.600
(32/20)
4th
1.363
(30/22)
5th
1.208
(29/24)
Top
1.086
(25/23)
Shiftforktogrooveclearance
0.10-
0.30
0.50
(0.004-
0.012)
(0.020)
Shiftforkgroovewidth
5.0-
5.1
.....
(0.197-0.201)
Shiftforkthickness4.8-4.9(0.189-0.193)
DrivechainTypeRK525SMOZ6
Links110links
20-pitchlengthI
Drivechainslack(onside-stand)20-30(0.79-1.18)
Gearshiftleverheight52-62(2.05-2.44)
THERMOSTAT+RADIATOR+FAN+COOLANT
319.4(12.57)
