Do not force the adjust screw past the stopped position, or you may damage the adjuster. Spring Part No. If the front forks are adjusted harder than the rear suspension, such as changing to heavier front fork oil, stiffer compression and rebound setting, air pressure build up in the forks and so on, the front forks will collapse less on bumps. NOTE: Mark the clutch cable at which the bracket slit set for correct reinstallation. NOTE: When installing a new connector, clean the exhaust pipe and joint of the muffler.
NOTE: Loosen the camshaft journal holder bolts diagonally. NOTE: When loosening the cylinder head bolts, loosen each bolt little by little diagonally. Page Cam Chain No. Fill the intake and exhaust ports with gasoline to check for leaks. Page Camshaft Automatic Decomp. NOTE: Loosen the clutch spring set bolts little by little and diagonally. Mark the paint mark. A Clutch driven No. NOTE: Mark the gearshift shaft head at which the gearshift lever slit set for correct reinstallation.
Gearshift fork to groove clearance Service Limit: 0. Crankshaft runout Service Limit: 0. Install the snap ring in the groove and locate its end as shown in the illustration. NOTE: Turn the gearshift cam to the neutral position and confirm that the driveshaft and countershaft turn without resistance. Page Crankcase Installation 2. Keep heat, spark and flame away. Clean the fuel strainer with compressed air. J 6 Starter jet 7 Pilot screw 8 Slow jet S. NOTE: Do not remove the throttle position sensor 2 unless it is neces- sary to replace it.
Lateral direction: Horizontal Carburetor set position Page Replace the O-rings with new ones. NOTE: Turn in the pilot screw 0 until it lightly seats, then back it out the counted number of turns. If engine cool- ant gets into the eyes or contacts the skin, flush the eyes or wash the skin thoroughly, with plenty of water.
If engine coolant is swallowed, induce vomiting and call a physician immediately. Is there connection in the ignition system couplers? Go to Step 2. Poor connection of couplers Step 2 1 Measure the ignition coil primary peak voltage. Go to Step 3.
Go to Step 9. Go to Step 8. Step 8 1 Check the stator. Is the stator OK? Faulty stator Step 9 1 Measure the engine stop switch resistance. NOTE: Use the special tool needle pointed probe , to prevent the rub- ber of the water proof coupler from damage.
Service Limit: 2. Brake fluid is harmful or fatal if swallowed, and harm- ful if it comes in contact with your skin or eyes. Keep brake fluid away from children. Page Brake Pads Replacement Replace the two pads as a set. Page Caliper Inspection! Call your doctor immediately if brake fluid is swallowed, and induce vomiting. Apply handle grip bond. NOTE: Mark the paint mark A to the matching surface of handlebar holder and handlebars before removing.
Record the set- ting before turning the adjuster. Use engine oil or transmission SS or equivalent rear suspension oil. For Canada Use only unleaded gasoline of at least 95 octane Research Method.
Page 15 — MEMO — Follow the guideline in the chart. The life of parts varies depending on the riding conditions. Perform more often than shown in the chart if you use the motorcycle under severe conditions. NOTE: Remove the dirt around the spark plug before removing the spark plug to prevent dirt from entering the combustion cham- ber.
NOTE: Running the engine without the air cleaner box lid can vary the carburetion. Do not run the engine without the air cleaner box lid. Cap to the front. Air cleaner box front wall NOTE Wait until the oil drain plug and exhaust pipe become cool enough to touch with bare hands before draining oil. Drain oil thoroughly. Do not open the radiator cap when the engine is hot. Wait until engine cools.
Keep engine coolant away from children and pets. Call your doctor immediately if engine coolant is swal- lowed and induce vomiting. If any defects are found, the fuel hose must be replaced. NOTE: The drive chain can hit a bent guide causing noise and drive chain wear. Inspect the chain guide defense 2 for wear. Use only DOT 4 brake fluid from a sealed container. Never use or mix different types of brake fluid. Inspect the spoke tension and then retighten the spoke nipple.
Tighten additionally the nipples after breaking-in runnning, until when initial looseness will eliminated. Page Lubrication A.
Lightweight oil such as WD or penetrating oil. Aerosol type Chain Lube. Follow the schedule closely. The disassembly necessary to lubricate many components is in itself valuable preventative maintenance.
It allows you to inspect for wear, fatigue, adjustment and fastener tightness and it Page 39 — MEMO — Page 45 — MEMO — Page Carburetor Tuning Riders who are not familiar with the operation and jetting procedures of the KEIHIN carburetor should have their local authorized Suzuki dealer perform these alterations.
Mechanically experienced riders can alter the carburetor settings based on the fol- lowing information and specifications. Throttle valve opening After touching the throttle stop screw to the Standard throttle valve, turn in the stop screw five to six turns to raise the throttle valve.
Described in this section are the bases for carburetor tuning required when coping with variations in air oxygen concentration. Variation in Air Oxygen Concentration and Carburetor Conditions As the air, affected by the temperature, altitude and humidity, gets expanded or compressed, air oxygen concentration varies accordingly.
Scratches or other damage on the inner tube or on the oil seal lip will cause oil leak. Scratches or other damage the on inner tube or on the oil seal lip will cause oil leak.
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